description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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BACKGROUND OF THE INVENTION
The present invention relates to a container for loose products in general, and in particular for confectionery products such as chocolates, caramels, tablets, sugar-coated pills or the like, formed from a flat, one-piece, die-cut blank, for example of cardboard, by folding along prearranged creasing lines, and such as to assume a substantially parallelepiped shape when assembled.
The object of the present invention is to provide a container which can be opened in a comfortable and simple manner for removing the required quantity of product and closed in a likewise comfortable and simple manner when the product has been removed, and which for obvious hygienic and other reasons also prevents accidental escape of the product contained therein.
SUMMARY OF THE INVENTION
In attaining this object, the container according to the present invention is opened and respectively closed by sliding in the manner of a drawer a part of the blank which is mounted on another part thereof, this sliding causing a mobile terminal part of the container, formed integrally with the flat blank, to open and close respectively. The container according to the invention also possesses numerous constructional characteristics which make it of easy and reliable assembly, either manually or by using automatic or semiautomatic sequentially operating machines.
DESCRIPTION OF THE DRAWINGS
The container according to the invention is described in detail hereinafter with reference to the accompanying drawings, in which:
FIG. 1 is a plan view of the inside face of the flat, one-piece, die-cut blank which is to form a first embodiment of the container according to the invention,
FIG. 2 is a partly sectional perspective side view of the container obtained from the flat blank of FIG. 1 in its assembled form,
FIG. 3 is a perspective side view of the container of FIG. 2 partly open,
FIG. 4 is a perspective side view of the container of FIG. 2, in its closed position,
FIG. 5 is a plan view of the inside face of the flat, one-piece blank for forming a second embodiment of the container according to the invention,
FIG. 6 is a partly sectional perspective side view of the container obtained from the flat blank of FIG. 5 in its assembled form,
FIG. 7 is a perspective side view of the container of FIG. 6 partly open, and
FIG. 8 is a perspective side view of the container of FIG. 6, in its closed position.
DETAILED DESCRIPTION
With reference to FIG. 1, the flat, one-piece die-cut blank for forming a first embodiment of a container according to the invention comprises:
an upper part 2, for forming the outer casing of the assembled container and divided by longitudinal creasing lines A, B, C into alternately-disposed major panels 3, 5 and minor panels 4, 6 of substantially rectangular shape.
The two specularly equal minor panels 4 and 6 for forming the side walls of the outer casing of the assembled container comprise, in their lower part starting from the creasing lines B and C respectively, opposing chamfered corners delimiting triangular cut-out zones 9 and 10.
The end major panel 3, for forming the outer base surface of the assembled container, has the same length as the minor panels 4 and 6 but is of considerably greater width.
The major panel 5 disposed between the minor panels 4 and 6 and designed to form the outer upper surface of the assembled container has a width equal to the width of the major panel 3, a length less than the length of the panels 3, 4 and 6, and is limited lowerly by the transverse creasing line F, which joins the upper vertices of the triangular cut-out zones 9 and 10 and connects the major panel 5 to the underlying rectangular lower panel 5', which is of the same width but of considerably smaller length than said major panel 5, such that the sum of the lengths of said panels 5 and 5' is slightly greater than the length of any one of the panels 3, 4 and 6.
The upper free edges of the major panels 3 and 5 each comprise a recess 8, the purpose of which is to facilitate the gripping of the inner casing of the assembled container, as is described hereinafter.
A further longitudinal creasing line D delimits a lateral end flap 7 which is to have adhesive applied to its rear for its sticking on to that surface of the major panel 3 shown in the figure along its longitudinal zone adjacent to its outer edge. Said lateral end flap 7 is substantially tapered outwards and in its upper edge comprises a recess 11 having the same shape as that part of the recess 8 of the major panel 3 disposed close to its outer lateral edge, so that the said part of the recess 8 of the major panel 3 and the recess 11 of the lateral end flap 7 coincide on assembly.
a central part 12 comprising: a major end rectangular panel 13 aligned with the major panel 3 of the upper part 2, and joined to it by the transverse creasing line E, and having the same width thereas but having a length equal to the minimum width of the lower part of the minor panels 4 and 6 of the upper part 2; two equal rectangular minor panels 14 and 16 having a width equal to the minimum width of the lower part of said panels 4 and 6, with which they are respectively aligned and to which they are joined by the transverse creasing lines E', and thus equal to the length of the major panel 13 of the central part 12. Said panels 14 and 16 have a length equal to one half the width of the major panel 13 and are to be stuck on to that surface of said major panel 13 shown in the figure, to which adhesive is suitably applied.
a lower part 19 to form the inner casing of the assembled container, and divided by longitudinal creasing lines A', B', C', which are substantially aligned with the corresponding longitudinal creasing lines A, B, C of the upper part 2, into major rectangular panels 20, 22 and minor rectangular panels 21, 23 which are substantially aligned with the corresponding panels 3, 5 and 4, 6 of the upper part 2 and being of equal widths alternately in pairs, these widths being slightly less than the width of the corresponding panels of the upper part 2 so as to allow them to slide when the container is assembled.
The minor panels 21 and 23, for forming the side walls of the inner casing of the assembled container, have equal dimensions and upperly delimit spaces 17, 18 of separation from the minor spaces 14, 16 of the central part 12, with which they are aligned. These are also suitably dimensioned relative to the corresponding panels 4 and 6 of the upper part 2 to allow axial sliding of the two assembled container parts.
The major panel 20, for forming the base surface of the outer casing of the assembled container, has an upper corner chamfered by the cutting line I, extending upwards from the creasing line A', to prevent any interference with the minor panel 14. Said major panel 20 is separated upperly from the corresponding major panel 13 of the central part 12 by the empty space 15 formed by the die-cutting operation.
The central major panel 22, for forming the upper surface of the inner casing of the assembled container, is aligned with the central major panel 5 and thus with the lower panel 5' of the upper part 2, and is connected to this latter by the transverse creasing line E", its width being equal to the width of the major panel 20 and its length being substantially equal to the sum of the lengths of the major panel 5 and lower panel 5' of the upper part 2.
Empty spaces 25, 26, formed by die-cutting and consecutive to the triangular cut-outs 9 and 10 laterally separate the upper part of the major panel 22 of the lower part 19 from the minor panels 14 and 16 of the central part 12. A further longitudinal creasing line H, parallel to the longitudinal creasing lines A', B', C', delimits a lateral end flap 24 joined to the major panel 20 and thus situated on the opposite side to the lateral end flap 7 of the upper part 2. That surface of said lateral end flap 24 shown in the figure is coated with adhesive for its sticking on to the rear of the minor panel 23.
major appendix panels 27 and 29 and minor appendix panels 28 and 30 of equal length equal to the width of the minor panels 21 and 23 of the lower part 19 and delimitated upperly by the transverse creasing line N which joins them to the lower part 19 of the flat blank 1, they being aligned respectively with the panels 20, 22 and 21, 23 of the lower part 19 and being separated from each other by longitudinal cuts A", B", C" which constitute the ideal prolongation of the longitudinal creasing lines A', B', C' of said lower part 19. Points or layers of adhesive are applied to the rear of the major appendix panel 29 for its sticking on to that surface of the major appendix panel 27 shown in the figure.
Again with reference to FIG. 1, the flat blank 1 is printed, folded, stuck down and assembled as follows.
The lower part 19 of the flat blank 1 as shown in the figure (which shows the inside face) is to be folded upwards and rearwards towards the surface of the upper part 2 shown in the figure, along the transverse creasing line E" which joins the lower panel 5' of the upper part 2 to the major panel 22 of the lower part 19. A part of that surface of the lower part 19 shown in the figure will thus lie on the outside of the assembled container, and the rear of that surface of the upper part 2 shown in the figure and the rear of the major panel 13 of the central part 12 will form the outer surface of the container. Consequently, the upper part 2 and the major panel 13 of the central part 12 will be printed on the outside face (i.e. on the cover) whereas any required printing on visible zones of the remainder of the flat blank 1 will be done on the inside face.
The flat blank printed in this manner is now assembled by folding the lower part 19 upwards and rearwards along the transverse creasing line E" which connects the lower panel 5' of the upper part 2 to the upper part of the major panel 22 of said lower part 19.
The result of this folding operation is that that surface of the lower part 19 shown in the figure becomes superposed on and in contact with that surface of the upper part 2 shown in the figure, whereas the panels 13, 14, 16 of the central part 12 maintain their initial position together with the upper part 2 after this folding.
A layer of vinyl or hot melt adhesive is applied manually or by machine to the rear of the lateral end flap 7 of the upper part 2 and to that surface of the lateral end flap 24 of the lower part 19 which is shown in the figure.
The flat blank 1 folded in this manner is further folded forwards firstly along the longitudinal creasing lines A, A' which have become superposed after folding the lower part 19 on to the upper part 2, and then again forwards along the longitudinal creasing lines C, C' which have become likewise superposed. The adhesive-coated lateral end flap 24 of the lower part 19 is then stuck on to the rear of a longitudinal zone adjacent to the outer edge of the minor panel 23 of said lower part 19, and the rear of the adhesive-coated lateral end flap 7 of the upper part 2 is stuck on to a longitudinal zone adjacent to the outer edge of the major panel 3 of said upper part 2.
The flat blank folded and stuck together in this manner gives rise to a two-dimensional foldable container of minimum bulk and thus simple to trasport and store, and which is ready for simple transformation into a three-dimensional container by exerting a manual or mechanical pressure along the opposing edges of the container corresponding to the superposed longitudinal creasing lines A, A' and C, C' to thus obtain a parallelepiped container which is open at its ends.
The rear part of the container is closed by folding the minor appendix panels 28 and 30 inwards, folding the major appendix panel 27 until it contacts the minor appendix panels 28 and 30, and folding the major appendix panel 29 until it contacts the major appendix panel 27, the folding being done along the respective portions of the creasing line N, then applying a layer of adhesive to the rear of the major appendix panel 29, and then sticking the adhesive-coated rear of this latter on to the major appendix panel 27 by applying pressure.
The chosen product is placed in the container arranged in this manner, the rectangular lower panel 5' is folded inwards so as to pass over the chamfers of the triangular zones 9 and 10, the minor panels 14 and 16 are folded inwards along the creasing lines E', a layer of adhesive is applied to that surface of the major panel 13 shown in the figure, and this is folded along the creasing line E towards the minor panels 14 and 16, and then stick on to the rear of these latter.
This first embodiment of the invention is thus finally assembled into its closed position. An adhesive sealing tab, stamp or label or the like can be applied between the lower panel 5' of the upper part 2 and the major panel 13 of the central part 12, or between the lower part 19 below the recess 8 and the adjacent outer surface of the upper part 2, to ensure that the package has not been tampered with when sold.
To open the container, it is necessary only to break any guarantee seal, then to grip the opposing major panels 20 and 22 of the inner casing of the container formed by the lower part 19 of the flat blank 1, between the fingers in those zones left uncovered by the profiled recesses 8 of the outer casing of the container formed by the upper part 2, and then slide the assembled inner lower part 19 in the only possible direction, i.e. outwards from the container as shown by the arrow 0 in FIGS. 2 and 3.
By means of this substantially drawer-like sliding, the major panel 22 of the lower part 19 of the flat blank 1 causes the lower panel 5' of the upper part 2, which is rigid therewith along the trasverse creasing line E", to rotate about the transverse creasing line F until an end position of maximum opening is reached in which the major panel 22 of the lower part 19 and the lower panel 5' of the upper part 2 are substantially aligned, such that that surface of the lower panel 5' shown in FIG. 1 is substantially in contact with that surface of the major panel 5 shown in FIG. 1 on a zone adjacent to the transverse creasing line F.
The product contained in the container can then be withdrawn through the aperture thus defined between the creasing line F and the free depressed edge of the mutually rigid panels 13, 14, 16, without danger of the product being able to fall out, also in case of limited inclinations of the container.
The container can then be again closed to await subsequent product withdrawal by simply sliding the inner casing into the outer casing in the reverse direction to the arrow 0 in the manner of a drawer, so that the major panel 22 urges the lower panel 5' outwards to cause it to rotate about the transverse creasing line F until that portion of the transverse creasing line E" which joins the major panel 22 of the inner casing to the lower panel 5' of the outer casing again comes into contact with the depressed free edges of the panels 14, 16, which are mutually rigid by way of the panel 13, i.e. substantially in line with the free edges of the chamfered corner ends 9 and 10 of the lateral walls formed by the minor panels 4 and 6, thus closing the container tightly by virtue of the fact that the lower panel 5' presses against the aforesaid depressed free ends, this pressing action being obtained by virtue of the fact that the total length of the major panel 5 plus lower panel 5' of the upper part 2 which form the upper surface of the outer casing of the container is slightly greater than the length of the opposing panel 3 which forms the lower surface of said outer casing.
A second embodiment of the container according to the invention will now be described in detail with reference to FIGS. 5 to 8. In these figures, elements similar to those of the preceding figures are indicated by the same reference letters and numerals in hundreds.
More particularly, with reference to FIG. 5, the flat, one-piece, die-cut blank 101 for forming a substantially parallelepiped container comprises:
an upper part 102 for forming the outer casing of the assembled container, divided by parallel longitudinal creasing lines A, B, C into substantially rectangular major panels 103 and 105 and minor panels 104 and 106, which are of equal length, and alternately of equal width in pairs. A further longitudinal creasing line D delimits an outwardly tapered lateral end flap 107 to be coated on its rear with adhesive for its sticking on to that surface of a longitudinal zone adjacent to the edge of the major panel 103 shown in the figure.
The widths of the major panels 103 and 105, which are to form respectively the base and upper surface of the outer casing of the assembled container, are substantially equal to each other and considerably greater than their adjacent minor panels 104 and 106 which are to form the lateral walls of the outer casing of the assembled container.
The upper free edges of the major panels 103 and 105 comprise a recess 108, the purpose of which has already been described with reference to the first embodiment of the invention.
a central part 112 comprising in succession an upper rectangular panel 131 and a lower rectangular panel 132, which are aligned longitudinally with the major panel 105 of the upper part 102.
The upper panel 131 is delimited upperly by the transverse creasing line M which connects it to the major panel 105 of the upper part 102, and is delimited lowerly by the transverse creasing line P which connects it to the successive lower panel 132, said transverse creasing line P comprising a suitably shaped cut P' in its central part. The width of the upper panel 131 is equal to the sum of the width of the major panel 105 of the upper part 102 and its creasing-line thicknesses, and its length is equal to the width of the minor panels 104 and 106 of the said upper part 102; the width of the lower panel 132 is slightly less than the width of the upper panel 131, whereas its length is the same.
a lower part 119 for forming the inner casing of the assembled container, and divided by the parallel longitudinal creasing lines A', B', C', aligned with the corresponding longitudinal creasing lines A, B, C of the upper part 102, into major rectangular panels 120 and 122 and minor rectangular panels 121 and 123, which are aligned with the corresponding rectangular panels 103, 105 and 104, 106 of the upper part 102, and are alternately of equal width in pairs, these widths being slightly less than the widths of said panels 103 to 106.
The lower part 119 is connected to the central part 112 by the transverse creasing line Q which joins the major panel 122 of the lower part 119 to the lower panel 132 of the central part 112.
A further parallel longitudinal creasing line D' joins a lateral end flap 124 to the minor panel 123. That surface of said lateral end flap 124 shown in FIG. 5 is to receive adhesive for its sticking on to the rear of the major panel 120.
The major panels 120 and 122 of the lower part 119, which are aligned respectively with the major panels 103 and 105 of the upper part 102, are to form the opposing major surfaces of the inner casing of the assembled container. The upper edge of the major panel 120 also comprises a substantially trapezoidal cavity 133 acting as a lead-in for withdrawing the product when the container is open.
The outwardly tapered lateral end flap 124 therefore has its upper edge shaped with a recess 134 of the same shape as that part of the recess 133 of the major panel 120 which is close to its outer lateral edge to allow suitable superposing on assembly.
The minor panels 121 and 123 of the lower part 119, which are aligned with the minor panels 104 and 106 of the upper part 102, are to form the lateral walls of the inner casing of the assembled container.
Major appendix panels 127 and 129 and major appendix panels 128 and 130 of equal length, substantially equal to the length of the minor panels 121, 123 of the lower part 119, and delimited upperly by a transverse creasing line N joining them to said lower part 119 of the flat blank 101, they being aligned respectively with the panels 120, 122 and 121, 123 of the lower part 119 and separated from each other by longitudinal cuts A", B", C" which constitute the ideal prolongation of the longitudinal creasing lines A', B', C' of the lower part 119. The width of the appendix panels 127 to 130 is substantially equal to the width of the corresponding panels 120 to 123 of the lower part 119.
Points or layers of adhesive are provided on the rear of the appendix panel 127 for its sticking on to that surface of the appendix panel 129 shown in the figure.
When the flat blank 101 has been printed in a manner substantially similar to that already described in relation to the flat blank 1, it is assembled by folding the lower part 119 together with the panel 132 of the central part 112 upwards and rearwards along the transverse creasing line P which joins the upper panel 131 to the lower panel 132 of the central part 112. By this folding action, those surfaces of the lower panel 132 of the central part 112 and of the lower part 119 shown in the figure become superposed on and in contact with those surfaces of the upper panel 131 of the central part 112 and, respectively, of the upper part 102 shown in the figure.
A layer of vinyl or hot melt adhesive is applied manually or by machine to the rear of the lateral end flap 107 of the upper part 102 and to that surface of the lateral end flap 124 of the lower part 119 shown in the figure.
The flat blank 101 is now folded forwards firstly along the longitudinal creasing lines C and C', which had become superposed when the lower part 119 was folded on to the upper part 102, and then forwards along the superposed longitudinal creasing lines A and A', taking care that the adhesive-coated lateral end flap 124 sticks on to the rear of a longitudinal zone adjacent to the edge of the major panel 120, both these pertaining to the lower part 119, and that the adhesive-coated lateral end flap 107 of the upper part 102 becomes inserted between those surfaces of the major panel 120 of the lower part 119 and of the major panel 103 of the upper part 102 which are shown in the figure, and that it becomes stuck along a longitudinal zone adjacent to the edge of said major panel 103.
Pressure is then applied to finally stick down the lateral end flap 124 on to the rear of the major panel 120 of the lower part 119, and the rear of the lateral end flap 107 on to the major panel 103 of the upper part 102.
When the flat blank 101 is folded and stuck together in this manner, it gives rise to a two-dimensional foldable container of minimum bulk and thus simple to transport and store, and ready for easy transformation into a three-dimensional container by manually or mechanically applying a pressure along the opposing corners of the container corresponding to the longitudinal superposed creasing lines A, A' and C, C', to thus obtain a parallelepiped container open at its ends.
Adhesive is applied to the rear of the major appendix panel 127, the minor appendix panels 128 and 130 are then folded inwards, the major appendix panel 127 is folded until it comes into contact with the minor appendix panels 128 and 130 and the major appendix panel 129 is folded until it comes into contact with the major appendix panel 127, the folds being made along the respective portions of the transverse creasing line N, after which the major appendix panel 129 is stuck down on to the rear of the adhesive-coated major appendix panel 127 by applying pressure. This further embodiment of the container according to the invention thus becomes finally assembled in its open position.
Referring now to FIGS. 6 to 8, which show the container obtained from the flat blank of FIG. 5 in its position of use, the container is filled with the chosen product manually or by machine.
The container is closed as follows.
The inner casing of the container, formed from the lower part 119 of the flat blank 101, is slid while inside the outer casing, formed from the upper part 102, in the only possible direction, i.e. outwards from the container as indicated by the arrow R of FIG. 7.
By means of this substantially drawer-like sliding action, the lower panel 132 of the central part 112, which is joined to the inner casing formed from the lower part 119 by the transverse creasing line Q, is pulled into the container and simultaneously rotated about the transverse creasing line Q towards the container body until it rests against its aperture by virtue of being connected to the upper panel 131 by the transverse creasing line P. This movement causes the upper panel 131 to simultaneously rotate through 90° about the transverse creasing line M until said panel 131 assumes a position such that its lateral edges and the cut portion P', which project beyond the edges of the aperture in the assembled container, come into contact with and rest against said edges of said aperture. The lower panel 132 assumes inside the container an obligatory oblique position which protects it against accidental opening due to the internal pressure of the product.
The thus assembled container can then be sealed by known means such as adhesive tabs, stamps or labels applied between the mobile side and the container body or between the lower part 119 below the recess 118 and the adjacent surface of the upper part 102, to ensure that the package has not been tampered with when sold.
To open this second embodiment of the container according to the invention, it is necessary only to break any guarantee seal and then to slide the inner casing within the outer casing in the opposite direction to the arrow R. In this manner, the major panel 122 pushes against and rotates the lower panel 132, which itself pushes the upper panel 131 outwards. The lower panel 132 and upper panel 131 rotate together about the respective transverse creasing lines Q and M, until the front panel 132 has rotated through about 180°.
The subsequent opening and closing operations fot withdrawing the product as required by the user are always carried out by simply sliding the inner casing formed from the lower part 119 of the flat blank 101 within the outer casing formed from the upper part 102.
Numerous modifications can be made to the container according to the invention with regard for example to the shape of the container cross-section, its dimensions or the material used for forming the flat blank, without leaving the scope of protection of the invention itself. | A parallelepiped container, in particular for loose confectionery products such as chocolates, caramels, tablets, sugar-coated pills or the like, which is formed from a flat, one-piece, die-cut blank by folding the constituent panels and end flaps of the flat blank along prearranged creasing lines, and sticking together prearranged zones, in such a manner as to obtain the container in the form of two parts which are axially slidable in the manner of a drawer one inside the other, the sliding causing mobile end panels of the container to rotate in order to open and/or close it. | 1 |
[0001] The present application is a continuation of U.S. application Ser. No. 10/391,621, filed Mar. 20, 2003, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an image forming apparatus and, in particular, to an image forming apparatus for preventing color mismatching, by rotating photosensitive bodies for respective colors in a matched state, and a method for preventing a color mismatch in the image forming apparatus.
[0004] 2. Description of the Related Art
[0005] Known is an image forming apparatus for forming a color image by arranging image forming sections for colors such as yellow (Y), magenta (M), cyan (C) and black (K) near a transfer belt along a running direction of the transfer belt and allowing images based on image data for respective colors to be color matched. The respective image forming section of this apparatus comprises a photosensitive drum, a control section configured to allow a light exposure to be applied to the photosensitive body, a developing agent supply section, and so on. In the image forming apparatus thus formed, it is considered necessary to set the portions of respective drums over a transfer belt and, by drawing lines on the transfer belt with an integral multiple of a circumference length of the drum and detecting the lines, a light exposure timing is controlled to prevent any adverse effect exerted by a rotation vibration on a transfer surface during a rotation of the drum about a drum shaft. By doing so, an image of respective color components is transferred to the transfer belt, avoiding color mismatching.
[0006] In the case where, however, a rotation vibration is involved in the photosensitive drum itself, an image interval to be formed on the transfer belt varies during a rotation cycle of the photosensitive drum and there occurs a matched image on the transfer belt at some area but there sometimes arises a color mismatch on the transferred image at other areas. As a result, image quality formed in the image forming apparatus is somewhat lowered.
[0007] Therefore, there is a need for an image forming apparatus which prevent an image from being transferred from the photosensitive drum for respective colors onto a transfer surface throughout the rotation cycle of the drum in a color-mismatched state.
BRIEF SUMMARY OF THE INVENTION
[0008] According to an aspect of the present invention, there is provided an image forming apparatus comprising photosensitive bodies each rotatable about a predetermined axis and configured to from a color image for respective colors; light exposure sections provided for the respective colors and configured to form a latent image corresponding to a line-like image of a predetermined pitch in an axial direction of the respective photosensitive body; developing sections provided for the respective colors and configured to supply a developing agent corresponding to the respective photosensitive body to allow the latent image which corresponds to the line-like image of the predetermined pitch to be developed; and a transfer belt configured to allow the developed line-like image of a predetermined pitch to be transferred. Further, the apparatus includes sensors each arranged at a predetermined position and configured to detect the presence or absence of any line of the line-like image for the respective colors transferred to the transfer belt, and an adjusting section configured to, based on the phases of waveforms for respective colors calculated from the pitch of the lines which has been detected, relative to the phase of a given photo-sensitive body adjust the rotation positions of the other photosensitive bodies to allow the phases of the other photosensitive bodies to be substantially matched to the phase of the given photosensitive body.
[0009] Objects and advantages of the invention will become apparent from the description which follows, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0010] The accompanying drawings illustrate embodiments of the invention, and together with the general description given above and the detailed description given below, serve to explain the principles of the invention.
[0011] FIG. 1 is a view showing a general arrangement of a color copier according to one embodiment of the present invention;
[0012] FIG. 2 is a view showing an arrangement of a transfer belt and respective image forming section;
[0013] FIG. 3 is a view showing a drive unit and drum unit;
[0014] FIG. 4 is a view showing another practical form of drive unit and drum unit;
[0015] FIG. 5 is a view showing another practical form of drive unit and drum unit;
[0016] FIG. 6 is a view showing a phase matching unit;
[0017] FIG. 7 is a view showing a reference position of a photosensitive drum;
[0018] FIG. 8 is a view showing one practical form of an arrangement of sensors;
[0019] FIG. 9 is a view showing a general control structure of the color copier;
[0020] FIG. 10 is a flow chant showing the process of a control section;
[0021] FIG. 11 is a view showing waveforms calculated from line intervals before a phase adjustment;
[0022] FIG. 12 is a view showing waveforms calculated from line intervals after the phase adjustment;
[0023] FIG. 13A is a view showing another form of a phase matching section;
[0024] FIG. 13B is a view showing one form of a dial; and
[0025] FIG. 14 is a view showing an arrangement of a sensor configured to read out color information or density information.
DETAILED DESCRIPTION OF THE INVENTION
[0026] With reference to the drawing an explanation will be made below about the respective embodiments of the present invention.
[heading-0027] (First Embodiment)
[0028] FIG. 1 is a view diagrammatically showing a structure of a four-series type color copier 1 having a plurality of electrophotographic image forming sections arranged relative to the same transfer belt. The color copier 1 has a scanner section 2 , a printer section 3 and a sheet supply section 4 . The color copier 1 has a document glass 2 a where a document, such as a to-be-copied material, is placed. The copier scans an image of the document on the document glass 2 a , applies a predetermined process to the scanned image data and, by doing so, forms a color image. As a type of image data used for forming an image in a color copier 1 , use is made of, for example, image data of yellow (Y), magenta (M), cyan (C) and black (K) color components which are generated from red (R), green (G), and blue (B) colors of image data corresponding to a scanned document image.
[0029] The printer section 3 has image forming sections 5 Y, 5 M, 5 C and 5 K configured to form an image corresponding to the Y, M, C and K color components. The image forming sections 5 Y, 5 M, 5 C and 5 K are arranged at predetermined intervals in an opposed relation relative to an endless type transfer belt 6 for conveying a sheet, etc., and at predetermined intervals L relative to the belt along a plane direction of the transfer belt 6 . It is to be noted that FIG. 2 shows an arrangement of the transfer belt 6 and image forming sections 5 Y, 5 M, 5 C and 5 K. In this embodiment, the image forming sections 5 Y, 5 M, 5 C and 5 K are arranged in that order as viewed from an upstream side of a sheet conveying direction.
[0030] In the image forming sections 5 Y, 5 M, 5 C and 5 K, corresponding photosensitive drum 7 Y, 7 M, 7 C and 7 K are provided so as to allow latent image corresponding to image data of Y, M, C and K to be formed. Further, in the image forming sections 5 Y, 5 M, 5 C and 5 K, developing units 8 Y, 8 M, 8 C and 8 K are incorporated each with a toner of a respective color (Y, M, C, K) held there to allow the latent images formed on the photosensitive drums 7 to be made a visible image.
[0031] Around the photosensitive drums 7 Y, 7 M, 7 C and 7 K of the image forming sections 5 Y, 5 M, 5 C and 5 K, transfer units 9 Y, 9 M, 9 C and 9 K are respectively arranged to allow corresponding toner images, which are formed on the corresponding drums 7 , to be transferred, under electrostatic attraction, to a conveying sheet on a transfer belt 6 in a sandwiched state. Further around the photosensitive drums 7 Y, 7 M, 7 C and 7 K cleaners 10 Y, 10 M, 10 C and 10 K, charge eliminators 11 Y, 11 M, 11 C and 11 K and chargers 12 Y, 12 M, 12 C and 12 K are arranged respectively, the cleaner being used to eliminate a residual toner on the drum left after a toner image has been transferred to the sheet by the transfer unit, the charge eliminator being used to eliminate a charge remaining on the drum after the toner has been cleaned by the cleaner, and the charger being used to apply a predetermined charge to the drum.
[0032] The transfer belt 6 is tensioned between a drive roller 13 a and a driven roller 13 b . By rotating the drive roller 13 a the transfer belt 6 is run in a predetermined direction. At a predetermined position near the driven roller 13 b , an attraction charger 14 is provided to electrostatically charge the sheet to allow the sheet to be attracted to the transfer belt 6 . At a somewhat downstream side in a sheet conveying direction at a position where a sheet from the sheet supply section 4 is set in contact with the transfer belt 6 , an attraction roller 19 is arranged to allow the sheet to be set in close contact with the transfer belt 6 which is electrically charged by the attraction charger 14 .
[0033] At a predetermined position above each image forming section ( 5 Y, 5 M, 5 C, 5 K) of the printer section 3 , a light exposure unit 15 is provided to allow an image forming signal, which is image-processed for each color image data by a later-described control section 51 , to be illuminated with a corresponding color laser beam at an image forming timing. In accordance with the image forming signal corresponding to each color, the light exposure unit 15 allows its own emitting laser beam to, while deflecting the beam by a polygon mirror 16 a , etc., in an axial direction of the respective photosensitive drum ( 7 Y, 7 M, 7 C and 7 K), be directed by a plurality of cylindrical lenses 16 b and plane mirrors 16 c , 16 d , etc., onto the photosensitive drums 7 Y, 7 M, 7 C, 7 K in a sequential fashion. By doing so, electrostatic latent images corresponding to the respective colors are formed on the photosensitive drums 7 Y, 7 M, 7 C and 7 K.
[0034] In a direction in which the sheet is conveyed on the transfer belt 6 , a fixing unit 17 is provided for allowing a toner image of four colors borne on the sheet to be fixed to the sheet. The fixing unit 17 comprises a heating roller having an inside heater and a pressing roller (not shown). The fixing unit 17 allows a sheet to pass between the heating roller and the pressing roller, while applying a predetermined pressure between the heating roller and the pressing roller, and electrostatically deposited toner on the sheet is fixed to the sheet under both heating and pressure. Thus, the color copier 1 forms a color image on the sheet.
[0035] Further, the color copier 1 has a color mode for forming a color image and a monochrome mode for forming a monochrome image. In the color mode, a color image is so formed that the photosensitive drums 7 Y, 7 M, 7 C and 7 K for Y, M, C and K colors are set in close contact with the transfer belt 6 . In the monochrome mode, the photosensitive drum 7 K for black color K is set in close contact with the transfer belt 6 to form an image, in which case the photosensitive drums 7 Y, 7 M and 7 C for Y, M, C colors are set away from the transfer belt 6 .
[0036] FIG. 3 is a view showing a practical form when any of the photosensitive drums 7 Y, 7 M, 7 C and 7 K are incorporated into the color copier 1 .
[0037] A drum unit 21 is provided which has a photo-sensitive drum 7 and a drive unit 20 configured to transmit a drive force to the photosensitive drum 7 from a drive source such as a motor, not shown. By connecting a coupling member 22 a of the drive unit 20 to a coupling member 22 b of a drum unit 21 , a drive force is transmitted from the drive unit 20 to the drum unit 21 . The coupling member 22 a of the drive unit 20 is coupled to a shaft 23 which is in mesh with a gear 24 . The gear 24 is rotationally driven upon receipt of a drive force from the drive source such as a motor, not shown. The shaft 23 is supported by a plurality of bearings 25 . A compression spring 28 is provided between a moving plate 26 , which configured to be moved by a solenoid mechanism section 27 , provided at a back surface of the coupling member 22 a and the bearing 25 nearest on the coupling member 22 a side to the moving plate. The drum 7 is rotated about a shaft 29 . The shaft 29 is journalled by a plurality of bearings 30 .
[0038] The solenoid mechanism section 27 operates a solenoid mechanism by a given instruction from a later-described control section 51 to move the moving plate 26 away from the photosensitive drum 7 . In synchronism with the moving of the moving plate 26 , the coupling member 22 a is moved in a direction away from the drum unit 21 . By doing so, the drive force from the gear 24 ceases to be transmitted to the drum unit 21 . Further, when the operation of the solenoid mechanism is stopped by a given instruction of the control section 51 , the coupling member 22 a is moved under a reaction force of the compression spring 28 to be connected to the coupling member 22 b . By doing so, the drive force from the gear 24 is transmitted to the photosensitive drum 7 .
[0039] The mechanism for transmitting a drive force from the drive unit 20 to the drum unit 21 may be so configured as to transmit a drive force by means of an electromagnetic clutch 35 , as shown in FIG. 4 . Further, a drive force transmitting structure may be provided by a one-way clutch 36 , configured to be rotated only in one direction and configured to be formed of shaft 23 and shaft 29 as shown in FIG. 5 .
[0040] FIG. 6 shows a mechanism of a phase matching section 31 for adjusting the phase of the photo-sensitive drum 7 . The phase matching section 31 is coupled to the shaft 29 of the photosensitive drum 7 . The phase matching section 31 is so arranged that a gear 31 a rotated in synchronism with the rotation of the shaft 29 of the photosensitive drum 7 is set in mesh with a gear 31 c which is driven by a drive source of motor 31 b . The motor 31 b has its drive controlled by the control section 51 . The phase matching section 31 is of a one-way clutch type such that a drive force from the motor 31 b is transmitted only when the gear 31 c is rotated in a direction opposite to that in which the gear 31 a is rotated. Further, a drum rotation angle read-out sensor 32 is set at a predetermined position near the shaft 29 to read out the rotation angle of the photosensitive drum 7 .
[0041] It is to be noted that, although the drum rotation angle read-out sensors 32 Y, 32 M, 32 C and 32 K are provided in a way to correspond to the photosensitive drums 7 Y, 7 M, 7 C and 7 K for respective colors, the phase matching section 31 is provided in a way to correspond to the photosensitive drums 7 Y, 7 M and 7 C other than that photosensitive drum serving as a standard for phase adjustment. This is because the rotation positions of these other photosensitive drums are adjusted to the reference photosensitive drum. As this standard drum, use is made, in this embodiment, of the photosensitive drum 7 K for K color.
[0042] Further, the rotation position of the photo-sensitive drum 7 has its given rotation standard position initially set as shown in FIG. 7 . The drum rotation angle reading-out sensor 32 reads out the rotation angle of the photosensitive drum 7 from the standard position. The rotation angle from the standard position is indicated by e.
[0043] FIG. 8 shows one practical arrangement of sensors at a portion of a downstream side of the transfer belt 6 which read out respective color lines for image formation on the transfer belt. A bar-like member 41 is provided somewhat above the transfer belt in a direction orthogonal to the longitudinal direction of the transfer belt 6 . Sensors 42 a , 42 b are arranged for detecting each color line transferred to a corresponding position at both end portions of the transfer belt 6 .
[0044] As shown in FIG. 9 , a schematic control structure of the color copier 1 comprises the control section 51 , scanner section 2 , memory section 52 , operation panel 53 , sheet supply section 4 , interface (I/F) section 54 and printer section 3 . Further, the control section 51 , scanner section 2 , memory section 52 , operation panel 53 , sheet supply section 4 , printer section 3 , and I/F section 54 are connected together via a bus line 56 .
[0045] The control section 51 comprises a CPU, ROM, RAM, etc., not shown. Based on a control program stored in the ROM, the control section 51 implements various kinds of operations on the color copier 1 . An adjusting section 57 , which adjusts a color mismatching, is provided in the control section 51 .
[0046] The scanner section 2 reads out image data from a document on the document glass 2 a as set out above. The memory section 52 stores image data, etc., of the document read out by the scanner section 2 . The sheet supply section 4 comprises cassettes for holding sheets to be supplied to the printer section 3 , a mechanism for supplying a sheet to the printer section 3 , etc., as shown in FIG. 1 .
[0047] The operation panel 53 receives a user's instruction from an input section 53 a under control of the control section 51 . Further, the operation panel 53 displays information to be notified to the user at a display section 53 b under control of the control section 51 . A switch is set by the user to an ON/OFF state. With the switch is in the ON state, a power source is rendered ON on the color copier 1 . The I/F section 54 is used to be connected to an external device, not shown.
[0048] The printer section 3 comprises the image forming sections 5 Y, 5 M, 5 C and 5 K for respective colors Y, M, C and K as set out above. In the image forming sections 5 Y, 5 M, 5 C, drum rotation angle reading-out sensors 32 Y, 32 M and 32 C and phase matching sections 31 Y, 31 M and 31 C are provided, respectively. The image forming section 5 K includes a drum section angle reading-out sensor 32 K but does not have a phase matching section because it includes the reference photosensitive drum 7 K. Further, a signal from the respective drum rotation reading-out sensor 32 is sent to the adjusting section 57 and a signal from the adjusting section 57 is sent to the phase matching section 31 .
[0049] With reference to FIG. 10 , an explanation will be made below about the process of the adjusting section 57 for adjusting the rotation position of the photo-sensitive drum 7 of each color.
[0050] In step ST 101 , the adjusting section 57 detects whether on not the power source is turned ON by rendering the switch 550 N. If the adjusting section detects the ON state of the power source, in step ST 202 , the adjusting section 57 controls the printer section 3 to form, for respective colors, lines at predetermined intervals at both end portions of the transfer belt 6 in a longitudinal direction of the photosensitive drum 7 . Although the lines are formed on the transfer belt 6 , lines for respective colors may be formed on a sheet coming from the sheet supply section 4 . If such lines are formed on a sheet, then the sheet involved becomes wasteful but it is advantageous to accurately detect the intervals between the lines by the sensors 42 a , 42 b.
[0051] In step ST 103 , the adjusting section 57 calculates, based on the information from the sensors 42 a , 42 b , the interval of lines for respective colors formed on the transfer belt 6 . FIG. 11 conceptually shows waveforms which are calculated from the line intervals for respective colors with the line interval and transfer belt's running direction plotted on the ordinate and abscissa, respectively. The phase displacement of the waveforms are caused by the rotation vibration of the photosensitive drum 7 . Since it is caused by the rotation vibration of the drum 7 , a waveform of substantially the same locus is described for each one cycle rotation of the drum 7 .
[0052] In step ST 104 , the adjusting section 57 calculates a phase displacement from the calculated waveform as described above. That is, with a waveform of the K color as a reference, calculation is made about each phase difference from those waveforms for Y, M and C colors. The phase of the waveform is such that, when the photosensitive drum 7 K for the K color, for example, is set to a position of angle θ, the interval of the waveform of the photosensitive drum 7 C is set to the widest position. At this time, with θ′ given as the widest waveform interval for the photosensitive drum 7 C spaced a distance L apart on the transfer belt 6 , a phase difference is so calculated as to satisfy θ′=θ+2πL/πD (D: the diameter of the respective photosensitive drum) with respect to the drum 7 K.
[0053] In step ST 105 , the adjusting section 57 calculates the photosensitive drum's rotation angle based on the phase displacement between the photo-sensitive drum 7 K as a standard and the photosensitive drum 7 Y, 7 M and 7 C.
[0054] In step ST 106 , the adjusting section 57 sets a monochrome mode for performing an image formation on the color copier 1 . In this mode setting, the photo-sensitive drum 7 K is set in close contact with the transfer belt 6 but the photosensitive drums 7 Y, 7 M and 7 C are set away from the transfer belt 6 . In this step ST 106 , even if the monochrome mode is not set, it is possible to replace it by an operation for spacing all the photosensitive drums 7 Y, 7 M, 7 C and 7 K away from the transfer belt 6 .
[0055] In step ST 107 , the adjusting section 57 operates the solenoid mechanism section 27 of the drive units 20 Y, 20 M and 20 C and prevents a drive force from being transmitted from the gear 24 .
[0056] In step ST 108 , the adjusting section 57 controls the phase matching sections 31 Y, 31 M and 31 C. That is, the rotation number of the motor for the phase matching sections 31 Y, 31 M and 31 C is rotation-controlled by the rotation angle calculated in step ST 104 . The rotation number of the photosensitive drums 7 Y, 7 M and 7 C at this time is read out by the rotation angle reading-out sensor 32 Y, 32 M and 32 C and, when the rotation is made through the calculated rotation angle, the adjusting section 57 stops the photosensitive drums 7 Y, 7 M and 7 C from being rotated.
[0057] In step ST 109 , the adjusting section 57 operates the solenoid mechanism section 27 of the drive units 20 Y, 20 M and 20 C and a drive force is transmitted from the corresponding gear 24 . This completes the process for adjusting the position of the drum 7 .
[0058] FIG. 12 shows practical waveforms calculated when the processes in steps ST 102 and ST 103 are done after adjustment has been made by the adjusting section 57 . As shown in FIG. 12 , adjustment is made to secure less phase displacement of the waveform. Since the rotation positions of the photosensitive drums 7 Y, 7 M and 7 C are so adjusted as to match the phase of the drum 7 K, it is possible to prevent color mismatching produced upon image formation. Further, the adjusting operation is performed each time to secure phase matching on the color copier 1 after the power source has been turned ON. Therefore, it is possible to cope with color mismatching which may be produced due to the rotation vibration resulting from ageing.
[0059] Further, at a time of the phase adjustment, the photosensitive drums 7 Y, 7 M and 7 C are spaced apart from the transfer belt 6 since the monochrome mode is set, and it is possible to prevent any damage to the transfer belt 6 at a time of making the phase adjustment.
[0060] Further, the phase adjustment is set at a time the power source is turned ON. However, the adjusting section 57 may be so configured as to include a count section for counting the number of copied sheets and a memory area for storing the number of sheets, such as 100 or 200 . In this case, the adjusting section 57 performs adjustment when the number counted by the count section reaches a set number of sheets. Further, a phase adjusting mode may be set to the input section 53 a of the operation panel 53 to adjust the phase of the photosensitive drum 7 and the above-mentioned process may perform when this mode is set. Further, it is possible to provide all these structures and perform phase adjustment the user wishes.
[heading-0061] (Second Embodiment)
[0062] An explanation will be made below about the second embodiment of the invention. The same reference numerals are employed to designate parts or elements corresponding to those shown in the first embodiment. A detailed description is omitted.
[0063] As shown in FIG. 13A , as phase matching section 31 ′ use is made of a rotation angle adjusting dial 31 ′ b provided on an end 31 ′ a of a substantially cylindrical body coupled to a photosensitive drum 7 . The dial 31 ′ is so configured as to be able to rotate through an angle of 360 as shown in FIG. 13B . The angle of the photosensitive drum 7 is adjusted in synchronism with the angle of the dial 31 ′ by the user. Even in this embodiment, a photosensitive drum 7 K serves as a reference photosensitive drum.
[0064] A key for an adjusting mode for adjusting the position of the photosensitive drum 7 is provided on an input section 53 a of an operation panel 53 . When this key is depressed by the user as an input operation, the processes in steps ST 102 to ST 105 as set out above are performed. That is, the phase mismatching of the photosensitive drums 7 Y, 7 M and 7 C relative to the photosensitive drum 7 K are calculated based on the interval of those lines detected by sensors 42 a , 42 b , and rotation angles for adjusting the rotation positions of the photosensitive drums 7 Y, 7 M and 7 C relative to the reference photosensitive drum 7 K are calculated, etc. And the rotation angle as a result of the process is displayed on a display section 53 b of the operation panel 53 b . The user, after seeing this display, rotates the dial 31 ′ b of the drums 7 Y, 7 M and 7 C through displayed angle and, while the angle is adjusted by the user, the photosensitive drums 7 Y, 7 M and 7 C are so set in a spaced-apart state as in steps ST 107 and ST 109 to prevent a drive force from being transmitted from a gear 24 . Setting the photosensitive drums 7 Y, 7 M and 7 C in close contact with, and away from, a transfer belt is accomplished by, for example, operating the input section 53 a of the operation panel 53 .
[0065] Even in such a structure, it is possible to prevent color mismatching which may be produced at the formation of an image on the color copier 1 . Since the adjustment of the dial 31 ′ b is performed by the user, a phase adjusting control structure can be simplified and a resultant color copier can be made lower in cost.
[0066] In both the embodiments above, it is possible to obtain a rotation angle through which the photo-sensitive drums 7 Y, 7 M and 7 C are rotated based on lines for respective colors which are formed at the end portions of the transfer belt 6 . As shown in FIG. 14 , however, a sensor 60 may be provided to read out color information or concentration information formed on the transfer belt 6 and, based on this information, any phase mismatch can be read out.
[0067] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the invention as defined by the appended claims and equivalents thereof. | An image forming apparatus is configured to develop a latent image corresponding to a line-like image of a predetermined pitch on photosensitive bodies provided for respective colors for a color image formation and rotatable about a predetermined axis and transfer the developed image to a transfer belt. The apparatus detects the presence or absence of any line from the transferred line-like image for respective colors and calculates a phase displacement, from a phase of a reference photosensitive drum, of the phases of the other photosensitive drums on the basis of waveforms calculated from the detected line pitches for respective colors. The apparatus adjusts the rotation positions of these other photosensitive drums to allow the phases of these other photosensitive bodies to be substantially matched to the phase of that given photosensitive body. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. patent application Ser. No. 10/710,246, filed Jun. 29, 2004, now U.S. Pat. No. 7,191,831 the content of which is incorporated herein by reference of all purposes.
BACKGROUND
Wells are generally drilled into the ground to recover natural deposits of oil and gas, as well as other desirable materials, that are trapped in geological formations in the Earth's crust. A well is drilled into the ground and directed to the targeted geological location from a drilling rig at the Earth's surface.
Once a formation of interest is reached, drillers often investigate the formation and its contents through the use of downhole formation evaluation tools. Some types of formation evaluation tools from part of a drill string and are used during the drilling process. These are called, for example, “logging-while-drilling” (“LWD”) tools or “measurement-while-drilling” (“MWD”) tools. Other formation evaluation tools are used sometime after the well has been drilled. Typically, these tools are lowered into a well using a wireline for electronic communication and power transmission. These tools are called “wireline” tools.
One type of wireline tool is called a “formation testing tool.” The term “formation testing tool” is used to describe a formation evaluation tool that is able to draw fluid from the formation into the downhole tool. In practice, a formation testing tool may involve many formation evaluation functions, such as the ability to take measurements (i.e., fluid pressure and temperature), process data and/or take and store samples of the formation fluid. Thus, in this disclosure, the term formation testing tool encompasses a downhole tool that draws fluid from a formation into the downhole tool for evaluation, whether or not the tool stores samples. Examples of formation testing tools are shown and described in U.S. Pat. Nos. 4,860,581 and 4,936,139, both assigned to the assignee of the present invention.
During formation testing operations, downhole fluid is typically drawn into the downhole tool and measured, analyzed, captured and/or released. In cases where fluid (usually formation fluid) is captured, sometimes referred to as “fluid sampling, ” fluid is typically drawn into a sample chamber and transported to the surface for further analysis (often at a laboratory).
As fluid is drawn into the tool, various measurements of downhole fluids are typically performed to determine formation properties and conditions, such as the fluid pressure in the formation, the permeability of the formation and the bubble point of the formation fluid. The permeability refers to the flow potential of the formation. A high permeability corresponds to a low resistance to fluid flow. The bubble point refers to the fluid pressure at which dissolved gasses will bubble out of the formation fluid. These and other properties may be important in making downhole decisions.
Another downhole tool typically deployed into a wellbore via a wireline is called a “coring tool.” Unlike the formation testing tools, which are used primarily to collect sample fluids, a coring tool is used to obtain a sample of the formation rock.
A typical coring tool includes a hollow drill bit, called a “coring bit,” that is advanced into the formation wall so that a sample, called a “core sample,” may be removed from the formation. A core sample may then be transported to the surface, where it may be analyzed to assess, among other things, the reservoir storage capacity (called porosity) and permeability of the material that makes up the formation; the chemical and mineral composition of the fluids and mineral deposits contained in the pores of the formation; and/or the irreducible water content of the formation material. The information obtained from analysis of a core sample may also be used to make downhole decisions.
Downhole coring operations generally fall into two categories; axial and sidewall coring. “Axial coring,” or conventional coring, involves applying an axial force to advance a coring bit into the bottom of the well. Typically, this is done after the drill string has been removed, or “tripped,” from the wellbore, and a rotary coring bit with a hollow interior for receiving the core sample is lowered into the well on the end of the drill string. An example of an axial coring tool is depicted in U.S. Pat. No. 6,006,844, assigned to Baker Hughes.
By contrast, in “sidewall coring,” the coring bit is extended radially from the downhole tool and advanced through the side wall of a drilled borehole. In sidewall coring, the drill string typically cannot be used to rotate the coring bit, nor can it provide the weight require to drive the bit into the formation. Instead, the coring tool itself must generate both the torque that causes the rotary motion of the coring bit and the axial force, called weight-on-bit (“WOB”), necessary to drive the coring bit into the formation. Another challenge of sidewall coring relates to the dimensional limitations of the borehole. The available space is limited by the diameter of the borehole. There must be enough space to house the devices to operate the coring bit and enough space to withdraw and store a core sample. A typical sidewall core sample is about 1.5 inches (˜3.8 cm) in diameter and less than 3 inches long (˜7.6 cm), although the sizes may vary with the size of the borehole. Examples of sidewall coring tools are shown and described in U.S. Pat. Nos. 4,714,119 and 5,667,025, both assigned to the assignee of the present invention.
Like the formation testing tool, coring tools are typically deployed into the wellbore on a wireline after drilling is complete to analyze downhole conditions. The additional steps of deploying a wireline formation testing tool, and then also deploying a wireline coring tool further delay the wellbore operations. It is desirable that the wireline formation testing and wireline coring operations be combined in a single wireline tool. However, the power requirements of conventional coring tools have been incompatible with the power capabilities of existing wireline formation testers. A typical sidewall coring tool requires about 2.5-4 kW of power. By contrast, conventional formation testing tools are typically designed to generate only about 1 kW of power. The electronic and power connections in a formation testing tool are generally not designed to provide the power to support a wireline sidewall coring tool.
it is noted that U.S. Pat. No. 6,157,893, assigned to Baker Hughes, depicts a drilling tool with a coring tool and a probe. Unlike wireline applications, drilling tools have additional power capabilities generated from the flow of mud through the drill string. The additional power provided by the drilling tool is currently unavailable for wireline applications. Thus, there remains a need for a wireline assembly with both fluid sampling and coring capabilities.
It is further desirable that any downhole tool with combined coring and formation testing capabilities provide one or more of the following features, among others: enhanced testing and/or sampling operation, reduced tool size, the ability to perform coring and formation testing at a single location in the wellbore and/or via the same tool, and/or convenient and efficient combinability of separate coring and sampling tools into the same component and/or downhole tool.
SUMMARY
In one aspect of the disclosure, a downhole tool having a housing and a coring bit disposed therein is disclosed. The coring bit is extendable from the housing for engaging a wellbore wall, and the sample chamber stores at least two formation samples obtained with the coring bit. The sample chamber further includes at least two portions for separately storing the formation samples.
In another aspect of the disclosure, a sample storage assembly for a downhole coring tool is disclosed. The sample storage assembly includes a first portion for receiving a first sample, and a second portion for receiving a second sample, such that the first and second samples are selectively isolated.
In another aspect of the disclosure, a method of storing a plurality of samples obtained from a subterranean formation is disclosed. The method includes removing a first sample from a coring bit, placing the first sample into an opening defining an entrance into a storage assembly, sealing the first sample in a first portion of the storage assembly, removing a second sample from a coring bit, placing the second sample into the opening, and sealing the second sample in a second portion of the storage assembly, wherein the first and second samples are isolated from each other.
In yet another aspect of the disclosure, a method of storing a plurality of samples obtained from a subterranean formation is disclosed. The method placing a first sample into a first portion of a storage assembly, the first portion having a first end and a second end, sealing the second end of the first portion, thereby defining a first end of a second portion, and placing a second sample into the second portion of the storage assembly.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a schematic of a wireline assembly that includes a formation testing tool and a coring tool.
FIG. 2A is a schematic of a prior art coring tool.
FIG. 2B shows a schematic of a coring tool in accordance with one embodiment of the invention.
FIG. 3 shows a chart that shows the efficiency of a coring motor as a function of power output for two different flow rates of hydraulic fluid to a coring motor.
FIG. 4 shows a graph of the torque required by a coring bit as a function of rotary speed and rate of penetration.
FIG. 5 shows a schematic of a weight-on-bit control system in accordance with one embodiment of the invention.
FIG. 6 shows a graph showing the mechanical advantage of a coring bit as a function of bit position for a typical coring bit.
FIG. 7A shows a cross section of a field joint before make-up, in accordance with one embodiment of the invention.
FIG. 7B shows a cross section of a field joint prior to make-up, in accordance with one embodiment of the invention.
FIG. 7C shows an enlarged section of a cross section of a field joint prior to make-up, in accordance with one embodiment of the invention.
FIG. 8A shows a cross section of a portion of a downhole tool in accordance with one embodiment of the invention.
FIG. 8B shows a cross section of a portion of a downhole tool in accordance with one embodiment of the invention.
FIG. 8C shows a cross section of a portion of a downhole tool in accordance with one embodiment of the invention.
FIG. 9 shows a cross section of a portion of a downhole tool in accordance with one embodiment of the invention.
FIG. 10 shows one embodiment of a method in accordance with the invention.
FIG. 11 shows one embodiment of a method in accordance with the invention.
FIG. 12 shows one embodiment of a method in accordance with the invention.
DETAILED DESCRIPTION
Some embodiments of the present invention relate to a wireline assembly that includes a low-power coring tool that may be connected to a formation testing tool. Other embodiments of the invention relate to a field joint that may be used to connect a coring tool to a formation testing tool. Some embodiments of the invention relate to a downhole tool that includes a combined formation testing and a coring assembly.
FIG. 1 shows a schematic of a wireline apparatus 101 deployed into a wellbore 105 from a rig 100 in accordance with one embodiment of the invention. The wireline apparatus 101 includes a formation testing tool 102 and a coring tool 103 . The formation testing tool 102 is operatively connected to the coring tool 103 via field joint 104 .
The formation testing tool 102 includes a probe 111 that may be extended from the formation testing tool 102 to be in fluid communication with a formation F. Back up pistons 112 may be included in the tool 101 to assist in pushing the probe 111 into contact with the sidewall of the wellbore and to stabilize the tool 102 in the borehole. The formation testing tool 102 shown in FIG. 1 also includes a pump 114 for pumping the sample fluid through the tool, as well as sample chambers 113 for storing fluid samples. Other components may also be included, such as a power module, a hydraulic module, a fluid analyzer module, and other devices.
The coring tool 103 includes a coring assembly 125 with a coring bit 121 , a storage area 124 for storing core samples, and the associated control mechanisms 123 (e.g., the mechanisms shown in FIG. 5 ). In some embodiments, as will be described later with reference to FIG. 2B , the coring tool 103 consumes less than about 2 kW of power. In certain specific embodiments, a coring tool 103 may consume less than about 1.5 kW, and in at least one embodiment, a coring tool 103 consumes less than 1 kW. This makes it desirable to combine the coring tool 103 with the formation testing tool 102 . The brace arm 122 is used to stabilize the tool 101 in the borehole (not shown) when the coring bit 121 is functioning.
The apparatus of FIG. 1 is depicted as having multiple modules operatively connected together. However, the apparatus may also be partially or completely unitary. For example, as shown in FIG. 1 , the formation testing tool 102 may be unitary, with the coring tool housed in a separate module operatively connected by field joint 104 . Alternatively, the coring tool may be unitarily included within the overall housing of the apparatus 101 .
Downhole tools often include several modules (i.e., sections of the tool that perform different functions). Additionally, more than one downhole tool or component may be combined on the same wireline to accomplish multiple downhole tasks in the same wireline run. The modules are typically connected by “field joints.” such as the field joint 104 of FIG. 1 . For example, one module of a formation testing tool typically has one type of connector at its top end and a second type of connector at its bottom end. The top and bottom connectors are made to operatively mate with each other. By using modules and tools with similar arrangements of connectors, all of the modules and tools may be connected end to end to form the wireline assembly. A field joint may provide an electrical connection, a hydraulic connection, and a flowline connection, depending on the requirements of the tools on the wireline. An electrical connection typically provides both power and communication capabilities.
In practice, a wireline tool will generally include several different components, some of which may be comprised of two or more modules (e.g., a sample module and a pumpout module of a formation testing tool). In this disclosure, “module” is used to describe any of the separate tools or individual tool modules that may be connected in a wireline assembly. “Module” describes any part of the wireline assembly, whether the module is part of a larger tool or a separate tool by itself. It is also noted that the term “wireline tool” is sometimes used in the art to describe the entire wireline assembly, including all of the individual tools that make up the assembly. In this disclosure, the term “wireline assembly” is used to prevent any confusion with the individual tools the make up the wireline assembly (e.g., a coring tool, a formation testing tool and an NMR tool may all be included in a single wireline assembly).
FIG. 2A is a schematic of a prior art wireline coring tool 210 . The coring tool 210 includes a coring assembly 204 with a hydraulic coring motor 202 that drives a coring bit 201 . The coring bit 201 is used to remove a core sample (not shown) from a formation.
In order to drive the coring bit 201 into the formation, it must be pressed into the formation while it is being rotated. Thus, the coring tool 210 applies a weight-on-bit (“WOB”) (i.e., the force that presses the coring bit 201 into the formation) and a torque to the coring bit 201 . The coring tool 210 shown in FIG. 2A includes mechanisms to apply both. Examples of a coring apparatus with mechanisms for applying WOB and torque are disclosed in U.S. Pat. No. 6,371,221, assigned to the assignee of the present invention.
The WOB in prior art coring tool 210 is generated by an AC motor 212 and a control assembly 211 that includes a hydraulic pump 213 , a feedback flow control (“FFC”) valve 214 , and a kinematics piston 215 . The AC motor 212 supplies power to the hydraulic pump 213 . The flow of hydraulic fluid from the hydraulic pump 213 is regulated by the FFC valve 214 , and the pressure of hydraulic fluid drives the kinematics piston 215 to apply a WOB to the coring bit 201 .
The torque is supplied by another AC motor 216 and a gear pump 217 . The second AC motor 216 drives the gear pump 217 , which supplies a steady flow of hydraulic fluid to the hydraulic coring motor 202 . The hydraulic coring motor 202 , in turn, imparts a torque to the coring bit 201 that causes the coring bit 201 to rotate. Typically, the gear pump 217 pumps about 4.5 gpm (˜17 lpm) of hydraulic fluid at a pressure of about 500 psi (˜3.44 MPa). This generates a torque of about 135 in.-oz. (˜0.953 N-M) while consuming between 2.5 kW and 4.0 kW, depending on the efficiency of the system. A typical operating speed of the coring bit 201 is about 3,000 rpm.
Referring now to FIG. 2B , a coring tool 220 in accordance with one embodiment of the invention uses two brushless DC motors 222 , 226 in place of the AC motors of FIG. 2A . The brushless DC motors 222 , 226 are designed to operate more efficiently than the AC motors, enabling the tool 220 to be operated with less power. The coring tool 220 of FIG. 2B may be used, for example, in the coring tool 103 of FIG. 1 . While the lower power capabilities of the coring tool make it usable in wireline applications (with or without an accompanying formation tester), it may also be usable in other downhole tools.
The first brushless DC motor 222 is operatively connected to a control assembly 221 including a hydraulic pump 223 , a valve 224 , and a kinematics piston 225 . The DC motor 222 drives the hydraulic pump 223 , and hydraulic fluid is pumped through a valve 224 . The valve 224 is preferably a pulse-width modulated (“PWM”) solenoid valve. The valve may be operated in a manner to control the WOB. As will be described with reference to FIGS. 6A and 6B , below, the solenoid valve may be controlled so that a kinematics piston 225 applies a constant WOB or so that the WOB is changed to maintain a constant torque on the coring bit 201 .
A second brushless DC motor 226 drives a high pressure gear pump 227 that supplies hydraulic fluid to the hydraulic coring motor 202 . In some embodiments, the high pressure gear pump 227 is use to deliver hydraulic fluid at a higher pressure and a lower flow rate than in prior art coring tools. This system provides what is referred to herein as “low-power.” For example, the coring tool 220 shown in FIG. 2B may pump hydraulic fluid at a rate of about 2.5 gpm (˜9.46 lpm) at a pressure of about 535 psi (˜3.7 MPa). The reduced flow rate of hydraulic fluid to the hydraulic coring motor 202 will operate the coring bit 201 at a lower speed. For example, a flow rate of 2.5 gpm at 535 psi (˜9.46 lpm and ˜3.7 MPa) may generate a coring bit speed of about 1,600 rpm.
Such a configuration may enable a coring tool 220 to consume less than 2 kW of power. In certain embodiments, a coring tool 220 may consume less than 1 kW of power.
FIG. 3 shows a graph 300 of the efficiency of a coring motor (Y-axis in %) versus the power output (X-axis in Watts) for two coring tools. This graph compares the efficiency versus power for the coring tool 210 of FIG. 2A and the coring tool 220 of FIG. 2B , within the operating range of up to about 300 Watts of power.
The first curve 301 shows the efficiency of coring motor 202 of FIG. 2A at a flow rate of 4.5 gpm (˜17.03 lpm). At 300 W, a typical maximum power output for a coring tool, the efficiency reaches its maximum 303 of about 30%. The second curve 302 shows the efficiency of the coring motor 202 of FIG. 2B at a flow rate of 2.5 gpm (˜9.46 lpm). The second curve 302 shows a maximum efficiency 304 of over 50% at the 300 W of output. Thus, by reducing the flow rate from 4.5 gpm (˜17.03 lpm) to 2.5 gpm (˜9.46 lpm), the efficiency of the coring motor can be increased to over 50%. At 300 W of power output, a coring motor with a 50% efficiency would require less than 1 kW of input power. This reduction in the required power enables a coring tool to be used in conjunction with a formation testing tool.
FIG. 4 shows a three-dimensional graph 400 of the required torque based on rpm and rate of penetration (“ROP”) for a typical formation. A typical coring tool drills a core sample in about 2-4 minutes. In that range, the required torque does not change much with respect to the speed of the drill bit. For example, at the point 402 for 3,000 rpm and 2 min/core, the coring tool will require slightly more than 100 in.-oz. of torque (˜0.706 N-M). At the point 404 for 1,500 rpm and 2 min/core, the drill bit also requires slightly more than 100 in.-oz. of torque (˜0.706 N-M). Thus, a coring tool in accordance with certain embodiments of the invention is designed to drill and obtain a core sample in the same amount of time as prior art coring tools, while using low power.
Typical formation testing tools are generally incapable of transmitting the power required by prior art coring tools. The low-power coring tool of FIG. 2B may consume less than about 1 kW of power. With this reduced power requirement, one or more embodiments of a low-power coring tool may be combined with a formation testing tool so that both fluid samples and core samples may be obtained during the same wireline run. An additional advantage is that a fluid sample and a core sample may be obtained from the same location in the borehole, enabling the analysis of both the formation rock and the fluid that it contains. The coring and testing tools may be positioned to perform tests and/or take samples from the same or relative locations. Still, a person having ordinary skill in the art will realize that one or more of the advantages of the present invention may be realized even without the use of a low-power coring tool.
FIG. 5 shows a control assembly 500 for regulating the WOB on a coring bit. The control assembly may be used, for example as the control assembly for the coring tool of FIG. 2B . The control assembly 500 includes a hydraulic pump 503 that pumps hydraulic fluid through a hydraulic line 506 to a kinematics piston 507 . The hydraulic pump 503 draws hydraulic fluid from a reservoir 505 and pumps the hydraulic fluid to the kinematics piston 507 though a flowline 506 . The kinematics piston 507 converts the hydraulic pressure to a force that acts on the coring motor 502 to provide a WOB. A valve 504 in a relief line 509 enables hydraulic fluid to be diverted from the flowline 506 in a controlled manner so that the hydraulic pressure in the flowline 506 , and ultimately the kinematics piston 507 , is precisely controlled.
The valve 504 may be a pulse-width modulated (“PWM”) solenoid valve. The valve 504 is operatively connected to a PWM controller 508 . The controller 508 operates the valve based on inputs from sensors 521 , 531 . Preferably, a PWM solenoid valve (i.e., valve 504 ) is switched between the open position and the closed position at a high frequency. For example, the valve 504 may be operated at a frequency between about 12 Hz and 25 Hz. The fraction of the time that the valve 504 is open will control the amount of hydraulic fluid that flows through the valve 504 . The greater flow rate through the valve 504 , the lower the pressure in the flowline 506 and the lower the WOB applied by the kinematics piston 507 . The smaller the flow rate through the valve 504 , the greater the pressure in the flowline 506 and the greater the WOB applied by the kinematics piston 507 .
A PWM controller 508 may be operatively connected to one or more sensors 521 , 531 . Preferably, the PWM controller 508 is coupled to at least a pressure sensor 521 and a torque sensor 531 . The pressure sensor 521 is coupled to the flowline 506 so that it is responsive to the hydraulic pressure in the flowline 506 , and the torque sensor 531 is coupled to the coring motor 502 so that it is responsive to the torque output of the coring motor 502 .
The valve 504 may be controlled so as to maintain an operating characteristic at a desired value. For example, the valve 504 may be controlled to maintain a substantially constant WOB. The valve 504 may also be controlled to maintain a substantially constant torque output of the coring motor 502 .
When the valve 504 is controlled to maintain a constant WOB, the PWM controller 508 will control the valve 504 based on input from the pressure sensor 521 . When the WOB becomes too high, the controller 508 may operate the valve 504 to be in an open position a higher fraction of the time. Hydraulic fluid in the flow line 506 may then flow through the valve 504 at a higher flowrate, which will reduce the pressure to the kinematics piston 507 , thereby reducing the WOB.
Conversely, when the WOB falls below the desired pressure, the controller 508 may operate the valve 504 to be in an closed position a higher fraction on the time. Hydraulic fluid in the flow line 506 flows through the valve 504 at a lower flowrate, which will increase the pressure to the kinematics piston 507 , thereby increasing the WOB.
When controlling the system based on torque, the torque sensor 531 measures the torque that is applied to the coring motor. For a given rotary speed, the torque applied by the coring motor 502 will depend on the formation properties and the WOB. The controller 518 operates the valve 504 so that the torque output of the coring motor 502 remains near a constant level. The desired torque output may vary depending on the tool and the application. In some embodiments, the desired torque output is between 100 in.-oz. (˜0.706 N-M) and 400 in.-oz. (˜2.82 N-M). In some embodiments, the desired torque output is about 135 in.-oz. (˜0.953 N-M). In other embodiments, the desired torque output is about 250 in.-oz. (˜1.77 N-M).
When the torque output of the coring motor 502 is above the desired level, the controller 508 operates the valve 504 to be open a higher fraction of the time. A higher flow rate of hydraulic fluid flows through the valve 504 . This decreases the pressure in the flow line 506 , which decreases the hydraulic pressure in the kinematics piston 507 . A decreased pressure in the kinematics piston 507 will result in a decreased WOB and a decreased torque required to maintain the rotary speed of the coring bit (not shown in FIG. 5 ). Thus, the torque output of the coring motor 502 will return to the desired level.
When the torque output of the coring motor 502 is below the desired level, the controller 508 operates the valve 504 to be in a closed position a higher fraction of the time. Hydraulic fluid flows through the valve 504 at a lower flow rate. This increases the pressure in the flow line 506 , which increases the hydraulic pressure in the kinematics piston 507 . An increased pressure in the kinematics piston 507 will result in an increased WOB and an increased torque required to maintain the rotary speed of the coring bit.
FIG. 5 shows a control system 500 that may control WOB to maintain a constant WOB or to maintain a constant torque on the coring bit. Other systems may include only one sensor and control a valve based on only one sensor measurements. Such embodiments do not depart from the scope of the invention.
FIG. 5 shows a configuration where, for example, the valve 504 is connected in a relief line 509 that flows to a reservoir 508 . The invention, however, is not so limited. Other configurations are envisioned, such as where the valve diverts flow in other ways, as is known in the art. Additionally, various combinations of pressure and/or torque control may be used.
FIG. 6 is a graph that shows the mechanical advantage (Y-axis) for the WOB based on bit position (X-axis in inches/centimeters) for a typical coring tool. The plot 601 shows that the mechanical advantage varies over the range of the bit position. Because the mechanical advantage varies, the actual WOB will also vary with bit position, even if the hydraulic pressure applied to the kinematics piston (e.g., 516 in FIG. 5 ) is constant. This graph indicates that carefully maintaining the hydraulic pressure will not generally maintain a constant WOB. Thus, in some situations it is preferable to control hydraulic pressure based on torque.
FIGS. 7A and 7B show cross sections of a field joint 700 in accordance with one embodiment of the invention. The field joint 700 may be used, for example, as the field joint 104 of FIG. 1 . This field joint may be used to combine various components or modules of any downhole tool, such as a wireline, coiled tubing, drilling or other tool. FIG. 7A shows an upper module 701 and a lower module 702 just before make-up. The upper module 701 includes a cylindrical sleeve 706 into which the lower module 702 fits.
The upper module 701 includes a male flowline connector 711 with seals 727 to prevent fluid from passing around the mate flowline connector 711 . The male flowline connector 711 may, for example, be threaded onto the upper module 701 (e.g., at area shown generally at 712 ). A female flowline connector 751 in the lower module 702 is positioned to receive the male flowline connector 711 when the field joint 700 is made-up (made-up condition shown in FIG. 7B ). The flowline connector 711 connects the flowline 717 in the upper module 701 to the flowline 757 in the lower module 702 so that there is fluid communication between the flow lines 717 , 757 .
The upper module 701 also includes a female socket bulkhead 714 . Socket holes 753 are located in the female socket bulkhead 714 . The socket holes 753 are positioned in the upper module 701 to prevent extraneous fluids from being trapped or collected in the socket holes 753 .
The lower module 702 includes a male pin bulkhead 754 with male pins 713 that extend upwardly from male pin bulkhead 754 . The male pin bulkhead 754 and the male pins 713 are disposed in a protective sleeve 773 . In some embodiments, the protective sleeve 773 is slightly higher than the top of the male pins 713 . In some embodiments, the male pin bulkhead 754 is moveable with respect to the lower module 702 and the protective sleeve 773 . For example, FIG. 7A shows a spring 780 that pushes the male pin bulkhead 754 into an upper most position.
Optionally, the upper surface of the male pin bulkhead 754 is covered by an interfacial seal 771 that is bonded to the top of bulkhead 754 and has raised bosses that seal around each male pin 713 . The interfacial seal 771 is shown in more detail in FIG. 7C . The male pins 713 extend upwardly from the male pin bulkhead 751 . A interfacial seal 771 is disposed at the top of the male pin bulkhead 754 . The interfacial seal 771 is preferably an elastomeric material, such as rubber, disposed around the male pins 713 to prevent fluid from entering the male pin bulkhead 754 and interfering with any circuitry that may be located inside the male pin bulkhead 754 . Additionally, the interfacial seal 771 seals against the face of bulkhead 714 to force fluid from the space between the male pin bulkhead 754 and the female socket bulkhead 714 . FIG. 7C shows a close-up made-up position. The raised bosses around each pin on the interfacial seal 771 seals the female socket holes 753 so that fluid may not enter the electrical connection area once the modules 701 , 702 are made up. This seal configuration is used to isolate each pin/socket electrically from other pins and from the tool mass.
The protective sleeve 773 may be perforated or porous. This enables fluids trapped within the protective sleeve 773 to flow through the protective sleeve to a position where the fluids will not interfere with the electrical connection between the male pins 713 and the female socket holes 753 when the field joint 700 is made-up.
FIG. 7B shows a cross section of the field joint 700 after make-up. The lower module 702 is positioned inside the cylindrical sleeve 706 of the upper module 701 . The seals 765 (e.g., o-rings) on the lower module 702 seal against the inside wall of the cylindrical housing 706 to prevent fluid from entering the field joint 700 .
The male flowline connector 711 of the upper module 701 is received in the female flowline connector 751 of the lower module 702 . Seals 728 on the male flowline connector 711 seal against the inner surface of the female flowline connector 751 to prevent fluid from flowing around the flow connector 711 . In the made-up position, the male flow connector 711 establishes fluid communication between the flowline 717 in the upper module 701 and the flow line 757 in the lower module 702 .
It is noted that this description refers to seals that are positioned in one member to seal against a second member. A person having ordinary skill in the art would realize that a seal could be disposed in the second member to seal against the first. No limitation is intended by any description of a seal being on or disposed in a particular member. Alternate configurations do not depart from scope of the invention.
In the made-up position, the female socket bulkhead 714 pushes downwardly on the male pin bulkhead 754 . The spring 780 allows for the downward movement of male pin bulkhead 754 . The male pins 713 are positioned in the female socket holes 753 to make electrical contact. The female socket bulkhead 714 is positioned at least partially inside the protective sleeve 773 .
In the field joint shown in FIG. 7B , the protective sleeve 773 remains stationary with respect to the lower module 702 . The male pins 713 are also preferably located within the protective sleeve 773 . During make-up, the female pins bulkhead fits into the protective sleeve 773 to mate with the male pins 713 on the male pin bulkhead 754 , while pushing the male pin bulkhead 754 downwardly.
FIG. 7C shows a close-up view of one section of the field joint ( 700 in FIGS. 7A and 7B ) in the made-up position. The lower face of female socket bulkhead 714 is positioned against the interfacial seal 771 on the top of the male pin bulkhead 754 . The male pins 713 are received in the female socket holes 753 . The interfacial seal 771 seals the female socket holes 753 so that fluid cannot enter the electrical contact area once the modules 701 , 702 are made-up.
The protective sleeve 773 may include a seal 775 . In the non-made-up position (shown in FIG. 7A ), the seal 775 seals against the male pin bulkhead 754 to prevent fluid from entering the lower module ( 702 in FIGS. 7A and 7B ). In the made-up position in FIGS. 7B and 7C , the female socket bulkhead 714 is positioned to be in contact with the seal 775 . In the made-up configuration, the seal 775 prevents fluid in the field joint from entering the area between the male pin bulkhead 754 and the female pin bulkhead 714 and interfering with the electrical contact. The seal 775 is also used to prevent fluid in the field joint from entering the lower module 702 .
As discussed above, the protective sleeve 773 may be perforated or porous to allow fluid to flow through the protective sleeve 773 . The protective sleeve 773 may be porous above the seal 775 , but fluid cannot flow through the protective sleeve 773 below the seal 775 . The seal 775 prevents fluid from flowing through the porous protective sleeve 773 and into a position between the male pin bulkhead 754 and the female pin bulkhead 714 , and into the lower module 702 .
FIGS. 8 and 9 show formation evaluation tools that include both coring and sampling capabilities. Such a tool may be a wireline tool or it may form part of other downhole tools, such as a drilling tool, coiled tubing tool, completion tool or other tool.
FIG. 8A shows a cross section of a downhole tool 800 with a combined formation testing and coring assembly 801 in accordance with one embodiment of the invention. The combined assembly may be positioned in the downhole tool or housed in a module combinable with the downhole tool.
The downhole tool 800 has a tool body 802 that surrounds the combined assembly 801 . An opening 804 in the roof body 802 enables core samples and fluid samples to be obtained from the formation. The opening 804 is preferably selectively closable to prevent the flow of fluid into the downhole tool. The combined assembly 801 includes a sampling block 806 . The sampling block 806 is positioned adjacent to the opening 804 so that the sampling block 806 has access to the opening 804 .
The sampling block 806 may include a fluid probe 807 and a coring bit 808 on adjacent sides. The sampling block 806 may be rotated so that either of the fluid probe 807 and the coring bit 808 is in a position to access the opening 804 . FIG. 8A shows a sampling block 806 in a position with the fluid probe 807 in a position to access the opening 804 .
The exact design of a fluid probe is not intended to limit the invention. The following description is provided only as an example. The fluid probe 807 includes a sealing surface 810 , such as a packer, for pressing against the borehole wall (not shown). When the sealing surface 810 creates a seal against the borehole wall, the flowline 812 in the fluid probe 807 is placed in fluid communication with the formation. The sealing surface 810 may comprise a packet or other seal to establish fluid communication between the flowline and the formation.
As shown in FIG. 8A , a tubing 813 may be used to connect the flowline 812 in the sample block 806 to the fluid sample line 814 in the tool 800 . The connection between the flowline 812 and the tubing 813 puts the sample probe 807 in fluid communication with fluid sample line 814 .
The tubing 813 is preferably a flexible tubing that maintains the connection between the second flowline 812 and the fluid sample line 814 when the sampling block 806 is rotated. The tubing 813 enables relative movement between the flowline 812 in the sample block 806 and the fluid sample line 814 in the tool 800 , while still maintaining the fluid communication. For example, FIG. 8B shows the tool 800 with the sample block 806 rotated so that the coring bit 808 is adjacent to the opening 804 . The tubing 813 has also moved so that fluid communication is still maintained between the flowline 812 in the sample block 806 and the fluid sample line 814 in the tool 800 .
In some embodiments, the tubing 813 is a telescoping hard tubing that allows for a dynamic range of positions. Other types of tubing or conduit may be used without departing from the scope of the invention.
To obtain a sample, the sample block 806 extends through the opening 804 so that the sealing surface 810 (e.g., a packer, as shown in FIGS. 8A and 8B ) contacts the formation (not shown). The sealing surface 810 presses against the formation so that the flowline 812 is in fluid communication with the formation. Formation fluid may be drawn into the tool body 802 through the flowline 812 .
The coring bit 808 in the sample block 806 may be advanced into the formation to obtain a core sample of the formation material. FIG. 8B shows the tool 800 with the sample block 806 rotated so that the coring bit 808 is adjacent to the opening 804 . In this position, the coring bit 808 may be extended to take a core sample from the formation (not shown). Once a core sample is captured in the coring bit 808 , the coring bit 808 may be retracted back into the tool 800 . FIG. 8B shows the coring bit 808 in a retracted position.
Referring again to FIG. 8A , once a core sample is captured in the coring bit 808 , the sampling block 806 may be rotated so that the coring bit 808 is in a vertical position. From this position, a core pusher 823 may push the sample core (not shown from the coring bit 808 into a core passage 822 . In some embodiments, the core may be stored in the core passage 822 . In other embodiments, the core passage 822 may lead to a core sample storage mechanism, such as the one shown in FIG. 8C .
FIG. 8C shows a core sample storage chamber 850 in accordance with one embodiment of the invention. The core sample storage chamber 850 may be located just below a coring bit and ejection mechanism, such as the coring bit 808 and core pusher 823 shown in FIG. 8A . A core sample may be moved or passed into the core sample chamber 850 so that it may be retrieved at a later time for analysis.
A core sample chamber 850 may include gate valves 852 , 853 . The gate valves 852 , 853 may be used to isolate sections of the core sample chamber 850 into separate compartments so that a plurality of core samples may be stored without contamination between the samples. For example, lower gate valve 853 may be closed in preparation for storing a core sample. A core sample may then be moved into the core sample chamber 850 , and the lower gate valve 853 will isolate the core sample from anything below the lower gate valve 853 (e.g., previously collected core samples). Once the core sample is in place, the upper gate valve 852 may be closed to isolate the core sample from anything above the upper gate valve 852 (e.g., later collected core samples). Using a plurality of gate valves (e.g., valves 852 , 853 ), a core sample chamber may be divided into separate compartments that are isolated from other compartments.
It is noted that isolation mechanisms other than gate valves may be used with the invention. For example, an iris valve or an elastomeric valve may be used to isolate a compartment in a core sample chamber. The type of valve is not intended to limit the invention.
In some embodiments, a core sample chamber 850 may be connected to the fluid sample line 814 by a fill line 857 . The fill line may include a fill valve 856 for selectively putting the core sample chamber 850 in fluid communication with the fluid sample line 814 . In some embodiments, the core sample chamber 850 may be connected to the borehole environment through an ejection line 855 . An ejection valve 854 may be selectively operated to put the core sample chamber 850 in fluid communication with the borehole. The term “borehole” is used to the inside of the borehole is sealed from the formation. Where the flowline (e.g., 812 in FIG. 8 A) is in fluid communication with the formation, in some embodiments, the ejection line 855 is in fluid communication with the borehole.
The fill line 857 enables a fluid sample to be stored in the same compartment of a core sample chamber as the sample core that was taken from the same position in the borehole. Once a core sample in a stored position (i.e., between gate valves 852 , 853 , which are closed), the fill valve 856 and sample fluid may be pumped into the core sample chamber, in the same compartment as the core sample. The ejection line 855 enables fluid to be ejected into the borehole until the core sample is completely immersed in the native formation fluid from that location.
In FIG. 8C , the fill line 857 is connected to a compartment (i.e., between gate valves 852 , 853 ) near the top of the compartment, and the ejection line 855 is connected near the bottom of the compartment. A core sample may be stored in a position with the edge that formed part of the borehole wall facing down. In this position, the areas of the core sample that have been affected by mud invasion are near the bottom of the core sample. By connecting the fill and ejection lines 857 , 855 at the top an bottom of the compartment, respectively, the sample fluid may flush the mud filtrate out of the core sample as the compartment is being filled with native formation fluid (i.e., a fluid sample).
FIG. 9 shows a cross section of a portion of a coring tool 900 including a combined formation testing and coring tool 901 in accordance with one embodiment of the invention. The combined formation testing and coring tool 901 includes a probe 903 with a coring bit 902 positioned therein. The probe may be selectively extended to contact the wellbore wall and create a seal with the formation. The coring bit 902 may then be selectively extended (with or without extension or retraction of the probe) to engage the wellbore wall.
the coring bit 902 of FIG. 9 is shown in a retracted position, but may be extended into the formation 912 to obtain a core sample. The coring tool 900 also preferably includes a core pusher or ejector 904 . Once a core sample is received in the coring bit 902 , the coring bit 902 may be rotated and the core pusher 904 may be extended to eject the core sample from the coring bit 902 and into a storage chamber (not shown). The combined formation testing and sampling assembly may be retracted into the downhole tool and rotated so that the core sample may be ejected into the sample chamber. Alternatively, the core sample may be retained in the coring bit for removal upon retrieval of the downhole tool to the surface.
The probe 903 also includes a fluid seal or packer 906 and a flowline 908 for taking fluid samples. When the packer 906 is pressed against the formation wall, the flowline 908 is isolated from the borehole environment and in fluid communication with the formation. Formation fluids may be drawn into the coring tool 900 through the flowline 908 .
The packer 906 creates a sealing area against the formation 912 . Fluid communication with the formation is established inside the packer sealing area. An opening of the flowline 908 is preferably located inside the sealing area adjacent the packer 906 . The flowline 908 is also preferably adapted to receive fluids from the formation via the sealing area. The coring bit 902 is extendable inside and through the sealing area of the packer 906 .
In some embodiments, the coring tool of FIGS. 8-9 may be provided with sample chambers for storing core samples and/or fluid samples. In at least one embodiment, the coring tool may be used with a sample chamber that stores core samples in formation fluid taken from the same location in the borehole as the fluid sample (e.g., the sample chamber 850 shown in FIG. 8C ). A downhole tool may include a separate sample chamber for storing fluid samples, as known in the art. The description above is not intended to limit the invention. The combined coring and sampling assembly may also be provided with a fluid pump (not shown), fluid analyzers and other devices to facilitate the flow of fluid the flowline and/or the analysis thereof.
FIG. 10 shows one embodiment of a method in accordance with the invention. The method includes lowering a wireline assembly into a borehole, at step 1002 . The method also includes activating a formation testing tool connected in the wireline assembly to withdraw formation fluid from the formation fluid, at step 1004 . The wireline assembly may also include a coring tool that is connected in the wireline assembly. The method may them include activating a coring tool connected in the wireline assembly to obtain a core sample, at step 1006 .
Next, the method may include directing the core sample into a sample chamber, at step 1008 ; and directing the fluid sample into the sample chamber, as 1010 . Steps 1008 , 1010 are shown in this order because the core sample is preferably moved into the sample chamber before the fluid sample is then directed into the sample chamber. This enables the sample chamber to be filled completely with sample fluid after the core sample is already positioned in the sample chamber. However, those having ordinary skill in the art will realize that these steps may be performed in any order. It is also noted that steps 1008 , 1010 are not required in all circumstances. For example, a core sample may remain in the coring bit for transportation to the surface.
Finally, the method may include retrieving the wireline assembly and analyzing the samples, at steps 1012 , 1014 . The analysis of the sample may provide information that is used in further drilling, completion, or production of the well.
FIG. 11 shows another embodiment of a method in accordance with the invention. The method includes obtaining a core sample of the formation rock, at step 1102 . This step may be accomplished by extending a coring bit to the formation and applying a torque and a WOB to the coring bit.
Next, the method may include rotating a sample block in the downhole tool, step 1104 . This will rotate the coring bit so that the sample core may be ejected from the coring bit, step 1106 . The method may also include establishing fluid communication between a flowline and the formation, step 1108 . Then, fluid may be withdrawn from the formation, step 1110 . Finally, sample fluid is preferably directed into a sample chamber, step 1112 .
FIG. 12 shows another embodiment of a method in accordance with the invention. The method includes establishing fluid communication with the formation, step 1202 . Next, the method may include obtaining a coring sample by extending the coring bit through a sealing area of the packer, step 1204 . It is noted that a core sample may be obtained before fluid communication is established. The order should not be construed to limit the invention.
The method may include ejecting the sample core from the coring bit into a sample chamber, step 1206 . The method may also include withdrawing a fluid sample from the packer seal, step 1210 .
Finally, the method may include directing the sample fluid into the sample chamber, step 1212 .
Embodiments of the present invention may present one or more of the following advantages. Some embodiments of the invention enable both a coring tool and a formation testing tool to be included on the same wireline or LWD assembly. Advantageously, this enables core samples and fluid samples to be obtained from the same position in a borehole. Having both a core sample and a fluid sample from the same position enables the analysis of the formation and its contents to be more accurate. Additionally, one or more separate or integral coring and/or sampling components may be provided in a variety of configurations about the downhole tool.
Advantageously, certain embodiments of a coring tool operate with a high efficiency. Higher efficiency enables a coring tool to be operated using less power.
Advantageously, embodiments of the invention that include a low-power coring tool enable a core sample to be obtained using less power than the prior art. In certain embodiments, a low-power coring tool uses less than 1 kW of power. Advantageously, the circuitry that is required to deliver power to a low-power coring tool is much less demanding than that required with prior art coring tools. Thus, a low-power coring tool may be used in the same wireline assembly with other downhole tools that typically cannot deliver the high power required by prior art coring tools.
Some embodiments of a coring tool in accordance with the invention include PWM solenoid valves as part of a feed-back loop to control the hydraulic pressure applied to a kinematics piston or other device that applies WOB. Advantageously, a PWM solenoid valve may be precisely controlled so that the WOB is maintained at or near a desired value.
In at least one embodiment, a PWM solenoid valve is controlled based on a torque that is delivered to a coring bit. Advantageously, a coring tool with such a control device may precisely control the PWM solenoid valve so that the pressure applied to a kinematics piston results in a substantially constant torque delivered to the coring bit.
Some embodiments of the invention relate to a wireline assembly that includes a field joint with female socket holes located in the bottom of a tool or module. Advantageously, fluid cannot be trapped in the female socket holes, and the field joint will be relatively free of interference with the electrical contacts. Advantageously, some embodiments include a protective sleeve to prevent damage to male pins that may be disposed at the top of a module or tool. Additionally, embodiments of a protective sleeve that are perforated or porous enable fluid that might interfere with an electrical contact to flow through the protective sleeve and away from the electrical contacts.
Some embodiments of a wireline assembly in accordance with the invention include a sample chamber that enables a core sample to be stored in the same chamber or compartment as a fluid sample. Advantageously, a core sample may be stored while being surrounded by the formation fluid that is native to the position where the core sample was taken.
Advantageously, a sample chamber with one or more fill and ejection lines enables formation fluid to be pumped through the sample chamber while a core sample is in the sample chamber. Advantageously, at least a portion of the mud filtrate in the core sample (i.e., the mud filtrate that invaded the formation before the core sample was obtained) may be purged from the core sample and from the sample chamber.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised that do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims. | A downhole tool positionable in a wellbore penetrating a subterranean formation is disclosed. The downhole tool includes a housing, a coring bit and a sample chamber. The coring bit is disposed in the housing and is extendable therefrom for engaging a wellbore wall. The sample chamber stores at least two formation samples obtained with the coring bit and includes at least two portions for separately storing the formation samples. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention generally relates to packet parameters processed at a receiving end of a data communication system, and more particularly, to centralized recording and processing of received packet parameters.
2. Description of the Related Art
For a packet-based or frame-based data communications system, such as a 1x Code Division Multiple Access 2000 (1x CDMA 2000) system, a 1x Evolution-Data Optimized (1x EVDO) system, an IEEE 802.11a/b/g system, and a Long Term Evolution (LTE) system, etc., the packets or frames communicating in the system on physical layers can be one of several types. Each type of packets or frames are defined by an underlying set of physical layer parameters, e.g. modulation type, coding type and rate, payload data rate, packet or frame duration, type of information being carried, number of users being addressed to, etc. The underlying set of parameters can dynamically change from packet to packet (or from frame to frame). A mechanism is typically adopted in a receiver of a packet-based or frame-based communications system to ensure that all of the parameters needed for decoding and post-processing of a packet (frame) are either dynamically made available to the receiver as the packet (frame) is being processed, or generated as part of the decoding process itself. Furthermore, status/quality information may be generated as part of the packet (frame) decoding process. Generally, the parametric information associated with a received packet (frame) can be categorized into at least 3 groups: 1). characterization parameters for that packet (frame) known beforehand, 2). characterization parameters discovered as part of the packet receiving process at physical layer, and 3). decoding status and/or packet (frame) quality information available after completion of reception and decoding of that packet (frame) at physical layer.
In addition, many packet (frame)-based data communications systems are designed to fragment a packet (frame) into smaller quanta and transmit each individual quantum associated with that packet (frame) in an interlaced manner with quanta associated with other packets (frames). The number of packets (frames) being thus interlaced can be different among various data communications systems, and is generally defined by the standard corresponding to the associated data communications system. For such an interlaced packets (frames) structure, some of the characterization parameters may stay the same from one quantum to another quantum of the fragmented packet (frame), while others may dynamically change with each quantum of the fragmented packet (frame). At the receiver end of a packet (frame)-based data communications system, higher layered information processing entities typically use the parametric information of the quantum of the packet (frame) provided by the physical layer to determine a next course of action for a payload data, as well as to generate performance metrics (packet or frame error rate, quality of reception, etc.) for the underlying physical layer.
FIG. 1 is a block diagram illustrating a conventional receiver of a generic data communications system. In a receiver 100 , the known-beforehand characterization parameters of the received packet (frame) or fragmented quantum thereof are transferred to a physical layer receiver module 10 in the physical layer. After a packet (frame) is received by the physical layer receiver module 10 , other characterization parameters are discovered during the packet (frame) receiving process and status/quality information is generated. The physical layer receiver module 10 then transfers the discovered characterization parameters and the status/quality information, along with payload data, to other parts or higher layers of the receiver 100 for subsequent processing. Note that the parametric information from the physical layer receiver module 10 is individually maintained and separately communicated to the other parts or higher layers of the receiver 100 . Thus, the higher layers of the receiver 100 must perform synchronization, maintenance, and sorting of the parametric information before the parametric information can be used. However, the distributed nature of the parametric information may result in inefficiencies in time and/or space when information is extracted. Specifically, information is inefficiently extracted by various parts of the receiver 100 when parameters to process associated payload data and/or generate physical-layer quality metrics are required. This is because each of the other parts or higher layers of the receiver 100 would have to read all of the individual pieces of parametric information one by one, associate them with current interlace being processed, and keep them synchronized to the system time reference, thereby requiring extra processing resources, e.g. clock-cycles required for processing, read and storage. This lowers data-delivery throughput in high data-rate data communications systems; especially for those that interlace different types of packet (frame) streams on underlying physical links. Also, this may result in a complex debugging process due to lack of availability of compact information about a given packet (frame) stream being debugged.
BRIEF SUMMARY OF THE INVENTION
Accordingly, embodiments of the invention provide centralized recording and processing of received packet parameters. In one aspect of the invention, a receiver for maintaining parameters of packets received from a transmitter is provided. The receiver comprises a first module, a record generating module, a buffering module, and a second module. The first module receives packets from the transmitter and decodes the packets to obtain corresponding payload data, wherein each received packet is transmitted in accordance with a first set of parameters predetermined before decoding of the packets, a second set of parameters which are dynamically determined when the packets are being decoded, and a third set of parameters which are determined after the packets have been decoded. The record generating module generates a record for each received packet, wherein the record comprises the first set, the second set, and the third set of parameters. The buffering module stores the record and corresponding payload data of each received packet. The second module retrieves the record and corresponding payload data from the buffering module, and processes the corresponding payload data according to the record.
In another aspect of the invention, a method for a receiver to maintain parameters of packets received from a transmitter is provided. The method comprises receiving packets from the transmitter and decoding the packets to obtain corresponding payload data, by a receiving module, wherein each received packet is transmitted in accordance with a first set of parameters predetermined before decoding of the packets, a second set of parameters which are dynamically determined when the packets are being decoded, and a third set of parameters which are determined after the packets have been decoded. A record for each received packet is generated, wherein the record comprises the first set, the second set, and the third set of parameters. The record and corresponding payload data of each received packet is stored, wherein the record and corresponding payload data is retrieved and the corresponding payload data is processed according to the record, by at least one subsequent processing module.
Other aspects and features of the invention will become apparent to those with ordinarily skilled in the art upon review of the following descriptions of specific embodiments of the methods for a receiver to maintain parameters of packets received from a transmitter, and receivers thereof.
BRIEF DESCRIPTION OF DRAWINGS
The invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
FIG. 1 is a block diagram illustrating a conventional receiver of a generic data communications system;
FIG. 2 is a block diagram illustrating a receiver of a data communications system according to an embodiment of the invention;
FIG. 3 is a block diagram illustrating a receiver of a generic data communications system according to another embodiment of the invention;
FIGS. 4A and 4B is a block diagram illustrating a receiver of a CDMA2000 1xHRPD system according to an embodiment of the invention;
FIG. 5 is a block diagram illustrating an enable signal generator according to an embodiment of the invention;
FIG. 6A to 6E is a block diagram illustrating the packet record buffers according to the embodiment shown in FIGS. 3A and 3B ;
FIG. 7 is a block diagram illustrating the fields of a packet record according to an embodiment of the invention; and
FIG. 8 is a flow chart illustrating the packet parameter maintenance method according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.
The invention provides a centrally synchronized structure to simplify maintenance, storage, and extraction of parametric information of each received packet (frame) or fragmented quantum thereof in an interlaced system. FIG. 2 is a block diagram illustrating a receiver of a data communications system according to an embodiment of the invention. As shown in FIG. 2 , a receiver 210 is provided for maintaining parameters of packets received from a remote transmitter 220 . The transmitter 220 may be located in a certain distance from the receiver 210 , and wirelessly connected with the receiver 210 via an air interface. The receiver 210 comprises a first module 211 , a record generating module 212 , a buffering module 213 , and a second module 214 . The first module 211 receives packets from the transmitter 220 , and then decodes the packets to obtain corresponding payload data. Note that each of the received packet is transmitted in accordance with a plurality of parameters, including a first set of parameters predetermined before decoding of the packets, a second set of parameters which are dynamically determined when the packets are being decoded, and a third set of parameters which are determined after the packets have been decoded. After the packets are decoded, the record generating module 212 generates a record for each received packet, wherein the record comprises the first set, the second set, and the third set of parameters. Subsequently, the record of each received packet is stored in the buffering module 213 for subsequent processing. In addition to storing the records, the buffering module 213 also stores the corresponding payload data of each received packet. As a beneficial result, the second module 214 can retrieve the record and corresponding payload data of each received packet from the buffering module 213 , and processes the corresponding payload data according to the record when necessary. Specially, all the parameters associated with a received packet are already collected in a corresponding record.
FIG. 3 is a block diagram illustrating a receiver of a generic data communications system according to another embodiment of the invention. In a receiver 300 , packets (frames) are received and decoded by a physical layer receiver module 10 . The characterization parameters and the status/quality information generated from the decoding process, along with a system time reference, are transferred to a timed control and assembly unit (TCAU) 30 . In addition, the known-beforehand characterization parameters of the received packet (frame) or fragmented quantum thereof are also transferred to the TCAU 30 . Next, the TCAU 30 generates necessary timing signals to extract and assemble all of the desired parametric information associated with the received packet (frame) or its fragmented quantum of current interlace into a compact record, which is referred to as a “packet record” or a “frame record” herein. Furthermore, the packet record is time-stamped using the system time reference to help other parts or higher layers of the receiver 300 to identify and use the parametric information of that received packet (frame) or its fragmented quantum. The time stamping further helps with identifying the associated interlace of the packet's (frame's) quantum in a system using interlaced data-streams on the underlying physical link. All of the static and dynamically extracted parameters associated with the packet (frame), or its fragmented quantum being decoded are compactly stored within the packet record. The extraction of the parametric information is based on certain input signals, such as slot boundary indicators of packets or their fragments. In an interlaced system, some of the characterization parameters may be needed only after a specified fragment of the packet has been received, while some other parameter(s) may require continual updating as subsequent fragments of the packet are received, and yet other parameter(s) may be required for processing of some of the fragments and not for other fragments of the packet. Accordingly, the TCAU 30 may output multiple packet records, one for each interlace, which may be further buffered per interlace for subsequent processing. Because of this compact availability of all parametric information associated with a received packet in a packet record, the other parts or higher layers of a system, which perform subsequent processing on the received packets, can efficiently read the entire record in fewer clock cycles than it would take to generate and read all of the parametric information individually as in the conventional receiver, and can further determine a next course of action to take on a packet's payload data. Moreover, availability of this snapshot of the parametric information simplifies any required debugging processes.
Note that the receiver in FIG. 1 is generic for all data communications systems, while the TCAU 30 is a system dependent design since different data communications systems may have different parametric information of the received packet or its fragmented quantum. Take a CDMA2000 1xHRPD (EVDO, rel-0, or A) system for example. The cdma2000 1xHRPD system's forward link (base station to mobile station) is designed to communicate data packets of varying lengths, from 128 bits to 5120 bits, fragmented in smaller sizes so as to fit within a “slot” of 1.6667 msec duration. Thus, each packet is fragmented into a number of slots standardized for the different available link data-rates, and further, those slots are sent over the physical link in an interlaced manner along with slots from other packets. Transmission of each packet starts with a preamble of standardized length that can be used by the receiver to detect a start and/or presence of the packet, as well as to detect the underlying user index that the packet is meant for. The underlying user index of a packet determines if the packet type is a single user specific packet, or a packet addressed to multiple users, or if the packet is a control packet broadcasted to all of the active users in the system. The cdma2000 1xHRPD system uses an interlace structure of four interlaces for one packet. The data-rates selected for the packets addressed to a single or multiple users are determined by the data-rate requested from the mobile-station. The mobile station periodically requests for one of the standardized data-rates from the sender based on the quality of the channel as determined by its receiver.
At the end of each slot, the receiver module of the mobile station attempts to decode each of the packets based on the slots received so far from the sender and sends a positive or negative acknowledgement back to the sender to indicate whether the decoding of the packet was successful or not. If a packet is successfully decoded before all of the slots associated with the packet have been transmitted, upon receiving a positive acknowledgement from the receiver, the sender may choose to discontinue transmission of the remaining slots of the decoded packet and start a new packet in the interlace that was being used for the decoded packet.
FIGS. 4A and 4B is a block diagram illustrating a receiver of a CDMA2000 1xHRPD system according to an embodiment of the invention. In the receiver 400 , the system time forms one of the two pieces of information known beforehand, i.e. information known before the received packet or fragmented quantum is processed. One piece of information known beforehand indicates which of the four interlaces is being received in any given slot. The other piece of information known beforehand is the data-rate format that was requested by the mobile station for the slot based on channel quality estimation. This information is termed as data-rate control (DRC) information and is four-bits wide to accommodate all of fifteen possible packet formats. At the end of every slot, the mobile station receiver estimates the channel quality from received signals in the slot, and selects an appropriate data-rate for likelihood of robust error-free reception of a packet in a next slot. Although the information is sent back to the base station for every slot, the base station uses the information to select the right packet format for the requested data-rate only at the beginning of a packet transmission in an interlace, and ignores any requested DRC information during subsequent fragment transmissions of a packet. Therefore, for a given packet, the DRC information remains the same for all of the constituent fragments. The TCAU 40 assures that the DRC information is saved into the packet record only for the slot in which start of a packet is detected, and the DRC information remains the same for any of the constituent slots of the packet, even though the requested DRC information being generated by the receiver may change for every slot.
The packet which may be received in any slot is further characterized by the receiver from the following pieces of information extracted during the decoding process: (a) an underlying media access control (MAC) index of the packet, as detected from the preamble of the packet by the receiver, which is a seven bit value to support up to 128 possible indices; (b) a fragment (slot) number within the packet; (c) a type of forward checksum (FCS) for the packet, which is 16-bit or 24-bit long; (d) an indicator for indicating whether the packet is a Broadcast-Multicast (BCMCS) type, and (e) a start-of-packet (SOP) indicator for indicating whether a given slot is the slot in which the packet was started, i.e., the very first slot of the packet. Note that while the information pieces (a), (c) and (d) stay the same for all slots of the packet sent by the base station, the information pieces (b) and (e) may change from slot to slot (fragment to fragment) within the packet. In addition, all of the pieces of information can change from interlace to interlace, since each interlace may be carrying an entirely different kind of packet.
After the physical layer receiver module 10 completes the packet decoding procedure in a given slot, the following pieces of additional information associated with the packet are made available: (i) a cyclic redundancy check (CRC) pass/failure indicator for indicating whether CRC checksum has passed or failed; (ii) a packet completed indicator for indicating whether the packet span is completed, i.e. if all of the possible slots in the packet have been received from the sender, or if the packet is successfully decoded with fewer slots; (iii) the actual size of the packet received; (iv) a usable packet indicator for indicating if the packet is a usable packet, i.e., if the packet is not meant for this user or is a redundant transmission by the sender; and (v) a packet valid indicator for indicating whether the packet record being maintained for the slot is valid, e.g. a packet record may be considered invalid if there was no data received in a given slot.
As shown in FIGS. 4A and 4B , the TCAU 40 processes and extracts the parametric information with different functional blocks according to the features of the parametric information. At every slot boundary, a few bits of a system time reference are saved into the corresponding packet record to keep it time-stamped. Additionally, the preamble detector module of the physical layer receiver module 10 continually detects if a preamble signal belonging to one of the expected MAC indices is present in the received signal. If a preamble signal belonging to one of the expected MAC indices is detected, the “macidfound” signal is generated along with the associated MAC index that was detected. Since the presence of a preamble signal in a received slot indicates the start of a new packet for the forward link, the TCAU 40 uses the “macidfound” signal to generate the Start-of-Packet (SOP) indicator bit. This indicator is set only for the slots in which a preamble signal is detected, and reset for the slots in which no preamble signal is detected. The “macidfound” signal indicates that a MAC Index was found by the Preamble Module. The “fn_slot” signal indicates a slot boundary. The SOP indicator bit indicates the start of a packet (frame). 2 bits from the system time counter, denoted as “st_timestmp[1:0]”, indicates the interlace number. Also a slot counter, denoted as “SlotCnt”, corresponding to the ongoing interlace is reset to start from zero whenever a preamble is detected in the slot. The slot counter is incremented by one for every slot of the packet until the last slot of this packet is received, or the packet is declared to be successfully decoded by the physical layer receiver module 10 . The packet complete indicator bit is set in the slot in which either of the two previous mentioned conditions is met. If no information in a slot is received, (i.e. no preamble detected), and no continuation of fragments of a previously ongoing packet, up until the end of the slot boundary marker, the packet record for the slot is declared to be invalid by the TCAU 40 . Otherwise the packet record for the slot is declared to be valid with the “pkt_vld” indicator in the packet record. For the slots, in which a valid packet is found, the TCAU 40 determines if the information received in this packet is usable, i.e. if it is meant for the mobile station and is not redundant, and sets/resets a corresponding usable packet indicator, denoted as “info_vld”, in the packet record. After extracting the parametric information, the TCAU 40 further assembles the parametric information in a compact 32-bit field of packet record, one for each of the four interlaces. In one embodiment, the packet record assembly unit may be a 32-bit bus which simply groups the parametric information together before storing it into the packet record buffers. In another embodiment, the packet record assembly unit may perform pre-processing of the parametric information before storing it into the packet record buffers. The subsequent processing modules can access the compact packet record to determine how it should proceed with the associated payload data and/or compute reception metrics about channel quality, packet error-rate, etc.
Note that necessary enable signals are generated by the enable signal generator 41 to help capture the various fields in a packet record. As shown in FIG. 5 , a start of slot boundary signal, denoted as “fn_slot”, is generated by the receiver and demodulator of the physical layer receiver module 10 based on system time reference. A pulse on the “macidfound” signal propagates to one of the “ld_mac” enable signals according to the interlace number. Similarly, the “ld_st” and “ldps” enable signals are generated according to the “fn_slot” and “EOS” (end of slot) indicators, respectively. In this embodiment, the “EOS” indicator is generated based on either a data ready indicator from the payload data decoder, or an end of slot boundary indicator obtained from the system time reference. In other embodiments, the “EOS” indicator may be generated differently. The different trigger signals are used to keep the saved parameters time-aligned despite different processing delays within the modules of the receiver 400 for extraction of different parametric information from the received signal. Note that, in this embodiment, there is a 2-slot delay between the time the data from the current slot of the packet is received and the time it is processed by the payload data decoder. Therefore, the trigger signals are accordingly time offset by 2 slots, as shown by the input arrangements of the Multiplexer and AND-gates to the “ld_st” and “ld_ps” enable signals in FIG. 5 .
FIG. 6A to 6E is a block diagram illustrating the packet record buffers according to the embodiment shown in FIGS. 4A and 4B . In this embodiment, 4 packet record buffers are used to maintain the parametric information from the TCAU 40 for each interlace, and in each packet record buffer, several flip-flops and counters, controlled by the enable signals from the enable signal generator 41 , serve as small memory units for storing the parametric information associated with the specific interlace number. The outputs, Q 0 to Q 3 , of the flip-flops and counters represent the parametric information for interface 0 to interlace 3 , which are further grouped together to form the compact packet records for each interlace, as shown in FIG. 7 . Note that different fields in the packet record may be used according to specific implementation requirements and the associated data communications system. In another embodiment, the packet record buffers may use other types of storage medium, such as caches, registers, and others, instead of the flip-flops.
FIG. 8 is a flow chart illustrating the packet parameter maintenance method according to an embodiment of the invention. Starting with step S 810 , a receiver receives packets from a transmitter and decodes the packets to obtain corresponding payload data, wherein each received packet is transmitted in accordance with a first set of parameters predetermined before decoding of the packets, a second set of parameters which are dynamically determined when the packets are being decoded, and a third set of parameters which are determined after the packets have been decoded. Generally, the step S 810 is performed by a receiver module in the physical layer of the receiver. Once the packet decoding procedure is completed, step S 820 is performed. In step S 820 , the receiver generates a record for each received packet, wherein the record comprises the first set, the second set, and the third set of parameters. Next, in step S 830 , the receiver stores the record and corresponding payload data of each received packet in a buffering module for temporary storage. Finally, in step S 840 , the subsequent processing modules of the receiver retrieve the record and corresponding payload data from the buffering module and process the corresponding payload data according to the record. Note that the receiver provides timing synchronization for the storing and retrieving of the record and corresponding payload data in step S 830 and S 840 , respectively, so that all the parameters of each received packet are provided to the subsequent processing modules of the receiver as a centrally synchronized and compact unit. Thus, higher payload data throughputs are achieved by the receiver, and debugging in design or in layout/field-testing phase is simplified, due to the method of the invention.
While the invention has been described by way of example and in terms of preferred embodiment, it is to be understood that the invention is not limited thereto. Those who are skilled in this technology can still make various alterations and modifications without departing from the scope and spirit of this invention. For example, the applied data communications system may be a 1x CDMA 2000 system, an IEEE 802.11 a/b/g system, or an LTE system, etc. Therefore, the scope of the invention shall be defined and protected by the following claims and their equivalents. | The invention relates to an internet application flow rate identification method based on message sampling and application signing, comprising the following steps: firstly, message sampling capture: in accordance with sampling strategy and sampling rate the message is captured and decoded; secondly, decoding: the flow information and application data of the message is analyzed by decoding the message; thirdly, flow classification: according to the flow information of the message, a flow state table is found and maintained; fourthly, flow state distinguishing: the signature is matched if the application type of the flow state found through the flow classification is unknown; finally, signature matching: according to the application signature bank, the application data of the message is matched, if matched successfully, the application type of the flow state is updated, and the flow information and application type of that data stream is output. The method is of high accuracy in identification, high efficiency in processing, good expandability, high possibility in realization, and is applicable not only for message processing, but also for flow data analysis. The invention can be achieved in not only the network equipment, but also the network analysis system. | 7 |
BACKGROUND OF THE PRESENT INVENTION
[0001] 1. Field of Invention
[0002] The invention belongs to the field of textile products, and particularly relates to a production method for high-low pile towel.
[0003] 2. Description of Related Arts
[0004] With continuous development of the social economy, the requirements on commodities from consumers are increasingly high, as the article of daily use, the towel product's attractiveness draws more and more attention from people. Being the main body of towel products, the visual effect of pile loops affects the appearance and grade of the product to a large extent. As the appearance for the pile loops of ordinary towels and products thereof is of a smooth type, the height of pile loops is uniform and consistent, it gives the visual effect of a level type to people; in order to overcome such defect of conventional towels, there are manufacturers designing high-low pile towels. However, the appearance for the pile loops of such high-low pile towels and products thereof is locally level, the conversion frequency of high and low piles is low, the conversion frequency is a conventional design approach with consistency in pile loop height for at least three adjacent pile loops, and there is high-low pile conversion only when at least more than three adjacent pile loops are arranged in a group of pile loops, thus this design gives the visual sense of strong regularity. Being the main style of towels, although these towels are widely accepted in the market, it always gives the sense of monotony to people, which is difficult to touch the market. Meanwhile the hand feel of these high-low pile towels is ordinary, the overall additional value is low, and the market reaction is common; the reason is mainly that it is limited by current weaving methods and design ideas, it cannot break through the traditional process and design ideas, and it seriously limits the design and production of high-low pile towels.
SUMMARY OF THE PRESENT INVENTION
[0005] Aiming to many problems existing in current high-low pile towels, the invention provides a brand-new production method for high-low pile towels. This method solves the problem of visual monotony for conventional towels and conventional high-low pile towels and breaks through the traditional design method of ordinary consistent height for two or three adjacent pile loops, it adopts the design method with inconsistency for adjacent two or three adjacent pile loops to weave, meanwhile it employs special dyeing and finishing treatment. The product after dyeing and finishing has special visual effect, the visual impact is strong, and the hand feel is fluffy and soft. Compared with existing products, the additional value is high without improving the cost for new products, it fills in the blank of high-low pile towels, and it can be widely popularized and applied.
[0006] It adopts the following technical scheme in the invention: a production method for high-low pile towels, it mainly comprises the processes of spinning, warping and sizing, weaving as well as dyeing and polishing after weaving, the specific steps are as below:
[0007] 1) Spinning: select towel yarn, the yarn count range is that single yarn: 6 s to 32 s, piled yarn: 40 s/2-8 s/2, the twist factor for pile warp is controlled to be 240 to 380, and the breaking strength is greater than 10.5 CN/tex;
[0008] 2) Warping and sizing: adopt conventional warping and sizing technology, wherein the speed of a warping car is controlled to be 550 m/min, and the speed of a sizing car during sizing is controlled to be 100 m/min;
[0009] The size formula during the sizing process is that:
[0010] Pile warp: add 23.2 kg of corn starch and 2 kg of liquid wax into 1000 kg of water;
[0011] Ground warp: add 116 kg of modified starch, 2 kg of solid wax blocks and 12 kg of propylene into 1000 kg of water.
[0012] 3) Weaving: it adopts a conventional high-low pile weaving method, wherein the high-low pile conversion frequency is that carry out pile loop height conversion within 3 pile loops, the high pile loop height is 1.1 to 1.6 cm per pile loop, and meanwhile control the height difference of adjacent high and low pile loops to maintain at is 0.3 to 0.5 cm per pile loop; and adjust the tensile force of pile warp yarn and ground warp yarn during the weaving process, which is respectively set to be 100-110 kgf and 270-280 kgf, and the speed of a loom is 400-450 r/min;
[0013] 4) Dyeing and polishing: put the towel cloth woven by the above method into a dyeing machine at 20-25° C., then inject the desizing agent, treat at 80° C. for 20 to 30 min, remove sizing agent on the original blank, and carry out bleaching and dyeing treatment. The proportion of bleaching agent adopted during bleaching is 27 vt % hydrogen peroxide: 6 g/L, NaOH: 2 g/L, refining agent: 1.5 g/L, hydrogen peroxide stabilizer: 1 g/L, chelating agent: 1 g/L, treat at 98° C. for 55 min; then carry out polishing treatment, and finally carry out dyeing.
[0014] The process adopted in said dyeing is of a conventional type, the specific dosages of the adopted dyeing agents are as below: reactive dyes: dystar RGB red: 0.001-10%; dystar RGB yellow: 0.001-10%; and dystar RGB blue: 0.001-10%;
[0015] Anhydrous sodium sulfate: 10-100 g/l, and sodium carbonate: 5-25 g/l.
[0016] For the adopted process, it can also refer to the following method:
[0017] Inject the reactive dye at room temperature (10 min)→circulate for 10 min→add anhydrous sodium sulfate (10 min)→circulate for 10 min→add sodium carbonate (10 min)→temperature rises to 60 degrees (2 degrees/min)→color fixing (time is determined by color depth)→wash in water for 5 min→carry out thermal washing for 15 min→carry out soaping for 15 min (depend on color depth)→wash in water→soften;
[0018] The above mentioned method is a conventional process, it can be randomly adjusted as per different production requirement so as to meet the requirement of manufacturing towels of different colors and styles, and it can be directly realized by employing existing equipment, it does not give unnecessary details herein, and the above dosage of reactive dyes is percentage of fabric mass;
[0019] In the above process, the adopted desizing agent is aqueous solution of desizing enzyme, with proportion of 0.5-1 g/L, that is, add 0.5-1 g of desizing enzyme into one liter of water; and the adopted desizing enzyme is α-amylase of Novozymes, the reason for choosing this desizing enzyme is mainly that such enzyme has specificity to starch desizing, it has better desizing effect, and it can lay the foundation for the processing of subsequent working procedures.
[0020] The adopted refining agent is clarite one from Huntsman, this refining agent can be used for emulsifying water repellent substances of waxes etc. on textile, which can improve hydrophilcity of textiles;
[0021] For hydrogen peroxide stabilizer, it can select Prestogen PL hydrogen peroxide stabilizer from BASF, and it can be used for stably decomposing hydrogen peroxide to increase its utilization;
[0022] For chelating agent, it employs MSD chelating agent from BASF, it can soften water quality, reduce hardness of water, meanwhile it can chelate copper and manganese ions in water, which facilitates reducing yellow spots and increasing whiteness of the product;
[0023] There is a major difference between the invention and the prior art, that is, arrange the polishing process ahead of the dyeing process, the reason for making such a choice is mainly that after employing the high-low pile process, it can better remove fuzzy balls and lower piles mixed in pile loops, and it has better dyeing effect. It takes common polishing measures, the specific polishing process parameters: pH=4.8-5.4, the dosage of polishing enzyme: 0.1-1.0 wt %, take polishing treatment for 60 min below 50° C., the adopted polishing enzyme is B939 acid polishing enzyme from Novozymes-novoprime.
[0024] In the above mentioned method, in order to achieve the optimum high-low pile appearance as well as fluffy and soft effect during spinning, and it particularly selects coarse count low-twisted single yarn or strand yarn, such as 21 s/2 weak twist piled yarn or 10 s weak twist piled yarn. The inventor discovers that the effect by adopting such yarn is obviously superior to that of 21 s single-yarn ordinary yarn generally applied to the existing high-low pile towels. By selecting the above mentioned yarn, with combination of the above mentioned spinning process, it can generate special visual effect, and it can also meet the basic requirement of weaving. For the parameters not mentioned in this operation, they all adopt the spinning parameters of existing ordinary high-low pile towels.
[0025] During the warping and sizing process, it selects the above mentioned suitable car speed by choosing the strength and number of warping yarns according to step 1 for warping; however, in the sizing process, it adopts the above mentioned starching process and sizing agent for pile warp yarn, it solves the problems of low strength of weak twist yarn, multiple broken ends and poor weaver's beam quality, meanwhile it realizes suitable and smooth hairiness, it increases strength and abrasion resistance, and it can ensure to achieve the weaving requirement. By selecting corn starch as main sizing agent, it can improve strength of yarn and realize smooth yarn hairiness, and by using liquid wax, it can make sure that the yarn is wear-resistant;
[0026] Ground warp adopts the above mentioned starching process and sizing agent, it improves abrasion resistance and strength of yarn, which ensures that the weaving efficiency is good; meanwhile, it adopts solid wax to use in afterwaxing, the obtained yarn is smoother than that by utilizing liquid wax, and it can get better using effect.
[0027] During the weaving process, the above mentioned parameters are controlled, the high and low pile conversion frequency is one high pile one low pile circulation or one high pile two low piles circulation or two high piles one low pile circulation or two high piles two low piles circulation, they can all guarantee pile height conversion within 3 pile loops, so that it reaches the purpose of optimum fluffy pile loop effect and prominent visual effect, and further increases the additional value of the products.
[0028] During the dyeing and polishing process, it is required to carry out bleaching and dyeing treatment on blank towels, however, in the whole process, it should note the soft and fluffy performance and the cleanliness of appearance after washing, hence the inventor specifies dosage for various auxiliaries and processing time, meanwhile, since such highly frequent high and low pile conversion in the invention can enable that there is voids between the high and the low piles of a towel, in the dyeing and finishing process, fallen piles can more easily hide in high pile loops, which affects the using process of towels. Consequently, the inventor specifies to enhance the above mentioned polishing treatment and washing treatment, so as to eliminate hiding of fuzzy balls caused by low piles within high and low pile loops to affect usage, and it further improves comfort degree of the product in use.
[0029] According to the above mentioned process and method, in order to further improve usability of towels, the inventor further employs softening agent to carry out treatment. The adopted softening agent belongs to hydrophilic fatty acid amide derivatives, and particularly it can select AQUASOFTER FX manufactured by AIRI CHEMICAL CO., LTD.
[0030] For process control procedures and parameters not mentioned in the above production process, they employ the parameters and control process of existing ordinary high and low pile production process, and it is not in detailed description herein.
[0031] To sum up, by adopting the special method provided by the invention, it can obtain brand-new high-low pile towels completely differing from the existing high-low pile towels, it breaks through visual monotony of common towels and conventional high-low pile towels, and it also breaks through the traditional design method with consistent pile loop height for ordinary three adjacent pile loops. It adopts the design method with inconsistent pile loop height for the adjacent two pile loops or three pile loops, meanwhile it adopts special dyeing and finishing treatment, after dyeing and finishing, the product has special visual effect, the visual impact is strong, the hand feel is fluffy and soft. Compared with existing products, the additional value is high without improving the cost for new products, it fills in the blank of high-low pile towels, and it can be widely popularized and applied.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is structure diagram of high-low pile towels obtained in the embodiment 1 of the invention;
[0033] FIG. 2 is structure diagram of high-low pile towels obtained in the embodiment 2 of the invention;
[0034] FIG. 3 is structure diagram of high-low pile towels obtained in the embodiment 3 of the invention;
[0035] FIG. 4 is structure diagram of high-low pile towels obtained in the embodiment 4 of the invention;
[0036] In the figures, 1 refers to the basal plane of a towel, 2 refers to high pile loops, and 3 refers to low pile loops.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Embodiment 1
[0037] A production method for high-low pile towels, and the specific steps are as below:
[0038] 1) Spinning: select towel yarn, the yarn count range is that single yarn: 6 s to 32 s, piled yarn: 40 s/2-8 s/2, the twist factor for pile warp is controlled to be 240 to 380, and the breaking strength is greater than 10.5 CN/tex; and the adopted yarn is 21 s/2 weak twist piled yarn or 10 s weak twist piled yarn;
[0039] 2) Warping and sizing: it adopts conventional warping and sizing technology, particularly it can refer to the following:
[0040] Number of warping yarns: 500, length: 5000 m, number of warp beams: 4, yarn count: 21 s/2, beam width: 2 m, warping equipment: Benninger warping machine, warping car speed: 500-600 m/min;
[0041] Sizing yarn length: 5000 m, number of sizing yarns: 2000, yarn count: 21 s/2, disc width: 186 cm, size concentration: 3%, size volume: 7001, unwinding tension: 250N, feeding tensile force: 200N, wet zone tensile force: 350N, squeezing pressure N1/N2: 8 Kn/12 Kn, dry zone tensile force: 1200N, winding tension: 1600N, toppin roller pressure: 1600N, extrusion weighing percentage: 100%, size immersion method: single immersion and single rolling, size temperature: 90° C., moisture regaining rate: 7%, elongation rate: 1%;
[0042] It is optimum to control the warping car speed at 550 m/min and the sizing car speed during the sizing process at 100 m/min;
[0043] The formula for sizing agent during the sizing process:
[0044] Pile warp: add 23.2 kg of corn starch and 2 kg of liquid wax into 1000 kg of water;
[0045] Ground warp: add 116 kg of modified corn starch (can be directly purchased from the market), 2 kg of solid wax blocks and 12 kg of propylene into 1000 kg of water.
[0046] 3) Weaving: it adopts a conventional high-low pile weaving method, wherein the high-low pile conversion frequency is one high pile and one low pile circulation, the high pile loop height is 1.1 to 1.6 cm per pile loop, and meanwhile control the height difference of adjacent high and low pile loops to maintain at is 0.3 to 0.5 cm per pile loop; and adjust the tensile force of pile warp yarn and ground warp yarn during the weaving process, which is respectively set to be 100-110 kgf and 270-280 kgf, and the speed of a loom is 400-450 r/min;
[0047] 4) Dyeing and polishing: put the towel cloth woven by the above method into a dyeing machine at 20-25° C., then inject the desizing agent, treat at 80° C. for 20 to 30 min, remove sizing agent on the original blank, and carry out bleaching and dyeing treatment. The proportion of bleaching agent adopted during bleaching is 27 vt % hydrogen peroxide: 6 g/L, NaOH: 2 g/L, refining agent: 1.5 g/L, hydrogen peroxide stabilizer: 1 g/L, chelating agent: 1 g/L, treat at 98° C. for 55 min; then carry out polishing treatment, and finally carry out dyeing;
[0048] Then carry out dyeing treatment on towels after processing, the adopted process is a conventional process during dyeing, the specific dosages of the adopted dyeing agents are as below: reactive dyes: dystar RGB red: 0.001-10%; dystar RGB yellow: 0.001-10%; and dystar RGB blue: 0.001-10%;
[0049] Anhydrous sodium sulfate: 10-100 g/l, and sodium carbonate: 5-25 g/l,
[0050] For the adopted process, it can also refer to the following method:
[0051] Inject the reactive dye at room temperature (10 min)→circulate for 10 min→add anhydrous sodium sulfate (10 min)→circulate for 10 min→add sodium carbonate (10 min)→temperature rises to 60 degrees (2 degrees/min)→color fixing (time is determined by color depth)→wash in water for 5 min→carry out thermal washing for 15 min→carry out soaping for 15 min (depend on color depth)→wash in water→soften;
[0052] In addition to this, it can adopt other conventional processes and reactive dye formulas;
[0053] In the above process, the adopted desizing agent is aqueous solution of desizing enzyme, with proportion of 0.5-1 g/L, that is, add 0.5-1 g of desizing enzyme into one liter of water; and the adopted desizing enzyme is a-amylase of Novozymes;
[0054] The adopted refining agent is clarite one from Huntsman;
[0055] For hydrogen peroxide stabilizer, it can select Prestogen PL hydrogen peroxide stabilizer from BASF;
[0056] For chelating agent, it employs MSD chelating agent from BASF;
[0057] The said polishing process is as blow:
[0058] It takes conventional polishing measures, the specific polishing process parameters: pH=4.8-5.4, the dosage of polishing enzyme: 0.2 wt %, take polishing treatment for 60 min below 50° C., the adopted polishing enzyme is B939 acid polishing enzyme from Novozymes-novoprime;
[0059] After dyeing, in order to further improve usability of towels, the inventor further employs softening agent to carry out treatment. The adopted softening agent belongs to hydrophilic fatty acid amide derivatives, and particularly it can select AQUASOFTER FX manufactured by AIRI CHEMICAL CO., LTD.;
[0060] Besides the above mentioned parameters, other processes and parameters adopted by the embodiment are similar to the weaving method for ordinary towels in the existing technology, and they are not in detailed description herein.
Embodiment 2
[0061] A production method for high-low pile towels, and the specific steps are as below:
[0062] 1) Spinning: select towel yarn, the yarn count range is that single yarn: 6 s to 32 s, piled yarn: 40 s/2-8 s/2, the twist factor for pile warp is controlled to be 240 to 380, and the breaking strength is greater than 10.5 CN/tex; and the adopted yarn is 21 s/2 weak twist piled yarn or 10 s weak twist piled yarn;
[0063] 2) Warping and sizing: it adopts conventional warping and sizing technology:
[0064] Warping: warping equipment: Benninger high-speed warping machine, yarn count: 12 s ring spinning, number of warping yarns: 500, number of warp beams: 4, warping car speed: 600 m/min; beam width: 200 cm, beam length: 2000 m;
[0065] Sizing: sizing equipment: kal-mayer sizing machine, yarn count: 12 s, number of sizing yarns: 2000, size concentration: 2%, size temperature: 90° C., unwinding tension: 300N, feeding tensile force: 250N, wet zone tensile force: 300N, dry zone tensile force: 1100N, winding tension: 1600N, toppin roller pressure: 1600N, moisture regaining rate: 7.0%, elongation rate: 0.8%, size immersion method: double immersion and double rolling, and to control the sizing car speed during the sizing process at 100 m/min;
[0066] The formula for sizing agent during the sizing process:
[0067] Pile warp: add 23.2 kg of corn starch and 2 kg of liquid wax into 1000 kg of water;
[0068] Ground warp: add 116 kg of modified corn starch, 2 kg of solid wax blocks and 12 kg of propylene into 1000 kg of water.
[0069] 3) Weaving: it adopts a conventional high-low pile weaving method, wherein the high-low pile conversion frequency is one high pile and two low piles circulation, the high pile loop height is 1.1 to 1.6 cm per pile loop, and meanwhile control the height difference of adjacent high and low pile loops to maintain at is 0.3 to 0.5 cm per pile loop; and adjust the tensile force of pile warp yarn and ground warp yarn during the weaving process, which is respectively set to be 100-110 kgf and 270-280 kgf, and the speed of a loom is 400-450 r/min;
[0070] 4) Dyeing and polishing: put the towel cloth woven by the above method into a dyeing machine at 20-25° C., then inject the desizing agent, treat at 80° C. for 20 to 30 min, remove sizing agent on the original blank, and carry out bleaching and dyeing treatment.
[0071] The proportion of bleaching agent adopted during bleaching is 27 vt % hydrogen peroxide: 6 g/L, NaOH: 2 g/L, refining agent: 1.5 g/L, hydrogen peroxide stabilizer: 1 g/L, chelating agent: 1 g/L, treat at 98° C. for 55 min; then carry out polishing treatment;
[0072] Then carry out dyeing treatment on towels after processing, the adopted process is a conventional process during dyeing, the specific dosages of the adopted dyeing agents are as below: reactive dyes: dystar RGB red: 0.001-10%; dystar RGB yellow: 0.001-10%; and dystar RGB blue: 0.001-10%;
[0073] Anhydrous sodium sulfate: 10-100 g/l, and sodium carbonate: 5-25 g/l,
[0074] For the adopted process, it can also refer to the following method:
[0075] Inject the reactive dye at room temperature (10 min)→circulate for 10 min→add anhydrous sodium sulfate (10 min)→circulate for 10 min→add sodium carbonate (10 min)→temperature rises to 60 degrees (2 degrees/min)→color fixing (time is determined by color depth)→wash in water for 5 min→carry out thermal washing for 15 min→carry out soaping for 15 min (depend on color depth)→wash in water→soften;
[0076] In addition to this, it can adopt other conventional processes and reactive dye formulas;
[0077] In the above process, the adopted desizing agent is aqueous solution of desizing enzyme, with proportion of 0.5-1 g/L, that is, add 0.5-1 g of desizing enzyme into one liter of water; and the adopted desizing enzyme is α-amylase of Novozymes;
[0078] The adopted refining agent is clarite one from Huntsman;
[0079] For hydrogen peroxide stabilizer, it can select Prestogen PL hydrogen peroxide stabilizer from BASF;
[0080] For chelating agent, it employs MSD chelating agent from BASF;
[0081] The said polishing process is as blow:
[0082] It takes conventional polishing measures, the specific polishing process parameters: pH=4.8-5.4, the dosage of polishing enzyme: 0.1 wt %, take polishing treatment for 60 min below 50° C., the adopted polishing enzyme is B939 acid polishing enzyme from Novozymes-novoprime;
[0083] After dyeing, in order to further improve usability of towels, the inventor further employs softening agent to carry out treatment. The adopted softening agent belongs to hydrophilic fatty acid amide derivatives, and particularly it can select AQUASOFTER FX manufactured by AIRI CHEMICAL CO., LTD.;
[0084] Besides the above mentioned parameters, other processes and parameters adopted by the embodiment are similar to the weaving method for ordinary towels in the existing technology, and they are not in detailed description herein.
Embodiment 3
[0085] A production method for high-low pile towels, and the specific steps are as below:
[0086] 1) Spinning: select towel yarn, the yarn count range is that single yarn: 6 s to 32 s, piled yarn: 40 s/2-8 s/2, the twist factor for pile warp is controlled to be 240 to 380, and the breaking strength is greater than 10.5 CN/tex; and the adopted yarn is 21 s/2 weak twist piled yarn or 10 s weak twist piled yarn;
[0087] 2) Warping and sizing: it adopts conventional warping and sizing technology, particularly it can refer to the following:
[0088] Number of warping yarns: 500, length: 5000 m, number of warp beams: 4, yarn count: 21 s/2, beam width: 2 m, warping equipment: Benninger warping machine, warping car speed: 500-600 m/min;
[0089] Sizing yarn length: 5000 m, number of sizing yarns: 2000, yarn count: 21 s/2, disc width: 186 cm, size concentration: 3%, size volume: 7001, unwinding tension: 250N, feeding tensile force: 200N, wet zone tensile force: 350N, squeezing pressure N1/N2: 8 Kn/12 Kn, dry zone tensile force: 1200N, winding tension: 1600N, toppin roller pressure: 1600N, extrusion weighing percentage: 100%, size immersion method: single immersion and single rolling, size temperature: 90° C., moisture regaining rate: 7%, elongation rate: 1%;
[0090] It is optimum to control the warping car speed at 500 m/min and the sizing car speed during the sizing process at 100 m/min;
[0091] The formula for sizing agent during the sizing process:
[0092] Pile warp: add 23.2 kg of corn starch and 2 kg of liquid wax into 1000 kg of water;
[0093] Ground warp: add 116 kg of modified corn starch, 2 kg of solid wax blocks and 12 kg of propylene into 1000 kg of water.
[0094] 3) Weaving: it adopts a conventional high-low pile weaving method, wherein the high-low pile conversion frequency is two high piles and one low pile circulation, the high pile loop height is 1.1 to 1.6 cm per pile loop, and meanwhile control the height difference of adjacent high and low pile loops to maintain at is 0.3 to 0.5 cm per pile loop; and adjust the tensile force of pile warp yarn and ground warp yarn during the weaving process, which is respectively set to be 100-110 kgf and 270-280 kgf, and the speed of a loom is 400-450 r/min;
[0095] 4) Dyeing and polishing: put the towel cloth woven by the above method into a dyeing machine at 20-25° C., then inject the desizing agent, treat at 80° C. for 20 to 30 min, remove sizing agent on the original blank, and carry out bleaching and dyeing treatment. The proportion of bleaching agent adopted during bleaching is 27 vt % hydrogen peroxide: 6 g/L, NaOH: 2 g/L, refining agent: 1.5 g/L, hydrogen peroxide stabilizer: 1 g/L, chelating agent: 1 g/L, treat at 98° C. for 55 min; then carry out polishing treatment;
[0096] Then carry out dyeing treatment on towels after processing, the adopted process is a conventional process during dyeing, the specific dosages of the adopted dyeing agents are as below: reactive dyes: dystar RGB red: 0.001-10%; dystar RGB yellow: 0.001-10%; and dystar RGB blue: 0.001-10%;
[0097] Anhydrous sodium sulfate: 10-100 g/l, and sodium carbonate: 5-25 g/l,
[0098] For the adopted process, it can also refer to the following method:
[0099] Inject the reactive dye at room temperature (10 min)→circulate for 10 min→add anhydrous sodium sulfate (10 min)→circulate for 10 min→add sodium carbonate (10 min)→temperature rises to 60 degrees (2 degrees/min)→color fixing (time is determined by color depth)→wash in water for 5 min→carry out thermal washing for 15 min→carry out soaping for 15 min (depend on color depth)→wash in water→soften;
[0100] In addition to this, it can adopt other conventional processes and reactive dye formulas;
[0101] In the above process, the adopted desizing agent is aqueous solution of desizing enzyme, with proportion of 0.5-1 g/L, that is, add 0.5-1 g of desizing enzyme into one liter of water; and the adopted desizing enzyme is α-amylase of Novozymes;
[0102] The adopted refining agent is clarite one from Huntsman;
[0103] For hydrogen peroxide stabilizer, it can select Prestogen PL hydrogen peroxide stabilizer from BASF;
[0104] For chelating agent, it employs MSD chelating agent from BASF;
[0105] The said polishing process is as blow:
[0106] It takes conventional polishing measures, the specific polishing process parameters: pH=4.8-5.4, the dosage of polishing enzyme: 0.5 wt %, take polishing treatment for 60 min below 50° C., the adopted polishing enzyme is B939 acid polishing enzyme from Novozymes-novoprime;
[0107] After dyeing, in order to further improve usability of towels, the inventor further employs softening agent to carry out treatment. The adopted softening agent belongs to hydrophilic fatty acid amide derivatives, and particularly it can select AQUASOFTER FX manufactured by AIRI CHEMICAL CO., LTD.;
[0108] Besides the above mentioned parameters, other processes and parameters adopted by the embodiment are similar to the weaving method for ordinary towels in the existing technology, and they are not in detailed description herein.
Embodiment 4
[0109] A production method for high-low pile towels, and the specific steps are as below:
[0110] 1) Spinning: select towel yarn, the yarn count range is that single yarn: 6 s to 32 s, piled yarn: 40 s/2-8 s/2, the twist factor for pile warp is controlled to be 240 to 380, and the breaking strength is greater than 10.5 CN/tex; and the adopted yarn is 21 s/2 weak twist piled yarn or 10 s weak twist piled yarn;
[0111] 2) Warping and sizing: it adopts conventional warping and sizing technology:
[0112] Warping: warping equipment: Benninger high-speed warping machine, yarn count: 12 s ring spinning, number of warping yarns: 500, number of warp beams: 4, warping car speed: 600 m/min; beam width: 200 cm, beam length: 2000 m;
[0113] Sizing: sizing equipment: kal-mayer sizing machine, yarn count: 12 s, number of sizing yarns: 2000, size concentration: 2%, size temperature: 90° C., unwinding tension: 300N, feeding tensile force: 250N, wet zone tensile force: 300N, dry zone tensile force: 1100N, winding tension: 1600N, toppin roller pressure: 1600N, moisture regaining rate: 7.0%, elongation rate: 0.8%, size immersion method: double immersion and double rolling, and to control the sizing car speed during the sizing process at 100 m/min;
[0114] The formula for sizing agent during the sizing process:
[0115] Pile warp: add 23.2 kg of corn starch and 2 kg of liquid wax into 1000 kg of water;
[0116] Ground warp: add 116 kg of modified corn starch, 2 kg of solid wax blocks and 12 kg of propylene into 1000 kg of water.
[0117] 3) Weaving: it adopts a conventional high-low pile weaving method, wherein the high-low pile conversion frequency is two high piles and two low piles circulation, the high pile loop height is 1.1 to 1.6 cm per pile loop, and meanwhile control the height difference of adjacent high and low pile loops to maintain at is 0.3 to 0.5 cm per pile loop; and adjust the tensile force of pile warp yarn and ground warp yarn during the weaving process, which is respectively set to be 100-110 kgf and 270-280 kgf, and the speed of a loom is 400-450 r/min;
[0118] 4) Dyeing and polishing: put the towel cloth woven by the above method into a dyeing machine at 20-25° C., then inject the desizing agent, treat at 80° C. for 20 to 30 min, remove sizing agent on the original blank, and carry out bleaching and dyeing treatment. The proportion of bleaching agent adopted during bleaching is 27 vt % hydrogen peroxide: 6 g/L, NaOH: 2 g/L, refining agent: 1.5 g/L, hydrogen peroxide stabilizer: 1 g/L, chelating agent: 1 g/L, treat at 98° C. for 55 min; then carry out polishing treatment;
[0119] Then carry out dyeing treatment on towels after processing, the adopted process is a conventional process during dyeing, the specific dosages of the adopted dyeing agents are as below: reactive dyes: dystar RGB red: 0.001-10%; dystar RGB yellow: 0.001-10%; and dystar RGB blue: 0.001-10%;
[0120] Anhydrous sodium sulfate: 10-100 g/l, and sodium carbonate: 5-25 g/l,
[0121] For the adopted process, it can also refer to the following method:
[0122] Inject the reactive dye at room temperature (10 min)→circulate for 10 min→add anhydrous sodium sulfate (10 min)→circulate for 10 min→add sodium carbonate (10 min)→temperature rises to 60 degrees (2 degrees/min)→color fixing (time is determined by color depth)→wash in water for 5 min→carry out thermal washing for 15 min→carry out soaping for 15 min (depend on color depth)→wash in water→soften;
[0123] In addition to this, it can adopt other conventional processes and reactive dye formulas;
[0124] In the above process, the adopted desizing agent is aqueous solution of desizing enzyme, with proportion of 0.5-1 g/L, that is, add 0.5-1 g of desizing enzyme into one liter of water; and the adopted desizing enzyme is α-amylase of Novozymes;
[0125] The adopted refining agent is clarite one from Huntsman;
[0126] For hydrogen peroxide stabilizer, it can select Prestogen PL hydrogen peroxide stabilizer from BASF;
[0127] For chelating agent, it employs MSD chelating agent from BASF;
[0128] The said polishing process is as blow:
[0129] It takes conventional polishing measures, the specific polishing process parameters: pH=4.8-5.4, the dosage of polishing enzyme: 1.0 wt %, take polishing treatment for 60 min below 50° C., the adopted polishing enzyme is B939 acid polishing enzyme from Novozymes-novoprime;
[0130] After dyeing, in order to further improve usability of towels, the inventor further employs softening agent to carry out treatment. The adopted softening agent belongs to hydrophilic fatty acid amide derivatives, and particularly it can select AQUASOFTER FX manufactured by AIRI CHEMICAL CO., LTD.;
[0131] Besides the above mentioned parameters, other processes and parameters adopted by the embodiment are similar to the weaving method for ordinary towels in the existing technology, and they are not in detailed description herein. | The present invention falls within the field of textile products, and specifically provides a brand new production method for a high-low pile towel. The method breaks through the visual monotony of conventional towels and a traditional design method in which two or three adjacent conventional pile loops have a consistent pile loop height in conventional high-low pile towels, but uses a design method in which two or three adjacent pile loops have a inconsistent pile loop height for weaving, and at the same time uses a special dyeing and finishing treatment, whereby the dyed and finished product has a special visual effect, a strong visual impact, and a fluffy and soft hand feel, and the product therefrom has a high additional value without improving the coats, compared with the existing products. The method fills up a blank of high-low pile towels, and can be widely popularized and applied. | 3 |
TECHNICAL FIELD
The present invention relates to a flexible container which may be reclosed using a reclosable closure system. More specifically, this invention relates to flexible bags, boxes, or similar containers having a novel adhesive strip thereon enabling an open end of the container to be secured to maintain closure of the container using the novel hinge strip of the invention. The strip preferably utilizes a removable adhesive which may be used multiple times to close the container and allows easy and effective closure of such flexible containers and bags. The strip is a unique hinge type closure wherein one side is permanently attached to the container and the other side has a tab and a removable adhesive adapted to be releasably secured to the container or bag when the tab grasped and the releasable adhesive is pressed into contact with the container so as to effect a closure. A unique feature of the invention is the ability to print on the shield permanent side as well as on the non-pressure sensitive adhesive surface of the strip so as to have permanent printing always associated with the closure system.
BACKGROUND OF THE INVENTION
There is known in general in the prior art a number of methods for protecting the contents of a container through the use of a reclosable closure. More particularly, these types of closure systems are adapted for potato chip bags, cereal bags, bread bags, or the like, and usually the bag itself is a plastic or coated paper system which is flexible and may easily be twisted or manipulated; and for rigid containers such as cereal and detergent boxes.
One of the most widely used methods for resealing or reclosing a flexible container involves a use of a separate component such as a metal wire twist tie which is covered with paper, or a plastic clip. These are typical methods for closing a loaf of bread. These methods, however, have several disadvantages due to the fact that the reclosable seals are not part of the container. The plastic clips or twist ties may often be misplaced between uses and also require some degree of fine motor control, therefor making their use difficult for the young, elderly, and the physically handicapped. Additionally, after repeated use, plastic clips often break and the twist ties expose their metal wires making their use potentially hazardous. These closures may also pose a risk of choking or other hazards for small children who may have access to them. These types of closures can also cause tears in the container.
Another known construction utilizes zip lock®, and similar zipper-like sealing means to provide the containers with the reclosable air tight seal. This construction adds substantially to the cost of the container and adds difficulty to its manufacture. Furthermore, these systems also require some fine motor control which may prove difficult again for the young, elderly or physically handicapped.
Previous attempts at developing reclosable sealing means involving pressure sensitive adhesives were largely unsuccessful or unnecessarily complex. Many resealable systems were unreliable in that after a limited number of reclosures, the seal would often fail to further adhere, or in other words, the pressure sensitive adhesive would lose its tack. Other systems require components which had to be manufactured using methods of die cutting or other off line processes thereby prohibitively raising the cost thereof.
One example of a reclosing system is shown in U.S. Pat. No. 4,552,269, which discloses a resealable device consisting of a paper or foil blank in a sealing flap. While this is an improvement over prior resealable devices, this device still requires production through die cutting means and provides only a limited size opening which can be resealed. Another system is shown in U.S. Pat. No. 4,584,201, which shows use of an adhesive strip positioned parallel to a top sealed edge of the bag. The top edge can be folded upon itself and then adhered to the strip to effect a closure.
One other closure system after which the instant invention is designed but is believed to represent an improvement thereover, is that shown in patent application Ser. No. 413,951, filed Sept. 28, 1989, by Kurt M. Schramer, for "A Reclosable Flexible Container and Method of Reclosing". The instant system is believed to represent an improvement thereover, because it is simpler to manufacture and apply, it allows advertisement as well as instructions for use associated with the closure throughout its useful life so as to give good promotional and use characteristics, and it is simple and effective to use.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide an inexpensive means for closing a bag, package, box or the like used to contain a loaf of bread, or cereal, or crackers, or baby wipes, or the like.
It is also an object to provide a means for closing the bread bag or other containers, bags, boxes, etc. which is reliable and can easily be used a multiple of times without failing to seal.
It is also an object of the invention to provide a means for closing the bag or other container which allows printing on the face shield of the adhesive strip associated with the invention, and which printing will always be present because the face shield or strip is permanently attached to the bag or other container.
It is also an object of the invention to provide a means for closing a bread bag which can be used or adapted for use on a large number of different types of bags or flexible and rigid containers.
It is also an object of the invention to provide a means for closing a bread bag such that it uses a removable adhesive which will maintain a closure when placed at a plurality of different spots on the bread bag itself.
It is a further object of the invention to provide the means for closing of the bag or other container which is designed to protect the pressure sensitive adhesive closure mechanism from contamination such as crumbs, dirt or other ingredients in the bag or container being closed so that the pressure sensitive adhesive will not lose its tack or ability to stick to achieve the closure desired.
It is a further object of this invention to provide a means for closing a bread bag and other flexible and rigid containers which is simple to use and requires a minimal amount of motor control or consumer education.
It is a further object of this invention to provide a means for closing a bread bag wherein the closure strip can be attached to the containers as a part of an in-line manufacturing of the product prior to its functional use with the bread or other products deposited therein.
These and other objects may be accomplished with the present invention which comprises a suitable bag, box or container for holding the product, such bag having at least one open end. The bag includes a reclosing strip shield having first and second surfaces which is positioned on the bag, and wherein the first surface contacts and bonds with the bag having a permanent adhesive strength, the first and second surfaces being on one side of the strip with an uncoated barrier between the adhesive surfaces whereby the strip can be bent on the uncoated area to expose the second surface to hold the bag in a closed position when the open end is pulled down to close the bag when the second adhesive surface is attached to the bag. Normally, the second adhesive surface includes a release liner to protect the adhesive thereon until the actual use of the second adhesive surface is required, and wherein such second adhesive surface is a removable adhesive. The invention also includes printing on the permanent stock face and/or shield of the strip for advertising, promotional or instructional purposes, such printing to be exposed whenever the bag container, etc. is opened, and folded back on itself in the closing configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference should be made to the accompanying drawings wherein;
FIG. 1 is an end elevational, cross-sectional view of a preferred embodiment of the hinge type closure comprising a preferred embodiment of the invention;
FIG. 2 is a similar cross-sectional elevation of the strip of FIG. 1 with one side of the adhesive system permanently attached to the bag material and the second side in position for actuation to act as a closure system;
FIG. 3 is the strip of FIG. 2 in the operative closure position showing the hinged folded back relationship to provide the closure from permanent adhesive on one side of the bag or container to removable adhesive attached to another portion of the bag;
FIG. 4 is an illustration of a clam shell container with the new hinge tab closure utilized to close the clam shell;
FIG. 5 shows the new hinge tab closure covering a pour opening on a box;
FIG. 6 illustrates the hinge tab of closure going around the corner of a box to hold a perforated flap closed;
FIG. 7 is an end elevational, cross-sectional view of an alternate embodiment of the hinge type closure with hinge means formed in the closure and a lift tab along one side thereof, and a continuous release liner;
FIG. 8 is a similar cross-sectional elevation of the strip of FIG. 7 with one side of the adhesive system permanently attached to the container material and the second side releasably secured to the container material for subsequent use;
FIG. 9 is the strip of FIG. 8 with its releasable end detached from its initial position as shown in FIG. 8 and in its operative closure position showing the hinged folded back relationship to provide the closure from permanent adhesive on one side of the container to removable adhesive attached to another portion of the container;
FIG. 10 is a perspective view illustrating the positioning of the closure strip on the bag in one location;
FIG. 11 illustrates an arrangement for positioning the twisted top of the bag over the top edge of the bag to be secured along the side of the bag;
FIG. 12 illustrates a modified arrangement for positioning the twisted top of the bag to the top edge of the material which is enclosed, rather than down the side of the bag as shown in FIG. 11;
FIG. 13 is a perspective view illustrating an alternate positioning of the closure strip on the bag as extending from a top edge thereof;
FIG. 14 is a cross-sectional view of the prior art closure system of pending application Ser. No. 413,951;
FIG. 15 is a side elevational cross-sectional view of a small container for hand cleaning towels known as handy wipes, which shows a face stock for lifting off a perfed opening in the container, but with the container in tact;
FIG. 16 is the container of FIG. 15 in the same view, but showing the lifting and perfing of the container itself as the face stock is lifted back to open up the container;
FIG. 17 is a top plan view showing the positioning of the face stock with the respective adhesive areas and the perfed relationship of the container itself;
FIG. 18 is an elevational view of a container having the strip of the invention having two permanent adhesives adhered to two separate surface conditions which may be perforated in the ungummed areas at the line of intersection between the top cap and the container; and
FIG. 19 is a plan view of a plastic bag which could be used to carry food showing the use of the strip of the invention for closing the lateral side of the bag;
FIG. 20 is a cross-sectional view substantially enlarged taken
on line 20--20 of FIG. 19, showing the particulars of the use of the strip of the invention in the closure mechanism for a food package;
FIG. 21 is a cross-sectional elevation of a modified hinge strip which includes permanent adhesive on one side, removable on an opposite spaced location, and printing essentially opposite the removable;
FIG. 21A illustrates the hinge strip of FIG. 21 folded back on itself into an operable position to operate as a closure showing how the permanent adhesive is attached to the container in the folded back condition, the removable is then attached to the container with the printing showing;
FIG. 22 is a cross-sectional elevational showing of a hinge strip having a permanent adhesive on one side and printing opposite, and removable adhesive in opposed relationships on the other end of the strip with the hinge in between;
FIG. 22A illustrates the hinge strip of FIG. 22 in operable position associated with the container showing how the strip folds back on itself and adheres to itself to hold a removed box plug out of the way to allow the contents of the container to be dispersed without contaminating the removable pressure sensitive adhesive; and
FIG. 23 is an enlarged cross-sectional elevational diagram of another embodiment of the hinge strip of the invention illustrating that a permanent adhesive or heat seal is on one end and surface, but that a plurality of other combinations of removable adhesive, permanent adhesive, or printing can be associated with the other three surfaces of the strip to achieve the desired objects.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings of FIG. 1 illustrates a preferred embodiment of the invention which incorporates a closure strip indicated generally by numeral 10 which incorporates a face material and/or shield 12 having a split pressure sensitive adhesive coating adhered thereto comprising a permanent adhesive 14 and a removable adhesive 16, these being adhered to the face stock or face layer and/or shield 12. A release liner 18 is removably attached to both pressure sensitive layers 14 and 16 by means of a silicone release coating 20, all in a manner well understood by one skilled in the art. Preferably, in order to have this closure strip function in the way preferred by the invention, the release liner 18 is slit at line 22 so that the section of the release liner covering the permanent adhesive 14 may be removed separately in machine application from that portion of the release liner covering the removable pressure sensitive layer 16. The release liner 16 is protected by the facing layer and/or shield 12.
The preferred strip 10 of the invention will include printing 24 on the face, which may be instructions or advertising or promotional material, or the like. Since the strip is permanently bonded to the container, the printing is always present. The face stock 12 may be paper, plastic, vinyl or any other suitable material, and may have some stiffness for particular applications.
The permanent adhesive layer 14 is designed to have a permanent adherence to the bag material or container to which it will be applied, and in use, as seen in FIG. 2, the release liner 18 and silicone coating 20 will be removed and split along the line 22, and then adhered to the bag or container in the form illustrated in FIG. 2. Normally, this will be done by an automatic operation through suitable machinery, and to prepare the bag with the sealing strip in place prior to inserting any material into the bag such as a loaf of bread or the like. Hence, it should be seen in FIG. 2 that the release liner 18 is still in place on the removable adhesive side. An exposed end 20a forms an easy release tab which when the face stock is bent up facilitates a manual removal of the release liner 18 from the removable side when it is desired to do that. It can be done with gloves.
In some instances, it may be desirable to not utilize the slit 22 and to simply strip the entire release liner 16 during the machine application and press both the permanent adhesive 14 and the removable adhesive 16 into position on the bag or container as shown in FIG. 8, thus assuring that the removable pressure sensitive adhesive layer 16 will not be contaminated, nor the release liner 18 cause any interference with the filling of the bag or other machine operations associated with the automatic handling of the bag or container during further processing. In other words, with the release liner 20 over the removable pressure sensitive adhesive actually removed during the application, the removable pressure sensitive adhesive can still be lifted in to operable position, particularly because of the release tab outer identified by numeral 17 as seen in FIGS. 7 through 9.
Referring to FIGS. 1-3, it should be understood that the attachment of the strip 10 by the permanent adhesive 14 allows the face stock and/or shield 12 to protect the other liner 18 to cover the removable adhesive 16 during mechanical processing when the strip is attached to the bag, as well as during filling of the bread or other materials into the bag, so the liner half 18 is not inadvertently stripped off before it is intended to be stripped by the end user. Also, of course, the instructions provided by the printing 24 will always be present thus giving an instruction reminder to the user of how to use the closure system during its repeated use.
The operability of the system is illustrated in FIG. 3 where one will manually open the hinge area of the face stock back on itself from about 20° to about the 180 degree relationship illustrated. This arrangement allows removal by the tab 20a popping out of the ungummed area 19. Using the tab 20a, one then removes the release liner, exposing the removable adhesive layer 16 which will be attached to the bag material in the manner better illustrated in FIGS. 10 and 11 of the drawings. Specifically, referring to FIGS. 10, the strip 10 is illustrated as being attached to the top end of a bag 30 with the permanent adhesive area 14 preferably being towards the open end of the bag 30, and the slit edge 22 being substantially parallel to the edge of the opening of the bag 30. The illustration in FIG. 10 shows the strip in the same configuration as in FIG. 2.
Now, in order to understand the operation of the system (see FIGS. 10 and 11), one must envision picking the bag 30 up in one hand and twisting it so as to form the slightly knotted bunched up portion 32, then lifting up the lower edge of the strip 10, removing the release liner 20, and folding the strip back along itself so as to effect a hinge relationship at the ungummed area 19, as seen in FIG. 2, between the permanent and removable pressure sensitive adhesive. Then the open end of the bag 30 is folded down allowing the exposed removable pressure sensitive adhesive layer 16 to adhere to the bag 30 where indicated, which results in the configuration of FIG. 3, and effectively folds the face stock on itself with the printing in the back to back relationship shown in FIG. 3. Note that the strip 10 shown in the chain dotted line of FIG. 11 is only half the size as in FIG. 10 because of the hinged back relationship.
Naturally, when one wants to open the bag they simply grab the folded down end of the bag and pull to release the releasable adhesive 16 from the bag material 30 which tends to cause the face stock to spring back to essentially a flat relationship again, thus exposing the printing, which might include instructions, advertising or promotional material or the like, and the face stock acts as a shield to protect the removable adhesive. The ungummed or non-adhesive area 19 acts as a separation between the permanent and removable pressure sensitive adhesive areas 14 and 16 and is important to the functioning of the strip 10 because, as the strip is grasped and the removable area is peeled from a position of adherence to the bag or container, toward a position of non-adherence, the strip snaps across the non-adhesive area to serve as an indication of sufficient peeling of the removable area from the bag or container. The same procedure is followed of twisting the top, folding the face stock back on itself and effecting the seal as bread is used from the loaf, or other ingredients are taken from the package reducing the quantity of the material in the package or bag itself. Because the removable adhesive has the characteristic to simply stick, in a removable manner to the bag material, it is easy to open the bag and reclose it many many times. In some instances to prevent contamination of the removable adhesive by bread crumbs, sugar, flour, handy disposable baby wipes or the like, it is preferable to always stick the removable adhesive portion of the strip back to the bag whether it is in the opened or closed position. Hence the removable tab is pressed into position to prevent it from getting contaminated.
FIG. 8 illustrate the removable adhesive portion of the strip in a sealed position to the container as initially applied. In this mode a release tab 17 is designed on the outer edge of the removable adhesive. In many instances this may be preferable since the removable liner 18 of FIG. 2 can catch on the machinery which fills the bag causing operating problems.
The respective terms, "permanent pressure sensitive adhesive" and "removable pressure sensitive adhesive" are used in their well known, art-recognized meanings. A permanent adhesive is one which forms a strong bond with the substrate to which it is applied, so that neither the adhesive nor any adherence surface (other than a release coated backing such as a silicone liner) can be used without damage. A removable pressure sensitive adhesive, on the other hand, is one which can be peeled off, together with the backing to which it is applied, from a substraight surface without damage to either the adhesive or the backing. In other words, in the instant situation, the removable adhesive will stay adhered to the face stock 12, but will easily remove from the bag material 30.
Representative removable pressure sensitive adhesives are those well known acrylic emulsions described in the following U.S. Pat. Nos.: 3,922,464, Spencer Silver et al, 4,645,711, Richard E. Bennet et al, 4,629,663, Francis W. Brown et al, and 4,599,265, Donald L. Emsay. These patents are incorporated herein by reference.
The earliest of these removable pressure sensitive acrylic emulsion adhesive patents (Silver et al.) comprises:
(a) a copolymer of from 88 to 99 parts by weight of at least one terminally unsaturated vinyl monomer, with 70-100% by weight of said vinyl monomer being a non-tertiary alkyl acrylate, each alkyl group having at least half its carbon atoms in a straight chain and having usually 4 to 12 carbon atoms;
(b) from 0.2 to 5 parts by weight of at least one vinyl unsaturated, homopolymerizable emulsifier monomer which is a surfactant having both hydrophobic and hydrophilic moieties and optionally may contain from 0 to 10 parts by weight of at least one Zwitterion monomer.
The Bennett et al. patent is an improvement on the Silver et al. patent and uses tackifier resin in amounts of 5-50% by weight, such as hydrogenated resin ester, polyterpene, polymerized alkyl styrene and polymerized petroleum-derived monomer resins to give the removable pressure sensitive adhesive better resistance to lifting forces at elevated temperatures while also being cleanly removable.
The Brown et al. patent teaches how to make removable pressure sensitive adhesives of the type used as automotive masking tape. The Esmay patent produces removable pressure sensitive adhesive from an alkyl acrylate polymer of low tack but sufficiently tacky to adhere to ordinary substrates by being cross-linked and nearly free of polar substituents. Thus, by adjusting the degree of cross-linking, the pullback or tack value of the adhesive can be made for use desired for the substrate. The usual automobile masking tapes are useful in this invention, particularly where the jacket is primed with a primer as described hereinafter.
The thickness, coating weight, and methods of application of the permanent and removable pressure sensitive adhesive layer 25 are similar to those of known teachings or are generally from about 0.5 to about 4 mils, desirably from about 1 to about 2 mils, preferably about 1.5 mils thick.
FIGS. 7-9 illustrate the same basic arrangement as FIGS. 1-3, except that a removable pressure sensitive adhesive layer 16 is coated so as to leave a slight uncoated area or tab at 17 at the edge of the strip to assist in one getting their finger or fingernail under and removing the release liner and release coating. The tab 17 assists in grasping the face stock 44 to assist in the hinge flap bending up the face stock into the doubled back position shown in FIG. 9, which, of course, is the operative position to hold the bag closed. FIGS. 7-9 also include a formed relationship of the hinge, which might be by a heat forming for example, and is indicated by numeral 15.
FIG. 12 illustrates the strip folded back on itself to attach to the top of the container or bag, rather than down the side as shown in FIG. 11.
FIG. 4 illustrates a clam shell type container 60 such as an insulated box for carrying a hamburger or the like and shows a closure strip having a permanent pressure sensitive adhesive layer attaching the top portion of the clam shell through the face stock and/or film shield to the bottom section which utilizes the removable pressure sensitive adhesive and the lift tab. Hence, one must simply grasp the lift tab and pull off the removable acting around the hinge point to allow opening of the clam shell and, of course, many times of reclosing.
FIG. 5 shows the same basic structural arrangement of the closure strip attached to the side of a box 70 with the ungummed area 72 extending over the opening 74 and the removable adhesive area being below the opening 74 and providing for the reclosing. The hinge 76 is at the upper edge of the opening 74 so as to facilitate a full opening of the area 74 when the lift tab actuates the opening.
FIG. 6 illustrates a closure strip utilized to close the top flap 80 of a box by the permanent adhesive being attached to the flap 80 and the removable adhesive being attached to the upper surface of the box. Hence, simply grasping the lift tab allows the closure strip to act to open and close the flap 80.
FIG. 13 illustrates a modified strip 50 which is positioned so that the permanent adhesive attaches right at the very top edge 52 of a bag 54, thus making it easier to remove the liner from the removable pressure sensitive adhesive and hinge the face stock back on itself to effect the same kind of closure as shown in FIGS. 10 and 11.
It should be understood that the embodiments of the invention illustrated in FIGS. 1-3 and in FIGS. 7-9 also include the printing on the face stock which will be for advertising, promotional or instructional purposes, and this printing always stays with the product.
It should be understood that while the strip is shown as being relatively small as compared to the entire bag, it can be of variable size, but that the important features of the invention are that the pressure sensitive adhesive is on only one side of the face stock, and combines the permanent and removable adhesive in the zone coated relationship as shown in FIGS. 1-3 and 7-9. This then, of course, allows the printing to take place on the unexposed and non-pressure sensitive side of the face stock so as to provide a permanent promotional or advertising space.
This should be contrasted to the prior art teaching of patent application Ser. No. 413,951 which is depicted in FIG. 14 of the drawings wherein a double faced pressure sensitive is applied around the central carrier, and while the release liner that is exposed can have printing thereon or advertising materials, once it is peeled off and thrown away, the advertising or instructional potential is lost.
FIGS. 15-17 illustrate a modification of the closure strip adapted to a small packet of handy wipes, for example, wherein a face stock 88 has two areas 90 and 96 of permanent adhesives, but of a different permanent adhesive. A first permanent adhesive illustrated at 90 adheres the face stock 88 permanently to the container 92. A hinged relationship is provided at 94 to facilitate a cooperation with second permanent adhesive 96 which is attached to a removable section 98 of the container 92. The removable section 98 is perfed at 100 to form a substantially rectangularly shaped removable section 98 that tears out when a lift tab 102 is grasped and pulled back in the direction shown in FIG. 16. The permanent adhesive 96 adheres the stock 88 to the section 98 so that entire section 98 tears out. The reclosable feature comes because the permanent adhesive 96 extends beyond the lateral edges of the removable section 98 and is designed for a releasable and reclosable relationship to the surfaces 104 of the container 92 at the lateral edges of the removed section 98, as seen in FIG. 17. The surfaces 104 are smooth so the permanent adhesive layer 96 is removable with respect thereto. Hence, the container 90 really can be substantially reclosed as the face stock is hinged at 94 and places the removed section 98 back into position and holds it in place by the adhesive around the lateral edges, which is best seen in FIG. 17. This type of container might contain the wetted hand towels and or sanitary napkins or the like, for reclosure and disposal if desired.
FIG. 18 is a bottle type container having a strip 110 with a first adhesive area 112 with a permanent adhesive that adheres well to a bottle surface 114 such as a polyethylene blow molded container and a second adhesive area 116 having an adhesive that may either permanently or removably adhere to a hard plastic cap 118. An ungummed area is provided at 120 which may be perfed as at 112 to facilitate tearing the label or strip 110 in half when the cap 118 is removed, or the adhesive 116 can be peeled back to removably release the cap 118.
Referring to FIGS. 19 and 20, the application of the strip of the invention to a food package will be explained. Specifically, the numeral 130 illustrates a food package, which normally will be made from plastic or the like, and is heat sealed top and bottom at 132 and -34 to normally seal the package. Normally, this type of package is blown in a tubular shape and cut off to the particular length so that once it is heat sealed at 132 and 134, the package is fully enclosed for such items as frozen vegetables or other food items, or the like. The modification of the package 130 contemplated herein is to slit the package down the lateral side 136 and then to utilize the strip of the invention, which is generally identified by numeral 138 in this figure, to effect the reclosure of the package after a portion of the contents are used. A better understanding of the strip 138 is seen in FIG. 20 showing that a permanent adhesive 140 attaches the strip 138 in a permanent manner to the package 130 as described previously. There is an ungummed area 142, and the removable adhesive is indicated by 144. A hinge area is indicated by 146. In this instance, a fold back tab 148 is formed on the removable adhesive side to assist in lifting up and removing the strip from the sealed relationship indicated or you may have an ungummed edge. Two perf lines or cuts 131 are formed on the side edges of the strip 138 inside the heat sealed lines 132 and 134 to allow the fold opening of the removable side of strip 138, thus giving access to the slit open edge 136 into the package 130. Again, the removable adhesive 144 allows for multiple repositioning and reclosure of the package 130 as many times as desired as the materials are taken from inside. The adhesives 140 and 144 should be of the freezer type or otherwise depending on the ingredients of the package, all of which is well understood by one skilled in the art so as to still function properly in a freezer or other environment. The tab 148 simply is the edge of the strip folded back on itself so that there is no adhesive, and it can be easily grasped between the thumb and forefinger, and the strip peeled back to actually open the package.
With reference to FIGS. 21 and 21A , the numeral 150 illustrates the face stock which incorporates a permanent adhesive at 152, a removable adhesive at 154, and printing at 156 with a hinge area at 158, and an ungummed area on the top surface indicated by numeral 160, and on the bottom surface indicated by numeral 162. This particular adaptation is designed for the permanent adhesive layer 152 to adhere to the container 164 as shown in FIG. 21A with the removable adhesive layer 154 that secured to container 164 by folding the face stock back on itself around the hinge 158 so as to have the strip act as a shield over a container opening 166. Note that the printing 156 is always exposed. A tab 168 is formed by the face stock 150 extending out past the edge of the removable adhesive 154. In this particular embodiment, the actual length and coverage of the permanent adhesive 152 as contrasted to the removable adhesive 154 can be over various sizes and with different spacings to accommodate the particular container with which this closure element is to be associated.
With reference to FIGS. 22 and 22A, in this instance the face stock is indicated by numeral 170 with the permanent adhesive indicated by numeral 172 and removable adhesive layers 174 and 176 on opposite sides of the face stock, and the printing area to 178 hinge is indicated by 180 between the printing and the top removable layer 174. A tab is formed on both sides of the face stock adjacent the removable layers 174 and 176 with the tab indicated by numeral 182. This particular hinge closure strip is perhaps best adapted for use with the container 183 illustrated in FIG. 22A wherein the lower removable pressure sensitive layer 176 contacts with and pulls out a box plug 184 from the container exposing a container opening 186, in the manner to allow the contents which might be soap, grass seed, etc., for example, to be poured out the opening 186. In order to prevent the pressure sensitive layer 176 from becoming contaminated by the soap as it is poured out, the removable adhesive layer 174 is folded back in the configuration illustrated in FIG. 22A and pressed into retain position on top of the printing 178, thus holding the entire closure hinge mechanism out of the way and allowing the soap powder to be poured from the opening 186. When it is desired to reclose the container, one simply grasps the tab 182 and removes layer 174 from the printing area 178 and then reapplies the extending adhesive layer 17 to push the box plug 184 back into position and hold it relative to the container 183. The box plug 184 will be perforated and removed in very much the same manner as described with respect to FIGS. 15-17 of the drawings, and again the removable pressure sensitive adhesive layer 176 will extend laterally past the sides of the opening 186 so as to removably and repeatedly reclose the container.
FIG. 23 is an illustration of the great flexibility and variations that can be incorporated into the hinge strip closure mechanism of the invention. Numeral 190 illustrates a face stock and/or film shield which might be thin and flexible plastic, or thicker more rigid material depending upon the particular circumstances. In any event, the essence of the invention is accomplished by including a permanent adhesive or heat seal indicated by 192 that will permanently attach the face stock 190 to the container. Three additional zones are contemplated, these being indicated by numerals 194, 196 and 198, and each of these zones or areas can be either a removable adhesive, a permanent adhesive, or simply be printing depending upon the particular closure mechanism characteristics desired at the particulars of the container with which this is associated. The criticality of the invention, however, is to include ungummed area between each of the respective sections, these being respectively indicated by numeral 200 on the bottom, and 202 on the top. The exact spaced relationship of the ungummed areas between areas 196 and 198 and 192 and 194, respectively can vary again depending upon the particulars of the closure mechanism and the container with which it is associated. Each of the ungummed areas 200 and 202 may include a hinge relationship which is illustrated at 200a on the bottom and 202a on the top, and again it should be understood that these hinged areas can be positioned anywhere in the ungummed area relative to the respective pressure sensitive adhesive and/or printed areas. Preferably, some ungummed area is provided at the ends of the film stock 190 adjacent to the areas 194 and 196 so as to form respective tabs 194a and 196a.
Thus, it should be understood that the exact size of the respective areas 192 through 198, as well as their positional relationship on the face stock 190 can all vary depending upon the particulars of the container which is being closed. When we refer to permanent adhesive associated with areas 194, 196 or 198, it should be understood that that will actually be removable from the area of the container to which it is attached because the entire unit must, in fact, be repeatedly removable to effect a reclosure of the container, and the only adhesive which remains in tact and holds the face stock always with respect to the container is the permanent adhesive or heat seal area 192. It should further be understood that there could be both printing and pressure sensitive adhesive in areas 194, 196 and 198, again depending upon the need for the closure system and whether or not the face stock 190 is clear or opaque.
It should further be understood that this invention is applicable to either being in a tape roll or a self wound configuration during manufacture. Also, it can be used in sheet label or sheet form. The hinge tab closure system can be die cut in various sizes and shapes. The spacing between the permanent pressure sensitive and removable pressure sensitive can vary depending upon the desired action of the hinge and the necessity of not attaching to a portion of the product, such as over the carton opening configuration shown in FIG. 5. It should be understood that the face stock may be clear or opaque and may include printing on one or both sides of the clear or on one side of the opaque. The pressure sensitive adhesive may be pigmented such as in a red to identify the release tab to the user. The red pigment in the adhesive may also act as a warning or as a protective label to identify to the user that this is a release tab and should be used as a closure system.
It should further be understood that in certain instances it may be desirable to use a heat seal in place of the permanent adhesive to the package, in which case it would not be necessary to utilize a permanent adhesive, but the heat seal itself would act as the permanent attachment of the tab. Finally, it should be understood that the closure strip or shield can employ any type of thickness or stiffness in the face material so as to facilitate the hinging action, and that the hinging action may be at one or more points in the middle so as to bend around a large radius corner or work more acceptably in the clam shell arrangement as shown in FIG. 4.
While in accordance with the patent statutes, only the preferred embodiment of the invention has been illustrated and described in detail, it is to be particularly understood that the invention is not limited thereto or thereby, but that the inventive scope is defined in the appended claims. | This invention relates to a hinge type pressure sensitive resealable closure system for a container. The invention comprises an essentially flat strip of suitable material that is permanently adhered at one surface to the container, such adherence normally by a permanent pressure sensitive adhesive, but it could be heat sealed or otherwise attached to the container in a permanent manner. Another surface of the strip is adapted by virtue of a removable pressure sensitive adhesive to be repeatedly removably attached to the container with the respective permanent and removable attachments closing the container in a repeatable resealable mode. The strip can include printing thereon, and other suitable surfaces could include more removable pressure sensitive adhesive for various more sophisticated closure techniques. The strip is provided with a hinge mechanism between the two surfaces thereby allowing the two surfaces to move relative to each other to be in different planes, thus allowing the strip to go around corners or be folded back on itself to effect different types of closure techniques for various containers. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cutting blades made of cermet (cermet cutting blades), and more particularly, relates to a cutting blade made of a titanium carbonitride-base cermet which exhibits excellent fracture resistance.
2. Description of the Related Art
In the early period after cermet cutting blades had been developed, TiC--Mo--Ni alloys were used as cermets. Such alloys were, however, remarkably inferior to cemented carbide in toughness though they were highly wear-resistant. This limited the use of the cermet cutting blades to high-speed-finish-cutting of steels. After that, the addition of a nitride compound such as TiN was found to be considerably effective in improving the toughness of cermets. The cutting blades made of such cermets, therefore, have been used for milling, which is substantially interrupted cutting, in addition to being used for turning of steels, with utilizing the advantages inherent in cermet, namely, high wear-resistance and capability of providing high-quality surface finish for products. Meanwhile, in cutting blades made of cemented carbide, coated carbide was developed. The coated carbide comprise a base material of a cemented carbide, and a coat of a hard compound such as TiC, Ti(C,N), Al 2 O 3 or the like provided on the surface of the base material. Such coated carbides exhibit improved wear-resistance without losing the toughness as the original characteristic of cemented carbide. Under such circumstances, cermet has been required to be further improved in toughness without losing its high wear-resistance.
In general, cermets have hard phases having a core/shell (or core/rim) structure in which a grain of Ti(C,N) or the like is surrounded with a carbonitride solid solution such as (Ti,Mo) (C,N). Noting this feature inherent in cermet, many investigations were made to improve the toughness of cermet. For example, the specification of U.S. Pat. No. 4,778,521 discloses a core/shell structure comprising three layers, namely, a core of Ti(C,N), a WC-rich intermediate layer surrounding the core, and an outer layer of (Ti,W) (C,N) surrounding the intermediate layer. Further, EP Publication No. 0,406,201 B1 discloses a cermet having two or more types of core/shell structures for its hard phases. Additionally, EP Publication No. 0,578,031 A2 discloses a cermet comprising a matrix of the conventional core/shell structure, and Ti-rich hard phases dispersed in the matrix.
Though some improvement has been accomplished, these cermets remain unsatisfactory in toughness since they are based on the conventional cermet structure which comprises a core of hard Ti compound grains or hard Ti-rich compound grains and a shell of a carbonitride solid solution surrounding the grains. An attempt to further enhance the toughness of such a cermet requires an increased content of a binder metal such as cobalt or nickel. This causes some problems, for example, decreased wear resistance and decreased plastic-deformation resistance.
Further, a characteristic of Ti, which is a principal ingredient of the hard phases in cermet, to easily react with nitrogen is utilized for producing highly wear-resistant cermet. Specifically, a hard layer hardened region can be formed on the surface of cermet by controlling the partial pressure of nitrogen in the sintering atmosphere. Actually, Japanese Laid-open Patent Publication No. 2-15139 discloses a cermet wherein wear resistance in the surface portion of the cermet is enhanced by using a technique like the above. Although this cermet is highly wear-resistant, it also remains to be improved in toughness since the texture of the cermet also comprises the core/shell structure as described above.
SUMMARY OF THE INVENTION
The present invention has been accomplished to solve the above-described problems, and an aspect of the present invention is as follows.
In a cutting blade made of a titanium carbonitride-base cermet comprising:
3 to 20% by weight of a metal binder phase, the principal ingredients of which are Co and/or Ni,
3 to 30% by weight of a single-structural hard phase comprising at least one component selected from the group consisting of carbide, nitride and carbonitride compounds of metal elements belonging to Groups 4a, 5a and 6a of the periodic table and a solid-solution comprising at least two said compounds, and
the balance being a double-structural hard phase which comprises a core portion and a shell portion completely surrounding said core portion, wherein said core and shell portions comprise as substituents titanium carbonitride and/or a carbonitride compound of Ti and at least one element M selected from metal elements belonging to Groups 4a, 5a and 6a of the periodic table other than Ti, except that the shell portion must contain a carbonitride compound of at least M, and wherein said shell portion has a lower content of Ti and a higher content of M than those in the core portion, respectively; and incidental impurities, the improvement comprising:
said double-structural hard phase is partly or wholly substituted with a discontinuous double-structural hard phase comprising a core portion and a shell portion, in which the shell portion is discontinuously distributed around the core portion so that the core portion is partially exposed to the metal binder phase, and said discontinuous double-structural hard phase occupies 30 or more area % of the total surface of the cermet in terms of electron-microscopic texture analysis, and whereby the cutting blade exhibits excellent fracture-resistance.
Further, another aspect of the present invention is a cutting blade made of a coated cermet based on the above-described cermet, wherein the cermet is coated with at least one compound selected from titanium carbide, titanium nitride, titanium carbonitride, titanium carbonate-nitride, (Ti,Al)N, and aluminum oxide in a thickness of 0.5 to 20 μm.
In the cermet cutting blade or coated cermet cutting blade of the present invention recited above, a hardened region may be present in their surface portion, wherein the peak of Vickers hardness higher than the Vickers hardness of the inner portion is present within a range from the top surface of the blade to 50 μm under the top surface.
Additionally, in the cermet cutting blade or coated cermet cutting blade of the present invention recited above, the mean grain sizes of the hard phases are preferably 0.1 to 1.5 μm, respectively, and more preferably, 0.5 to 1.2 μm, respectively.
Further, in the coated cermet cutting blade of the present invention recited above, the coating may contain a (Ti,Al)N coating layer having a thickness of 0.5 to 5 μm and being provided by a PVD method; or may contain a TiCN coating layer having a thickness of 0.5 to 5 μm and being provided by a MT-CVD method so that the grain of TiCN grows as longitudinal crystals in the direction perpendicular to the surface of the cermet.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 3 are schematic drawings showing internal textures of the cermet cutting blades according to the claimed invention, observed by the electron microscope. FIGS. 2 and 4 are similar but are of cermet cutting blades not according to the claimed invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The inventors investigated improving the toughness of cermet to be used for cutting blades, noting the core/shell structure employed in the prior inventions.
In general, cermets contain Ti compounds for improving wear resistance. The Ti compounds are present in cermets principally as cores in hard phases, namely, as cores of Ti(C,N) or Ti-rich carbonitride solid solution grains, and each core is surrounded with a shell, namely, other carbonitride solid solution grains which contain lower contents of Ti than the former grains. Though both crystal structures of the core grains and shell grains are of an NaCl type, these grains are different in the coefficient of thermal expansion due to the difference in the ingredient composition. Accordingly, there is a thermal stress between the core and the shell which is caused by such difference. Since the mode of the thermal stress varies depending on the ingredient contents of the core and the rim, it cannot be uniformly determined which of the core and the shell is affected by tensile stress, or how strong the stress is. Nevertheless, the core, which contains a larger amount of Ti, seems to be much more affected by tensile stress than the rim, which contains relatively large amounts of W and Mo. The grains having a NaCl type crystal structure, such as the core and the shell above, do not exhibit slide deformation while the grains having a WC type crystal structure do. The phases constituted with the former grains are, therefore, brittle and easily broken by tensile stress. Consequently, decreasing the thermal stress in the core/shell structure is recognized as important for improving the toughness of cermet. In Japanese Laid-open Patent Publication No. 6-248385, there is disclosed a cermet containing the phases of Ti(C,N) grains which have a single structure, namely, which have a non-core/shell structure. In this cermet, however, the content of such phases is as low as 1 through 5% by volume, and most of the phases constituting the cermet are of the ordinary core/shell structure type. The thermal stress is, therefore, not sufficiently decreased in this cermet. Further, even if the content of the single-structural phases of the Ti(C,N) grains can be raised, the portion comprising such grains will be low in hardness, and the wear resistance will decrease since the binding strength between the Ti(C,N) grains and the metal binder phases is small.
Under such circumstances, the inventors reached an idea as follows: Thermal stress inherent in the ordinary core/shell structure may be decreased by making the core/shell structure incomplete, namely, by allowing the hard grains of Ti(C,N) or of a Ti-rich complex-metal carbonitride compound (these grains correspond to the core of the ordinary core/shell structure) to be in the state of mutually contacting with grains which have relatively low Ti contents (these grains correspond to the shell of the ordinary core/shell structure); or by allowing the hard grains of Ti(C,N) or of a Ti-rich complex-metal carbonitride compound to be in the state of being incompletely surrounded with grains which have relatively low Ti contents, wherein a part of the former grain is exposed. In other words, the inventors conceived of a structure for cermet in which a part of the core is exposed to the metal binder phases, and the shell is discontinuously distributed around the core.
Such a structure could be actually accomplished as follows. At first, Ti(C,N) powder produced directly from a titanium oxide compound was selected as a raw material. Then, in the process of sintering the mixed powder of raw materials, the sintering was stopped before a core/shell structure could sufficiently be developed. On a cermet thus obtained, a cutting test was performed and revealed that the cermet having such a structure has, along with the above anticipation, both high wear resistance and high toughness.
The present invention has been accomplished according to the above findings. Typically, the cermet of the present invention comprises metal binder phases, single-structural hard phases, double-structural hard phases each of which comprise a core portion and a shell portion completely surrounding the core portion, and double-structural hard phases each of which comprise a core portion and a shell portion discontinuously distributed around the core portion.
As principal ingredients of the metal binder phases in cermets, Co and/or Ni are ordinarily used. With a content of these elements below 3% by weight, the cermet will be brittle due to too a small amount of metal binding phases which supports the toughness of the cermet. On the other hand, with a content exceeding 20% by weight, the cermet will be low in hardness and cannot be applied to cutting blades. For these reasons, the content of Co and/or Ni has been determined to be 3 to 20% by weight in the cermet of the present invention.
Further, the content of metal carbonitride compounds, which constitute the single-structural hard phases in the cermet of the present invention, has been specified to be 3 to 30% by weight. With a content below 3% by weight, the desired improving effect in wear resistance cannot be achieved. On the other hand, with a content exceeding 30% by weight, fracture resistance of the cermet will deteriorate.
Among the double-structural hard phases in the cermet of the present invention, the double-structural hard phases in which the shell portion is discontinuously distributed around the core portion has been specified to occupy 30 area % or more of the total surface of the cermet. With a ratio below 30 area %, sufficient effect of decreasing thermal stress inherent in the core/shell structure cannot be achieved. When such a cermet is used for a cutting blade, the phases in the composition will be crushed during the cutting procedure. In other words, fracture resistance of the cermet cannot be markedly improved with such a ratio.
As described above, by controlling the sintering atmosphere, the cermet can be produced so that the portions near the surface of the composition have small amounts of metal binder phases while having large amounts of hard phases. According to this, a cutting blade can be provided with a hardened region at its surface portion, and the wear resistance of the blade can be improved. Here, the cermet cutting blade can possess much higher toughness as well as high wear resistance by providing, using the cermet of the present invention as the base, such hardened regions at the top surface portion of the blade. Such cermet cutting blades were actually manufactured and a cross section of each cutting blade was examined for hardness using a micro Vickers hardness meter. As a result, a hardness gradient was observed in the cross section of each cutting blade. The hardness gradient started at a point 0.5 to 1 mm under the surface, and ascended substantially continuously toward the surface. In each cutting blade, the peak of the hardness value, which was higher than those of the inner portions of the cutting blade, was measured within a range from the top surface to 50 μm under the top surface, but were not measured in further deeper portions. According to this, in the cermet cutting blade of the present invention, the peak of Vickers hardness could be specified to be present at a position within a range from the top surface to 50 μm under the top surface. As to the ratio of the peak hardness value to the hardness value of the inner portion, a desired wear resistance cannot be fully achieved with a ratio below 1.3, and the surface of the cutting blade becomes too hard and tends to be easily broken with a ratio exceeding 1.8. Accordingly, the ratio of peak hardness value to hardness value of the inner portion should preferably be 1.3 to 1.8 in the cutting blade of the present invention.
Depending on the conditions for manufacturing, the top surface of the cutting blade may be provided also with softened regions which comprise bonding phases alone or comprise metal binding phases and hard phases merely having a single structure, and which have lower hardness values than those of the inner portions. Such softened regions may coexist with the above-described hardened regions at the top surface of the cermet cutting blade of the present invention.
Frequently, cermets are used as a base for cutting blades which should be manufactured by coating the base with a titanium carbide, a titanium nitride, a titanium carbonitride, and a titanium carbonate-nitride (hereinafter, these are referred to as Ti-compounds), (Ti,Al)N, aluminum oxide and/or the like by a CVD method or a PVD method. Here, the effect attributed to coating will be further enhanced by using the cermet of the present invention as the base, which has high toughness and excellent wear resistance.
The thickness of the coating layer provided on the surface of a cermet base material should preferably be 0.5 to 20 μm.
In the PVD methods, the depositing rate is relatively slow, and the resultant coating layer will easily cause spalling due to compressive residual stress in the coating when the coating is too thick. For these reasons, the thickness of the coat formed by the PVD method should be 0.5 to 15 μm, and preferably, 1 to 10 μm.
Since the (Ti,Al)N coat formed by the PVD method is highly thermally conductive, markedly improved thermal-shock resistance will be achieved particularly in the products in which the cermet of the present invention having high toughness and excellent wear resistance is used as a substrate and a (Ti,Al)N coat is provided on the surface of the substrate.
In coating a substrate of the cermet with Ti-compounds or aluminum oxide by a CVD method, when the substrate is coated at a high temperature (i.e. using a HT-CVD method) with TiC or Ti(C,N) which has high wettability with the ingredients of the metal binder phases in the cermet, the ingredients of the metal binder phases, especially Ni, will be dispersed into the coat to decrease wear resistance of the coated product. For this reason, when a CVD method is employed, a substrate of the cermet should be coated preferably at a low temperature, namely, by using a MT-CVD method which can coat the substrate with Ti(C,N) at 1000° C. or below. This inhibits the dispersion of ingredients of the metal binder phases into the coating layer. Alternatively, the following coating process may be employed: At first, a coat with TiN, which has low wettability with the ingredients of the metal binder phases, is formed by a HT-CVD method; on the coat thus formed, a Ti(C,N) coat is formed by a MT-CVD method; and further, a coat with aluminum oxide or the like is formed thereon.
A Ti(C,N) coating layer to be formed by a MT-CVD method can be a thick layer, by allowing to grow as longitudinal crystals in the direction perpendicular to the surface of the substrate, without decreasing the strength of the cutting edge of the cutting blade to be produced therewith. This remarkably improves wear resistance of products. The effect attributed to such coating will be enhanced particularly by using, as the substrate, the cermet of the present invention which has high toughness and excellent wear resistance.
Additionally, the compounds such as (Ti,Al)N which are rarely applicable to CVD methods can be introduced into a cermet as a coating layer by employing a PVD method in combination. Specifically, a core with a coating material is first formed by a CVD method, and a coat with (Ti,Al)N or the like is formed on the first formed coat by a PVD method.
In the cermet cutting blade and coated cermet cutting blade according to the present invention, the cermet as the substrate is a titanium carbonitride-base cermet principally comprising titanium, and all of the hard phases in the composition have a crystal structure of NaCl type.
In general, the hard phases which are constituted principally with titanium are hard and brittle, and are easily broken by concentration of stress when the grain sizes of hard phases exceed 1.5 μm. On the other hand, when the grain sizes are smaller than 0.1 μm, wear resistance of the hard phases become lower and craters due to wear easily become larger, and in addition, plastic deformation will easily occur. For these reasons, the grain sizes of the hard phases should be 0.1 to 1.5 μm, and preferably, 0.5 to 1.2 μm according to the present invention.
As to metal elements other than titanium, M, which belongs to Group 4a, 5a or 6a of the periodic table, when the content of M exceeds 50% by weight, the relative content of Ti will be low, and therefore, wear resistance of a cermet to be produced will decrease since Ti is an effective ingredient for raising hardness of cermets. For this reason, the content of M should be 50% or less by weight.
The content of nitrogen in a titanium carbonitride-base cermet increases the amount of M present in the metal binder phases as solid-solution to solid-solution-harden the bonding phases. In addition, the nitrogen improves the toughness of hard phases and inhibits the granular growth of the grains in hard phases during the sintering process. The content of nitrogen calculated from the formula expressed in terms of moles, N/(C+N), should preferably be 0.1 to 0.6. When the content expressed by the above formula is below 0.1, the desired effect as above cannot be achieved. On the other hand, when the content expressed by the above formula exceeds 0.6, the degree of sintering will decrease and pores will frequently remain in the cermet.
EXAMPLE 1
Cermet cutting blades according to the present invention, EX 1 to EX 10, and cermet cutting blades for comparison, CE 1 to CE 10, were respectively manufactured as follows.
As raw materials, the powders listed below were prepared. Each powder had a predetermined mean particle size within a range of 0.5 to 2 μm.
Ti(C,N) powder (C/N=50/50 by weight), TiN powder,
TaC powder, NbC powder, WC powder, Mo 2 C powder, VC powder, ZrC powder, Cr 3 C 2 powder,
(Ti,W,Mo) (C,N) powder (Ti/W/Mo=70/20/10, C/N=70/30),
(Ti,Ta,V) (C,N) powder (Ti/Ta/V=70/20/10, C/N=60/40),
(Ti,Nb,Mo) (C,N) powder (Ti/Nb/Mo=80/10/10, C/N=50/50),
Co powder, Ni powder, and graphite powder C.
These powders were mixed so as to have the formulations shown in Table 1, respectively, and each mixture was wet-blended for 24 hours and dried. The resultant formulations were pressed into shapes with a pressure of 1 t/cm 2 to obtain green compacts A to J.
TABLE 1__________________________________________________________________________GreenFormulation (% by weight)CompactTi (C,N) TiN TaC NbC WC Mo.sub.2 C Co Ni C Other__________________________________________________________________________A 55 10 5 10 5 10 2 1 2B 15 13 16 1 3 2 (Ti,W,Mo) (C,N):50C 60 5 6 12 8 2 5 2D 65 7 7 7 3 6 2 ZrC:3E 35 14 6 8 6 3 7 1 (Ti,Ta,V) (C,N):20F 55 10 8 11 7 3 1 Cr.sub.3 C.sub.2 :5G 50 8 2 6 5 16 6 6 1H 45 10 10 5 5 7 7 1 (Ti,Nb,Mo) (C,N):10I 50 10 14 10 8 7 1J 45 14 5 10 5 12 8 1__________________________________________________________________________
Each of the above-prepared green compacts A to J was sintered using the following sintering conditions: At first, in a vacuum atmosphere of 0.05 torr, the sintering temperature was raised from room temperature to 1300° C. at a rate of 2° C./min.; the atmosphere was then changed to a nitrogen atmosphere of 10 torr or below, and the sintering temperature was raised to a predetermined temperature within a range of 1380° C. to 1460° C. at the same temperature-ascending rate; after the sintering temperature reached the predetermined temperature, the atmosphere was changed to a vacuum atmosphere of a predetermined pressure within a range of 0.5 to 30 torr, and the state was retained for 60 min.; and furnace cooling was performed in the same atmosphere. According to the above sintering procedure, ten cermet cutting blades of the present invention, EX 1 to EX 10, were manufactured. Each cermet cutting blade had cutting inserts having ISO Standards of CNMG120408.
For comparison, another set of the green compacts A to J were prepared and sintered using the same procedure as above, except that the sintering temperature was raised to a higher predetermined temperature within a range of 1530° C. to 1560° C., to obtain ten cermet cutting blades for comparison, CE 1 to CE 10.
Subsequently, a cross section of each cermet cutting blade was examined for Vickers hardness successively from the top surface to an inner portion of the blade in order to determine the depth where the peak of the Vickers hardness was present Further, an inner position in the cross section of the blade was properly selected and the texture around this position was observed by an electron microscope, and the formation and percentage of hard phases in the texture were analyzed by an image analysis system.
Additionally, the mean grain size of the hard phases was also measured by an image analysis.
FIGS. 1 and 2 are schematic drawings showing internal textures of the cermet cutting blades EX 7 and CE 7, respectively, observed by the electron microscope.
In these schematic drawings, indications of the numerals are as follows.
The numeral 1 indicates metal binder phases principally constituted with Co and/or Ni.
The numeral 2 indicates hard phases having a double structure. In detail, the numeral 2a indicates core portions comprising a carbonitride compound and/or a titanium carbonitride, the carbonitride compound comprising Ti and at least one element M selected from metal elements belonging to Groups 4a, 5a and Ga of the periodic table other than Ti. On the other hand, the numeral 2b indicates shell portions comprising a (Ti,M)-carbonitride compound while the content of Ti is smaller and that of M is larger than in the core portions.
The numeral 3 indicates hard phases having a single structure which comprise at least one compound which is selected from carbide, nitride or carbonitride compounds of metal elements belonging to Group 4a, 5a or 6a of the periodic table; and a solid-solution constituted with at least two of these compounds.
Further, the fracture resistance of each cermet cutting blade manufactured as described above was evaluated by measuring the flank-wear breadth of the cutting edge after wet interrupted-cutting was performed under the following conditions.
Steel material to be cut: a round bar standardized as JIS S20C, DIN CK22, ANSI 1020, which has four flutes provided in the longitudinal direction at regular intervals;
Cutting speed: 250 m/min.;
Feed rate: 0.2 mm/rev.;
Depth of cut: 2 mm; and
Cutting time: 20 min.
The results are shown in Tables 2 and 3.
TABLE 2__________________________________________________________________________ Area Percentage (%) of Hard Phases Double StructuralCement HavingCutting Discontin- Mean Grainblade Hardness of Hardness of Having ously Size ofof the Surface Inner Completely Distributed Hard Flank-WearPresentGreen Portion Portion Single Surrounding Surface Phases BreadthInventionCompact (HV) (HV) Total Sturctural Surface Portion Portion (μm) (mm)__________________________________________________________________________EX 1 A 2020 2020 95 8 32 55 0.9 0.09EX 2 B 1920 1930 95 3 31 61 1.3 0.09EX 3 C 1970 1980 94 10 53 31 0.5 0.13EX 4 D 1900 1880 93 6 12 75 1.5 0.15EX 5 E 1860 1850 92 4 21 67 1.2 0.18EX 6 F 1850 1850 89 3 49 37 0.9 0.17EX 7 G 1700 1720 89 14 45 44 0.8 0.21EX 8 H 1650 1660 87 3 27 57 0.6 0.24EX 9 I 1600 1610 89 9 30 50 1.2 0.24EX 10J 1530 1530 85 22 0 63 1.0 0.27__________________________________________________________________________
TABLE 3__________________________________________________________________________ Area Percentage (%) of Hard Phases Double StructuralCement HavingCutting Discontin- Mean Grainblade Hardness of Hardness of Having ously Size ofof the Surface Inner Completely Distributed Hard Flank-WearPresentGreen Portion Portion Single Surrounding Surface Phases BreadthInventionCompact (HV) (HV) Total Sturctural Surface Portion Portion (μm) (mm)__________________________________________________________________________CE 1 A 2030 2000 95 2 93 -- 1.8 *(2 min.)CE 2 B 1930 1940 95 2 93 -- 1.7 *(2 min.)CE 3 C 1960 1950 95 0 95 -- 1.4 *(5 min.)CE 4 D 1890 1890 92 1 91 -- 1.2 *(5 min.)CE 5 E 1870 1870 90 0 90 -- 1.5 *(8 min.)CE 6 F 1870 1850 88 0 88 -- 1.4 **(10 min.)CE 7 G 1690 1700 89 1 88 -- 2.0 *(8 min.)CE 8 H 1610 1630 88 2 86 -- 2.2 *(15 min.)CE 9 I 1620 1610 88 0 88 -- 1.8 *(10 min.) CE 10J 1530 1530 85 2 83 -- 1.7 **(15 min.)__________________________________________________________________________ *Blade inoperable by the time shown in the parentheses due to breakaqe. **Blade inoperable by the time shown in the parentheses due to chippinq
From the results of the above image analyses, all of the cermet cutting blades of the present invention, EX 1 to EX 10, were found to contain 30 area % or more of double-structural hard phases, the shell portion of which is discontinuously distributed around the core portion. On the other hand, all of the cermet cutting blades for comparison, namely, conventional cermet cutting blades, CE 1 to CE 10, were found to comprise double-structural hard phases, the shell portion of which is completely distributed around the core portion, namely, completely surrounding the core portion; and/or single-structural hard phases.
As is obvious from the results shown in Tables 2 and 3, the cermet cutting blades of the present invention are provided with much more excellent fracture-resistance as compared to the conventional cermet cutting blades.
EXAMPLE 2
Another set of the green compacts A to J were prepared, and some of these green compacts were sintered under the following conditions to manufacture six cermet cutting blades of the present invention, EX 11 to EX 16: At first, in a vacuum atmosphere of 0.05 torr, the sintering temperature was raised from room temperature to 1300° C. at a rate of 2° C./min.; the atmosphere was then changed to a nitrogen atmosphere of 5 torr, and the sintering temperature was raised to a predetermined temperature within a range of 1400° C. to 1460° C. at the same temperature-ascending rate; after the sintering temperature reached the predetermined temperature, the atmosphere was changed to a vacuum atmosphere of a predetermined pressure within a range of 0.01 to 0.1 torr, and the state was retained for 60 min.; and furnace cooling was performed in the same atmosphere. Each cermet cutting blade thus obtained had cutting inserts having ISO Standards of CNMG120408.
For comparison, another set of the green compacts A to J were prepared and some of these green compacts were sintered using the same procedure as above, except that the sintering temperature was raised to a higher predetermined temperature within a range of 1530° C. to 1560° C. and that the atmosphere for the sintering step at this temperature is a nitrogen atmosphere of a predetermined pressure within a range of 5 to 15 torr, to obtain six cermet cutting blades for comparison, CE 11 to CE 16.
Subsequently, a cross section of each cermet cutting blade was examined for Vickers hardness successively from the top surface to an inner portion of the blade in order to determine the depth where the peak of hardness was present. Further, an inner position in the cross section of the blade was properly selected and the texture around this position was observed by an electron microscope, and the formation and percentage of hard phases in the texture was analyzed by an image analysis system.
Additionally, the mean grain size of hard phases was also measured by an image analysis.
FIGS. 3 and 4 are schematic drawings showing internal textures of the cermet cutting blades EX 14 and CE 14 observed by the electron microscope, respectively.
Further, the fracture resistance of each cermet cutting blade manufactured as described above was evaluated by measuring the flank-wear breadth of the cutting edge after wet interrupted-cutting was performed under the following conditions.
Steel material to be cut: a round bar standardized as JIS S20C, DIN CK22, ANSI 1020, which has four flutes provided in the longitudinal direction at regular intervals;
Cutting speed: 300 m/min.;
Feed rate: 0.2 mm/rev.;
Depth of cut: 2 mm; and
Cutting time: 20 min.
The results are shown in Tables 4 and 5.
TABLE 4__________________________________________________________________________ Area Percentage (%) of Hard Phases Double StructuralCement Having MeanCutting Having Discontin- Grainblade Hardness of Completely ously Size Flank-of the Surface Peak of Hardness Hardness of Surrounding Distributed Hard WearPresent Green Portion Depth Hardness Inner Portion Single Surface Surface Phases BreadthInvention Compact (HV) (μm) (HV) (HV) Total Structural Portion Portion (μm) (mm)__________________________________________________________________________EX 11 A 2500 10 2930 2010 96 5 23 68 0.8 0.06EX 12 C 1820 25 2860 2100 94 8 54 32 1.2 0.12EX 13 D 2610 0 2610 1820 92 12 0 60 1.4 0.14EX 14 G 1370 50 2390 1500 66 24 23 39 0.8 0.19EX 15 I 1760 10 2020 1430 65 9 27 49 0.6 0.25EX 16 J 1810 15 1980 1320 81 30 0 51 0.7 0.24__________________________________________________________________________
TABLE 5__________________________________________________________________________ Area Percentage (%) of Hard Phases Double StructuralCement Having MeanCutting Having Discontin- Grainblade Hardness of Completely ously Size Flank-of the Surface Peak of Hardness Hardness of Surrounding Distributed Hard WearPresent Green Portion Depth Hardness Inner Portion Single Surface Surface Phases BreadthInvention Compact (HV) (μm) (HV) (HV) Total Structural Portion Portion (μm) (mm)__________________________________________________________________________CE 11 A 2800 15 2960 2000 96 1 95 -- 1.8 *(1 min)CE 12 C 2790 5 2810 1940 93 0 93 -- 1.7 *(3 min)CE 13 D 2210 10 2600 1860 93 1 92 -- 1.5 *(5 min)CE 14 G 1960 0 1960 1620 87 2 85 -- 1.3 *(7 min)CE 15 I 1830 15 1920 1510 85 0 8S -- 1.3 **(16 min)CE 16 J 1790 10 1890 1390 80 1 79 -- 1.2 **(18__________________________________________________________________________ min) *Blade inoperable by the time shown in the parentheses due to breakage. **Blade inoperable by the time shown in the parentheses due to chipping.
From the results of the above image analyses, all of the cermet cutting blades of the present invention, EX 11 to EX 16, were found to have a hardened region in the surface portion, and contain 30 area % or more of double-structural hard phases, the shell portion of which is discontinuously distributed around the core portion. On the other hand, all of the cermet cutting blades for comparison, namely, conventional cermet cutting blades, CE 11 to CE 16, were found to comprise double-structural hard phases, the shell portion of which is completely distributed around the core portion, namely, completely surrounding the core portion; and/or single-structural hard phases.
As is obvious from the results shown in Tables 4 and 5, the cermet cutting blades of the present invention are provided with much more excellent fracture-resistance as compared to the conventional cermet cutting blades.
EXAMPLE 3
Another set of the cermet cutting blades EX 1 to EX 10 according to the present invention were manufactured, and some of these were used as substrates and coated by the methods shown in Table 6 to obtain coated cermet cutting blades of the present invention, EXc 1 to EXc 12, each cutting blade having the coating formulation and the mean layer thickness shown in Table 6.
The coating conditions were as follows when an arc ion plating system, which is a system for physical vapor deposition, was used.
Raw materials: Ti, Ti--Al target, and reactor gas (CH 4 and N 2 )
Coating temperature: 700° C.
Coating pressure: 2×10 -2 Torr
Bias voltage: -200 V
When a chemical vapor deposition system was used, the coating conditions were as follows.
Coating material: reactor gas (TiCl 4 , CH 4 , N 2 and H 2 ; When TiCN should be deposited, CH 3 CN was used instead of CH 4 .)
Coating temperature: 1010° C.; 890° C. when TiCN should be deposited.
Coating pressure: 100 Torr; 50 Torr when TiCN should be deposited.
For comparison, another set of the cermet cutting blades for comparison, CE 1 to CE 10, were manufactured, and some of these were subjected to the same procedure as above to manufacture coated cermet cutting blades for comparison, CEc 1 to CEc 12.
On each cermet cutting blade manufactured as described above, the fracture resistance was evaluated by measuring the flank-wear breadth of the cutting edge after wet interrupted-cutting was performed under the following conditions.
Steel material to be cut: a round bar standardized as JIS S20C, DIN CK22, ANSI 1020, which has four flutes provided in the longitudinal direction at regular intervals;
Cutting speed: 350 m/min.;
Feed rate: 0.2 mm/rev.;
Depth of cut: 2 mm; and
Cutting time: 20 min.
The results are shown in Table 6.
TABLE 6__________________________________________________________________________ Formulation of Hard Coating Layers Flank- and Mean Thickness Wear Thereof (μm) Coating Breadth Base ←(Lower Layer)(Upper Layer)→ Method (mm)__________________________________________________________________________Coated EXc 13 Coated EX 1 TiN 0.5!-Ti(C,N) 3!-TiN 0.5! PVD 0.14Cerment EXc 14 Cerment EX 3 (Ti,Al)N 3!-TiN 0.2! PVD 0.11Cutting EXc 15 Cutting EX 4 TiN 2!-(Ti,Al)N 6! PVD 0.14Blade EXc 16 Blade EX 7 TiN 1!-(Ti,Al)N 4!-TiN 0.5! PVD 0.15of the EXc 17 of the EX 9 Ti(C,N) 1!-(Ti,Al)N 6! PVD 0.16Present EXc 18 Present EX 10 TiN 0.5!-Ti(C,N) 1!- PVD 0.19Invention Invention (Ti,Al)N 2!-TiN 0.2! EXc 19 EX 1 Ti(C,N) 5!-TiN 1! CVD 0.11 EXc 20 EX 3 TiN 0.5!-Ti(C,N) 4!- CVD 0.09 Al.sub.2 O.sub.3 1!-TiN 0.5! ExC 21 EX 4 Ti(C,N) 5!-Ti(C,O) 0.5!- CVD 0.11 Al.sub.2 O.sub.3 5! EXc 22 EX 7 TiN 1!-Ti(C,N) 3!-TiN 1! CVD 0.17 EXc 23 EX 9 TiN 0.5!-Ti(C,N) 5!-TiC 2!- CVD 0.16 Al.sub.2 O.sub.3 2!-TiN 0.5! ExC 24 EX 10 TiN 0.5!-TiCN 0.5!- CVD 0.16 Ti(C,N,O) 1!-Al.sub.2 O.sub.3 5!- TiN 0.5!Coated CEc 13 Coated CE 1 TiN 0.5!-Ti(C,N) 3!-TiN 0.5! PVD *(1 min)Cerment CEc 14 Cerment CE 3 (Ti,Al)N 3!-TiN 0.2! PVD *(3 min)Cutting CEc 15 Cutting CE 4 TiN 2!-(Ti,Al)N 6! PVD *(5 min)Blade CEc 16 Blade CE 7 TiN 1!-(Ti,Al)N 4!-TiN 0.5! PVD *(9 min)for CEc 17 for CE 9 Ti(C,N) 1!-(Ti,Al)N 6! PVD *(7 min)Comparison CEc 18 Comparison CE 10 TiN 0.5!-Ti(C,N) 1!- PVD **(10 min) (Ti,Al)N 2!-TiN 0.2! CEc 19 CE 1 Ti(C,N) 5!-TiN 1! CVD *(2 min) CEc 20 CE 3 TiN 0.5!-Ti(C,N) 4!- CVD *(2 min) Al.sub.2 O.sub.3 1!-TiN 0.5! CEc 21 CE 4 Ti(C,N) 5!-Ti(C,O) 0.5!- CVD *(4 min) Al.sub.2 O.sub.3 5! CEc 22 CE 7 TiN 1!-Ti(C,N) 3!-TiN 1! CVD *(5 min) CEc 23 CE 9 TiN 0.5!-Ti(C,N) 5!-TiC 2!- CVD *(6 min) Al.sub.2 O.sub.3 2!-TiN 0.5! CEc 24 CE 10 TiN 0.5!-TiCN 0.5!- CVD *(6 min) Ti(C,N,O) 1!-Al.sub.2 O.sub.3 5!- TiN 0.5!__________________________________________________________________________ *Blade inoperable by the time shown in the parentheses due to breakage. **Blade inoperable by the time shown in the parentheses due to chipping.
As is obvious from the results shown in Table 6, the coated cermet cutting blades of the present invention, EXc 1 to EXc 12, the substrate of each cutting blade being a cermet which comprises double-structural hard phases wherein the shell portion is discontinuously distributed around the core portion, are provided with much more excellent fracture-resistance as compared with the coated cermet cutting blades for comparison, CEc 1 to CEc 12, the substrate of each cutting blade for comparison being a cermet which comprises double-structural hard phases wherein the shell portion is completely distributed around the core portion, namely, completely surrounding the core portion; and/or single-structural hard phases.
EXAMPLE 4
Another set of the cermet cutting blades EX 11 to EX 16 according to the present invention were manufactured, and these were used as substrates and coated by the methods shown in Table 7 to obtain coated cermet cutting blades of the present invention, EXc 13 to EXc 24, each cutting blade having the coating formulation and the mean layer thickness shown in Table 7. An arc ion plating system, which is a system for physical vapor deposition, or a chemical deposition system was used for coating under the same coating conditions as in Example 3.
For comparison, another set of the cermet cutting blades for comparison, CE 11 to CE 16, were manufactured, and these were subjected to the same procedure as above to manufacture coated cermet cutting blades for comparison, CEc 13 to CEc 24.
On each cermet cutting blade manufactured as described above, the fracture resistance was evaluated by measuring the flank-wear breadth of the cutting edge after wet interrupted-cutting was performed under the following conditions.
Steel material to be cut: a round bar standardized as JIS S20C, DIN CK22, ANSI 1020, which has four flutes provided in the longitudinal direction at regular intervals;
Cutting speed: 400 m/min.;
Feed rate: 0.2 mm/rev.;
Depth of cut: 2 mm; and
Cutting time: 20 min.
The results are shown in Table 7.
TABLE 7__________________________________________________________________________ Formulation of Hard Coating Layers Flank- and Mean Thickness Wear Thereof (μm) Coating Breadth Base ←(Lower Layer)(Upper Layer)→ Method (mm)__________________________________________________________________________Coated EXc 13 Coated EX 11 TiN 0.5!-Ti(C,N) 2!-TiN 0.5! PVD 0.17Cerment EXc 14 Cerment EX 12 (Ti,Al)N 2!-TiN 0.2! PVD 0.15Cutting EXc 15 Cutting EX 13 TiN 1!-(Ti,Al)N 4! PVD 0.15Blade EXc 16 Blade EX 14 TiN 0.5!-(Ti,Al)N 2!- PVD 0.16of the of the TiN 0.5!Present EXc 17 Present EX 15 Ti(C,N) 1!-(Ti,Al)N 3! PVD 0.18Invention EXc 18 Invention EX 16 TiN 0.5!-Ti(C,N) 0.5!- PVD 0.20 (Ti,Al)N 1!-TiN 0.2! EXc 19 EX 11 Ti(C,N) 2!-TiN 0.5! CVD 0.12 EXc 20 EX 12 TiN 0.5!-Ti(C,N) 2!- CVD 0.10 Al.sub.2 O.sub.3 1!-TiN 0.5! EXc 21 EX 13 Ti(C,N) 3!-Ti(C,O) 0.5!- CVD 0.11 Al.sub.2 O.sub.3 3! EXc 22 EX 14 TiN 1!-Ti(C,N) 3!-TiN 1.5! CVD 0.12 EXc 23 EX 15 TiN 0.5!-Ti(C,N) 2!-TiC 1!- CVD 0.14 Al.sub.2 O.sub.3 2!-TiN 0.5! EXc 24 EX 16 TiN 0.5!-TiCN 0.5!- CVD 0.15 Ti(C,N,O) 0.5!-Al.sub.2 O.sub.3 5!- TiN 0.5!Coated CEc 13 Coated CE 11 TiN 0.5!-Ti(C,N) 2!-TiN 0.5! PVD *(3 min)Cerment CEc 14 Cerment CE 12 (Ti,Al)N 2!-TiN 0.2! PVD *(5 min)Cutting CEc 15 Cutting CE 13 TiN 1!-(Ti,Al)N 4! PVD *(5 min)Blade CEc 16 Blade CE 14 TiN 0.5!-(Ti,Al)N 2!- PVD *(5 min)for for TiN 0.5!Comparison CEc 17 Comparison CE 15 Ti(C,N) 1!-(Ti,Al)N 3! PVD *(7 min) CEc 18 CE 16 TiN 0.5!-Ti(C,N) 0.5!- PVD **(10 min) (Ti,Al)N 1!-TiN 0.2! CEc 19 CE 11 Ti(C,N) 2!-TiN 0.5! CVD *(1 min) CEc 20 CE 12 TiN 0.5!-Ti(C,N) 2!- CVD *(1 min) Al.sub.2 O.sub.3 1!-TiN 0.5! CEc 21 CE 13 Ti(C,N) 3!-Ti(C,O) 0.5!- CVD *(1 min) Al.sub.2 O.sub.3 3! CEc 22 CE 14 TiN 1!-Ti(C,N) 3!-TiN 1.5! CVD *(3 min) CEc 23 CE 15 TiN 0.5!-Ti(C,N) 2!-TiC 1!- CVD *(2 min) Al.sub.2 O.sub.3 2!-TiN 0.5! CEc 24 CE 16 TiN 0.5!-TiCN 0.5!- CVD *(4 min) Ti(C,N,O) 0.5!-Al.sub.2 O.sub.3 5!- TiN 0.5!__________________________________________________________________________ *Blade inoperable by the time shown in the parentheses due to breakage. **Blase inoperable by the time shown in the parentheses due to chipping.
As is obvious from the results shown in Table 7, the coated cermet cutting blades of the present invention, EXc 13 to EXc 24, the substrate of each cutting blade being a cermet which comprises double-structural hard phases wherein the shell portion is discontinuously distributed around the core portion, are provided with much more excellent fracture-resistance as compared with the coated cermet cutting blades for comparison, CEc 13 to CEc 24, the substrate of each cutting blade for comparison being a cermet which comprises double-structural hard phases wherein the shell portion is completely distributed around the core portion, namely, completely surrounding the core portion; and/or single-structural hard phases.
As described in Examples 1 to 4 above, the cermet cutting blades or the coated cermet cutting blades according to the present invention have excellent fracture-resistance, and therefore, chipping or fracture does not occur at the cutting edges during continuous cutting, in addition, even during interrupted cutting under a severe cutting condition. Accordingly, the cermet cutting blades or the coated cermet cutting blades of the present invention can exhibit excellent cutting performance for a long time, and are advantageous from an industrial view.
The disclosures of Japan priority patent applications HEI 8-266017 and HEI 8-266018, each filed Oct. 7, 1996, and HEI 8-189184, filed Jul. 18, 1996, are hereby incorporated by reference.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | In a cutting blade made of a titanium carbonitride-base cermet comprising:
3 to 20% by weight of a metal binder phase, the principal ingredients of which are Co and/or Ni,
3 to 30% by weight of a single-structural hard phase comprising at least one component selected from the group consisting of carbide, nitride and carbonitride compounds of metal elements belonging to Groups 4a, 5a and 6a of the periodic table and a solid-solution comprising at least two said compounds, and
the balance being a double-structural hard phase which comprises a core portion and a shell portion completely surrounding said core portion, wherein said core and shell portions comprise as substituents titanium carbonitride and/or a carbonitride compound of Ti and at least one element M selected from metal elements belonging to Groups 4a, 5a and 6a of the periodic table other than Ti, except that the shell portion must contain a carbonitride compound of at least M, and wherein said shell portion has a lower content of Ti and a higher content of M than those in the core portion, respectively; and incidental impurities, the improvement comprising:
said double-structural hard phase is partly or wholly substituted with a discontinuous double-structural hard phase comprising a core portion and a shell portion, in which the shell portion is discontinuously distributed around the core portion so that the core portion is partially exposed to the metal binder phase, and said discontinuous double-structural hard phase occupies 30 or more area % of the total surface of the cermet in terms of electron-microscopic texture analysis and whereby the cutting blades exhibit excellent fracture-resistance. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to network communication systems. It finds particular application in conjunction with controlling admission of Voice-Over IP (VoIP) calls to a packet-based network, and efficiently selecting paths for the admitted calls, so as to balance the packet loads within the network. However, it is to be appreciated that the present invention is also amenable to any type of service requiring connection management, irrespective of traffic burstiness or other factors, and to other like applications such as TCP requiring admission control, video or data transport where a need exists to improve the quality of service (QoS) of data transfer over a network including network scenarios with multiple applications having distinct QoS constraints.
The internet, intranets, and other internet protocol (IP) networks are handling ever increasing volumes of data. Beyond the worldwide web and e-mail capabilities of such networks, applications and protocols are being developed to further add to the volume of traffic. Among these are voice related applications such as telephony or Voice-Over IP, and video applications, such as video telephony, video conferencing, and the like. Unfortunately, even at current usage levels packet loss due to congestion is becoming problematic degrading the performance of data transfer.
Streams of packets typically enter the network from packet switching edge devices or gateways which serve as portals to the interconnected web of routers comprising the network. Typically these gateways are indiscriminant in their treatment of packet streams in that they merely port the packet streams onto the network without regard for congestion levels or likelihood of the packets reaching their final destination. Moreover, the networks typically are unaware of any coherence or association among packet streams, and merely forward individual packets from router to router on a first-come-first-served basis, without regard to their relative priorities. These two limitations severely constrain the ability to provide quality-of-service guarantees for real-time services such as voice in IP-based networks.
Some attempts have been made to address portions of this problem. For example, packet prioritization schemes such as differentiated services or Diffserv distinguish packet streams among several classes. Protocols are also evolving which route higher priority packets more reliably, for example, by allocating certain bandwidth on links between routers for each class. Another partial solution that has been articulated is that of establishing explicit routing paths through the network between frequently traveled points. Multi-protocol label switching (MPLS) is a protocol which enables a label to be assigned to a packet stream which specifies a predetermined path through the network. This allows better monitoring and control of congestion over the paths taken by voice streams, for example. However, the problem introduced by edge-devices not being aware of the congestion levels within the interior of the network still remains. One strategy being pursued to tackle this limitation is to dedicate a certain amount of bandwidth for each MPLS path, on each network link that it traverses. This creates a set of voice trunks among all pairs of nodes, much akin to the telephone trunk routes currently employed between circuit switches, and hence abandon the inherent flexibility afforded by the IP network. In particular, this strategy does not lead to a scalable solution. The number of trunks grows as the square of the number of edge nodes, and the consequent bandwidth fragmentation among hundreds or thousands of MPLS paths can exhaust the link capacities rather quickly. Furthermore, the servicing and provisioning of the multitude of voice trunks across the network are both cumbersome and slow to accommodate new nodes within the network.
The present invention contemplates a new and improved method and apparatus for call management over IP networks which overcomes the above-referenced problems and others associated with the existing approaches.
BRIEF SUMMARY OF THE INVENTION
The above problems are alleviated and an advance is made over the prior art in accordance with the teachings of applicants' invention wherein, a method of regulating admission of packet streams to a network includes at selected times sending path status messages along a set of paths in the network. A cost metric in each path status message is updated at the intermediate nodes as the message progresses along its defined path. Based on the final cost metric values collected upon receipt of the status messages at the respective path edges, subsequent packet stream arrivals are selectively blocked or admitted to the network.
In accordance with another aspect of the present invention, the method further provides choosing an optimal path between a source and a destination gateway.
In accordance with another aspect of the present invention, the paths through the network include a plurality of interconnected links, each potentially operating at different capacities or utilizations. The “choosing an optimal path” step optionally includes determining a most utilized bottleneck link for each of the alternative path choices through the network (for the source and destination gateways in question), and then selecting the path whose bottleneck link is the least utilized among the set of bottleneck links corresponding to the available path choices.
In accordance with another aspect of the invention, the paths through the network include a plurality of interconnected links, each path potentially having different numbers of links. The “choosing an optimal path” step optionally includes selecting a path through the network based on the combination criteria of having smaller bottleneck link utilization and having fewer links compared to other paths.
In accordance with another aspect of the present invention, the path includes a plurality of links interconnecting routers. The “updating a cost metric” step includes measuring link usage at the routers.
In accordance with another aspect of the present invention, each path is comprised of links that are adapted to discriminate between different classes of packet streams. The “updating a cost metric” step includes measuring usage by individual class.
In accordance with another embodiment of the present invention, a system for controlling admission of a packet stream along a path includes a plurality of routers adapted to update a cost metric in a path status message upon receipt of the message at each router. The system further includes a plurality of links interconnecting the routers where selected links and routers together comprise the path through the network.
In accordance with another aspect of the present invention, the plurality of routers are further adapted to generate, and send, the path status message along the determined path at selected times.
In accordance with another aspect of the present invention, the system alternately includes a gateway adapted to generate, and send, the path status message along the predetermined path at selected times.
In accordance with another aspect of the present invention, each of the plurality of routers is further adapted to select an optimum path through the network in response to receipt of a packet stream admission request.
In accordance with another aspect of the present invention, the plurality of routers are further adapted to discriminate between path status messages, and other (payload) packets.
In accordance with another aspect of the present invention, the plurality of links interconnecting the routers are adapted to discriminate between classes of packet streams, e.g., via Weighted Fair Queuing or WFQ.
In accordance with another embodiment of the present invention, a method includes sending a path status message along a defined path and, as the path message progresses through a plurality of routers in the path, updating a cost metric in the path status message at the routers that it transits through.
In accordance with another aspect of the present invention, the method further includes generating an indicator where the indicator shows an optimal path between a source and a destination, or where the indicator shows that no path presently meets admission control criteria.
In accordance with another aspect of the present invention, the “generating an indicator” step showing that an optimal path exists between a given source destination node pair optionally includes determining a most utilized bottleneck link for each candidate path through the network between these two nodes. The method further includes optionally selecting as the optimal path, the path whose bottleneck link utilization is the smallest among the set of bottleneck links of the candidate paths, and placing an identifier for the selected optimal path into the path status message.
In accordance with another aspect of the present invention, the “generating an indicator” step to show an optimal path optionally includes selecting a path through the network based on the combination criteria of having smaller bottleneck link utilization and having fewer links compared to other path alternatives.
In accordance with another aspect of the present invention, the method further includes discriminating between path status messages and other (payload) packets.
In accordance with another aspect of the present invention, “the updating a cost metric” step includes measuring link usage at individual routers.
In accordance with another aspect of the present invention, each path is comprised of a set of links which are adapted to discriminate between classes of packet streams, and the “updating a cost metric” step includes determining cost data by packet class.
One advantage of the present invention resides in accurately sensing individual link utilizations by periodically measuring traffic flow.
Another advantage of the present invention resides in the system being distributed across the network, thus not requiring any centralized database.
Still another advantage of the present invention resides in providing quality of service guarantees to packet streams entering the network.
Still another advantage of the present invention resides in the inherent flexibility and scalability of the call admission and load balancing systems.
Still further advantages and benefits of the present invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the invention.
FIG. 1 is a simplified illustration of a network upon which the present invention may be practiced;
FIG. 2 is an illustration of a single path through the network of FIG. 1;
FIG. 3 is a generic path utilization status message, PUSM, for propagation along a determined path;
FIG. 4 is a graphical depiction of alternative levels of the protocol hierarchy at which the path utilization status message processing can occur;
FIG. 5 is a more detailed illustration of a network upon which the present invention may be practiced;
FIG. 6 shows an embodiment of a recommended packet forwarding strategy used in the invention, by focusing on a single path between edge routers;
FIG. 7 illustrates one embodiment of functionality allocation among routers and gateways in order to implement the invention; and
FIG. 8 shows an alternate embodiment with the routers requiring fewer control capabilities compared to the variant shown in FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The distributed scheme for CAC and LB is measurement-based. Thus, traffic measuring points, such as the IP routers, are directly involved in monitoring the link occupancy status and generating the intelligence for making call control decisions. To this end, suitable traffic measurement capabilities are implemented at the routers. Desirably, this does not depend on the ability to precisely specify the projected traffic profile of each call during setup. Rather, it adopts a learning approach based on actual measurements.
Referring to FIG. 1, the IP transport network 10 supports certain basic QoS features. In the simplified illustration, gateways 12 provide connectivity through edge routers 14 to network of transit routers 16 and interconnecting links 18 . Here some form of defined path routing, for example MPLS, is preferably in place to carry the application payload subject to the CAC and LB function; this facilitates better control of QoS. To this end, multiple spatially diverse MPLS explicit paths (unidirectional) dedicated to the application are set up from each edge router 14 to every other edge router 14 . Path redundancy serves to improve reliability and allows load balancing. Furthermore, a packet prioritization scheme such as Diffserv is implemented at the routers to support QoS management. Those skilled in the art however, recognize the desirability of functional independence between MPLS and traffic prioritization, if implemented. To be specific, no bandwidth is reserved per MPLS path since that would limit scalability and achievable statistical multiplexing gains. In contrast, a certain aggregate bandwidth is reserved on each network link 18 for the application in question, by virtue of a suitable Diffserv policy (e.g., WFQ) implemented at the routers 14 , 16 . The MPLS paths carrying traffic belonging to this application are then allowed to fully share the reserved bandwidth segment. One way towards achieving this capability is to perform only packet forwarding based on the MPLS shim header, with traffic prioritization (e.g., WFQ) being based on the class-based queueing (CBQ) field within the IP header that distinguishes its service class.
With a Diffserv arrangement, the portion of the network bandwidth resources dedicated to the application in question can be isolated from other traffic streams, in which case it may be regarded as a distinct sub-network for traffic management purposes. With this perspective, the term link henceforth refers to the portion of the capacity of the physical link 18 dedicated to the candidate application. Also, references to link occupancy measurements are to be interpreted as occupancies of the reserved portions.
As mentioned previously, link traffic measurements implemented at the IP routers 14 , 16 form the foundation of the measurement-based algorithm to be presented. In contrast, schemes that make use of declared values of bandwidth usage require highly predictable traffic behavior. Measurement-based approaches such as the one presented here, on the other hand, give the power to learn and abstract from the observed behavior of the composite traffic.
Alternatives exist for the nature of traffic measurements implemented at the routers 14 , 16 , for example measurements may be either link utilizations or, alternately residual bandwidths, as observed over specified measurement intervals. For traffic streams such as voice with fairly deterministic behavior, an average value over each measurement interval will usually suffice. More sophisticated approaches may however be needed for relatively bursty applications such as TCP. For example, each measurement interval may be divided into suitably chosen sub-intervals, with peak values being reported.
Reference to FIG. 2 illustrates a family of cost functions usable by the distributed CAC and LB algorithm (more fully described below). A path from edge node 14 a to edge node 14 b traverses n links 18 , indexed 1, 2, . . . , n−1, n.
In order to discuss cost the following parameters are defined:
C 1 (i)≡the cost of link i, i=1,2, . . . , n;
C p ≡the cost of the MPLS path; and
C p (i,j) ≡the cost of the partial path segment comprised of links i, i+1, . . . , j. Clearly, C p =C p (1,n) .
The distributed algorithm will work in conjunction with the family of cost functions that satisfy the following memoryless property:
C p (1,1) =C 1 (1);
C p (1,i+1) =F(C p (1,i) , C 1 (i+1)), i=2, . . . , n,
where F(x,y) is any arbitrary scalar operator on x and y.
Assuming that there are r distinct (spatially diverse) MPLS paths across the IP network from edge node 14 a to edge node 14 b , let the path cost associated with any alternative i be represented by C p (i), i=1, . . . , r. Now the optimal path k from edge node 14 a to edge node 14 b is selected based on the rule that its associated path cost C p (k) is less than or equal to the cost C p (i) associated with every other path i, from among the available set of alternatives 1, . . . , r.
Examples of path cost metrics that satisfy the above conditions include the following:
1. Maximum Utilization:
C 1 (i) is the percentage utilization of link i, and F(x,y)≡Max(x,y). In other words, the chosen path is that one with the least loaded bottleneck link (in a percentage utilization sense).
2. Minimum Residual Capacity:
C 1 (i) is the negative of the residual capacity on link i, and F(x,y)≡Max(x,y). This is similar to the previous example, except that an absolute residual capacity is used instead of percentage utilization.
3. Additive Cost Metrics:
C 1 (i) is some non-decreasing concave function of the percentage utilization of link i that reaches large values as the utilization approaches 100% (e.g., tan(utilization×π/2)), and F(x,y)≡x+y. This example, besides minimizing the load on the bottleneck link, encourages selection of shorter paths (when there are alternatives with comparable congestion levels, but widely different path lengths).
With cost metrics presented, a generic framework for the distributed algorithm for CAC and LB is needed. Slight variations will be necessary for deployment in actual applications, and specific implementations to support VoIP applications will be explored below.
In order to discuss a generic framework, the following parameters are defined:
m e : Number of edge routers 14 in the network 10 .
r: Number of MPLS paths set up for the candidate application from each edge router 14 to each of the other edge routers 14 . This need not be identical throughout the network but we will make that assumption here for convenience.
T: Duration of a status update interval (defined below)
Assuming the implementation of Diffserv at the routers, the number of distinguishable traffic classes on each link is represented by J. In general, each application has an associated class identifier j∈1, . . . , J. As discussed above, each router 14 , 16 will report a distinct occupancy measurement (cost) corresponding to each class on each incident link 18 . Accordingly we have the following variant of the link cost parameter C 1 (i) defined above when discussing cost metrics.
C 1 (t, j)≡The cost of link t, corresponding to traffic class j∈1, . . . , J
To simplify the discussion, here a call is regarded as a single unidirectional flow of IP packets. Those skilled in the art will appreciate that actual applications, such as VoIP, for example, could involve two flows, one in each direction. Customization of the generic framework to the VoIP application scenario will be more fully discussed below. As is clear, there are a total of m e (m e −1)r unidirectional MPLS paths in the network dedicated to the candidate application.
The algorithm is based on the propagation of a special type of control message, referred to as a Path Utilization Status Message (PUSM) among the routers 14 , 16 . Besides the capability to measure link occupancies, the routers are equipped with a few additional capabilities to support CAC and LB. In particular, each transit router 16 implements a special function, which we will refer to as Path Status Processor (PSP). Similarly each edge router 14 implements two functions, which we will refer to as PUSM Generator (Pgen) and Path Selector (PSEL). The roles of these modules will become clear below. Note that these capabilities may be implemented at the routers 14 , 16 as applications that ride above layer 3 , or may be more closely integrated with the MPLS label switching function. These alternatives are discussed in greater detail below.
To illustrate the Pgen functionality at a specific edge router E, r outgoing MPLS paths from node E destined for each other edge router are indexed as 1, 2, . . . , r. The Pgen module is programmed to be aware of the following mappings, corresponding to each remote edge router F and each path i destined to it:
Lnk ER (F, i): The outgoing link corresponding to path i leading to the remote edge router F.
Tag ER (F, i): The outgoing MPLS tag corresponding to path i leading to the remote edge router F.
(Note: the ER subscript is used here to differentiate the above mappings from analogous yet slightly different mappings used at the transit routers 16 .)
The above two parameters designate the contents of a Next Hop Label Forwarding Entry (NHLFE) in the MPLS Incoming Label Map (ILM) at node E, that the path i destined for remote node F is bound to. As mentioned earlier, node E maintains a link cost parameter C 1 (t, j) for each outgoing link t and traffic class j∈1, . . . , J, which is updated at regular intervals of length T by virtue of the measurement capability, this parameter can be queried by Pgen. At regular intervals of T, Pgen at node E generates a set of PUSM's, one for each outgoing MPLS path (r(m e −1) altogether). The PUSM format is illustrated in FIG. 3 .
The Class_id field 30 is always set to the traffic class identification number that corresponds to the application in question. As will become clear, this parameter is used to extract the particular measurements that pertain to the link bandwidth segments allocated to the application in question. Note, however, that the Class_id field 30 can be eliminated if instead an additional field indicating the traffic class number is included as part of each NHLFE in the MPLS ILM tables. Those skilled in the art will appreciate that while the class information is carried in the PUSM, it could alternately be effectively carried by modified ILM tables or other data structures.
For the message corresponding to MPLS path i destined for edge router F, Fwd_id 32 is set to i, Tag 34 is set to Tag ER (F, i), and Cost_metric 36 is set to C 1 (Lnk ER (F, i), Class_id). Rev_opt 38 is set to the index of the currently known optimal (reverse) path from node F to node E. Note that the latter index has only local significance at the path originating edge node F, and here it relays its identity back to node F in “piggyback” style. As further discussed below, this index is available from the variable Best_Revpath(F) which is maintained and periodically updated by the PSEL module, based on information gathered from the received PUSM's corresponding to the reverse paths. Also, a negative value assigned to Best_Revpath(F), or Rev_opt, is understood to mean that all paths from the remote node F to node E are blocked. The PUSM thus programmed is forwarded by Pgen to the respective adjacent node over link Lnk ER (F, i); the IP link referred to here could also be an ATM VP, in an IP-over-ATM scenario.
While a PUSM propagates one hop at a time, between physically adjacent IP nodes 14 , 16 , a few alternatives for implementing PUSM forwarding and their processing at the transit nodes 16 are examined below.
As in the case of the edge routers 14 , each transit router 16 implements a traffic measurement function which reports a link cost C 1 (t, j) for each outgoing link t and each traffic class j∈1, at regular intervals of length T; this parameter can be queried by the PSP function. The PSP at each transit node 16 is preferably aware of the following mappings:
Lnk TR (k): The outgoing link 18 corresponding to incoming MPLS tag k
Tag TR (k): The outgoing MPLS tag corresponding to incoming MPLS tag k.
These can be obtained from the MPLS ILM table. Upon the arrival of a PUSM at a transit node, with Class_id=j and Tag=k in , PSP performs the following modifications on it:
Cost_metric 36 ←F(Cost_metric, C 1 (Lnk TR (k in ), j));
Tag 34 ←Tag TR (k in );
where F(x,y) is any arbitrary cost mapping function satisfying the conditions given above. The modified PUSM is then forwarded by PSP to the next node over the link Lnk TR (k in ).
The PSEL function at each edge router E maintains the following set of variables, corresponding to every other edge router F:
Path_Cost(F, i): Latest estimate of the cost of the incoming MPLS path i from remote edge router F, i=1, . . . , r; again, the index i has only local significance to the originating node F.
Best_Fwdpath(F): If non-negative, this parameter indicates the index (local to and recognizable by the path originating node E only) of the preferred MPLS path from this edge node (node E) to the remote edge node F. If negative it signifies that all paths from node E to node F are blocked.
Best_Revpath(F): If non-negative, this parameter indicates the index (local to and recognizable by the path originating node F only) of the preferred MPLS path from edge node F to edge node E. If negative it signifies that all paths from node F to node E are blocked.
Upon receiving a PUSM propagated from another edge router F, PSEL performs the following updates:
Best_Fwdpath(F)←Rev_opt 38 ;
Path_Cost(F, Fwd_id)←Cost_metric 36 ;
where Rev_opt 38 and Cost_metric 36 refer to the values in the respective fields of the PUSM that just arrived.
In general, failures at links and/or nodes are detected by separate network management functions. However, additional reliability measures may be built into the above procedures on an optional basis. With the latter, note that PSEL expects to receive successive PUSM's for each remote edge node F and index i within a maximum interval αT, where α is a constant>1 suitably chosen to allow some grace period. A logical timer can be employed to this effect. If the timer expires prior to receiving an expected PUSM for edge node F and index i, Path_Cost(F, i) is set to ∝ (or −∝, depending on the cost function used) signifying that the referenced path is not available. This action is taken to ensure robustness against link/node failures. However, a similar action is not performed on Best_Fwdpath(F) since PUSM's carrying Rev_opt 38 from node F can arrive on any of the r spatially diverse alternate paths. Indeed, this parameter could reflect obsolete and incorrect data if all paths from node F fail (to be distinguished from all paths being congested/blocked) or node F itself fails. However, the former, which amounts to a catastrophic event, as well as the latter would be detected by external network management functions. If indeed robustness against such catastrophic failures should be incorporated within the CAC and LB scheme, a similar yet distinct logical timer may be applied in connection with successive PUSM's from each remote node F, without regard to the path index field (Fwd_id). Should this timer expire prematurely, Best_Fwdpath(F) may be set to a negative value indicating that all paths are blocked, or suitable alarms triggered to notify the catastrophic event.
Once every T seconds, PSEL at node E updates Best_Revpath(F)∈{1, . . . , r} for each remote node F according to the following rules:
Path_Cost(F, Best_Revpath(F))≦Path_Cost(F, i), i=1, . . . , r;
If [MAXCOST≦Path_Cost(F, Best_Revpath(F))] then Set Best_Revpath(F) to a negative value.
Here the limit MAXCOST is a system-wide constant; in the context of a percentage utilization measure for example, MAXCOST could be, say, 95%.
The procedures to be taken during the arrival of a new call at an edge node E, destined for edge node F, are straightforward. Specifically, the value stored in the register Best_Fwdpath(F) is examined. If negative, the call is blocked and cleared (the CAC decision). Otherwise the MPLS path corresponding to the index i stored in this register is chosen to carry the packets belonging to the new call (the LB decision). From now on, the payload packets belonging to the new call will be forwarded on the outgoing link Lnk ER (F, Best_Fwdpath(F)) with MPLS tags set to Tag ER (F, Best_Fwdpath(F)). These two parameters are provided by the MPLS ILM table at edge node E.
Artisans will recognize that the strategy used in the description of the CAC and LB algorithm given above is to return the identity of the best forward path from the path terminating edge router to the path originating edge router, by piggybacking on the PUSM's flowing in the reverse direction. A distinct advantage of this embodiment, referred to as Variant A, is that the CAC and LB decisions can be made instantaneously upon call arrival at the source node itself. Nonetheless, this is achieved by adding only an extra variable (Rev_opt) to the PUSM, and hence has little impact on protocol complexity. However, there is a time lag of T between the determination of the optimal reverse path at the terminating edge node 14 b and its availability at the originating edge node 14 a . If T is chosen to be small compared to the dynamics of the call arrival-departure processes across the network (as is desirable), this concern would be marginalized in an asymptotic sense.
On the other hand if T is relatively large then possibly the control decisions at the source nodes will be based on obsolete information. There are two alternatives to overcome this limitation, which we will refer to as Variant B and Variant C. In both cases, the piggybacking operation is eliminated and replaced with other functions. Consequently, the PUSM will no longer have a Rev_opt field. The specific details of the two variants are given below:
Variant B:
A distinct Path Identity Indicator Message (PIIM) is propagated from an MPLS terminating edge node F to the originating edge node E, whenever a change occurs to the value of the register Best_Revpath(E) at node F. Upon receiving a PIIM from node F, node E updates the local Best_Fwdpath(F) with its content. For added reliability, a “Keepalive” strategy may optionally be adopted by enforcing the transmission of PIIM's at least once every τ sec with a logical timer. In this case, the originating node E would set Best_Fwdpath(F) to a negative value if it did not receive a PIIM from the terminating node F within an expected maximum interval. Note that unlike a PUSM, which propagates from one node to its adjacent neighbor at a time, a PIIM flows directly between edge nodes and hence will rely on a routing capability. One option is to send it as a regular IP packet using standard IP addressing, from the terminating node to the originating node. Another option is to use one of the reverse MPLS paths from the terminating node to the originating node. For example, a PIIM from edge node F to edge node E could be transmitted along the path indicated by the Best_Fwdpath(E) register stored at node F.
Variant B retains the advantage of being able to make instantaneous CAC and LB decisions at the source nodes. However, the protocol is a little more complicated, with the addition of a separate PIIM messaging. As discussed below however, this complexity can be virtually eliminated in some cases such as VoIP, by taking advantage of certain existing protocol features provided by the application.
Variant C:
Apart from dropping the Rev_opt field from PUSM's, Variant C also eliminates the Best_Fwdpath(.) registers at the originating edge routers. Consequently the ability to make instantaneous CAC and LB decisions at the source nodes is lost. When a call destined for edge node F arrives at edge node E, a Path Status Query Message (PSQM) is transmitted from the latter to the former. In response, node F relays the contents of the local Best_Revpath(E) in a Path Status Response Message (PSRM) to node E, and the latter makes the CAC and LB decisions based on the content of the received PSRM. Both PSQM and PSRM are transmitted based on standard IP addressing and forwarding.
As is clear, the disadvantage with Variant C is that it slows the CAC and LB decision somewhat, due to the need to query the terminating end-points. However, in applications such as VoIP, this may not have any perceptible effect since both end-points are queried in any case due to the bi-directional nature of the traffic payload or packet streams.
Reference to FIGS. 4A-C illustrates three embodiments capable of implementing the PUSM processing (Pgen/PSEL at the edge routers 14 and PSP at the transit routers 16 ) and forwarding capabilities. For convenience, these are labeled (A) full integration with MPLS, (B) partial integration with MPLS and (C) complete decoupling from MPLS. In all the three cases, the PUSM processor has access to the link measurement parameters in a uniform fashion.
In the fully integrated embodiment of FIG. 4-A, the PUSM processing function is tightly integrated with MPLS. Specifically, the shim header that facilitates label switching is expanded to include an additional bit called the PUSM bit. With this in place, each PUSM packet can be forwarded like any label-switched packet, along the path for which it is tracking the cost metric. The difference, however is that the PUSM bit is set to FALSE for normal MPLS packets carrying payload traffic, whereas it is set to TRUE for PUSM packets. In fact there is no need to add a new bit to the MPLS label format, since one of the already available “experimental bits” in the label can be used for the PUSM bit. With the MPLS encapsulation, a distinct Tag field 34 is no longer needed within the PUSM payload as shown in FIG. 3, and this can be eliminated. The MPLS forwarding paradigm may be modified to examine the status of the PUSM bit. If FALSE, forwarding should proceed in the conventional manner. If TRUE, the PUSM processing function (Pgen/PSEL at the edge nodes and PSP at the transit nodes), which now forms an integral part of MPLS, should be invoked prior to forwarding the packet. The latter would then access the ILM database to extract Lnk (.) and Tag (.) to perform the Pgen and PSP operations described above. From a protocol perspective, the PUSM processing capability now resides at layer 3 , as a sub-function of the MPLS module (FIG. 4 -A). Note that this approach offers significant simplicity and elegance, however it needs modifications to the existing MPLS forwarding paradigm.
In the partially integrated embodiment of FIG. 4-B, PUSM processing is implemented separately from MPLS, as a distinct module above layer 3 . However, the former is allowed to read the Tag(.) and Lnk(.) parameters (Pgen and PSP) from the forwarding ILM database maintained by the latter. PUSM packets are now transmitted from one node to an adjacent neighbor based on its IP header address field; MPLS forwarding is not invoked. This implies that a distinct Tag field 34 should be retained within the PUSM payload, as indicated in FIG. 3 . One way to recognize a received PUSM packet in this case and pass on to the local PUSM processing function is to assign a special value to the Class-Based Queueing (CBQ) field in its IP header. Alternately the class of service may be specified as TCP/UDP, with a special SAP port being designated to link such packets to the PUSM processing function. In any case, it is not clear whether a full-scale IP header and the associated processing is necessary here, since the transmission of PUSM's is only between adjacent neighbors at a time. While this approach does not demand modifications to the existing MPLS protocol, it takes advantage of the simplicity in extracting the necessary parameters directly from the ILM database maintained by MPLS. This requires that suitable hooks are in place such that the PUSM processing function, which is now external to the MPLS forwarding mechanism, is allowed to access the forwarding ILM.
The completely decoupled embodiment of FIG. 4-C is similar to case B described above, with the additional restriction that sharing of the ILM database is not allowed. In this sense, the PUSM processor can be built as an independent application above layer 3 and no modifications or hooks, whatsoever, is required of the MPLS forwarding engine. Undesirably, however, the PUSM processor now needs to maintain a copy of the forwarding database, albeit limited in scope to the explicit MPLS paths that carry QoS-sensitive and connection-oriented applications. This copy of the forwarding database is referred to here as the ILM mirror.
As may be expected, a given router could be a transit node in regard to certain MPLS paths, and an edge node in regard to the others. Thus a generic router that supports the capabilities discussed here is equipped with all the three functional modules, namely, Pgen, PSP and PSEL. A question however exists as to how a router can determine whether an incoming PUSM is destined for the PSP module (if the router is a transit node) or the PSEL module (if the router is the terminating edge node). Preferably, the NHLFE in the ILM database (actual or the mirror), corresponding to the incoming PUSM's Tag, indicates a “stack pop” operation when the terminating end has been reached. Thus, by examining this condition, a decision can be made as to which module should receive the PUSM in question.
Those skilled in the art will recognize that the methodology proposed will carry through naturally to the hierarchical variant of MPLS. In this case the MPLS shim header appended to each packet is comprised of a stack of labels, each of which corresponds to a different level of the hierarchy. This allows effective “tunneling” of MPLS paths and optimizes the use of the MPLS tag address space.
With reference now to FIG. 5, an exemplary Voice-over-IP (VoIP) application of the methodology is depicted. One key difference here is that each call manifests as two distinct flows of packets. The forward and reverse voice paths for each active voice call are treated as independent; in particular they could traverse completely different physical routes. Referring to FIG. 5, an embodiment that is applicable in an exemplary VoIP network scenario based on the generalized H.323 model is illustrated. Since each gateway 60 in this scenario can independently format and insert voice packets into the network, the MPLS paths should ideally originate at the gateways 60 for simplicity. However, distinct MPLS paths are envisaged only among pairs of edge routers 64 , not among pairs of gateways 60 . The latter is less attractive from a scalability point of view, given that there could be multiple gateways homing on to each edge router. Note also that there are no distinct edge and transit routers in FIG. 5 . For example, router 64 A is an edge node for paths originating or terminating at the gateways 60 attached to it, whereas it can be a transit router for a path between router 64 B and router 64 C.
The need for distinct MPLS paths between every pair of gateways is eliminated here (and substituted by distinct paths set up between each pair of routers) by using the hybrid forwarding strategy shown in FIG. 6. A transmitting edge router 70 and a receiving edge router 72 are shown with three attached gateways each: 74 1 . . . 74 3 and 740 1 . . . 740 3 . For ease of description, a single MPLS path is set up between the two edge routers 70 , 72 ; i.e., there is no load balancing option. Additionally, a call is in progress from transmitting VG 74 1 , to receiving VG 740 1 , one from transmitting VG 74 2 to receiving VG 740 2 and one from transmitting VG 74 3 to receiving VG 740 3 .
Each transmitting gateway 74 has available two pieces of information for the call it handles, namely, the IP address of the receiving gateway 740 and an MPLS tag for the path (in this case unique) from the transmitting edge router 70 to the receiving edge router 72 . Each voice packet is first encapsulated into an IP packet the address field of which is set to the receiving gateway's address, and then into an MPLS frame with its tag set to that of the preset path. Note that all the three transmitting VG's 74 are programmed to use the same MPLS tag, which gets mapped into an identical NHLFE within the transmitting edge router's ILM. Hence the packet streams that the three transmitting VG's 74 generate are merged at the transmitting edge router 70 , and forwarded along the unique MPLS path to the receiving edge router 72 . The NHLFE corresponding to the composite stream within the receiving edge router's ILM is programmed to indicate a “stack pop” operation. As a result, the MPLS stack of each received packet becomes empty and is therefore handed off to the conventional IP forwarding engine. Since the IP address field indicates the specific receiving voice gateway, each packet is delivered to the appropriate destination.
For the establishment of a voice call, the VoIP system includes, besides the voice gateways 74 , 740 and the IP transport network shown in FIGS. 5-6, a set of signaling gateways, voice gateway controllers and gatekeepers along with the associated database engines. Call signaling proceeds according to the standard procedures stipulated by the H.323 protocol model. A circuit-switched voice path is first established across the PSTN domain between the calling end-user and the nearest voice gateway 74 . A signaling message is then propagated through the SS 7 network attached to the caller side PSTN to a signaling gateway which routes this message to a suitable voice gateway controller. The latter alerts the calling end voice gateway 74 and propagates the key parameters to a gatekeeper responsible for gateway 74 . The gatekeeper identifies and negotiates with another gatekeeper responsible for the receiving end of the call (if different from the calling end gatekeeper). The latter in turn identifies the receiving end voice gateway 740 and signals the PSTN network on the receiving side. A circuit-switched voice path is then established across the receiving end PSTN between the receiving voice gateway 740 and the called end-user. Once these conventional steps are completed, a few additional actions need to be taken to implement call admission control and load balancing using the algorithm proposed here. These are described below.
To facilitate call management each VG 74 , 740 maintains the vector [Best_Fwdpath(.)] with n e −1 entries, one corresponding to each of the n e −1 remote edge nodes (excluding the one to which the VG is attached). As explained below, this vector is periodically updated as a result of PUSM propagation (customized to VoIP). In addition, each VG 74 , 740 also maintains the static matrix [Tag ER (F, i)] of dimension (n e −1)×r. As described above, each entry in this matrix stores the outgoing MPLS tag corresponding to one of the r paths to one of the n e −1 remote edge routers, excluding the one to which the VG 74 , 740 is attached. As is clear, there is no need to maintain the matrix [Lnk ER (F, i)] here since the VG 74 , 740 is strictly an access device and there is a unique outgoing link. Indeed, the algorithms can be generalized to the scenario where each VG may home on to multiple edge routers.
For example, two gateways 74 1 and 740 2 are assigned to a candidate call, having routers 70 and 72 attached. During call setup, VG 74 1 receives from the associated gatekeeper the IP address of the remote voice gateway VG 740 2 as well as the identity of the remote edge router 72 . The latter is used to look up the corresponding local Best_Fwdpath(.) entry. For the purpose of identifying the remote router 72 , either its IP address, or a globally consistent VoIP index number assigned to it, may be conveyed. The latter has the advantage of simplifying the table lookup at the gateway to an array indexing operation. Note that agreeing on such an indexing scheme is not difficult, since there could be perhaps 100 or at the most 1000 edge nodes supporting VoIP services within an administrative domain. The candidate call is deemed admissible at VG 74 1 if all of the following conditions are satisfied:
1. A free voice port is available at VG 1 74 1 to carry the new call
2. There is adequate residual bandwidth available to support the call on the forward link to router 70
3. There is adequate residual bandwidth available to support the call on the reverse link from router 70
4. Best_Fwdpath>0
An analogous procedure occurs at gateway VG 740 2 . Once the CAC decisions at both ends are successful, a confirmation is returned to the gatekeeper(s) involved and the call is now complete. If a failure occurs at either end, the call is blocked and cleared. Upon successful completion VG 74 1 would use the IP address of VG 740 2 provided by the gatekeeper, and the MPLS tag provided by the map Tag ER (R 2 , Best_Fwdpath(R 2 )), for forwarding all payload packets belonging to the call. Similarly, VG 740 2 would use the IP address of VG 74 1 , obtained from its gatekeeper and the MPLS tag provided by the local map Tag ER (R 1 , Best_Fwdpath(R 1 )). To complete the description, it is noted that there are a few additional standard procedures implemented for distinguishing the particular call (from other calls at the two end gateways. These procedures are based on well-known protocols and functions implemented above the IP layer (e.g., RTP), as known to those skilled in the art.
With reference to FIG. 7, all transit nodes could include the PSP module and all edge routers could include the Pgen and PSEL modules. Due to the possible overlap in the edge and transit roles of routers, all the three modules may need to be implemented on all routers 80 . The PSEL function tailored to generalized VoIP needs a small enhancement though. Whenever the value of Best_Fwdpath(F) at an edge node E corresponding to another node F changes as a result of the actions discussed earlier, the new value is relayed to all the gateways attached to node E. The gateways 82 in turn use the new value to update their own [Best_Fwdpath(.)] vectors. The relaying of these parameters from edge routers to the attached gateways can be based on conventional IP forwarding.
An alternative option exists where the IP routers, including transit as well as edge nodes, implement only the PSP module. The advantage here is that the routers are now required to provide only a uniform and relatively simple capability, namely, PSP. They are unburdened from performing the relatively complex operations needed by Pgen and PSEL, and furthermore, from having to maintain path state variables, i.e., [Best_Fwdpath(.)], [Best_Revpath(.)] and [Path cost(., .)]. This mode of implementation is illustrated in FIG. 8 where one of the gateways attached to each edge router is designated as a master voice gateway 90 ; the remaining gateways are slave voice gateways 92 . The master VG 90 now implements Pgen and PSEL. Consequently the PUSM's 94 are generated and inserted into the network by the master VG's. Edge routers 96 behave exactly like transit routers, processing and forwarding PUSM's either towards an adjacent router or the attached master VG 90 depending on the direction of propagation. Thus a PUSM 94 originates at a master gateway 90 and terminates at another master gateway 90 ′ at a remote point. With this PUSM propagation model, the links that attach the master gateways 90 to the corresponding edge routers are treated as bandwidth unlimited; i.e., the associated link costs are zero by definition. This is because the management of VG-to-router links is not regarded as part of the distributed CAC and LB function. These links are locally managed by the VG's, as indicated by the second and third clauses of the admissibility criteria given above. As is clear, the master VG 90 now maintains and manipulates all the key data structures such as [Best_Fwdpath(.)], [Best_Revpath(.)] and [Path_Cost(., .)]. Furthermore, whenever a change occurs to the value of Best_Fwdpath(F) at a master VG corresponding to the remote edge router F, the new value is relayed to all the slave VG's that share a common edge router with the master VG. This is done by conventional IP forwarding via the common edge router.
So far the discussion on VoIP CAC & LB implicitly assumed the adoption of Variant A of the algorithm. However, the strategy shown in FIG. 8 allows elegant mechanisms to adopt Variant B and Variant C as well. In both cases, the Rev_opt field 38 is eliminated from the PUSM.
Variant B for VoIP:
As discussed before, here an explicit PIIM is sent from a terminating edge node 96 ′ to the originating edge node 96 , in order to convey the identity of the preferred path to be used by the latter 96 , as determined by the former 96 ′. This capability may be easily integrated within the existing VoIP primitives. Specifically, the RTP sessions that carry live voice calls between master gateways 90 would have associated RTCP sessions for performance monitoring purposes. The PIIM's may be piggybacked on the RTCP packets sent routinely from terminating master VG's 90 ′ to originating master VG's 90 . However, at least one RTCP session should always be active between every pair of master gateways for this approach to be reliable.
Variant C for VoIP:
As discussed, Variant C allows the path terminating nodes to make CAC and LB decisions, rather than the originating nodes. This however necessitates additional interactions between the edge nodes during call setup, which can be a nuisance for unidirectional calls. On the other hand, a VoIP call by nature sets up two circuits, and the associated interactions between the two end-points are already in place. Thus, Variant C does not incur additional burden in the VoIP application scenario. In this embodiment, the set of variables [Best_Fwdpath(.)] are eliminated at the master 90 as well as slave VG's 92 . Also, the master VG relays to slave VG's the value of Best_Revpath(.) instead, during changes.
In this embodiment when a gateway VG 1 either initiates a call to a remote gateway VG 2 attached to router R 2 , or receives a setup request from the remote end forwarded by the local gatekeeper, it simply returns the value of Best_Revpath(R 2 ) to the gatekeeper. If this shows a negative value it automatically implies call rejection. To be precise, the gateway also checks the port and access link bandwidth availability as described earlier, and forces the return of a negative value to the gatekeeper if one of these clauses failed. The gatekeeper(s) checks the values returned by the two gateways; if either is negative, the call is blocked and cleared. Otherwise the gatekeeper(s) swaps the path index numbers it obtained from the concerned VG's and relays them back to the VG's. Call set up is now complete and the VG's can send the voice payload over the paths corresponding to the indices forwarded to them by the gatekeeper(s).
The invention has been described with reference to the preferred embodiments. Modifications and alterations will occur to others upon a reading and understanding of the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. | A method and apparatus to control call admission to a packet-based network and achieve load balancing over a packet-based network includes at selected times generating and sending a path status message along a defined path, such as an MPLS path, through the network. As the message travels along the path, a cost metric field within the message is updated. The cost metric may reflect available bandwidth, or percentage utilization of the aggregate bandwidth, on the most congested (bottleneck) link in the path that it tracks. The cost metric is determined for each link at a data measuring point, such as individual routers, along the path. The optimum path between two gateways is determined, and further packet streams are routed onto the optimum path. In the event that no paths between a source and destination gateway meet predetermined utilization criteria, a packet stream block indicator is set which shows a requesting edge router that no paths are currently available for a packet stream requesting routing between particular source and destination gateway. The path utilization status message may be generated alternately in routers or in a master gateway. In either case, the messages are sent and the status of the network is determined in a distributed fashion at selected times, such as a regular timed interval. | 7 |
BACKGROUND OF INVENTION
[0001] 1. Field of Invention
[0002] This invention relates tools for the determination of formation properties; particularly, this invention relates to nuclear tools having neutron generators and neutron monitors.
[0003] 2. Background Art
[0004] In hydrocarbon exploration and production, it is important to determine whether an earth formation contains hydrocarbon and how much hydrocarbon is in the formation.
[0005] Underground hydrocarbons, as well as water, are typically contained in pore space in the formations. Neutron “porosity” tools are traditionally used to determine the amount of hydrocarbon and water present in pore spaces of earth formations because of their unique abilities to detect such fluids.
[0006] A neutron tool contains a neutron-emitting source (either a chemical source or a neutron generator) and one or more axially spaced detectors that respond to the flux of impinging neutrons or gamma-rays resulting from the interactions of neutrons with nuclei within the borehole and formation in the vicinity of the borehole. The basic concept of a neutron porosity tool is predicated on the fact that (a) hydrogen is the most effective moderator of neutrons and that (b) most hydrogen found in earth formations is contained in liquid in the pore space of the formation, either as water or as liquid hydrocarbon or gas. For neutrons emitted with a fixed energy by the source, the count rates recorded by the detectors typically decrease as the volumetric concentration of hydrogen (e.g., porosity) increases.
[0007] FIG. 1 shows a simplified schematic illustrating a wireline neutron logging operation.
[0008] As shown in FIG. 1 , a neutron tool 11 is disposed in a wellbore 12 . The neutron tool 11 includes a neutron source 13 and one or more neutron detectors 14 . The neutron source, which may be a chemical source or an electronic neutron generator, emits neutrons into the formation 15 surrounding the wellbore 12 . The emitted neutrons traverse the formation 15 and interact with matter in the formation. As a result of such interactions, the neutrons lose some of their energy. Consequently, the neutrons may arrive at the detector 14 with lower energies. By analyzing the response of the detectors to these neutrons, it is possible to deduce the properties of the surrounding formations.
[0009] Traditional neutron tools with chemical sources are able to measure the porosity of a formation in the form of a thermal neutron porosity reading. The chemical source typically relies on a-beryllium reactions in a 241 Am-Be mixture. The interaction of the alpha particle with the Beryllium results in the release of a neutron. The average energy of the emitted neutrons is about 4 MeV. These high-energy neutrons interact with nuclei in the formation and become slowed mainly by elastic scattering to near thermal energies. The slowing-down process is dominated by hydrogen. At thermal energies, the neutrons diffuse through the material until they undergo thermal capture. Capture is dominated by hydrogen and thermal neutron absorbers, such as chlorine or iron.
[0010] FIG. 2A shows one example of a chemical source neutron tool (e.g., CNL® from Schlumberger Technology Corp., Houston. Tex.). As shown in FIG. 2A , the chemical source neutron tool 120 includes a chemical source 125 , which includes a radioactive material, such as AmBe. The chemical source neutron tool 120 also includes a near detector 124 and a far detector 122 to provide a countrate ratio, which is used to calculate the porosity of a formation. The near detector 124 and far detector 122 are thermal detectors. In addition, the tool 120 includes shielding materials 123 that prevent the neutrons generated by the chemical sources from directly reaching the detectors, minimizing the interference from the neutron source 125 .
[0011] Neutron tools using chemical sources have been around for a long time. As a result, users are more familiar with the thermal neutron porosity measurement acquired with chemical source neutron tools. In addition, petrophysicists typically use thermal neutron porosity for specific minerals as part of their formation analysis. However, chemical sources are less desirable due to their constant emission of radiation and strict government regulations. In addition, the material for many of these chemical sources is becoming scarce. Therefore, there is a need to develop neutron tools that do not rely on chemical sources.
[0012] In response to the desire to move away from chemical source neutron tools, some modern neutron tools have been equipped with electronic neutron sources, or neutron generators (minitrons). Neutron generators contain compact linear accelerators and produce neutrons by fusing hydrogen isotopes together. The fusion occurs in these devices by accelerating either deuterium ( 2 H=D) or tritium ( 3 H=T), or a mixture of these two isotopes, into a metal hydride target, which also contains either deuterium ( 2 H) or tritium ( 3 H), or a mixture of these two isotopes. In about 50% of the cases, fusion of deuterium nuclei (d+D) results in the formation of a 3 He ion and a neutron with a kinetic energy of approximately 2.4 MeV. Fusion of a deuterium and a tritium atom (d+T) results in the formation of a 4 He ion and a neutron with a kinetic energy of approximately 14.1 MeV.
[0013] These neutrons, when emitted into formations, interact with matter in the formations and gradually lose energy. This process is referred to as slowing down. The slowing-down process is generally dominated by the elastic scattering of neutrons by hydrogen nuclei, and is characterized by a slowing-down length. Eventually, the high-energy neutrons are slowed down enough to become epithermal neutrons or thermal neutrons. Thermal neutrons typically have an average kinetic energy of 0.025 eV at room temperature, while epithermal neutrons typically have energies corresponding to kinetic energies in the range of 0.4-10 eV. However, neutrons with energies as high as 1 keV may be considered epithermal. One of ordinary skill in the art would appreciate that these energy ranges are general guidelines, rather than clear-cut demarcations. The slowed-down neutrons are typically detected by detectors in the tools, which may include fast neutron detectors, epithermal neutron detectors, and thermal neutron detectors.
[0014] FIG. 2B shows one example of an electronic source neutron tool (e.g., APS® from Schlumberger Technology Corp., Houston, Tex.). Examples of such tools can be found in U.S. Pat. No. 6,032,102 issued to Wijeyesekera et al., and in U.S. Pat. No. Re. 36,012 issued to Loomis et al. These patents are assigned to the present assignee and are incorporated by reference in their entirety. As shown in FIG. 2B , the electronic source neutron tool 121 uses an electronic neutron source to produce high-energy (e.g., 2.4 or 14 MeV) neutrons. The high-energy neutrons emitted into formations are slowed to epithermal and thermal energies by interactions with matter (nuclei) in the formations. The epithermal or thermal neutrons are detected by detectors on the neutron tool 121 , such as near detector 126 , array detector 127 , and far detector 129 . By measuring epithermal neutrons, the detector responses are primarily dominated by the hydrogen content in the formation, without complication from neutron absorbers. Thus, the electronic neutron tool 121 may conveniently provide measurements for hydrogen index. In addition, the neutron tool 121 may also include an array thermal detector 128 to detect thermal neutrons that returned from the formation. The epithermal neutron and thermal neutron measurements obtained with this tool can be used to derive various formation parameters.
[0015] Between the chemical source and the electronic source, the chemical source has the advantage of having a stable and predictable neutron output. The change of their neutron output is dominated by the half-life of the primary alpha source used to generate the nuclear reaction. Given the half-life of the alpha sources typically used (e.g., 241 Am: T 1/2 =430 yrs), it is sufficient to determine or verify the neutron output at intervals of several months.
[0016] In contrast, the neutron output of an electronic source varies over time due to internal effects in the electronic source and its power supplies. In addition, the neutron output of an electronic source is also influenced by external factors, such as temperature, shock, and vibration. If an electronic neutron source is to be used for absolute measurements, it is necessary to have a device that monitors its instantaneous output.
[0017] The need for neutron monitors has been recognized in the past. At present, downhole neutron monitors rely exclusively on scintillation detectors, in particular plastic detectors, for neutron output monitoring. These monitors rely on the proton recoil following elastic neutron scattering in the organic scintillator. Such technologies are described in U.S. Pat. Nos. 6,166,365 and 6,884,994 issued to, both of which are issued to Simonetti et al. and U.S. Pat. Nos. 6,495,837 and 6,639,210, both of which are issued to Odom et al. See also, U.S. Pat. No. 6,754,586, issued to Adolph et al., which discloses monitors for use to calibrate the outputs of electronic neutron sources.
[0018] While the prior art scintillation type monitors provide accurate monitoring of neutron outputs form electronic neutron generators, there remains a need for better monitors.
SUMMARY OF INVENTION
[0019] One aspect of the invention relates to nuclear tools. A nuclear tool in accordance with one embodiment of the invention includes a tool housing configured to move in a wellbore penetrating a formation; a neutron generator disposed in the tool housing; and a solid-state neutron monitor disposed proximate the neutron generator for monitoring outputs of the neutron generator.
[0020] Another aspect of the invention relates to methods for constructing a nuclear tool. A method in accordance with one embodiment of the invention includes disposing a neutron generator in a tool housing; and disposing a solid-state neutron monitor proximate the neutron generator for monitoring outputs of the neutron generator.
[0021] Another aspect of the invention relates to methods for logging a formation. A method in accordance with one embodiment of the invention includes disposing a nuclear tool in a wellbore penetrating the formation, wherein the nuclear tool comprises a neutron generator and a solid-state neutron monitor disposed proximate the neutron generator; generating neutrons from the neutron generator; monitoring neutrons generated by the neutron generator using the solid-state neutron monitor; detecting signals generated from the neutrons traveling in the formation; and correcting the detected signals, based on signal strength detected by the solid-state neutron monitor, to produce corrected signals.
[0022] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0023] FIG.1 shows a conventional nuclear logging tool disposed in a wellbore.
[0024] FIGS. 2A and 2B show two schematics representing a conventional chemical source neutron tool and a conventional electronic source neutron tool, respectively.
[0025] FIGS. 3A and 3B show two configurations of conventional scintillation monitors used in electronic source neutron tools.
[0026] FIG. 4 shows a schematic illustrating a solid state detector for use in neutron output monitoring in accordance with one embodiment of the invention.
[0027] FIG. 5 shows a schematic of a nuclear tool having a solid-state neutron monitor in accordance with one embodiment of the invention.
[0028] FIG. 6 shows another schematic of a nuclear tool having a solid-state neutron monitor in accordance with one embodiment of the invention.
[0029] FIG. 7 shows another schematic of a nuclear tool having a solid-state neutron monitor in accordance with one embodiment of the invention.
[0030] FIG. 8 shows another schematic of a nuclear tool having a solid-state neutron monitor in accordance with one embodiment of the invention.
[0031] FIG. 9 shows another schematic of a nuclear tool having a solid-state neutron monitor in accordance with one embodiment of the invention.
[0032] FIG. 10 shows a flow chart illustrating a method for formation logging in accordance with one embodiment of the invention.
DETAILED DESCRIPTION
[0033] Embodiments of the invention relate to solid-state detectors for monitoring neutron outputs and tools having an electronic neutron source and such a monitor. The small size of a solid-state monitor allows for easier integration of the solid-state neutron monitor with a neutron generator.
[0034] Conventionally, neutron output monitors (or neutron monitors) used in neutron logging tools rely on plastic scintillation crystals to convert neutron energies into photons. See for example, U.S. Patent Application Publication No. 2006/0226351 by Stoller et al. These materials respond to neutron radiation passing through them by producing light. These light signals are then converted into electrical signals by photomultipliers.
[0035] FIG. 3A shows a prior art neutron tool 20 that includes a neutron monitor 21 disposed near the electronic neutron generator 22 . The neutron monitor 21 comprises a scintillator crystal 23 and a photomultiplier 24 . The electronic neutron generator comprises an ion source 25 and a target 26 . The neutron monitor 21 (i.e., scintillator crystal 23 and photomultiplier 24 ) is attached to the neutron tool 20 radially from the target 26 outside of the generator housing 27 . The neutron monitor 21 is disposed as close as possible to the target 26 in order to get sufficient counts for a high precision measurement and minimize the contribution from indirect (scattered) neutron radiation.
[0036] With the addition of a scintillator and photomultiplier, the diameter of the tool is typically increased by about 20 mm, which is a substantial increase in view of the limited dimension of the tool. The relatively large sizes of such conventional neutron monitors make it difficult to use them in small diameter tools. One alternative is to place such neutron monitors at the ends of neutron generators, instead of on the side.
[0037] As shown in FIG. 3B , the neutron monitor 21 is disposed axially from the neutron generator 22 —at one end of the neutron generator. Furthermore, the scintillator crystal 23 is disposed as close as possible to the neutron generator 22 in order to increase the sensitivity of the neutron monitor 21 . Although this arrangement avoids the limitation of the small housing inner diameter, this puts the neutron monitor 21 at a larger distance from the target 26 , which leads to a significant decrease in the monitor count rates. This deteriorates accuracy and precision of the measurement. Furthermore, this may interfere with the shielding material that is typically disposed at the end of the neutron generator 22 .
[0038] To avoid the bulkiness problem associated with the conventional neutron monitors, embodiments of the invention use small solid-state neutron monitors. Solid-state neutron monitors of the invention are characterized as having small sizes, such as between 0.5 and about 2 cm (preferably about 1 cm) in diameter and about 0.1 to about 1 cm (preferably about 0.1 mm to over 1.0 mm) thick. FIG. 4 illustrates one example of a solid-state neutron monitor (i.e., a semiconductor radiation detector) that may be used with embodiments of the invention. Examples of semiconductor detectors may be found in U.S. Pat. No. 5,854,506 issued to Fallica. Such solid-state monitors typically comprise carbon nuclei (e.g., in diamond or silicon carbide (SiC)) that react with the impinging radiation (e.g., neutron radiation).
[0039] Neutrons can interact with carbon nuclei in a solid-state neutron monitor in several different ways. Possible reactions between neutrons and carbon nuclei (found in a diamond detector or a SiC detector) include: (i) Elastic scattering on C-nuclei: 12 C (n, n′) 12 C; (ii) Inelastic interactions with the carbon nuclei; (iii) Inelastic neutron scattering: C (n, n′) 12 C; (iv) Inelastic reaction: 12 C (n, α) 9 Be; and (v) Inelastic reaction: 12 C (n, n′)
[0040] Elastic and inelastic scatterings lead to a variety of recoil energies of the carbon nuclei, depending on the scattering angles. The maximum energy that can be transferred to the carbon nucleus in an elastic central collision with a 14 MeV neutron is about 1 MeV. In inelastic collision 12 C (n, α) 9Be, the total amount of energy deposited in the detector is well defined, resulting in a spectral line. In contrast, elastic scattering and inelastic reactions 12 C (n, n′) 3α result in continuous spectra because the energies deposited in the carbon nuclei depend on kinematics of the collision, i.e., the neutron exiting the collision carries way a variable amount of energy depending on its scattering angle. Similar interactions occur with 28 Si. The reaction that results in the creation of charged particles alone will generally lead to a line in the resulting monitor spectrum.
[0041] In addition to diamond and SiC noted above, other materials suitable for use in a solid state detector include silicon (Si). Although Si is among the most commonly used materials in solid state detectors, it has a small band gap and is not optimal for high temperature applications. At high temperatures such as those encountered in downhole environments, the best materials to use are those with large band gaps. Such large band gap materials, for example, include synthetic diamonds (e.g., polycrystalline diamond or homoepitaxial synthetic diamond, which has a band gap of 5.5 eV) or SiC. Relatively large homoepitaxial synthetic diamonds can now be produced by chemical vapor deposition (CVD) and are becoming preferred materials, as compared to the older polycrystalline diamonds.
[0042] As illustrated in FIG. 4 , a semiconductor detector 41 comprises electrodes 42 and diamond (e.g., homoepitaxial synthetic diamond) 43 . Radiation (e.g., neutrons) that impinges on the diamond 43 may move electrons into the conduction band of the diamond lattice. Once the electrons have been moved to the conduction band (and holes exist in the valence band), they will be able to produce a current when a potential difference is supplied across the detector. Thus, by monitoring the current intensity flowing between electrodes, one can deduce the amount of carbon excitation, which is then used as an indication of the amount of radiation.
[0043] While the simplest approach may be to measure the average current passing through the device, it is more useful to measure and count the single current pulses produced by neutrons interacting with the diamond. In particular, the use of a pulse-height spectrum offers a way to measure and control the gain of the device and to discriminate against undesired radiation. Such undesired radiation, for example, may include x-rays generated in the neutron generator vacuum tube (minitron) or gamma-rays induced by neutron interactions with the tool, borehole or formation.
[0044] While there may be various ways to count the radiation impinging on a solid state monitor or to analyze pulse-height spectrum, one simple example is to connect the monitor 41 to an outside circuit 45 , which sets up a gate of an extremely short period. During this period, the circuit measures the amount of energy that passes through the detector. If the energy is above a certain threshold, this gate is counted as a one, if not it is counted as a 0. After a given duration, the total is summed to find a quantitative measurement for the amount of radiation passing through the semiconductor detector. Furthermore, one can vary the gain and/or threshold in such a circuit to perform pulse-height analysis, if so desired.
[0045] In accordance with embodiments of the invention, such solid-state radiation monitors may be incorporated into nuclear tools for downhole use. Due to their reduced sizes, such neutron monitors may be easily incorporated into a downhole nuclear tool in various configurations. FIGS. 5-9 illustrate some of possible configurations.
[0046] FIG. 5 shows one embodiment of a solid state detector 51 used as a neutron monitor in a downhole tool 50 . In this embodiment, the solid-state neutron monitor is mounted next to the neutron generator 54 , which comprises an ion source 5 5 and a target 53 . In this particular configuration, the neutron monitor 51 is mounted outside of the generator housing 52 radially from the target 53 , but inside of the tool housing 56 . Although this configuration is similar to the conventional tool shown in FIG. 3A , it takes up little inner space of the tool because of the small size of the solid-state neutron monitor. A typical solid-state neutron monitor may have a diameter on the order of 1 cm and a thickness on the order of 0.1 mm to 1 mm (or more, depending on the homoepitaxial growth). In general, thicker layer of diamond will result in increased numbers of counts, and it would also improve the spectral resolution because more of the neutron particles will be stopped. However, the thickness is often limited by the homoepitaxial growth process.
[0047] The small size of a solid-state neutron monitor allows for flexible arrangement of the neutron monitor in the tool. FIG. 6 shows another embodiment of the invention, in which a solid state detector 51 is mounted axially at one end of the neutron generator 54 . In this configuration, the neutron monitor 51 is farther from the target 53 , which might result in a slight decrease in the count rates. However, due to its small size, the solid state detector 51 would take up only a small space that is typically reserved for shielding materials 61 . Therefore, the placement of the neutron monitor 51 at this location would have little impact on the placement of shielding material 61 . This in turn will result in significant improvements in the measurement performance of the shielded detectors. As noted above in FIG. 3B , with the conventional scintillator crystal and photomultiplier, because of its larger size, this arrangement will significantly interfere with the placement of shielding materials, leading to less precise measurements.
[0048] FIG. 7 shows another embodiment of the invention, in which the small size solid-state detector 51 is disposed inside the neutron generator housing 52 . This would have been difficult to achieve with the larger scintillation crystal detector and a photomultiplier and would have required an impractically large generator housing diameter. In the configuration shown in FIG. 7 , the neutron monitor 51 is disposed proximate the ion source 55 . In an alternative configuration, the neutron monitor 51 may be disposed proximate the target 53 . However, this alternative configuration is less preferred because it might interfere with the high voltage insulation that is normally present here. To avoid this problem, the orientation of the neutron generator may be flipped; as shown in FIG. 8 , and the target is operated at ground instead of being at a negative high voltage (about −115 kV).
[0049] FIG. 8 shows an embodiment of the invention, in which a solid state detector 51 is disposed inside the generator housing 52 , but mounted radially from the target 53 instead of the ion source 55 . In this configuration, both the neutron monitor 51 and the target 53 are located away from the high voltage section 81 and the target 53 is operated at ground potential. The operation of this neutron generator differs from the traditional setup because the ion source 55 is normally operated at ground potential and the target is operated at about −100 kV. However, in this invented generator configuration, the target 53 is operated at ground and the ion source 55 is operated at a positive high voltage (e.g., about +100 kV). The grounded target configuration, as shown in FIG. 8 , is technically more challenging because it is necessary to operate and control the ion source at a high positive potential.
[0050] FIG. 9 shows another configuration, in which the solid state detector 51 is integrated within the neutron generator vacuum tube 91 near the target 53 . This configuration may be the most desirable because it will be convenient to place this neutron generator-monitor assembly in a tool. However, the neutron monitor for use in this configuration should be robust (e.g., radiation resistant) and reliable. Otherwise, the need to replace the neutron monitor will increase the costs or shorten the useable life of the neutron generator. Thus, this configuration is desirable, but may not be the most cost effective.
[0051] The above examples show some configurations that are possible with the small size solid-state neutron monitors. One of ordinary skill in the art would appreciate that these are for illustration only and other modifications and variations are possible without departing from the scope of the invention.
[0052] Some embodiments of the invention relate to methods for logging the formations using a tool of the invention. As shown in FIG. 10 , a method 100 in accordance with one embodiment of the invention includes disposing a nuclear tool in a wellbore penetrating a formation (step 101 ). The nuclear tool includes a d-D or a d-T neutron generator and a solid-state neutron monitor. The solid-state neutron monitor is disposed proximate the neutron generator to monitor the burst outputs of the neutrons. In addition, the nuclear tool may include one of more nuclear detectors, such as fast neutron detectors, epithermal neutron detectors, thermal neutron detectors, or gamma-ray detectors. Once the tool is lowered to the desired depth, the d-D or d-T neutron generator is pulsed to emit neutrons into the formation (step 102 ). The neutrons thus emitted may have energies of 2.4 MeV (from d-D neutron generator) or 14 MeV (from d-T generator). The outputs of the neutron pulse are monitored with the solid-state neutron monitor. After interactions with nuclei in the formations, these neutrons lose some of their energies and become epithermal or thermal neutrons. Some of these neutrons may also be captured by the nuclei in the formations. Such interactions may also generate gamma rays. The neutrons or gamma rays that return to the tool will be detected with one or more detectors (step 103 ). The detected signals may be adjusted (or corrected) for any variation in the neutron outputs as measured by the solid-state neutron monitor (step 104 ). Finally, such measurements may be used to determine various formation properties, such as formation slowing down time, formation porosity, formation neutron capture cross section, formation bulk density, or lithology of the formation (step 105 ).
[0053] Advantages of the invention may include one or more of the following. A neutron tool in accordance with embodiments of the invention includes a solid-state neutron monitor for accurately monitoring the outputs of the electronic source in the tool. The solid-state monitor has a small size and can be disposed close to the electronic neutron sources in various configurations without taking up precious space in the tool. The small sizes of the solid-state neutron monitors allow these monitors to be included inside the neutron generator housings. This would simplify the neutron tool manufacturing processes.
[0054] While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims. | A nuclear tool includes a tool housing; a neutron generator disposed in the tool housing; and a solid-state neutron monitor disposed proximate the neutron generator for monitoring the output of the neutron generator. A method for constructing a nuclear tool includes disposing a neutron generator in a tool housing; and disposing a solid-state neutron monitor proximate the neutron generator for monitoring the output of the neutron generator. A method for logging a formation includes disposing a nuclear tool in a wellbore penetrating the formation, wherein the nuclear tool comprises a neutron generator and a solid-state neutron monitor disposed proximate the neutron generator; generating neutrons from the neutron generator; monitoring neutrons generated by the neutron generator using the solid-state neutron monitor; detecting signals generated from the neutrons traveling in the formation; and correcting the detected signals, based on signal strength detected by the solid-state neutron monitor, to produce corrected signals. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to devices for the controlled tightening of threaded fasteners, and more particularly to tightening wrenches with angle indicating devices for the tightening of screws or bolts and nuts to a predetermined tensile stress.
2. Description of the Prior Art
In many applications of threaded fasteners, especially highly stressed clamping screws and clamping bolts, it is essential that the fasteners be subjected to a predetermined clamping preload, not only in order to avoid accidental loosening of the fastener combination, but, more importantly, in order to preclude unacceptable stress reversals in the fasteners and in the clamped parts. The establishment of a controlled fastener preload is particularly important in connection with applications where a series of fasteners is involved and where variations in the clamping tensions from fastener to fastener would not only risk the failure of certain fasteners, but also result in distortions of the parts which are clamped together.
The most common approach taken in order to achieve this result concerns itself with the application of a predetermined tightening torque to the fasteners, under the assumption that the torque applied is a reliable indicator of the tensile stress condition created in the fastener members. Accordingly, there are available in the prior art numerous suggestions of torque limiting and torque indicating devices, known under the general designation of torque wrenches, which are intended to establish a controlled predetermined tightening condition in threaded fasteners. But, no matter how precisely the devices themselves limit the torque applied to a clamping screw or nut, they cannot take into consideration differences and irregularities that exist in the relationship between the applied torque and the tensile stress created in the fastener combination by that torque. This relationship is greatly influenced by the friction conditions between the mating threads, on the one hand, and by the friction between the rotationally sliding clamping faces of the fastener and one of the clamped parts, on the other hand. Obviously, various factors may influence the actual friction conditions, chief among them being the state of lubrication and the quality of the machined surfaces, or of the applied surface coatings, for example. Small differences in lubrication, for example, may result in considerable variations in bolt tensions, even though a uniform torque was applied in all cases to the bolt head or to the nut.
It has therefore already been suggested that, in order to avoid this source of unpredictability in the tightening of threated fasteners, the latter should first be pre-tightened with a small torque, and that the final tightening to the desired tension near the yield stress of the fastener combination should be controlled on the basis of a particular angle of tightening rotation between the fastener members, rather than on the basis of a particular torque applied thereto. It has thus been suggested that such a tightening wrench for screws, or bolts and nuts include an angle indicating device with means for adjusting the starting angular position of the indicating device and means producing a reading of the angular displacement during the final tightening operation. The adjustability of the starting angular position is necessary, because it is generally accepted as impossible or impractical to eliminate the randomness of the angular relationship between the torque transmitting surfaces on the fastener members, e.g. the hexagon facets of a nut or bolt, and the threads of that part.
One prior art solution, therefore, suggests an angle indicating device for use in conjunction with a tightening wrench, where the device includes a stationary member engaging one of the clamped parts in the area surrounding the screw or nut and carrying a reference disc with angular gradations, the latter being angularly adjustable in relation to the stationary member, being frictionally held in place with the aid of permanent magnets. A hub which is solidary with a centrally located torque transmitting member carries one or several pointers which move over the gradations of the reference disc. The stationary member, when not engaged against the clamped parts, is loosely carried by the central hub of the tightening wrench. This device is disclosed in the German Pat. No. 1,603,768.
Among the shortcomings of the device just described are its structural complexity and its manufacturing cost, in addition to its considerable bulk. The device is also limited in regard to its use, being dependent upon a particular structural cooperation between the stationary member of the angle indicating device and the clamped part which is to position the former.
Another prior art solution, intended to have a greater versatility of application, suggests an angle indicating device which consists of two elements which are structurally separate from the tightening wrench itself and of which one can be attached to the wrench, while the other is intended for attachment to the clamped part or some other nearby stationary reference support. Again, permanent magnets are used to provide the necessary angular adjustability. As an alternative to attaching the pointer member to the tightening wrench, it is further suggested to use an indicator disc which slips over the hexagon profile of the bolt or nut. Such a device is disclosed in the German Auslegeschrift (Published Allowed Application) No. 2,128,348.
The above prior art device has many of the shortcomings of the earlier-described prior art device, requiring attachment of the stationary indicator member to the clamped part or to some other stationary support which, consequently, needs to be of magnetically permeable metal. The fact that the component members of the indicating device are not attached to one another and to the wrench further necessitates special care in the alignment of these parts and entails the risk of loss of a component.
Still another prior art device is disclosed in U.S. Pat. No. 2,889,729. There, the tightening wrench carries an indexing ring which is rotatably connected to the wrench head and which has an angular gradation. In the handle of the wrench is incorporated a spring-loaded pawl engaging a notch of the indexing ring as long as the torque remains below a predetermined pre-tightening limit determined by a spring-biased handle portion of the wrench. Upon reaching the pre-tightening torque, the pawl of the wrench releases the indexing ring, which is then manually held in place with a finger which engages a protruding knob of the ring, so that the subsequent angular advance of the tightening wrench is indicated by the movement of the released pawl with respect to the gradation on the indexing ring.
This device is comparatively complex in structure and accordingly costly. It requires a flat space around the head of the wrench and, for proper operation, necessitates a certain degree of skill in the manual release and positioning of the indexing ring.
SUMMARY OF THE INVENTION
It is a primary objective of the present invention to provide an improved tightening wrench and angle indicating device in which most or all of the aforementioned disadvantages and shortcomings are eliminated. Another objective of the invention is to provide a device which is simple in structure and therefore inexpensive, while being compact in its dimensions and suitable for use in a great variety of bolt tightening situations.
The present invention proposes to attain the above objectives by suggesting a novel tightening wrench and angle indicator, in which the angle indicating device is characterized by a wrench-supported independent pointing member which is rotatable with respect to the wrench head and which assumes and maintains a predetermined angular orientation with respect to stationary structure, an orientation which will not change under angular displacement of the tightening wrench. It follows that the latter, when equipped with a suitably graduated disc, will produce an angular reading of tightening displacement relative to the fixed angular position of the pointing member.
This novel device has the particular advantage of not necessitating the establishment of an angular reference point for the tightening angle prior to each final tightening operation, because the pointing member finds and maintains its angular position automatically at all times. The only operative adjustment step necessary is a simple rotation of the graduated reference disc to a convenient reference position, such as a zero-mark, at the beginning of the final tightening operation. This means that the novel device dispenses with any need for a structural interrelationship between the angle indicating device and the clamped parts. It also means that the device can be more compact and much lighter than prior art devices, and that the adaptability of the device to various types of wrenches and to various limitations of available space, is greatly increased. The last mentioned feature is particularly important with respect to recessed, not readily accessible screw heads and nuts.
The present invention also lends itself conveniently for incorporation in a regular torque wrench, thereby offering a combination of the advantages of the latter, for the establishment of a given pre-tightening torque, with the features of the angle indicating device, for the final tightening of the fastener members over a given angle.
In one preferred embodiment of the invention, the independent pointing member relies on the action of gravity on a pendulum or weighted pointer for the establishment of the reference orientation which, in this case, is either vertical, or coincident with a vertical plane, if the axis of rotation is not horizontal. The gravity-controlled pointing member is thus simply a freely rotatable, unilaterally weighted pointer.
In another preferred embodiment of the invention, the independent pointing member relies for the establishment of a fixed angular orientation on an ambient magnetic field, for instance the magnetic field of the earth. The angle indicating device may thus be a simple compass whose needle maintains its orientation independently of the angular position of the compass housing. The latter is preferably attached to the top of the tightening wrench and angularly adjustable relative to the latter against a friction resistance. Instead of using a simple needle compass, it is of course also possible to use more complex compasses, such as a liquid compass, or a gyrocompass.
In general, the independent pointing member may be any type of device which is capable of maintaining a fixed angular orientation under angular displacement of the supporting structure. Accordingly, one could also utilize for this purpose a motor-driven gyro, or the independent pointing member may simply be an element of great rotary inertia which is rotatably supported with minimal friction, so that the angular displacement of the support is incapable of imparting an angular movement to the pointing member.
BRIEF DESCRIPTION OF THE DRAWINGS
Further special features and advantages of the invention will become apparent from the description following below, when taken together with the accompanying drawings which illustrate, by way of example, several embodiments of the invention, represented in various figures as follows:
FIG. 1 is a frontal view of a tightening wrench with a gravity-controlled angle indictor, representing a first embodiment of the invention;
FIG. 2 is a side view of the device of FIG. 1;
FIG. 3 shows in a plan view a magnetic-field-responsive compass-type angle indicating device incorporated in a torque wrench and representing a second embodiment of the invention;
FIG. 4 shows, in a partially cross-sectioned side view, a modified version of the embodiment of FIG. 3, using a liquid compass; and
FIG. 5 shows, in a view similar to FIG. 4, still another embodiment of the invention, featuring a motor-driven gyro as part of the angle indicating device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2 of the drawing, there can be seen a box end tightening wrench 1 of conventional shape, to the upper side of which is attached a short supporting bracket 2. This bracket carries a graduated disc or dial 3 in axial alignment with the rotational axis 4 of the fastener combination (not shown), as represented by the axis of the box end opening of the wrench 1. Above the dial 3 is supported a pendulum or weighted pointer 5 whose shorter extremity forms a needle pointer 5a producing a reading on the dial 3. The weighted pointer 5 is rotatably supported with respect to the bracket 2 and dial 3 about the axis 4. The dial 3 is likewise rotatable with respect to the supporting bracket 2, but engages the latter with a certain amount of friction so as to normally follow the angular movements of the tightening wrench 1, while being conveniently resettable by hand against the friction.
The tightening wrench of FIGS. 1 and 2, because of its reliance upon a pendulum or weighted pointer, will not operate, when the fastener axis is vertical or near vertical. The latter is therefore preferably horizontal, but may also be inclined, provided the pointer is journalled in a rigid low-friction bearing.
The screw or nut which is to be tightened with this tightening wrench is first pre-tightened with a predetermined torque, whereupon the box end of the wrench is engaged over the screw head or nut and the dial 3 is manually rotated until the zero mark is at the highest point of the dial 3, in alignment with the extremity 5a of the pointer 5. During the subsequent final tightening operation over a prescribed angle, the dial 3 rotates with the tightening wrench 1, while the weighted pointer 5 remains in the upwardly pointing position, thereby giving a convenient reading of the angular displacement executed by the tightening wrench.
In FIG. 3 is shown a second embodiment of the invention, where the regular box end wrench of the previous embodiment has been replaced with a torque wrench 6. This torque wrench makes it possible to conveniently adjust and establish the required pre-tightening torque on the fastener combination, without removing the tool from the screw head or nut prior to the final tightening operation. The pre-tightening torque can be adjusted by adjusting the axial position of the set screw 6b in relation to the torque limiting spring 6a. The wrench of FIG. 3 further features a reversible ratchet mechanism 6c by means of which repeated pre-tightening and/or tightening movements can be executed, without disengaging the wrench from the fastener, and which also permits reversal of the tool for a fastener unscrewing operation.
On the upper side of the ratchet head of the wrench 6 is arranged, in axial alignment with the driver, a magnetic compass 7 whose housing 7b is rotatably adjustable in relation to the driver against a frictional resistance. The magnetic compass 7 includes a compass needle 7a of which one arm is made of magnetically permeable metal so as to point at all times to the magnetic north pole of the earth, or to some other stationary magnetic north pole created for this purpose.
This tightening wrench is not suitable for operation on fasteners with a horizontal axis, but is preferably used for vertically oriented fasteners only. A complete screw or nut tightening operation can be performed with this wrench, without removing it from the screw head or nut. As the particular fastener is being progressively tightened with a reciprocating angular ratchet movement, the torque wrench 6 will indicate when the pre-tightening condition is reached, whereupon the housing 7b of the compass indicator is rotated so that its zero mark is in alignment with the compass needle 7a. The final tightening operation can then be performed by advancing the wrench 6 over the required tightening angle.
In the embodiment of FIG. 4 the needle compass of the previously described embodiment has been replaced with a liquid compass 8, thereby rendering the tightening wrench suitable for use on bolts and screws of any orientation. The wrench itself is again a torque wrench 6 which may include a reversible ratchet mechanism (not shown). The spherical housing 8a of the liquid compass 8 has a cylindrical socket extension reaching in a matching axial bore of the driver 6d, a friction ring 8c being interposed between the socket extension of the compass housing 8a and the bore of the driver 6d.
This device, by virtue of the self-orienting feature of the spherical liquid compass, is suitable for all fastener orientations. The liquid compass consists essentially of a transparent spherical housing 8a marked with gradations. Inside of it is arranged a spherical compass element which floats in relation to the housing 8a in a supporting liquid. The spherical compass element 8b is weighted so that it will always assume an upright position, regardless of the orientation of the axis 4 of the compass housing 8a. Suitable meridian lines on the spherical compass member 8b cooperate with the gradations of the compass housing 8a to produce the desired angular reading during the tightening operation.
It should be understood that the axial alignment between the compass and the driver of the torque wrench on the rotational axis 4 of the latter is not a necessary prerequisite for the proper operation of the device of this invention.
In FIG. 5 is illustrated a fourth embodiment of the invention, featuring again a torque wrench 6, to the upper side of which is connected a motor-driven gyro 9. The gyro 9 is arranged inside a gyro housing 9a which is attached to the head of the tightening wrench 6. The cross-sectional representation of FIG. 5 shows a dial disc 9c arranged inside the hemisphere-shaped housing of the gyro 9, floats 9d being attached to the dial 9c. The floats 9d are surrounded by mercury 9b. The lid 9e of the gyro housing is transparent, a centering pin 9f reaching through the lid 9b to the gyro. Like the previously described embodiment of FIG. 4, this embodiment of the tightening wrench is operable under any angular orientation of the fastener members.
Instead of using a magnetically responsive member in order to establish an absolute angular orientation of the latter independently of the angular position of the tightening wrench, it is also possible to simply use a large mass for the indicator sphere of FIG. 4, for example, which mass is supported on a low-friction support, so that no angular movement is transmitted to the indicator member, when the tightening wrench is rotated. The sphere then simply maintains its orientation, regardless of the movements of the tightening wrench. The use of a liquid for the support of the sphere, as suggested in the liquid compass of FIG. 4, makes it possible to obtain a virtually friction-free support of the sphere inside the surrounding housing. The latter is again rotatably adjustable in relation to the tightening wrench, so that the desired angular readings are produced between the markings on the non-rotating sphere and on the transparent housing surrounding the latter.
It should be understood, of course, that the foregoing disclosure describes only preferred embodiments of the invention and that it is intended to cover all changes and modifications of these examples of the invention which fall within the scope of the appended claims. | A tightening wrench with an angle indicator for the final tightening operation on threaded fasteners, the angle indicator having a pointer or other angle indicating element which assumes a given angular orientation under the influence of an ambient force field of gravity or magnetism and maintains this orientation while the wrench is rotated, thereby giving an angular reading of the tightening angle. Gravity is used with a weighted pointer, magnetism with a needle compass or liquid compass. Also usable is a gyro, or a freely rotatable mass of high inertia. The wrench may be a torque wrench. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application claims the benefit of priority under 35 U.S.C. 119(e) to U.S. Provisional Application No. 61/220,120, filed Jun. 24, 2009, of U.S. Provisional Application No. 61/238,195, filed Aug. 30, 2009, both of which are incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally relates to apparatus and methods for assembling pipes, and more particularly to methods and systems for joining tubes for solar receivers.
[0004] 2. Description of Related Art
[0005] Solar thermal power plants may be used to obtain electric power from the sun. In such plants, the solar flux impinges on tubes through which a heat exchange medium flows. In some solar thermal power plants, tubes are situated in a solar collector, such as along the axis of a parabolic trough. The heated heat exchange medium from the tubes may be used in a thermodynamic cycle to generate electric power.
[0006] FIGS. 1-3 show a typical prior art tube 100 for use in solar thermal plants. Tubes 100 are sometimes referred to as “solar receiver tubes” or “heat collection elements (HCE).” Tube 100 may be, for example and without limitation, a SCHOTT solar receiver tube model PTR 70 (SCHOTT Solar, Inc., Albuquerque N. Mex.). Tube 100 having a length L includes an outer tube 110 having a diameter D capped at each end by a flange 115 , an inner tube 111 coaxial with outer tube 110 and having a diameter d, and a bellows 113 that connects the flange and inner tube. Tubes 110 and 111 , bellows 113 and flange 115 are sealed to form a volume 112 , which is evacuated to provide a high thermal insulation between tubes 110 and 111 .
[0007] In general, the length L is from 5 feet (1.5 m) to 20 feet (6 m), the diameter D is from 2 inches (50 mm) to 7 inches (0.18 m), and the diameter d is from 1 inch (25 mm) to 4 inches (0.1 m).
[0008] Typically, tube 110 is a glass tube, and tube 111 , flange 115 , and bellows 113 are metal. Tube 110 is generally transparent to sunlight to facilitate the solar heating of a heat exchange medium that may flow through tube 111 , as indicated by arrows in FIG. 1 .
[0009] In certain embodiments, tube 111 protrudes longitudinally beyond the end of each flange 115 by a distance S, which it typically from 0.375 inches (10 mm) to 4 inches (0.1 m). The portion of tube 111 that so protrudes is referred to as a collar 114 . In certain other embodiments, solar energy systems are formed from multiple solar receiver tubes 100 by joining collars 114 of adjacent tubes. Collar 114 may includes an index, which may be the center line of the tube weld joint, which may be used to rotationally align adjacent tubes for welding.
[0010] Due their length, L, and glass components, solar receiver tubes tend to be fragile, and difficult to join, typically by welding, since the collars 114 protrude beyond the ends of the glass outer tube 110 by a relatively small distance from each end. Further, collars 114 are adjacent to bellows 113 , on whose integrity the vacuum of volume 112 depends. Solar receiver tube are thus difficult to join without damaging the more fragile glass outer tube 110 or the bellows 113 joining tubes 110 and 111 . There is a need in the art for methods and apparatus that permit the easy and rapid joining of such tubes to facilitate more efficient assembly of solar energy systems.
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention overcomes the limitations and problems of the prior art by providing an apparatus and method for rapidly tubes, which maybe used for solar energy systems. A welding station provides for rapidly assembling tubes by welding together two or more such tubes.
[0012] In one embodiment, an apparatus for joining two or more tubes is provided. Although not part of the invention, the solar receiver tubes have a longitudinal axis extending from a first end and a second end, and include an outer tube and a coaxial inner tube. The apparatus includes a weld head, a first means for receiving a first solar receiver tube, and a second means for receiving a second solar receiver tube. The first means allows the first end of the inner tube of the first solar receiver tube to be positioned near the weld head. The second means for receiving the second solar receiver tube, where the second means allows the first end of the outer tube of the second solar receiver tube to be positioned with the first end of inner tube of the second solar receiver tube near the weld head. The apparatus further includes translations stages to position the first ends of the received inner tubes in the weld head.
[0013] In another embodiment, the apparatus accepts a third solar receiver tube and joins three tubes. In yet another embodiment, the weld head is an orbital weld head.
[0014] In one embodiment, a method for joining tubes in a welding apparatus having a first weld head and a second weld head is provided. The method includes accepting a first solar receiver tube into the welding apparatus; accepting a second solar receiver tube into the welding apparatus; adjusting a welding apparatus translation stage to abut ends of the first and second solar receiver tube; orbital welding the first and second solar receiver tubes using the first weld head; accepting a third solar receiver tube into the welding apparatus; adjusting a welding apparatus translation stage to abut ends of the first and second solar receiver tube; and orbital welding the second and third solar receiver tubes using the second weld head.
[0015] These features together with the various ancillary provisions and features which will become apparent to those skilled in the art from the following detailed description, are attained by the joining apparatus and method of the present invention, preferred embodiments thereof being shown with reference to the accompanying drawings, by way of example only, wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a side view of a prior art solar receiver tube;
[0017] FIG. 2 is an end view 2 - 2 of the tube of FIG. 1 ;
[0018] FIG. 3 is a cross-sectional view 3 - 3 of the tube of FIG. 1 ;
[0019] FIG. 4 is a side view of one embodiment of a welding station;
[0020] FIG. 5 is a top view of the welding station of FIG. 4 ;
[0021] FIG. 6 is an end view of the welding station of FIG. 5 ;
[0022] FIG. 7 is a side view of a second embodiment of a welding station;
[0023] FIG. 8 is a sectional top view of an alternative embodiment welding station;
[0024] FIG. 9 is an end view of the welding station of FIG. 8 ;
[0025] FIG. 10 is one embodiment of a purge trap disc assembly;
[0026] FIGS. 11A-11C illustrates a process for welding together solar receiving tubes;
[0027] FIG. 12 illustrates two tubes welded together;
[0028] FIG. 13 an embodiment of a double joining welding station;
[0029] FIG. 14 illustrates three tubes welded together;
[0030] FIG. 15 is a side view of a second embodiment of double joining welding station for joining three tubes;
[0031] FIG. 16 is a top view of the welding station of FIG. 15 ;
[0032] FIG. 17 is an end view of the welding station of FIG. 15 ;
[0033] FIG. 18A is a top view 18 - 18 of FIG. 16 illustrating a first position of an end cap assembly;
[0034] FIG. 18B is top view 18 - 18 of FIG. 16 illustrating a second position of an end cap assembly;
[0035] FIG. 19A is a side view 19 - 19 of FIG. 15 illustrating a first position of an end cap assembly;
[0036] FIG. 19B is side view 19 - 19 of FIG. 15 illustrating a second position of an end cap assembly;
[0037] FIG. 20A is a top view 20 - 20 of FIG. 16 illustrating a retracted position of a weld head and process chamber;
[0038] FIG. 20B is a top view 20 - 20 of FIG. 16 illustrating an extended position of the weld head and process chamber with a sealed process chamber;
[0039] FIG. 21A is a side view 21 - 21 of FIG. 15 illustrating a retracted position of the weld head and process chamber;
[0040] FIG. 21B is a side view 21 - 21 of FIG. 15 illustrating an extended position of a weld head and process chamber;
[0041] FIG. 21C is a side view 21 - 21 of FIG. 15 illustrating the extended position of a weld head and process chamber with a sealed process chamber;
[0042] FIG. 21D is a side view 21 D- 21 D of FIG. 21C ;
[0043] FIG. 21E is a side view 21 E- 21 E of FIG. 21C ; and
[0044] FIG. 22 is a view of one embodiment of a welding station control panel.
[0045] Reference symbols are used in the Figures to indicate certain components, aspects or features shown therein, with reference symbols common to more than one Figure indicating like components, aspects or features shown therein.
DETAILED DESCRIPTION OF THE INVENTION
[0046] FIGS. 4-6 are schematics of one embodiment of a welding station 400 , where FIG. 4 is a side view, FIG. 5 is a top view, and FIG. 6 is an end view. Welding station 400 includes a stand 416 for positioning the welding station on the ground G and to support tube stations 410 , specifically a first tube station 410 - 1 and a second tube station 410 - 2 , at a height H. The height H may be, for example and without limitation, from 3 feet (0.3 m) to 5 feet (1.5 m) above the ground.
[0047] Tube stations 410 - 1 and 410 - 2 are each adapted to receive a solar receiver tube, such as two tubes 100 , and both stations include two or more assemblies 422 for supporting the tube ends. Thus, for example and without limitation, four assemblies 422 - 1 , 422 - 2 , 422 - 3 , and 422 - 4 are shown in FIG. 4 , with station 410 - 1 associated with first assembly 422 - 1 and second assembly 422 - 2 , and station 410 - 2 associated with third assembly 422 - 3 , and fourth assembly 422 - 4 . In general, assemblies 422 are positioned near the ends of tubes provided to stations 410 - 1 and 410 - 2 .
[0048] Assemblies 422 may each be the same or may be different, and may include, for example and without limitation, various combinations of tube guides, supports, translation stages, and locking mechanisms to aid in the guiding, positioning and restraining of each tube within welding station 400 .
[0049] Welding station 400 also includes a weld head 425 and an associated weld head process chamber 424 located between stations 410 - 1 and 410 - 2 , and ancillary equipment for welding including, for example, a process gas supply 426 , supply line 421 to provide gas to an accepted tube 100 , a process gas controller 427 , a power supply 428 , a welding remote control unit 429 , and a welding process controller and cooling unit 430 .
[0050] Weld head 425 is adapted to fit with space 2 S and a distance (D-d)/2 to weld adjacent tubes within tube stations 410 - 1 and 410 - 2 . Weld head 425 may be any weld head suitable for welding the ends of pipes, and may be, for example and without limitation, a standard orbital welder or a rotational welder, with unit 430 selected as an appropriate unit. Thus, for example and without limitation, weld head 425 may be used with an Arc Machine 9-7500 welder (Arc Machines, Inc., Pacoima, Calif.) and unit 430 may include an Arc Machines model 207 power supply controller with its mating 207-CW cooling package.
[0051] Weld head process chamber 424 may include two halves, which may or may not be hinged, to permit the chamber to open and receive tubes 100 , and may also include connections to receive a gas from process gas controller 427 . Process gas may thus be provided to the outside of tubes 100 during welding.
[0052] In one embodiment, as illustrated in FIG. 6 , assemblies 422 include lowering guides 631 , also referred to as a “V supports,” to guide accepted solar receiver tubes 100 (shown in phantom lines) into welding station 400 . Lowering guides 631 may also include several rubber protected, radius-saddle type supports that form to the curvature and support the outer diameter of an accepted tube 100 .
[0053] As further illustrated in FIG. 6 , one or more components of assembly 422 may include one or more translation stages 632 to permit adjusting of an accepted solar receiver tube 100 along one or more of: the length of the tube (the “X” axis); in the plane of stand 416 and transverse to the length of an accepted tube (the “Y” axis); and in the plane of stand 416 and traverse to X and Y (the height along the “Z” axis). In addition and without limitation, weld head 425 , and or lowering guides 631 may also be mounted on individual translation stages 632 .
[0054] FIG. 7 is a side view of a second embodiment of a welding station 700 . Welding station 700 is generally similar to welding station 400 , except were explicitly noted.
[0055] Welding station 700 includes: assembly 422 - 2 including perch 723 - 1 and a support 631 - 1 mounted on an X-Y translation stage 734 - 1 and Z-axis translation stage 740 ; and assembly 422 - 3 which includes perch 723 - 2 and a support 631 - 2 mounted on an X-Y translation stage 734 - 2 .
[0056] For an orbital weld head 425 , the weld head includes an electrode 742 and a rotor 745 that may be moved into place for welding via a retraction mechanism 744 , and adjusted using fine tuning adjustments of X-Y translation stage 733 , X-axis translation stage 739 , Z-axis translation stage 735 and 741 . Alternatively, weld head 425 may translate relative to stand 416 and not include retraction mechanism 744 .
[0057] Translation stages 734 - 1 and 734 - 2 , 733 , 735 , 739 , 740 , and 741 may be, for example and without limitation, screw slide mechanisms.
[0058] For illustrative purposes, welding station 700 is shown as having accepted first tube 100 - 1 , having a glass outer tube 110 - 1 and a flange 115 - 1 , and second tube 100 - 2 , having a glass outer tube 110 - 2 and a flange 115 - 2 . In addition, each glass tube 110 - 1 and 110 - 2 is shown as having a corresponding nipple 736 - 1 and 736 - 2 that remains from the tube manufacturing process. In one embodiment, nipples 736 - 1 and 736 - 2 are aligned and oriented in the same plane.
[0059] Perches 723 - 1 , 723 - 2 are adapted to accept and support tubes, such as tubes 100 - 1 and 100 - 2 . Thus, for example, perches 723 - 1 , 723 - 2 each have a radius that is adapted to accept metal flange portion 115 and tube 110 , respectively. In addition, one or more of perches 723 - 1 , 723 - 2 may be grounded to form a ground for welding adjacent tubes. Other means for restraining the tube 100 for welding include, but are not limited to, clamps, saddles, perches, straps, and combinations thereof.
[0060] Process chamber 424 may be positioned to cover weld head 425 and provides a protected or sealed environment around the ends of accepted solar receiver tubes 100 - 1 and 100 - 2 . In one embodiment, the interior of process chamber 424 is configured to be purged with a gas provided, for example, by process gas supply 426 .
[0061] Translation stages 739 , 740 , 741 provide adjustments of accepted tubes 100 - 1 and 100 - 2 along the X, Y, and Z axes. Specifically, X-axis translation stage 739 permits adjustment of the electrode 742 for alignment of the weld joint with the tube ends, translation stage 740 permits adjustment of tube-to-tube alignment in the plane of the stand, and the Z axis translation stage 741 permits vertical adjustments to fine tune electrode concentricity for welding. In one embodiment, glass supports 631 are mounted to the stages 740 in the welding station stand and restrain outer glass tubes of the solar receiver tubes.
[0062] Retraction mechanism 744 allows weld head 425 , including the electrode 742 and rotor 745 , into position for welding. Retraction mechanism 744 may, for example and without limitation, be slide mounted and air or electrically actuated. Preferably, the weld head 425 is retractable to a position that is below the bottom edge of the received solar receiver tubes 100 - 1 , 100 - 2 . The retractable weld head 425 facilitates placement of the solar receiver tubes 100 - 1 , 100 - 2 during loading and unloading.
[0063] In one embodiment, translation stages 733 , 734 - 1 and 734 - 2 permitting fine adjustment in the X-Y plane for tube-to-tube alignment of accepted tubes 100 - 1 and 100 - 2 . In an alternative embodiment, the translation stages 734 - 1 and 734 - 2 include the V-support 631 , and the Y-axis adjustment may be achieved by sliding weld head 425 in a machined slot mounted to stand 416 . Thus, for example, tubes are manually presented to the rotational weld fixture and indexed on receiver tube metal collar/bellows not requiring a Z-axis adjustment on receiver tube supports. Z-axis adjustment using translation stage 735 may provide for adjusting the position of electrode 742 , enabling centerline seem adjustment of the electrode to the joint.
[0064] In certain embodiments, it is advantageous to provide a process gas to a joining location on the inside of accepted tubes 100 , especially when the tubes are being welded. FIG. 10 shows a purge trap disc assembly 1000 . Assembly 1000 is used to provide control of gases on the interior of tubes 111 - 1 and 111 - 2 near ends that are being joined. Assembly 1000 includes a first disc 1001 and a second disc 1003 . Discs 1001 and 1003 have outer diameters that match the inner diameters of tubes 111 , and has a pair of circular seals 1005 that seat against the metal tube 111 of each tube, isolating a region about the abutted collars such that process gas can be provided to the inside metal surface near the location at which welding will occur. Disc 1103 has a line 1104 that may be connected to supply line 421 , and disc 1101 has an opening 1102 . Assembly 1000 may thus receive gas from supply 427 , which purges the space within tubes 111 between discs 1001 and 1003 . A sparging process gas is vented through the sealed portion of tube during welding, eliminating metal oxidation on the interior of weld seam.
[0065] FIG. 8 is a sectional top view of an alternative embodiment welding station 800 , and FIG. 9 is an end view of the embodiment of welding station 800 . Welding station 800 is generally similar to welding stations 400 and 700 , except where explicitly discussed.
[0066] Welding station 800 includes a supporting channel 846 , optionally equipped with a protective cap 847 , attached to the welding station stand 416 , an assembly 422 - 1 including a saddle support 837 - 1 ; and an assembly 422 - 4 including a saddle support 837 - 2 . Saddle supports 837 - 1 , 837 - 2 are adapted to accept and support tubes, such as tubes 100 - 1 and 100 - 2 .
[0067] In welding station 800 , supporting channels 846 has a width sufficient to support the outer diameter of solar receiver tubes 100 - 1 , 100 - 2 on saddles 837 - 1 , 837 - 2 , respectively, each of which may be coupled to a translation stage 734 . One or more channels may be connected together, or be individually fixed to a welding station stand. In one embodiment, the outer glass portions 110 of the solar receiver tubes longitudinally contact cushions on the saddles 837 . In this embodiment, the lowering guides 631 , and stages 734 are both optional.
[0068] FIGS. 11A-11C are illustrative of, but not meant to limit, one method of using a welding station, such as welding station 400 , 700 , or 800 . Initially, any clamps on assemblies 422 , weld head 425 , and process chamber 424 are open, permitting acceptance of solar receiver tubes 100 .
[0069] For embodiments where the weld head 425 is mounted on a retraction mechanism 744 , the weld head 425 is positioned below the tubes until needed for welding, at which time it is raised into welding position, and the tubes are translated relative to the electrode 742 .
[0070] First, as shown in FIG. 11A , a first receiver tube 100 - 1 is lowered onto lowering guides 631 of assemblies 422 - 1 and 422 - 2 .
[0071] One illustrative example, which is not meant to limit the scope of the present invention, is described with reference to the embodiment of FIG. 7 . The lowering guides facilitate placement of the solar receiver tube on the perch 723 . Thus, for example the electrode 742 is required to rotate about the adjoining solar receiver tube ends with a nearly constant arc gap. The lowering guides direct the metal-flanged ends 115 of the solar receiver tubes onto the perches 723 and coarsely index mating the tube ends end-to-end. The X axis position may then be adjusted so that the electrode 742 points to the centerline (dashed line) of the eventual weld joint.
[0072] In certain embodiments, lowering guides 631 include a portion that accepts the collar 114 index to maintain the weld stub of the tube in proper rotational relationship to a rotational weld fixture electrode of the welding station.
[0073] Next, with reference to FIG. 11B , a second tube 100 - 2 is lowered onto lowering guides 631 of second tube station 410 - 2 . In one embodiment, the weight of tubes 100 - 1 and 100 - 2 is sufficient to secure the tubes for welding. In another embodiment, positive restraint mechanisms, such as clamps, are provide to restrain one or more of tubes 100 - 1 , 100 - 2 . X-Y translation stages 632 , 733 , 734 - 1 and 734 - 2 are then adjusted for tube-to-tube alignment of accepted tubes 100 - 1 and 100 - 2 such that the ends of their respective tubes 111 are in contact.
[0074] Next, with reference to FIG. 11C , purge trap disc assembly 1000 is attached to supply line 421 and is inserted into an open end of the metal tube 111 of tube 100 - 1 , and process chamber 424 is placed about the ends of tubes 100 - 1 and 100 - 2 . Process gas is then supplied to assembly 1000 and process chamber 424 to provide a controlled gas mixture for the welding of tubes 100 - 1 , 100 - 2 to eliminate or reduce metal oxidation at the weld site.
[0075] At this point tubes 100 - 1 and 100 - 2 are ready for welding. An operator engages the sequence start button of the welding process controller and cooling unit 430 , and a preprogrammed weld sequence fuses the ends of their respective tubes 111 .
[0076] After welding, assembly 1000 is removed from the welded tubes 1200 , process chamber 424 is opened, any straps or clamps are opened, and the welded tubes 1200 are removed from welding station 700 . FIG. 12 shows the welded tubes 1200 as including tubes 100 - 1 and 100 - 2 .
[0077] FIG. 13 is an embodiment of a double joining welding station 1300 for joining three tubes 100 . Welding station 1300 is generally similar to welding stations 400 , 700 , and 800 except where explicitly discussed.
[0078] Welding station 1300 includes first tube station 410 - 1 , second tube station 410 - 2 ,and a third tube station 410 - 3 . Tube stations 410 - 1 and 410 - 2 are adapted to receive tubes 100 - 1 and 100 - 1 , as described in other embodiments of the welding station, and tube station 410 - 3 includes assemblies 422 - 5 and 422 - 6 to accept a third tube 100 - 3 . Assemblies 422 - 5 and 422 - 6 are generally similar to previously discussed assembly 422 .
[0079] Welding station 1300 includes a first weld head 425 - 1 and a second weld head 425 - 2 . Weld heads 425 - 1 and 425 - 2 are generally similar to weld head 425 , including mounting, positioning and translation capabilities. Welding station 1300 also includes a first weld head process chamber 424 - 1 and a second weld head 425 - 2 disposed inside a second weld head process chamber 424 - 2 . Weld heads 425 - 1 and 425 - 2 are generally similar to weld head 425 , including mounting, positioning and translation capabilities, and process chambers 424 - 1 and 424 - 2 are generally similar to process chamber 424 .
[0080] Welding station 1300 also includes a first supply line 421 - 1 and a second supply line 422 - 2 . First supply line 421 - 1 provides gas to a first disc assembly 1000 that may be inserted to the junction of tubes 100 - 1 and 100 - 2 . Second supply line 421 - 2 provides gas to a second disc assembly 1000 that may be inserted to the junction of tubes 100 - 2 and 100 - 3 .
[0081] Welding station 1300 is used in a manner similar to the method illustrated in FIG. 7 . A first tube 100 - 1 is placed in station 410 - 1 and a second tube 100 - 2 is placed in station 410 - 2 . Tubes 100 - 1 and 100 - 2 are welded, and then a third tube 100 - 3 is placed in station 410 - 3 . Third tube 100 - 3 is then welded to tube 100 - 3 .
[0082] After welding, assemblies 1000 are removed from the welded tubes 1400 , process chambers 424 - 1 and 424 - 2 are opened, any straps or clamps are opened, and the welded tubes 1400 are removed from welding station 1300 . FIG. 14 shows the welded tubes 1400 as including tubes 100 - 1 , 100 - 2 , and 100 - 3 .
[0083] FIGS. 15-22 are illustrative of a second embodiment of double joining welding station 1500 for joining three tubes 100 . Welding station 1500 is generally similar to welding stations 400 , 700 , 800 , and 1300 , except where explicitly discussed.
[0084] FIG. 15 is a side view, FIG. 16 is a top view, and FIG. 17 is an end view of welding station 1500 . Welding station 1500 includes two weld head and process chambers 1540 : a first weld head and process chamber 1540 - 1 and a second weld head and process chamber 1540 - 2 . Weld head and process chamber 1540 may be generally similar to weld head 425 and weld head process chamber 424 .
[0085] When adapted to weld three tubes, welding station 1500 includes three tube stations 1510 for accepting tubes 100 . Tube stations 1510 may be generally similar to tube stations 410 . Tube stations 1510 include a tube station 1510 - 1 is adapted to accept tube 100 - 1 , a tube station 1510 - 2 to accept tube 100 - 2 , and a tube station 1510 - 3 to accept tube 100 - 3 . Tube stations 1510 - 1 and 1510 - 2 may be used to position end of tubes 100 - 1 and 100 - 2 near or within weld head and process chamber 1540 - 1 . Tube stations 1510 - 2 and 1510 - 3 may be used to position end of tube 100 - 2 and 100 - 3 is near or within weld head and process chamber 1540 - 2 .
[0086] Tube stations 1501 - 1 , 1501 - 2 , and 1501 - 3 include assemblies 1520 for supporting tubes 100 , which may be generally similar to assemblies 422 . Thus, for example and without limitation, welding station 1500 includes six assemblies 1520 - 11 , 1520 - 12 , 1520 - 21 , 1520 - 22 , 1520 - 31 , and 1520 - 31 , with tube station 1510 - 1 associated with first assembly 1520 - 11 and second assembly 1520 - 12 , tube station 1510 - 2 associated with first assembly 1520 - 21 and second assembly 1520 - 22 , and tube station 1510 - 3 associated with first assembly 1520 - 31 and second assembly 1520 - 32 . Assemblies 1520 may also include guides 631 .
[0087] In one embodiment, welding station 1500 includes an adjustable stand 1530 for positioning the welding station on the ground G and to support tube stations 1510 . Stand 1530 , which may be generally similar to stand 416 , includes legs 1531 , 1533 , 1535 , and 1537 which support platforms 1538 - 1 , 1538 - 2 , 1538 - 3 , and 1538 - 4 . Platform 1538 - 1 includes assembly 1520 - 11 , platform 1538 - 2 includes assemblies 1520 - 12 and 1520 - 21 , platform 1538 - 3 includes assemblies 1520 - 22 and 1520 - 31 , and platform 1538 - 4 includes assembly 1520 - 32 .
[0088] Pairs of rails 1539 - 1 , 1539 - 2 , and 1539 - 3 are connected at assemblies 1520 to form a rigid stand 1530 . In one embodiment, rails 1539 - 1 , 1539 - 2 , and 1539 - 3 are segments of rails spanning the length of welding station 1500 , and support platforms 1538 - 1 , 1538 - 2 , 1538 - 3 , and 1538 - 4 may be placed along the rail to adapt the length of tubes 100 - 1 , 100 - 2 , 100 - 3 . In another embodiment, rails 1539 - 1 , 1539 - 2 , and 1539 - 3 are separate rails that telescope in support platforms 1538 - 1 , 1538 - 2 , 1538 - 3 , and 1538 - 4 to adapt the length of tubes 100 - 1 , 100 - 2 , and 100 - 3 .
[0089] FIG. 17 shows one embodiment of platform, such as 1538 - 1 , as including a pair of tubular portions 1703 and 1705 which are connected to legs 1531 , and spanning portion 1701 . Tubular portions 1703 and 1705 are sized to accept tubular portions 1539 as an insert. Spanning portion 1701 may include components to support tubes, weld heads, and/or process chambers.
[0090] Weld head and process chamber 1540 is provided on stand 1530 to allow each weld head 425 to retract (move down) to allow tubes 100 to be placed and extended (moved up) to weld tubes. Thus, for example, weld heads 425 - 1 , 425 - 2 are attached to platforms 1538 - 2 , 1538 - 3 via retraction mechanisms 744 - 1 , 744 - 2 , and the platforms each have a hole 1601 - 1 , 1601 - 2 to permit movement of weld heads 425 - 1 , 425 - 2 for tube placement and welding (as in FIGS. 21A , 21 B, and 21 D) Weld heads and process chambers 1540 also permit outside covering of tubes 100 by process chambers 424 , as described subsequently.
[0091] FIGS. 18A and 18B are top views 18 - 18 of FIG. 16 and FIGS. 19A and 19B are side views 19 - 19 of FIG. 15 illustrating the end cap in the first and second position, respectively.
[0092] Welding station 1500 includes a pair of end cap assemblies 1800 at the each end of the tubes which are to be welded. In the embodiment illustrated, welding station 1500 includes a pair of end cap assemblies 1800 , one at an end of tube 100 - 1 and at one at an end of tube 100 - 3 . End cap assemblies 1800 may be used to push the tubes 100 together for welding and/or provide access to a process gas, such the gas from process gas supply 426 . End cap assembly 1800 may, for example, form part of an end assembly 1520 - 11 and 1520 - 32 .
[0093] End cap assembly 1800 includes a perch 1801 having a curved surface to accept a tube 100 , a motor 1803 which is attached to platform 1538 , a rod 1805 , and an end cap 1807 having a line 1810 that passes through the end cap within the location of an accepted tube 111 . One or more of end cap assembly 1800 may also provide an electrical connection to an accepted tube 111 for grounding the tube.
[0094] Motor 1803 pushes or pulls on rod 1805 , moving end cap 1807 in a longitudinal direction of accepted tube 100 . In the first position of FIGS. 18A , 19 A, motor 1803 pushes end cap 1807 to an extreme position, permitting the easy acceptance and placement of tube 100 . In the second position of FIGS. 18B , 20 B, motor 1803 pulls end cap 1807 onto the end of tube 111 . Motor 1803 may provide sufficient force to move tubes 100 together. Motor 1803 may also provide sufficient force to provide a seal of end cap 1807 on tube 111 . Line 1801 , which passes through end cap 1807 , may then be used to provide and/or remove purge cases from tubes 111 - 1 , 111 - 2 , and 111 - 3 .
[0095] Motor 1803 may be, for example and without limitation, a pneumatic device such as a model CDY2S25H-100 pneumatic air linear table slide (SMC Corporation of America, Noblesville, Ind.).
[0096] FIGS. 20 and 21 illustrate various configurations of the weld head and process chamber, where FIG. 20A is a top view 20 - 20 of FIG. 16 illustrating a retracted position, FIG. 20B is a top view 20 - 20 of FIG. 16 illustrating an extended position with a sealed process chamber, FIG. 21A is a side view 21 - 21 of FIG. 15 illustrating a retracted position, FIG. 21B is a side view 21 - 21 of FIG. 15 illustrating an extended position, FIG. 21C is a side view 21 - 21 of FIG. 15 illustrating the extended position with a sealed process chamber, FIG. 21D is sectional view 21 D- 21 D of FIG. 21C , and FIG. 21E is a sectional view 21 E- 21 E of FIG. 21C .
[0097] Weld head and process chambers 1540 - 1 , 1540 - 2 each includes a weld head retraction mechanism 744 which includes a motor 2101 attached to a platform, such as platform 1538 - 3 , through translation stage 632 . Retraction mechanism 744 further includes a rod 2103 that extends from motor 2101 to platform 2104 , on which weld head 425 is mounted. As shown in FIGS. 20A and 21A , a process chamber bottom portion 2105 is attached to platform 1538 - 3 surrounding hole 1601 - 2 , permitting welding head 425 to move to tubes 100 , as shown, for example, in FIGS. 21A and 21B .
[0098] In one embodiment, platform 2104 seats against portion 1701 , and a removable lid 2007 may be placed on bottom portion 2105 after tubes for welding have been received to form process chamber 424 , as shown, for example in FIGS. 21B and 21D .
[0099] Welding station 1500 may alternatively include clamps to restrain on or more tubes 100 . As an example, which is not meant to limit the scope of the present invention, center tube 100 - 2 is held in place at each end with clamp 2000 - 1 , 2000 - 2 (or, in general, clamp 2000 ), as shown in FIGS. 15 , 16 , 17 , 20 A, 20 B, 21 A, 21 B, and 21 C. Clamp 2000 may, for example and without limitation be a swivel clamp (manufactured, for example, by DE-STA-CO Industries, Auburn Hills, Mich.) having a motor that rotates an arm 2101 to accept a tube (as in FIG. 20A ) or over an accepted tube, and then pulls the tube onto the stand 1530 .
[0100] Thus, for example, with tubes 100 placed in tube stations 1501 - 1 , 1501 - 2 , and 1501 - 3 , the center tube is clamped by clamps 2000 ( FIGS. 20A and 21A ). Tubes 100 are aligned using the various translation stages. In one embodiment, tubes 100 are aligned in the y-z plane. Thus, for example, FIG. 21E illustrates a saddle 2109 , which may be part of assembly 422 , which includes a curved portion 2111 , and is attached to translation stages to affect y and z axis adjustments. In another embodiment, a laser alignment system is used to illuminate the tube ends to facilitate alignment. End cap assemblies 1800 are then moved to force end caps 1807 onto the tube ends. Lines 1801 may then be attached to lines 421 . Retraction mechanism 744 raises weld head 415 to a pair of adjacent tubes 100 ( FIGS. 20B and 21B ). Lid 2107 is then be placed on bottom portion 2105 to form process chambers 724 , as is shown, for example, in FIG. 21D . Process gas is then provided to process chambers 724 and the interior of tubes 111 , and the tubes are welded.
[0101] As shown in FIG. 22 , which is one of a pair of control panel 2200 for each weld head of welding station 1400 which may include, but is not limited to: providing high and low flow rates to tubes 111 for purging and exhaust 2201 , process gas flow rate and pressure sensors and meters 2203 , an oxygen analyzer 2205 to measure and monitor the quality of the purge gases; switch 2207 to control end cap assemblies 1800 ; switch 2209 to control clamp 2000 ; switch 2211 to control retraction mechanism 744 ; and safety interlocks 2113 for purge, pneumatics, welding.
[0102] Reference throughout this specification to “one embodiment,” “an embodiment,” or “certain embodiments” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment” or “in certain embodiments” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.
[0103] Similarly, it should be appreciated that in the above description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this invention. | A system for rapidly assembling solar receiving tubes and solar energy systems comprises a welding station is described. The welding station provides for rapidly assembling solar receiver tubes by welding together two or more solar receiving tubes and comprises means for receiving and restraining solar receiver tubes and a welding station comprising an orbital or a rotational weld head. | 8 |
The invention disclosed herein was made with Government support under NIH grants CA65512 and CA55652, the American Cancer Society RPG MGO-97551 and by the NCIC/Canadian Breast Cancer Research Initiative and the Medical Research Council of Canada. Accordingly, the U.S. Government, the American Cancer Society, and the Government of Canada may have certain rights in this invention.
1. FIELD OF THE INVENTION
This invention relates to a newly identified Src oncogene mutation, polypeptides containing such mutation, and polynucleotides encoding such mutation. This invention also relates to methods of identifying the Src mutation, to the use of such methods in therapy and diagnosis, and to methods of identifying agonist and antagonist compounds useful for treating and/or preventing clinical conditions associated with or caused by Src mutation. Methods and compositions are provided for identifying and treating malignant cells in a host such as human. Mutated DNA sequence probes and primers are made for determining the expression of mutated nucleic acid.
2. BACKGROUND OF THE INVENTION
The discovery of Rous sarcoma virus (RSV) led to the identification of a cellular oncogene Src (c-Src) (SEQ ID NO. 1), which encodes a non-receptor tyrosine kinase (phosphoprotein of molecular weight 60,000 Dalton or pp60c-Src) (SEQ ID NO. 2). The Src oncogene has been implicated in the development of numerous types of cancers via a yet to be elucidated mechanism (see for example Stehelin, D., Varmus, H. E., Bishop, J. M. & Vogt, P. K. Nature 260, 170-173 (1976); Brugge, J. S. & Erikson, R. L. Identification of a transformation-specific antigen induced by an avian sarcoma virus. Nature 269, 346-348 (1977); Jove, R. & Hanafusa, H. Cell transformation by the viral Src oncogene. Annu Rev Cell Biol 3, 31-56 (1987); Thomas, S. M. & Brugge, J. S. Cellular functions regulated by Src family kinases. Annu Rev Cell Dev Biol 13, 513-609 (1997)). The nucleic acid sequence of normal c-Src is as follows:
atgggtagca acaagagcaa gcccaaggat gccagccagc ggcgccgcag cctggagccc
60
(SEQ ID NO.1)
gccgagaacg tgcacggcgc tggcgggggc gctttccccg cctcgcagac ccccagcaag
120
ccagcctcgg ccgacggcca ccgcggcccc agcgcggcct tcgcccccgc ggccgccgag
180
cccaagctgt tcggaggctt caactcctcg gacaccgtca cctccccgca gagggcgggc
240
ccgctggccg gtggagtgac cacctttgtg gccctctatg actatgagtc taggacggag
300
acagacctgt ccttcaagaa aggcgagcgg ctccagattg tcaacaacac ggagggagac
360
tggtggctgg cccactcgct cagcacagga cagacaggct acatccccag caactacgtg
420
gcgccctccg actccatcca ggctgaggag tggtattttg gcaagatcac cagacgggag
480
tcagagcggt tactgctcaa tgcagagaac ccgagaggga ccttcctcgt gcgagaaagt
540
gagaccacga aaggtgccta ctgcctctca.gtgtctgact tcgacaacgc caagggcctc
600
aacgtgaagc actacaagat ccgcaagctg gacagcggcg gcttctacat cacctcccgc
660
acccagttca acagcctgca gcagctggtg gcctactact ccaaacacgc cgatggcctg
720
tgccaccgcc tcaccaccgt gtgccccacg tccaagccgc agactcaggg cctggccaag
780
gatgcctggg agatccctcg ggagtcgctg cggctggagg tcaagctggg ccagggctgc
840
tttggcgagg tgtggatggg gacctggaac ggtaccacca gggtggccat caaaaccctg
900
aagcctggca cgatgtctcc agaggccttc ctgcaggagg cccaggtcat gaagaagctg
960
aggcatgaga agctggtgca gttgtatgct gtggtttcag aggagcccat ttacatcgtc
1020
acggagtaca tgagcaaggg gagtttgctg gactttctca agggggagac aggcaagtac
1080
ctgcggctgc ctcagctggt ggacatggct gctcagatcg cctcaggcat ggcgtacgtg
1140
gagcggatga actacgtcca ccgggacctt cgtgcagcca acatcctggt gggagagaac
1200
ctggtgtgca aagtggccga ctttgggctg gctcggctca ttgaagacaa tgagtacacg
1260
gcgcggcaag gtgccaaatt ccccatcaag tggacggctc cagaagctgc cctctatggc
1320
cgcttcacca tcaagtcgga cgtgtggtcc ttcgggatcc tgctgactga gctcaccaca
1380
aagggacggg tgccctaccc tgggatggtg aaccgcgagg tgctggacca ggtggagcgg
1440
ggctaccgga tgccctgccc gccggagtgt cccgagtccc tgcacgacct catgtgccag
1500
tgctggcgga aggagcctga ggagcggccc accttcgagt acctgcaggc cttcctggag
1560
gactacttca cgtccaccga gccccagtac cagcccgggg agaacctcta g
1611
The c-Src nucleic acid sequence (SEQ ID NO. 1) encodes for a tyrosine kinase protein pp60, which has a following sequence:
1
MGSNKSKPKD ASQRRRSLEP AENVHGAGGC AFPASQTPSK PASADCHRGP SAAFAPAAAE
(SEQ ID NO.2)
61
PKLFGGFNSS DTVTSPQRAG PLAGGVTTTV ALYDYESRTE TDLSFKKGER LQIVNNTEGD
121
WWLAHSLSTG QTGYIPSNYV APSDSIQAEE WYFGKITRRE SERLLLNAEN PRGTFLVRES
181
ETTKGAYCLS VSDFDNAKGL NVKHYKIRKL DSGGFYITSR TQFNSLQQLV AYYSKHADGL
214
CHRLTTVCPT SKPQTQGLAK DAWEIPRESL RLEVKLGQGC FGEVWMGTWN GTTRVAIKTL
301
KPGTMSPEAF LQEAQVMKKL RHEKLVQLYA VVSEEPIYIV TEYMSKGSLL DFLKGETGKY
361
LRLPQLVDMA AQIASGMAYV ERMNYVHRDL RAANILVGEN LVCKVADFGL ARLIEDNEYT
421
ARQCAKFPIK WTAPEAALYG RFTIKSDVWS FGILLTELTT KGRVPYPGMV NREVLDQVER
481
GYRMPCPPEC PESLHDLMCQ CWRKEPEERP TFEYLQAFLE DYFTSTEPQY
531
QPGENL
Amino acids are abbreviated as 1-letter codes and corresponding 3-letter codes as follows: Alanine is A or Ala; Arginine R or Arg, Asparagine N or Asn; Aspartic acid D or Asp; Cysteine C or Cys; Glutamine Q or Gln; Glutamic acid E or Glu; Glycine G or Gly; Histidine H or His; Isoleucine I or Ile; Leucine L or Leu; Lysine K or Lys; Methionine M or Met; Phenylalanine F or Phe; Proline P or Pro; Serine S or Ser; Threonine T or Thr; Tryptophan W or Trp; Tyrosine Y or Tyr; and Valine V or Val.
The cellular Src oncogene (c-Src) (SEQ ID NO. 1) is the normal counterpart of the transforming viral Rous sarcoma oncogene (v-Src). v-Src has been shown to induce the production of specific metalloproteinases (Hamaguchi, M. et al. Augmentation of metalloproteinase (gelatinase) activity secreted from Rous sarcoma virus-infected cells correlates with transforming activity of Src. Oncogene 10, 1037-1043 (1995)) and to foster the metastatic phenotype (Egan, S. et al. Transformation by oncogenes encoding protein kinases induces the metastatic phenotype. Science 238 202-205 (1987); Tatsuka, M. et al. Different metastatic potentials of ras- and Src-transformed BALB/c 3T3 A31 variant cells. Mol. Carcinog. 15, 300-308 (1996)). However, as opposed to cellular c-Src (SEQ ID NO. 1) the retroviral v-Src has 19 C-terminal residues replaced by a sequence of 12 amino acids, lacking the regulatory tyrosine.
The non receptor tyrosine kinase c-Src consists of an SH3, SH2 and tyrosine kinase domain. c-Src appears to be the most important to the normal function of osteoclasts, as determined from studies of Src-knock-out mice (see for example U.S. Pat. No. 5,541,109). The catalytic activity of c-Src and other nonreceptor tyrosine kinases is inhibited by the intramolecular association of their intrinsic SH2 domain to the carboxy-terminal tail upon phosphorylation of Tyr (position 530, avian position 527). Protein tyrosine phosphorylation is believed to be an important regulatory event in cell growth and differentiation. Phosphorylation on tyrosine can either decrease or increase the enzymatic activity of substrate proteins. Tyrosine phosphorylated sequences associate with Src homology 2 (SH2) domains, and thus tyrosine phosphorylation also serves to regulate protein/protein interactions. Many protein tyrosine kinases have been described to date: several are the receptors for peptide growth factors; others are expressed in the cytoplasm and nucleus. Tyrosine kinases can be of the receptor type (having extracellular, transmembrane and intracellular domains) or the non-receptor type (being wholly intracellular). There are 19 known families of receptor tyrosine kinases including the Her family (EGFR, Her 2, Her 3, Her 4), the insulin receptor family (insulin receptor, IGF-1R, insulin-related receptor), the PDGF receptor family (PDGF-R alpha and beta, CSF-1R, Kit, Flk2), the Flk family (Flk-1, Flt-1, Flk-4), the FGF-receptor family (FGF-Rs 1 through 4), the Met family (Met, Ron), etc. There are 11 known families of non-receptor type tyrosine kinases including the Src family (Src, Yes, Fyn, Lyn, Lck, Blk, Hck, Fgr, Yrk), Abl family (Abl, Arg), Zap 70 family (Zap 70, Syk) and Jak family (Jak 1, Jak 2, Tyk 2, Jak 3). Many of these tyrosine kinases have been found to be involved in cellular signaling pathways leading to pathogenic conditions such as cancer, psoriasis, hyperimmune response, etc. Other roles for tyrosine kinases include cellular responses to a variety of extracellular signals, such as those arising from growth factors and cell-cell interactions, as well as in differentiating developmental processes in both vertebrates and invertebrates.
Among various types of tumors, e.g., sarcoma, neuroblastoma, breast carcinoma among many others, c-Src has been found to be activated, particularly in colon cancers, especially in those metastatic to the liver (Rosen, N. et al. Analysis of pp60c-Src protein kinase activity in human tumor cell lines and tissues. J Biol Chem 261, 13754-13759 (1986); Bolen, J., Veillette, A., Schwartz, A., DeSeau, V. & Rosen, N. Activation of pp60c-Src protein kinase activity in human colon carcinoma. Proc. Natl Acad. Sci. USA 84, 2251-2255 (1987); Cartwright, C., Kamps, M., Meisler, A., Pipas, J. & Eckhart, W. pp60c-Src activation in human colon carcinoma. J. Clin. Invest. 83, 2025-2033 (1989); Talamonti, M. A., Roh, M. S., Curley, S. A. & Gallick, G. E. Increase in activity and level of pp60c-Src in progressive stages of human colorectal cancer. J. Clin. Invest. 91, 53-60 (1991); Cartwright, C., Coad, C. & Egbert, B. Elevated c-Src tyrosine kinase activity in premalignant epithelia of ulcerative colitis. J. Clin. Invest. 93, 509-515 (1994); Termnuhlen, P. M., Curley, S. A., Talamonti, M. S., Saboorian, M. H. & Gallick, G. E. Site-specific differences in pp60c-Src activity in human colorectal metastases. J. Surg. Res. 54, 293-298 (1993); Mao, W. et al. Activation of c-Src by receptor tyrosine kinases in human colon cancer cells with high metastatic potential. Oncogene 15, 3083-3090 (1997)).
Studies of the mechanism of c-Src regulation have suggested that c-Src kinase activity can be downregulated by phosphorylation of an amino acid tyrosine at position 530 (Tyr 530 in human c-Src, which is equivalent to Tyr 527 in chicken Src) of the C-terminal regulatory region (Cooper, J., Gould, K., Cartwright, C. & Hunter, T. Tyr 527 is phosphorylated in pp60c-Src: implications for regulation. Science 231, 1431-1434 (1986); Cartwright, C., Eckhart, W., Simon, S. & Kaplan, P. Cell transformation by pp60c-Src mutated in the carboxy-terminal regulatory domain. Cell 49, 83-91 (1987); Kmiecik, T. & Shalloway, D. Activation and suppression of pp60c-Src transforming ability by mutation of its primary sites of tyrosine phosphorylation. Cell 49, 65-73 (1987); Piwnica-Worms, H., Saunders, K. B., Roberts, T. M., Smith, A. E. & Cheng, S. H. Tyrosine phosphorylation regulates the biochemical and biological properties of pp60c-Src. Cell 49, 75-82 (1987); Reynolds, A. B. et al. Activation of the oncogenic potential of the avian cellular Src protein by specific structural alteration of the carboxy terminus. Embo J. 6, 2359-2364 (1987); Jove, R., Hanafusa, T., Hamaguchi, M. & Hanafusa, H. In vivo phosphorylation states and kinase activities of transforming p60c-Src mutants. Oncogene Res. 5, 49-60 (1989); Bjorge, J. et al. Characterization of two activated mutants of human pp60c-Src that escape c-Src kinase regulation by distinct mechanisms. J. Biol. Chem. 270, 24222-24228 (1995)). It is possible that other mutations and phosphorylation processes involving tyrosine and other amino acids encoded by Src oncogene might be linked to tumorigenesis. For example, in chickens a single point mutation at residues Thr 338, Glu 378, Ile 441 or Arg 95 appears to activate the transforming ability of pp60c-Src (Wang P, Fromowitz F, Koslow M, Hagag N, Johnson B, Viola M. c-Src structure in human cancers with elevated pp60c-Src activity. Br J Cancer Sep; 64(3):531-3, 1991). However, according to the current state of the art, nothing has been identified in the human species that is as important as phosphorylation of Tyr 530 residue. For example, phosphorylation of Tyr 419 is not essential for tumor transformation (Snyder, M. A., Bishop, J. M., Colby, W. W. & Levinson, A. D. Phosphorylation of tyrosine-416 is not required for the transforming properties and kinase activity of pp60v-Src. Cell 32, 891-901 (1983)). While this Tyr 530 mutation might be responsible for tumor formation it may not be the only cause and there is thus a continuing need to identify and further characterize the c-Src gene and pp60 as targets for drug discovery. The present inventors have surprisingly discovered for the first time that a novel mutation at SRC 531 is responsible for malignant transformation and metastasis. The existence of a mutant form of c-Src (SEQ ID NO. 3) is disclosed that plays a role in Src activation in cancer.
3. SUMMARY OF THE INVENTION
The present invention relates to mutated c-Src, in particular to Src polynucleotides and c-Src polypeptides and methods of using them in fields of diagnosis, therapy, and prevention arts. More specifically, the present invention provides a recombinant nucleic acid or oligonucleotide consisting essentially of SEQ ID NO. 3 and a polypeptide encoded by this nucleic acid (SEQ ID NO. 4). The oligonucleotide having a sequence complementary to the SEQ ID NO. 3 is also provided. Preferably the c-Src oncogene of the invention is truncated and preferably this truncation occurs at the 3′ end. As a result of the truncation the expression of truncated c-Src preferably results in loss of one or more amino acids in the C-terminal end of phosphoprotein pp60c-Src. An isolated DNA molecule is contemplated which comprises a nucleic acid sequence encoding a mutated protein comprising Src protein tyrosine kinase activity, lacking the carboxy-terminal end. Also contemplated is an isolated nucleic acid consisting of the nucleotide sequence of SEQ ID NO. 3 or a contiguous fragment thereof wherein said isolated nucleic acid encodes a polypeptide having the biological activity of tyrosine kinase protein. Also contemplated is an isolated nucleic acid consisting of a nucleotide sequence that is at least 90% identical to the nucleotide sequence of SEQ ID NO. 3.
The instant invention also provides a polypeptide of about 400 to 530 amino acids in length and having at least 80% amino acid homology to the mutated c-Src 531 polypeptide of SEQ ID NO. 4, wherein said homologous polypeptide displays tyrosine kinase activity. Accordingly, methods are provided for producing and purifying these polypeptides. These methods include the steps of culturing the c-Src mutant transformed host cell under conditions suitable for the expression of the polypeptide and recovering the mutant c-Src polypeptide from the host cell or the host cell culture.
This invention also provides a method of screening agonist and antagonist compounds for the treatment of mutant Src associated or caused diseases. A method of treating a cancer is provided by administering to cancerous cells exhibiting a c-Src mutation at SRC 531 an effective amount of a compound capable of inhibiting the excess kinase activity resulting from the c-Src mutation or capable of inhibiting expression of the c-Src mutant gene (SEQ ID NO. 3). Preferred compounds of the invention comprise an antisense oligonucleotide, or a preparation of antibodies, or other molecules which specifically bind to c-Src SRC 531 mutant (SEQ ID NO. 3).
Another preferred embodiment of the invention comprises an expression construct for expressing all or a portion of c-Src SRC 531 mutant (SEQ ID NO. 3). Such a construct comprises a promoter; and an oligonucleotide segment having at least one mutated nucleic acid residue of c-Src mutant and located downstream from the promoter, wherein transcription of the segment is initiated at the promoter. A replicable vector comprising the nucleic acid of mutant c-Src is also provided.
The present invention entails a host cell containing a replicable vector or a recombinant host cell having at least one nucleic acid sequence encoding for SRC 531 (SEQ ID NO. 4) mutant as well as a cell line transformed with SRC 531 mutant Src-oncogene (SEQ ID NO. 3). Also contemplated is a host cell comprising the isolated purified nucleic acid corresponding to SRC 531 mutant Src-oncogene.
Various methods are provided for detecting the presence of SRC 531 mutation in Src oncogene contained in a sample. Such methods can include contacting the sample with two primers that are upstream and downstream of SRC 531 region, amplifying the SRC 531 region according to standard procedures, and detecting whether the amplified sequence is present or absent in the nucleic acid sample. Accordingly primers capable of recognizing and binding to SRC 531 region and nucleic acid probes having an affinity to SRC 531 mutated region of Src oncogene are preferred means of supporting such methods. Without limiting to these diagnostic methods a method is provided for detecting SRC 531 mutation whereby a restriction enzyme Sca I is used to recognize the lack or presence of restriction site at the mutated codon. Thus, also envisioned in the present invention is a diagnostic kit for detecting mutant Src oncogene related malignancy in an animal. Such a kit preferably comprises multiple containers wherein included is a set of primers useful for PCR detection of the mutated region of Src oncogene, and optionally a positive control comprising mutated Src sequence and a negative control comprising a non-mutated Src sequence.
The present invention also comprises a transgenic animal such as a mouse whose somatic and germ cells contain a gene (SEQ ID NO. 3) encoding for SRC 531 (SEQ ID NO. 4), said gene operably linked to a promoter, wherein expression of said SRC 531 gene results in the formation of inborn abnormalities or tumors in the mouse.
Preferably, a composition comprising the c-Src mutant polypeptide (SEQ ID NO. 4) is provided in combination with an immune adjuvant. This composition serves as a cancer vaccine comprising as an immunogen at least one immunogenic epitope of the SRC 531 mutant protein.
4. BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 . illustrates identification of the SRC 531 mutation in human tumors. a, Direct sequence analysis depicting the C-→T mutation. While the genomic mutation is heterozygous, a manual sequencing gel derived from cloned PCR products is shown. b and c, RFLP analysis of PCR products from liver metastases (LM) and primary tumors that metastasized distantly to the liver and other organs (Dukes' stage D) tumors and normal matched tissues. The uncut 248 bp product is indicated as well as the 188 bp cut band when present. Negative control reflects normal DNA; positive control reflects plasmid bearing the SRC 531 mutation. d, Src kinase assay indicating that tumors with the SRC 531 mutation also display increased kinase activity.
FIG. 2 . illustrates confirmation of SRC 531 mutation in tumors by mutant allele specific PCR.
FIG. 3 . illustrates kinase activity and phosphorylation phosphotyrosine analysis sites of normal and mutant Src proteins. a, Lysates from cells transfected with empty vector, c-Src vector (wild type), SRC 531 vector or v-Src vector are immunoprecipitated and subjected to kinase assays of autophosphorylation and phosphorylation of the exogenous substrate, enolase. b and c, Comparison of kinase activity phosphotyrosine levels with Src protein levels in wild type and mock, c-Src, SRC 531, or v-Src transfected cells using phosphotyrosine Western blot analyses. Human colon cancer cells transfected with c-Src (KM12C-c-Src) are shown for comparison. d, CNBr cleavage mapping indicates the sites of phosphorylation of c-Src, SRC 531, and v-Src.
FIG. 4 illustrates analysis of fibroblasts transfected with the SRC 531 expression construct for cellular transformation and metastatic potential. a, Soft agar assay demonstrates anchorage independent growth in b cells transfected with v-Src and SRC 531 but not c-Src. b, Photograph depicting v-Src and SRC 531 clones growing in soft agar. Transfectants expressing SRC 531 produced smaller colonies. c, Analysis of capacity of various transfected cells to produce foci as a measure of cellular transformation independent of clonal variation artifact. d, Evidence for invasive activity of fibroblasts transfected with either v-Src or SRC 531 expression constructs versus c-Src as control. e, Survival analysis of mice injected with 1×105 cells/0.1 ml I.V. in an experimental lung metastasis assay. Photomicrographs inset show histology of lung tumors that formed in mice injected with v-Src and SRC 531 transfectants.
BRIEF DESCRIPTION OF THE SEQUENCES
SEQ ID NO. 1 is the normal or wild-type cellular oncogene Src (c-Src).
SEQ ID NO. 2 is the non-receptor tyrosine kinase (phosphoprotein of molecular weight 60,000 Dalton or pp60c-Src; 536 amino acids long) encoded by the wild-type c-Src (SEQ ID NO. 1).
SEQ ID NO. 3 is a mutant form of the c-Src oncogene, having a C→T transition mutation at nucleotide 1591, thereby encoding a stop signal (-uag-) at codon 531 (corresponding to nucleotides 1591-1593).
SEQ ID NO. 4 is the mutant (truncated) c-Src 531 polypeptide (530 amino acids long) encoded by the mutant c-Src oncogene (SEQ ID NO. 3).
SEQ ID NO. 5 is a 3′ mutant allele specific primer containing the complement to the mutant base at the 3′ end and a 3-nitropyrrole residue (n) 4 bases upstream of the 3′ end.
SEQ ID NO. 6 is a wild-type (WT) 3′ primer, which is able to amplify both normal wild-type DNA as well as mutant DNA.
SEQ ID NO. 7 is an exemplary sequence of an antisense molecule that is complimentary to the 5′ region of the c-Src gene.
DETAILED DESCRIPTION OF THE INVENTION
By restriction fragment length polymorphism analysis (RFLP), mutant allele-specific PCR analysis, and direct sequencing, a truncating mutation in Src at codon 531 is identified in 12% of cases of advanced human colon cancer. Other cancers with activated tyrosine kinase are also identified as having SRC 531 mutation (see Example infra). The mutation is found as being activating, transforming, tumorigenic, and metastasis promoting. These observations provide, for the first time, the genetic evidence that the activating SRC mutation plays a significant role in the malignant progression of cancer.
To assess the potential for SRC mutations in cancer, polymerase chain reaction (PCR) primers are constructed to specifically amplify exon 12 of human Src sequences from genomic DNA.
Surprisingly, automated sequencing of PCR products reveals a heterozygous C-T transition mutation in codon 531. This is further confirmed by manual sequencing (FIG. 1 a ) in several human colon cancer specimens with known elevated c-Src protein kinase activity. Because the mutation in codon 531 generates a ScaI restriction site, a rapid screen for the SRC 531 mutation is developed using a ScaI-based restriction fragment length polymorphism (RFLP) assay.
FIG. 1 b, c discloses that, 124 early stage (TanyNanyM0) tumors without distant metastases and late stage (TanyNanyM1) colon cancer specimens with distant metastases (including direct analysis of liver-metastatic lesions) are screened for point mutation of codon 531. Nine positive samples are confirmed by direct sequencing analysis. All tumors (100%) harboring the mutation are of late stage (M1) and, of those available for testing, all demonstrate high levels of c-Src protein kinase activity (FIG. 1 d ). None of the tumors harboring the mutation demonstrate microsatellite instability or any other gross genomic aberration. The SRC 531 mutation results in the production of a stop codon at residue 531, thereby truncating the c-Src protein (SEQ ID NO. 2) directly C-terminal to the regulatory Tyr 530, producing the mutated c-Src 531 polypeptide of SEQ ID NO. 4. Although 46 primary, early stage, human colon cancer specimens are screened with this assay, no SRC 531 mutation is detected in any of these tumors. No DNA derived from normal adjacent matched tissue samples or in normal genomic DNA samples from patients with tumors harbor the SRC 531 mutation.
To confirm the presence of the SRC 531 mutation, an allele-specific oligonucleotide PCR based assay (Guo, Z., Liu, Q. & Smith, L. M. Enhanced discrimination of single nucleotide polymorphisms by artificial mismatch hybridization. Nat. Biotechnol. 15, 331-335 (1997)) is also performed by amplifying the mutant allele using one base mismatch PCR primers containing one 3′ end and a 3-nitropyrrole residue (FIG. 2 ). PCR products are created with a 3′ mutant allele specific primer (5′ TAGAGGTTCTCCCCZGGCTA 3′) (SEQ ID NO. 5) containing the complement to the mutant base at the 3 ′ end and a 3-nitropyrrole residue (Z) 4 bases upstream of the 3′ end. The mutant allele specific primer is capable of amplifying mutant DNA derived from frozen or paraffin-embedded tumors, but is unable to produce a product from normal DNA. At the same time, a wild-type (WT) 3′ primer (5′ TAGAGGTTCTCCCCGGGCTG 3′) (SEQ ID NO. 6) is able to amplify both normal wild-type DNA as well as mutant DNA. These experiments show that the mutant allele is amplified in tumor samples, whereas the wild-type allele is not amplified in normal adjacent tissues. Moreover, the SRC 531 mutation is clonal in origin. When careful tumor microdissection is performed in attempt to increase the relative percentage of tumor cells in any given sample, the ratio of the T:C alleles increase proportionately.
To test the hypothesis that SRC 531 is a transforming mutation, the SRC 531 mutant cDNA is expressed from a mammalian vector with the CMV promoter into rat 3Y1 fibroblasts and NIH 3T3 fibroblasts. To ensure that observed biologic effects are attributable to the SRC 531 mutation, this construct is derived by recombining exon 12 containing a single mutation (SRC 531) derived from a human colon cancer with exons 1-11 derived from normal human c-Src cDNA. Src Western blots show that the 60 kD SRC 531 mutant protein level is elevated approximately 5-10 fold over mock controls, but levels of expression are equivalent to cells transfected with normal human c-Src vector (FIG. 3 a ). The kinase activity of cells overexpressing SRC 531 is approximately 6 fold greater than that of cells overexpressing similar amounts of c-Src, but less than that of v-Src. By comparison, the kinase activity of cells overexpressing v-Src is more than 12 fold greater than cells overexpressing c-Src. Quantitation of Src protein kinase activity is based on phosphorylation of the exogenous substrate, enolase, and is normalized to Src protein expression levels shown in the Src Western blot. Note that v-Src transfectants generally produce less Src protein than other transfectants. Quantitation of Src autokinase levels found c-Src overexpressing clones with 3-5 fold greater activity than mock or wild type cells, whereas the overexpressing SRC 531 clone and the v-Src clone produced autokinase levels that are increased 2-4 fold further.
The levels of total protein tyrosine phosphorylation increase with the degree of expression and mutational activation: mock<c-Src<SRC 531<v-Src (FIG. 3 b,c ). Various clones expressing SRC 531 shown in panel c show significant increases in Src phosphotyrosine levels and phosphorylation of new substrates when compared with mock transfected controls or one representative clone overexpressing wild-type c-Src. Quantitation of Src phosphotyrosine levels when normalized to protein levels of Src found the c-Src overexpressing clone with 2.2 fold greater levels than mock transfected cells whereas SRC 531 overexpressing clones had 3.9-6.6 fold greater levels than mock transfected cells. As expected, v-Src transfectants had phosphotyrosine levels that are significantly greater (18 fold) than mock transfected cells. Consistent with these findings, in vitro levels of autokinase activity and levels of activity towards the exogenous substrate enolase are significantly elevated in the mutant forms of Src (FIG. 3 a ).
To address the mechanism of activation of SRC 531, cyanogen bromide cleavage mapping is performed on orthophosphate-labeled Src from fibroblasts stable transfected with vectors encoding c-Src (wild type) (SEQ ID NO. 2), SRC 531 (SEQ ID NO. 4), or v-Src. These experiments demonstrate that the autophosphorylation site, Tyr 419 present in the 10 kD band, is highly phosphorylated in both the mutant SRC 531 and in the v-Src transfectants, consistent with elevations in Src autokinase activity. In contrast, the cells transfected with wild-type c-Src (SEQ ID NO. 1) show only significant phosphorylation of the 4-6 kD fragment known to contain the C-terminal Tyr 530 (FIG. 3 d ). Tyr 530 in SRC 531 is shifted to 3.5 kD, consistent with a truncated peptide 6 amino acids shorter and is phosphorylated. These results indicate that in the SRC 531 mutant (SEQ ID NO. 4), Tyr 530 phosphorylation is present but not capable of functioning in a negative regulatory role as postulated for wild type c-Src (SEQ ID NO. 2), in the prior art.
The SRC 531 interfering compounds of the present invention can occur as racemates, racemic mixtures, and as individual enantiomers or diastereoisomers, with all isomeric forms being included in the present invention as well as mixtures thereof.
Pharmaceutically acceptable salts of the compounds of the invention where a basic or acidic group is present in the structure, are also included within the scope of this invention. When an acidic substituent is present, such as —COOH, there can be formed the ammonium, sodium, potassium, calcium salt, and the like, for use as the dosage form. When a basic group is present, such as amino or a basic heteroaryl radical, such as pyridyl, an acidic salt, such as hydrochloride, hydrobromide, acetate, maleate, pamoate, methanesulfonate, p-toluenesulfonate, and the like, can be used as the dosage form.
Also, in the case of the —COOH being present, pharmaceutically acceptable esters can be employed, e.g., methyl, tert-butyl, pivaloyloxymethyl, and the like, and those esters known in the art for modifying solubility or hydrolysis characteristics for use as sustained release or prodrug formulations.
In addition, some of the compounds of the instant invention can form solvates with water or common organic solvents. Such solvates are encompassed within the scope of the invention.
The term “therapeutically effective amount” shall mean that amount of drug or pharmaceutical agent that will elicit the biological or medical response of a tissue, system, animal, or human that is being sought by a researcher, veterinarian, medical doctor or other clinician. Generally, a daily dose of about 0.5 mg/Kg to 100 mg/Kg body weight in divided doses is suggested. Such dosage has to be individualized by the clinician.
The present invention also has the objective of providing suitable topical, oral, and parenteral pharmaceutical formulations for use in the novel methods of treatment of the present invention. The compounds of the present invention can be administered orally as tablets, aqueous or oily suspensions, lozenges, troches, powders, granules, emulsions, capsules, syrups or elixirs. The composition for oral use can contain one or more agents selected from the group of sweetening agents, flavoring agents, coloring agents and preserving agents in order to produce pharmaceutically elegant and palatable preparations. The tablets contain the acting ingredient in admixture with non-toxic pharmaceutically acceptable excipients which are suitable for the manufacture of tablets. These excipients can be, for example, inert diluents, such as calcium carbonate, lactose, calcium phosphate or sodium phosphate; granulating and disintegrating agents, such as corn starch or alginic acid; binding agents, such as starch, gelatin or acacia; and lubricating agents, such as magnesium stearate, stearic acid or talc. These tablets can be uncoated or coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate can be employed.
Formulations for oral use can be in the form of hard gelatin capsules wherein the active ingredient is mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin. They can also be in the form of soft gelatin capsules wherein the active ingredient is mixed with water or an oil medium, such as peanut oil, liquid paraffin or olive oil.
Aqueous suspensions normally contain the active materials in admixture with excipients suitable for the manufacture of aqueous suspension. Such expicients can be: suspending agent such as sodium carboxymethyl cellulose, methyl cellulose, hydroxypropylmethylcellulose, sodium alginate, polyvinylpyrrolidone, gum tragacanth and gum acacia; dispersing or wetting agents which can be naturally occurring phosphatide such as lecithin; a condensation product of an alkylene oxide with a fatty acid, for example, polyoxyethylene stearate; a condensation product of ethylene oxide with a long chain aliphatic alcohol, for example, heptadecaethylenoxycetanol; a condensation product of ethylene oxide with a partial ester derived from a fatty acid and hexitol such as polyoxyethylene sorbitol monooleate, or a condensation product of ethylene oxide with a partial ester derived from fatty acids and hexitol anhydrides, for example polyoxyethylene sorbitan monooleate.
The pharmaceutical compositions can be in the form of a sterile injectable aqueous or oleagenous suspension. This suspension can be formulated according to known methods using those suitable dispersing or wetting agents and suspending agents which have been mentioned above. The sterile injectable preparation can also comprise a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that can be employed are water, Ringer's solution, and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose, any bland fixed oil can be employed including synthetic mono- or diglycerides. In addition, fatty acids such as oleic acid find use in the preparation of injectables.
Compounds of the invention can also be administered in the form of suppositories for rectal administration of the drug. These compositions can be prepared by mixing the drug with a suitable non-irritating excipient which is solid at ordinary temperature but liquid at the rectal temperature and will therefore melt in the rectum to release the drug. Such materials are cocoa butter and polyethylene glycols.
The compounds of the present invention can also be administered in the form of liposome delivery systems, such as small unilamellar vesicles, large unilamellar vesicles, and multilamellar vesicles. Liposomes can be formed from a variety of phospholipids, such as cholesterol, stearylamine, or phosphatidylcholines.
Antisense oligonucleotides according to the invention are perfectly suitable for the inhibition of mutant c-Src expression. In the context of this invention, the term “oligonucleotide” refers to an oligomer or polymer of ribonucleic acid (RNA) or deoxyribonucleic acid (DNA) or mimetics thereof. Thus, they represent preparations for inhibiting the over-expressed c-Src in well-calculated fashion. This offers new possibilities of being able to treat by means of gene therapy various diseases linked with the anomalous tyrosine kinase biosynthesis, particularly tumor diseases. The antisense compounds in accordance with this invention preferably comprise from about 8 to about 120 nucleobases. Particularly preferred are antisense oligonucleotides comprising from about 8 to about 30 nucleobases (i.e. from about 8 to about 30 linked nucleosides). As is known in the art, a nucleoside is a base-sugar combination. The base portion of the nucleoside is normally a heterocyclic base. The two most common classes of such heterocyclic bases are the purines and the pyrimidines. Nucleotides are nucleosides that further include a phosphate group covalently linked to the sugar portion of the nucleoside. For those nucleosides that include a pentofuranosyl sugar, the phosphate group can be linked to either the 2′, 3′ or 5′ hydroxyl moiety of the sugar. In forming oligonucleotides, the phosphate groups covalently link adjacent nucleosides to one another to form a linear polymeric compound. In turn the respective ends of this linear polymeric structure can be further joined to form a circular structure, however, open linear structures are generally preferred. Within the oligonucleotide structure, the phosphate groups are commonly referred to as forming the internucleoside backbone of the oligonucleotide. The normal linkage or backbone of RNA and DNA is a 3′ to 5′ phosphodiester linkage.
Specific examples of preferred antisense compounds useful in this invention include oligonucleotides containing modified backbones or non-natural internucleoside linkages. As defined in this specification, oligonucleotides having modified backbones include those that retain a phosphorus atom in the backbone and those that do not have a phosphorus atom in the backbone. For the purposes of this specification, and as sometimes referenced in the art, modified oligonucleotides that do not have a phosphorus atom in their internucleoside backbone can also be considered to be oligonucleosides.
Preferred modified oligonucleotide backbones include, for example, phosphorothioates, chiral phosphorothidates, phosphorodithioates, phosphotriesters, aminoalkylphosphotriesters, methyl and other alkyl phosphonates including 3′-alkylene phosphonates and chiral phosphonates, phosphinates, phosphoramidates including 3′-amino phosphoramidate and aminoalkylphosphoramidates, thionophosphoramidates, thionoalkylphosphonates, thionoalkylphosphotriesters, and boranophosphates having normal 3′-5′ linkages, 2′-5′ linked analogs of these, and those having inverted polarity wherein the adjacent pairs of nucleoside units are linked 3′-5′ to 5′-3′ or 2′-5′ to 5′-2′. Various salts, mixed salts and free acid for also included.
Representative U.S. patents that teach the preparation of the above phosphorus-containing linkages include, but are not limited to, U.S. Pat. Nos. 3,687,808; 4,469,863; 4,476,301; 5,023,243; 5,177,196; 5,188,897; 5,264,423; 5,276,019; 5,278,302; 5,286,717; 5,321,131; 5,399,676; 5,405,939; 5,453,496; 5,455,233; 5,466,677; 5,476,925; 5,519,126; 5,536,821; 5,541,306; 5,550,111; 5,563,253; 5,571,799; 5,587,361; and 5,625,050, each of which is herein incorporated by reference.
Preferred modified oligonucleotide backbones that do not include a phosphorus atom therein have backbones that are formed by short chain alkyl or cycloalkyl internucleoside linkages, mixed heteroatom and alkyl or cycloalkyl internucleoside linkages, or one or more short chain heteroatomic or heterocyclic internucleoside linkages. These include those having morpholino linkages (formed in part from the sugar portion of a nucleoside); siloxane backbones; sulfide, sulfoxide and sulfone backbones; formacetyl and thioformacetyl backbones; methylene formacetyl and thioformacetyl backbones; alkene containing backbones; sulfamate backbones; methyleneimino and methylenehydrazino backbones; sulfonate and sulfonamide backbones; amide backbones; and others having mixed N, O, S and CH 2 component parts.
Representative U.S. patents that teach the preparation of the above oligonucleosides include, but are not limited to, U.S. Pat. Nos. 5,034,506; 5,166,315; 5,185,444; 5,214,134; 5,216,141; 5,235,033; 5,264,562; 5,264,564; 5,405,938; 5,434,257; 5,466,677; 5,470,967; 5,489,677; 5,541,307; 5,561,225; 5,596,086; 5,602,240; 5,610,289; 5,602,240; 5,608,046; 5,610,289; 5,618,704; 5,623,070; 5,663,312; 5,633,360; 5,677,437; and 5,677,439, each of which is herein incorporated by reference.
In other preferred oligonuclcotide mimetics, both the sugar and the internucleoside linkage, i.e., the backbone, of the nucleotide units are replaced with novel groups. The base units are maintained for hybridization with an appropriate nucleic acid target compound. One such oligomeric compound, an oligonucleotide mimetic that has been shown to have excellent hybridization properties, is referred to as a peptide nucleic acid (PNA). In PNA compounds, the sugar-backbone of an oligonucleotide is replaced with an amide containing backbone, in particular an aminoethylglycine backbone. The nucleobases are retained and are bound directly or indirectly to aza nitrogen atoms of the amide portion of the backbone. Representative U.S. patents that teach the preparation of PNA compounds include, but are not limited to, U.S. Pat. Nos. 5,539,082; 5,714,331; and 5,719,262, each of which is herein incorporated by reference. Most preferred embodiments of the invention are oligonucleotides with phosphorothioate backbones and oligonucleosides with heteroatom backbones. Also preferred are oligonucleotides having morpholino backbone structures of the above-referenced U.S. Pat. No. 5,034,506.
Modified oligonucleotides can also contain one or more substituted sugar moieties as described in U.S. Pat. No. 5,945,290 and the content of which is herein incorporated by reference.
Oligonucleotides can also have sugar mimetics such as cyclobutyl moieties in place of the pentofuranosyl sugar. Representative U.S. patents that teach the preparation of such modified sugar structures include, but are not limited to, U.S. Pat. Nos. 4,981,957; 5,118,800; 5,319,080; 5,359,044; 5,393,878; 5,446,137; 5,466,786; 5,514,785; 5,519,134; 5,567,811; 5,576,427; 5,591,722; 5,597,909; 5,610,300; 5,627,0531 5,639,873; 5,646,265; 5,658,873; 5,670,633; and 5,700,920, and each of which is herein incorporated by reference. Oligonucleotides can also include nucleobase (often referred to in the art simply as “base”) modifications or substitutions. As used herein, “unmodified” or “natural” nucleobases include the purine bases adenine (A) and guanine (G), and the pyrimidine bases thymine (T), cytosine (C) and uracil (U). Modified nucleobases include other synthetic and natural nucleobases such as 5-methylcytosine (5-me-C), 5-hydroxymethyl cytosine, xanthine, hypoxanthine, 2-aminoadenine, 6-methyl and other alkyl derivatives of adenine and guanine, 2-propyl and other alkyl derivatives of adenine and guanine, 2-thiouracil, 2-thiothymine and 2-thiocytosine, 5-halouracil and cytosine, 5-propynyl uracil and cytosine, 6-azo uracil, cytosine and thymine, 5-uracil (pseudouracil), 4-thiouracil, 8-halo, 8-amino, 8-thiol, 8-thioalkyl, 8-hydroxyl and other 8-substituted adenines and guanines, 5-halo particularly 5-bromo, 5-trifluoromethyl and other 5-substituted uracils and cytosines, 7-methylguanine and 7-methyladenine, 8-azaguanine and 8-azaadenine, 7-deazaguanine and 7-deazaadenine and 3-deazaguanine and 3-deazaadenine. Further nucleobases include those disclosed in U.S. Pat. No. 3,687,808. Certain of these nucleobases are particularly useful for increasing the binding affinity of the oligomeric compounds of the invention. These include 5-substituted pyrimidines, 6-azapyrimidines and N-2, N-6 and O-6 substituted purines, including 2-aminopropyladenine, 5-propynyluracil and 5-propynylcytosine.
Representative U.S. patents that teach the preparation of certain of the above noted modified nucleobases as well as other modified nucleobases include, but are not limited to, the above noted U.S. Pat. No. 3,687,808, as well as U.S. Pat. Nos. 4,845,205; 5,130,302; 5,134,066; 5,175,273; 5,367,066; 5,432,272; 5,457,187; 5,459,255; 5,484,908; 5,502,177; 5,525,711; 5,552,540; 5,587,469; 5,594,121, 5,596,091; 5,614,617; 5,750,692; and 5,681,941, each of which is herein incorporated by reference.
Another modification of the oligonucleotides of the invention involves chemically linking to the oligonucleotide one or more moieties or conjugates which enhance the activity, cellular distribution or cellular uptake of the oligonucleotide. Such moieties include but are not limited to lipid moieties such as a cholesterol moiety, a thioether, e.g., hexyl-S-tritylthiol, an aliphatic chain, e.g., dodecandiol or undecyl residues, a phospholipid, e.g., di-hexadecyl-rac-glycerol or triethylammonium 1,2-di-O-hexadecyl-rac-glycero-3-H-phosphonate, a polyamine or a polyethylene glycol chain, or adamantane acetic acid, a palmityl moiety, or an octadecyl amine or hexylamino-carbonyl-oxycholesterol moiety. Representative U.S. patents that teach the preparation of such oligonucleotide conjugates include, but are not limited to, U.S. Pat. Nos. 4,828,979; 4,948,882; 5,218,105; 5,525,465; 5,541,313; 5,545,730; 5,552,538; 5,578,717, 5,580,731; 5,580,731; 5,591,584; 5,109,124; 5,118,802; 5,138,045; 5,414,077; 5,486,603; 5,512,439; 5,578,718; 5,608,046; 4,587,044; 4,605,735; 4,667,025; 4,762,779; 4,789,737; 4,824,941; 4,835,263; 4,876,335; 4,904,582; 4,958,013; 5,082,830; 5,112,963; 5,214,136; 5,082,830; 5,112,963; 5,214,136; 5,245,022; 5,254,469; 5,258,506; 5,262,536; 5,272,250; 5,292,873; 5,317,098; 5,371,241, 5,391,723; 5,416,203, 5,451,463; 5,510,475; 5,512,667; 5,514,785; 5,565,552; 5,567,810; 5,574,142; 5,585,481; 5,587,371; 5,595,726; 5,597,696; 5,599,923; 5,599,928 and 5,688,941, each of which is herein incorporated by reference.
It is not necessary for all positions in a given compound to be uniformly modified, and in fact more than one of the aforementioned modifications can be incorporated in a single compound or even at a single nucleoside within an oligonucleotide. The present invention also includes antisense compounds which are chimeric compounds. “Chimeric” antisense compounds or “chimeras,” in the context of this invention, are antisense compounds, particularly oligonucleotides, which contain two or more chemically distinct regions, each made up of at least one monomer unit, i.e., a nucleotide in the case of an oligonucleotide compound. These oligonucleotides typically contain at least one region wherein the oligonucleotide is modified so as to confer upon the oligonucleotide increased resistance to nuclease degradation, increased cellular uptake, and/or increased binding affinity for the target nucleic acid. An additional region of the oligonucleotide can serve as a substrate for enzymes capable of cleaving RNA:DNA or RNA:RNA hybrids. By way of example, RNase H is a cellular endonuclease which cleaves the RNA strand of an RNA:DNA duplex. Activation of RNase H, therefore, results in cleavage of the RNA target, thereby greatly enhancing the efficiency of oligonucleotide inhibition of gene expression. Consequently, comparable results can often be obtained with shorter oligonucleotides when chimeric oligonucleotides are used, compared to phosphorothioate deoxyoligonucleotides hybridizing to the same target region. Cleavage of the RNA target can be routinely detected by gel electrophoresis and, if necessary, associated nucleic acid hybridization techniques known in the art.
Chimeric antisense compounds of the invention can be formed as composite structures of two or more oligonucleotides, modified oligonucleotides, oligonucleosides and/or oligonucleotide mimetics as described above. Such compounds have also been referred to in the art as hybrids or gapmers. Representative U.S. patents that teach the preparation of such hybrid structures include, but are not limited to, U.S. Pat. Nos. 5,013,830; 5,149,797; 5,220,007; 5,256,775; 5,366,878; 5,403,711; 5,491,133; 5,565,350; 5,623,065; 5,652,355; 5,652,356; and 5,700,922, each of which is herein incorporated by reference.
The antisense compounds used in accordance with this invention can be conveniently and routinely made through the well-known technique of solid phase synthesis. Equipment for such synthesis is sold by several vendors including, for example, Applied Biosystems (Foster City, Calif.). Any other means for such synthesis known in the art can additionally or alternatively be employed. It is well known to use similar techniques to prepare oligonucleotides such as the phosphorothioates and alkylated derivatives.
The antisense compounds of the invention are synthesized in vitro and do not include antisense compositions of biological origin, or genetic vector constructs designed to direct the in vivo synthesis of antisense molecules. The compounds of the invention can also be admixed, encapsulated, conjugated or otherwise associated with other molecules, molecule structures or mixtures of compounds, as for example, liposomes, receptor targeted molecules, oral, rectal, topical or other formulations, for assisting in uptake, distribution and/or absorption. Representative U.S. patents that teach the preparation of such uptake, distribution and/or absorption assisting formulations include, but are not limited to, U.S. Pat. Nos. 5,108,921; 5,354,844; 5,416,016; 5,459,127; 5,521,291; 5,543,158; 5,547,932; 5,583,020; 5,591,721; 4,426,330; 4,534,899; 5,013,556; 5,108,921; 5,213,804; 5,227,170; 5,264,221; 5,356,633; 5,395,619; 5,416,016; 5,417,978; 5,462,854; 5,469,854; 5,512,295; 5,527,528; 5,534,259; 5,543,152; 5,556,948; 5,580,575; and 5,595,756, each of which is herein incorporated by reference.
The antisense compounds of the invention encompass any pharmaceutically acceptable salts, esters, or salts of such esters, or any other compound which, upon administration to an animal including a human, is capable of providing (directly or indirectly) the biologically active metabolite or residue thereof. Accordingly, for example, the disclosure is also drawn to prodrugs and pharmaceutically acceptable salts of the compounds of the invention, pharmaceutically acceptable salts of such prodrugs, and other bioequivalents.
The term “prodrug” indicates a therapeutic agent that is prepared in an inactive form that is converted to an active form (i.e., drug) within the body or cells thereof by the action of endogenous enzymes or other chemicals and/or conditions. In particular, prodrug versions of the oligonucleotides of the invention are prepared as SATE [(S-acetyl-2-thioethyl)phosphate] derivatives according to the methods disclosed in WO 93/24510 to Gosselin et al., or in WO 94/26764 to Imbach et al.
The term “pharmaceutically acceptable salts” refers to physiologically and pharmaceutically acceptable salts of the compounds of the invention: i.e., salts that retain the desired biological activity of the parent compound and do not impart undesired toxicological effects thereto. Pharmaceutically acceptable base addition salts are formed with metals or amines, such as alkali and alkaline earth metals or organic amines. Examples of metals used as cations are sodium, potassium, magnesium, calcium, and the like. Examples of suitable amines are N,N′-dibenzylethylenediamine, chloroprocaine, choline, diethanolamine, dicyclohexylamine, ethylenediamine, N-methylglucamine, and procaine. The base addition salts of said acidic compounds are prepared by contacting the free acid form with a sufficient amount of the desired base to produce the salt in the conventional manner. The free acid form can be regenerated by contacting the salt form with an acid and isolating the free acid in the conventional manner. The free acid forms differ from their respective salt forms somewhat in certain physical properties such as solubility in polar solvents, but otherwise the salts are equivalent to their respective free acid for purposes of the present invention. As used herein, a “pharmaceutical addition salt” includes a pharmaceutically acceptable salt of an acid from one of the components of the compositions of the invention. These include organic or inorganic acid salts of the amines. Preferred acid salts are the hydrochlorides, acetates, salicylates, nitrates and phosphates. Other suitable pharmaceutically acceptable salts are well known to those skilled in the art and include basic salts of a variety of inorganic and organic acids, such as, for example, with inorganic acids, such as for example hydrochloric acid, hydrobromic acid, sulfuric acid or phosphoric acid; with organic carboxylic, sulfonic, sulfo or phospho acids or N-substituted sulfamic acids, for example acetic acid, propionic acid, glycolic acid, succinic acid, maleic acid, hydroxymaleic acid, methylmaleic acid, fulmaric acid, malic acid, tartaric acid, lactic acid, oxalic acid, gluconic acid, glucaric acid, glucuronic acid, citric acid, benzoic acid, cinnamic acid, mandelic acid, salicylic acid, 4-aminosalicylic acid, 2-phenoxybenzoic acid, 2-acetoxybenzoic acid, embonic acid, nicotinic acid or isonicotinic acid; and with amino acids, such as the 20 alpha-amino acids involved in the synthesis of proteins in nature, for example glutamic acid or aspartic acid, and also with phenylacetic acid, methanesulfonic acid, ethanesulfonic acid, 2-hydroxyethanesulfonic acid, ethane-1,2-disulfonic acid, benzenesulfonic acid, 4-methylbenzenesulfonic acid, naphthalene-2-sulfonic acid, naphthalene-1,5-disulfonic acid, 2- or 3-phosphoglycerate, glucose-6-phosphate, N-cyclohexylsulfamic acid (with the formation of cyclamates), or with other acid organic compounds, such as ascorbic acid. Pharmaceutically acceptable salts of compounds can also be prepared with a pharmaceutically acceptable cation. Suitable pharmaceutically acceptable cations are well known to those skilled in the art and include alkaline, alkaline earth, ammonium and quaternary ammonium cations. Carbonates or hydrogen carbonates are also possible.
For oligonucleotides, preferred examples of pharmaceutically acceptable salts include but are not limited to (a) salts formed with cations such as sodium, potassium, ammonium, magnesium, calcium, polyamines such as spermine and spermidine, etc.; (b) acid addition salts formed with inorganic acids, for example hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid and the like; (c) salts formed with organic acids such as, for example, acetic acid, oxalic acid, tartaric acid, succinic acid, maleic acid, fumaric acid, gluconic acid, citric acid, malic acid, ascorbic acid, benzoic acid, tannic acid, palmitic acid, alginic acid, polyglutamic acid, naphthalenesulfonic acid, methanesulfonic acid, p-toluenesulfonic acid, naphthalenedisulfonic acid, polygalacturonic acid, and the like; and (d) salts formed from elemental anions such as chlorine, bromine, and iodine. The antisense compounds of the present invention can be utilized for diagnostics, therapeutics, prophylaxis and as research reagents and kits. For therapeutics, an animal, preferably a human, suspected of having a disease or disorder which can be treated by modulating the expression of c-Src is treated by administering antisense compounds in accordance with this invention. The compounds of the invention can be utilized in pharmaceutical compositions by adding an effective amount of an antisense compound to a suitable pharmaceutically acceptable diluent or carrier. Use of the antisense compounds and methods of the invention can also be useful prophylactically, e.g., to prevent or delay infection, inflammation or tumor formation, for example.
The antisense compounds of the invention are useful for research and diagnostics, because these compounds hybridize to nucleic acids encoding c-Src, enabling sandwich and other assays to easily be constructed to exploit this fact. Hybridization of the antisense oligonucleotides of the invention with a nucleic acid encoding c-Src can be detected by means known in the art. Such means can include conjugation of an enzyme to the oligonucleotide, radiolabelling of the oligonucleotide or any other suitable detection means. Kits using such detection means for detecting the level of c-Src in a sample can also be prepared.
The present invention also includes pharmaceutical compositions and formulations which include the antisense compounds of the invention. The pharmaceutical compositions of the present invention can be administered in a number of ways depending upon whether local or systemic treatment is desired and upon the area to be treated. Administration can be topical (including ophthalmic and to mucous membranes including vaginal and rectal delivery), pulmonary, e.g., by inhalation or insufflation of powders or aerosols, including by nebulizer; intratracheal, intranasal, epidermal and transdermal), oral or parenteral. Parenteral administration includes intravenous, intraarterial, subcutaneous, intraperitoneal or intramuscular injection or infusion; or intracranial, e.g., intrathecal or intraventricular, administration. Oligonucleotides with at least one 2′-O-methoxyethyl modification are believed to be particularly useful for oral administration.
Pharmaceutical compositions and formulations for topical administration can include transdermal patches, ointments, lotions, creams, gels, drops, suppositories, sprays, liquids and powders. Conventional pharmaceutical carriers, aqueous, powder or oily bases, thickeners and the like can be necessary or desirable. Coated condoms, gloves and the like can also be useful.
Compositions and formulations for oral administration include powders or granules, suspensions or solutions in water or non-aqueous media, capsules, sachets or tablets. Thickeners, flavoring agents, diluents, emulsifiers, dispersing aids or binders can be desirable.
Compositions and formulations for parenteral, intrathecal or intraventricular administration can include sterile aqueous solutions which can also contain buffers, diluents and other suitable additives such as, but not limited to, penetration enhancers, carrier compounds and other pharmaceutically acceptable carriers or excipients.
Pharmaceutical compositions and/or formulations comprising the oligonucleotides of the present invention can also include penetration enhancers in order to enhance the alimentary delivery of the oligonucleotides. Penetration enhancers can be classified as belonging to one of five broad categories, i.e., fatty acids, bile salts, chelating agents, surfactants and non-surfactants. One or more penetration enhancers from one or more of these broad categories can be included.
Various fatty acids and their derivatives which act as penetration enhancers include, for example, oleic acid, lauric acid, capric acid, myristic acid, palmitic acid, stearic acid, linoleic acid, linolenic acid, dicaprate, tricaprate, recinleate, monoolein (a.k.a. 1-monooleoyl-rac-glycerol), dilaurin, caprylic acid, arichidonic acid, glyceryl 1-monocaprate, 1-dodecylazacycloheptan-2-one, acylcarnitines, acylcholines, mono- and di-glycerides and physiologically acceptable salts thereof (i.e., oleate, laurate, caprate, myristate, palmitate, stearate, linoleate, etc. Examples of some presently preferred fatty acids are sodium caprate and sodium laurate, used singly or in combination at concentrations of 0.5 to 5%.
Various natural bile salts, and their synthetic derivatives, act as penetration enhancers. Thus, the term “bile salt” includes any of the naturally occurring components of bile as well as any of their synthetic derivatives. A presently preferred bile salt is chenodeoxycholic acid (CDCA) (Sigma Chemical Company, St. Louis, Mo.), generally used at concentrations of 0.5 to 2%.
Complex formulations comprising one or more penetration enhancers can be used. For example, bile salts can be used in combination with fatty acids to make complex formulations. Preferred combinations include CDCA combined with sodium caprate or sodium laurate (generally 0.5 to 5%).
Chelating agents include, but are not limited to, disodium ethylenediaminetetraacetate (EDTA), citric acid, salicylates (e.g., sodium salicylate, 5-methoxysalicylate and homovanilate), N-acyl derivatives of collagen, laureth-9 and N-amino acyl derivatives of beta-diketones (enamines). Chelating agents have the added advantage of also serving as DNase inhibitors.
Surfactants include, for example, sodium lauryl sulfate, polyoxyethylene-9-lauryl ether, polyoxyethylene-20-cetyl etherand perfluorochemical emulsions, such as FC-43.
Non-surfactants include, for example, unsaturated cyclic ureas, 1-alkyl- and 1-alkenylazacyclo-alkanone derivatives and non-steroidal anti-inflammatory agents such as diclofenac sodium, indomethacin and phenylbutazone.
As used herein, “carrier compound” refers to a nucleic acid, or analog thereof, which is inert (i.e., does not possess biological activity per se) but is recognized as a nucleic acid by in vivo processes that reduce the bioavailability of a nucleic acid having biological activity by, for example, degrading the biologically active nucleic acid or promoting its removal from circulation. The coadministration of a nucleic acid and a carrier compound, typically with an excess of the latter substance, can result in a substantial reduction of the amount of nucleic acid recovered in the liver, kidney or other extracirculatory reservoirs, presumably due to competition between the carrier compound and the nucleic acid for a common receptor. For example, the recovery of a partially phosphorothioated oligonucleotide in hepatic tissue is reduced when it is coadministered with polyinosinic acid, dextran sulfate, polycytidic acid or 4-acetamido-4′-isothiocyano-stilbene-2,2′-disulfonic acid.
In contrast to a carrier compound, a “pharmaceutically acceptable carrier” (excipient) is a pharmaceutically acceptable solvent, suspending agent or any other pharmacologically inert vehicle for delivering one or more nucleic acids to an animal. The pharmaceutically acceptable carrier can be liquid or solid and is selected with the planned manner of administration in mind so as to provide for the desired bulk, consistency, etc., when combined with a nucleic acid and the other components of a given pharmaceutical composition. Typical pharmaceutically acceptable carriers include, but are not limited to, binding agents (e.g., pregelatinized maize starch, polyvinylpyrrolidone or hydroxypropyl methylcellulose, etc.); fillers (e.g., lactose and other sugars, microcrystalline cellulose, pectin, gelatin, calcium sulfate, ethyl cellulose, polyacrylates or calcium hydrogen phosphate, etc.); lubricants (e.g., magnesium stearate, talc, silica, colloidal silicon dioxide, stearic acid, metallic stearates, hydrogenated vegetable oils, corn starch, polyethylene glycols, sodium benzoate, sodium acetate, etc.); disintegrates (e.g., starch, sodium starch glycolate, etc.); or wetting agents (e.g., sodium lauryl sulphate, etc.). Sustained release oral delivery systems and/or enteric coatings for orally administered dosage forms are described in U.S. Pat. Nos. 4,704,295; 4,556,552; 4,309,406; and 4,309,404.
The compositions of the present invention can additionally contain other adjunct components conventionally found in pharmaceutical compositions, at their art-established usage levels. Thus, for example, the compositions can contain additional compatible pharmaceutically-active materials such as, e.g., antipruritics, astringents, local anesthetics or anti-inflammatory agents, or can contain additional materials useful in physically formulating various dosage forms of the composition of present invention, such as dyes, flavoring agents, preservatives, antioxidants, opacifiers, thickening agents and stabilizers. However, such materials, when added, should not unduly interfere with the biological activities of the components of the compositions of the invention.
Regardless of the method by which the antisense compounds of the invention are introduced into a patient, colloidal dispersion systems can be used as delivery vehicles to enhance the in vivo stability of the compounds and/or to target the compounds to a particular organ, tissue or cell type. Colloidal dispersion systems include, but are not limited to, macromolecule complexes, nanocapsules, microspheres, beads and lipid-based systems including oil-in-water emulsions, micelles, mixed micelles, liposomes and lipid:oligonucleotide complexes of uncharacterized structure. A preferred colloidal dispersion system is a plurality of liposomes. Liposomes are microscopic spheres having an aqueous core surrounded by one or more outer layer(s) made up of lipids arranged in a bilayer configuration.
Certain embodiments of the invention provide for liposomes and other compositions containing (a) one or more antisense compounds and (b) one or more other chemotherapeutic agents which function by a non-antisense mechanism. Examples of such chemotherapeutic agents include, but are not limited to, anticancer drugs such as daunorubicin, dactinomycin, doxorubicin, bleomycin, mitomycin, nitrogen mustard, chlorambucil, melphalan, cyclophosphamide, 6-mercaptopurine, 6-thioguanine, cytarabine (CA), 5-fluorouracil (5-FU), floxuridine (5-FUdR), methotrexate (MTX), colchicine, vincristine, vinblastine, etoposide, teniposide, cisplatin and diethylstilbestrol (DES). See, generally, The Merck Manual of Diagnosis and Therapy, 15th Ed., Berkow et al., eds., 1987, Rahway, N.J. Anti-inflammatory drugs, including but not limited to nonsteroidal anti-inflammatory drugs and corticosteroids, and antiviral drugs, including but not limited to ribivirin, vidarabine, acyclovir and ganciclovir, can also be combined in compositions of the invention. See, generally, The Merck Manual of Diagnosis and Therapy, 15th Ed., Berkow et al., eds., 1987, Rahway, N.J., pages 2499-2506. Other non-antisense chemotherapeutic agents are also within the scope of this invention. Two or more combined compounds can be used together or sequentially.
In another related embodiment, compositions of the invention can contain one or more antisense compounds, particularly oligonucleotides, targeted to a first nucleic acid and one or more additional antisense compounds targeted to a second nucleic acid target. Two or more combined compounds can be used together or sequentially.
The formulation of therapeutic compositions and their subsequent administration is believed to be within the skill of those in the art. Dosing is dependent on severity and responsiveness of the disease state to be treated, with the course of treatment lasting from several days to several months, or until a cure is effected or a diminution of the disease state is achieved. Optimal dosing schedules can be calculated from measurements of drug accumulation in the body of the patient. Persons of ordinary skill can easily determine optimum dosages, dosing methodologies and repetition rates. Optimum dosages can vary depending on the relative potency of individual oligonucleotides. Antisense oligonucleotides according to the invention can be given a person as such, individually or in combination. However, they can also be expressed within the person by means of an expression vector containing sequences encoding for them.
Those of skill in treating disorders which are amenable to regulation by antisense constructs can determine the effective amount of a particular antisense construct to be formulated in a pharmaceutical preparation. In general it is contemplated than an effective amount would be from 0.001 mg/kg to 50 mg/kg body weight and more preferably from 0.01 mg/kg to 10 mg/kg body weight. There are numerous methods that have been formulated for inhibiting specific gene expression which have been adopted to some degree and have been defined as antisense nucleic acids, e.g., U.S. Pat. No. 5,856,103. The basic approach is that an antisense oligonucleotide (ASO) analog complimentary to a specific targeted messenger RNA or mRNA sequence is used. The term “antisense” as used herein is a term denoting a novel approach to chemotherapy which is based upon the complementary pairing of ASO nucleic acids with a target nucleic acid. The use of such a compound requires a complementarity of the antisense base sequence to a target zone of an mRNA, so that the antisense ASO will bind to that mRNA target sequence and will bring about selective inhibition of gene expression.
When the method of the present invention is used to enhance the immune response of a subject who has a cancer, hypersensitivity disease, or autoimmune disorder, the method can be used to correct a deficiency or imbalance in the immune system. The method of the present invention can be used to alter the immune response of a subject so as to prompt the suppressor cells to mount an immunological attack on the aberrant T/cells.
When the immune system of a subject is enhanced by challenging the immune system with an antigen responsible for tumorigenesis (SRC 531 mutant), the method of the present invention can be used prophylactically or therapeutically. For example, the method can be used prophylactically when the immune response of a subject is enhanced before the subject is afflicted with a disease. Hence, the immune system response of a subject can be enhanced to increase the vigor of the immune response prior to acquiring the disease.
The method of the present invention can also be used therapeutically such as when a subject has a disease, i.e., colon cancer, so that said cancer is eliminated or spread of metastatic cells is reduced or eliminated. Subjects in need of such an intervention can be vaccinated according to the methods of the present invention in order to alter the immune system response of the subject and achieve a beneficial therapeutic effect.
6. EXAMPLES
6.1 Example
PCR and RFLP Analysis of Tumors
Total RNA is isolated from frozen human tumor specimens expressing various levels of Src kinase activity and subjected to RT-PCR using primers designed to amplify the 600 base pairs (bp) at the 3′ end of the cDNA as described in Tanaka, A. et al. DNA sequence encoding the amino-terminal region of the human c-Src protein: implications of sequence divergence among Src-type kinase oncogenes. Mol Cell Biol 7, 1978-1983 (1987) and Tanaka, A. & Fujita, D. J. Expression of a molecularly cloned human c-Src oncogene by using a replication-competent retroviral vector. Mol Cell Biol 6, 3900-3909 (1986). RT-PCR products are cloned and sequenced manually as well as by automated sequencing. Tumors are screened for presence of the SRC 531 mutation by RFLP analysis of PCR products 248 bp in length digested to completion with ScaI restriction enzyme. Other technical variations of above disclosed means of manipulating DNA, preparing primers, and restriction enzyme analysis are well known in the art such as disclosed for example in U.S. Pat. No. 5,783,182.
6.2 Example
Soft Agar and Matrigel Invasion Assays
v-Src has been shown earlier to induce the production of specific metalloproteinases and to foster the metastatic phenotype. For this reason, SRC 531 transfectants are assessed in vitro for potential to invade matrigel. To determine transformation potential of SRC 531, fibroblasts stably transfected with c-Src (SEQ ID NO. 1), SRC 531 (SEQ ID NO. 3) or v-Src are subjected to soft agar colony formation assays to assess C, anchorage independent growth (FIG. 4 a,b ). Equal numbers of 3Y1 cells, either wild type cells or cells transfected with pcc-Src, pcSrc531RI, or a vector carrying v-Src are seeded in 0.5% agar and cells are incubated for 10-14 days until colonies are formed. These experiments demonstrate significant colony formation for only the mutant forms of Src, although very small, slowly growing colonies are occasionally detected in normal human c-Src transfectants. Because these assays examine essentially single clones of transfected cells, focus formation assays are performed to assess the ability of the SRC 531 mutant to transform populations of cells. Again, these experiments demonstrate (FIG. 4 c ) the capacity for both mutant forms of Src to produce foci, although the v-Src transfectants consistently produce more foci in less time than SRC 531 transfectants. Note that v-Src associated foci are visible within 10 days with 1 μg (micrograms) DNA, whereas SRC 531 associated foci are visible only after 21 days of culture at doses of 10 μg (micrograms) DNA. Furthermore, rapid subcutaneous tumor growth results from tumor cells inoculated into the nude mouse in all clones tested (see Example infra).
For the Matrigel assay, 5×10 4 cells are seeded into matrigel chambers in 200 ml serum free medium with 800 ml full medium in the well below. The cells are allowed to grow for 48 h, after which the layer of cells in the chamber is carefully scraped off and cells adhering to the membrane beneath the chambers are stained with crystal violet and counted.
Both SRC 531 and v-Src transfectants readily invade matrigel, whereas c-Src transfectants does not (FIG. 4 d ).
6.3 Example
Src Protein Kinase Activity Assay and Immunoblotting
Tumor lysales are prepared in radioimmunoprecipitation assay (RIPA) buffer (10 mM Tris pH 7.4, 150 mM NaCl, 10% glycerol, 5 mM EDTA, 1% Triton-X 100, 0.5% deoxycholate, 1 mM PMSF, 1 mM Na orthovanadate, 10 mg/ml leupeptin, 10 mg/ml apoprotinin), clarified by microcentriftigation for 15 min at 4° C., immunoprecipitated with anti-Src Ab (MAB 327), and then washed three times with RIPA buffer and three times in Tris buffer (40 mM Tris pH 7.4). The samples are then resuspended in 30 ml of kinase reaction buffer (20 mM Tris pH 7.4, 5 mM magnesium chloride, 10 mm sodium orthovanadate) containing 20 μCi (microcuries) [ 32 P]ATP/sample and enolase (1 mg/sample) as exogenous substrate. The obtained samples are incubated for 15 min at room temperature, resuspended in electrophoresis sample buffer, boiled 5 min and loaded onto a SDS-10% polyacrylamide gel.
Immunoblotting or Western Blot is performed as previously described (Mao, W. et al. Activation of c-Src by receptor tyrosine kinases in human colon cancer cells with high metastatic potential. Oncogene 15, 3083-3090 (1997)). At the end of the incubation period, the filters are washed and incubated with the appropriate horseradish peroxidase-conjugated secondary antibodies for 1 hour at room temperature. The filters are then washed and exposed with the enhanced chemiluminescence detection system (Amersham).
6.4 Example
CNBr Cleavage Studies
Cells transfected with pcc-Src, pcSrc531RI, and v-Src are labeled with 3.3 mCi each of inorganic 32 P for 4 hours. Cell lysates are immunoprecipitated with α-Src (alpha-Src) monoclonal antibody and washed immunoprecipitates are subjected to SDS-PAGE, the gel dried and exposed to X-ray film. The visible Src bands are excised and incubated with 50 mg/ml CNBr in 70% formic acid for 1 h at room temperature as described (Jove, R., Hanafuisa, T., Hamaguchi, M. & Hanafusa, H. In vivo phosphorylation states and kinase activities of transforming p60c-Src mutants. Oncogene Res. 5, 49-60 (1989); Jove, R., Kombluth, S. & Hanafusa, H. Enzymatically inactive p60c-Src mutant with altered ATP-binding site is fully phosphorylated in its carboxy-terminal regulatory region. Cell 50, 937-943 (1987)). The bands are washed in water, dried, and placed in the wells of a 16.5% polyacrylamide gel containing 10% glycerol.
6.5 Example
Cloning of SRC 531 and Transfection of Mammalian Cells
The mutant SRC 531 cDNA is cloned into the expression vector pcDNA3.1 (Invitrogen) creating pcSrc531RI. Normal human SRC cDNA is also inserted into pcDNA3.1-, creating pcc-Src. 3Y1 rat fibroblast cells are transfected with pcSrc531RI, pcc-Src, and a v-Src vector; transfectants are selected with G418. Those colonies overexpressing the Src protein are expanded and used for further tests.
6.6 Example
Mouse Studies
The in vivo potential of transfected cells to metastasize to the lungs following intravenous injection is assessed. Fifteen Balb/c nude mice are injected through the tail vein with 5×10 5 cells in PBS. Five mice are injected with each of the 3Y1 cell lines transfected with pcc-Src, pcSrc531RI, or v-Src. Each mouse is also injected with the same cells subcutaneously to monitor tumor growth. Tumors are measured every two days, and mice are sacrificed as they become ill. The lungs are removed to observe metastatic lesions, and are subjected to immunocytochemical studies to determine the levels of Src protein.
v-Src and SRC 531 transfectants both produce extensive experimental lung metastases, while c-Src and mock controls produce none (FIG. 4 e ). The SRC 531 transfectants cause 100% mortality after 27 days, whereas v-Src transfectants expressing a more active form of Src cause earlier mortality by day 12. In contrast, c-Src transfectants produce no lung metastases and all mice survive beyond 45 days.
6.7 Example
Findings of SRC 531 Mutant in Other Types of Tumors
Mutated pp60c-Src activity is elevated in all five hairy cell leukemia specimens and in a number of the large cell and immunoblastic lymphomas; neoplasms representing later stages in B-cell development. pp60c-Src activity is low in neoplastic cells which correspond to early and intermediate stages in B-cell development (acute and chronic lymphatic leukemia, lymphoblastic lymphoma, small lymphocytic lymphoma).
Mutated pp60c-Src activity is elevated in tested specimens from other varieties of advanced tumors such as fibrosarcoma, myxosarcoma, liposarcoma, chondrosarcoma, osteogenic sarcoma, chordoma, angiosarcoma, Kaposi's sarcoma, endotheliosarcoma, lymphangiosarcoma, lymphangioendotheliosarcoma, synovioma, mesothelioma, Ewing's tumor, leiomyosarcoma, rhabdomyosarcoma, rhabdosarcoma, colorectal carcinoma, pancreatic cancer, breast cancer, ovarian cancer, prostate cancer, squamous cell carcinoma, basal cell carcinoma, adenocarcinoma, sweat gland carcinoma, sebaceous gland carcinoma, papillary carcinoma, papillary adenocarcinomas, cystadenocarcinoma, medullary carcinoma, bronchogenic carcinoma, renal cell carcinoma, hepatoma, bile duct carcinoma, choriocarcinoma, seminoma, embryonal carcinoma, Wilms' tumor, cervical cancer, testicular tumor, lung carcinoma, small cell lung carcinoma, bladder carcinoma, epithelial carcinoma, glioma, astrocytoma, medulloblastoma, craniopharyngioma, ependymoma, pinealoma, hemangioblastoma, acoustic neuroma, oligodendroglioma, meningioma, neuroblastoma, retinoblastoma, and myeloma albeit at lesser frequency.
6.8 Example
Tumors with Aberrant Src Protein Elicit T Cells Specific Against Mutant Src and Vaccine Against Src-caused Cancer and Metastases
The following experiments show that aberrant pp60 protein produced by tumor cells elicits T cells, which proliferate specifically in response to the altered region of the pp60 protein. B6 mice are immunized twice at two-week intervals with cells transfected with pcSrc531RI. Normal human SRC cDNA is also inserted into pcDNA3.1-. 3Y1 rat fibroblast cells are transfected with pcSrc531RI or normal pcc-Src. Spleen cells from mice immunized with FBL transfected with the T24 oncogene proliferate in response to the mutant Src, whereas spleen cells from mice immunized with fibroblasts transfected with normal c-Src do not respond.
The finding that tumors which express aberrant Src pp60 in vivo can elicit src-specific T cells strongly implies that pp60 is available to antigen-presenting cells (APC) for processing and presentation to class II-restricted T cells in vivo. Presentation of the activated pp60 in proximity to tumor cells elicits class II-restricted T cells which can provide substantial therapeutic effects in vivo against tumors even if the latter do not express class II MHC molecules and cannot be directly recognized. The tumor, which expresses a transfected mutant Src oncogene and is tumorigenic in BALB/c mice, is used in therapy. Small doses of tumor cells (3×10 6 ), injected i.v., kill animals within 4 weeks. A T cell line specific for the altered region of pp60 is tested for the ability to protect BALB/c mice against challenge with tumor cells. In repeated experiments, mice injected with tumor alone all died by day 27, whereas mice injected concurrently with tumor cells plus Src specific T cells (2×10 7 cells) all survived without evidence of tumor for greater than 8 weeks of observation. Therefore, Src-specific class II-restricted T cells mediate anti-tumor protection in vivo.
From a patient with a late stage metastatic colon carcinoma a biopsy of tumor cells is surgically excised from a liver. Obtained tissue is minced, cells enzymatically isolated and either frozen in liquid nitrogen or cultured in vitro under typical conditions. Alternatively, normal host cells are transfected with a vector disclosed in Example 6.5 so that cells overexpressing the Src protein are expanded and used for further manipulations. After obtaining a suitable number of cells, they are lysed and mixed with antigen-presenting dendritic cells of a patient in need of a vaccine. Dendritic cells are further incubated for 1-3 days with appropriate stimuli such as IL-2 or other growth factor. Then the mixture (about 5×10 6 cells per injection) is subcutaneously or intravenously administered back to the patient. The preparation is used either with or without additional immunoadjuvants. Four injections are administered in two weeks intervals followed by three injections once a month. If necessary injections are continued in two months intervals. This so-called “vaccine therapy” approach primes the patient's immune system against his own tumor cells and helps to eliminate tumor cells. The survival of six out of eleven treated patients for over 3 years is statistically better in comparison with survival of less than 2% for patients who are not vaccinated with the vaccine based on use of SRC 531 mutation.
Other means of preparing cancer vaccine and using vaccine are known in the art, such as for example disclosed in U.S. Pat. Nos. 5,156,841, 5,039,522, 5,635,188, 5,646,009, 5,338,674, 5,158,769 and are equally suitable as long as they are adaptable for a practical use within the scope of the present invention.
6.9 Example
Screening for Inhibitory Compounds Using Mutant pp60
A library of peptides to be tested as antagonists of pp60 c-Src mutant tyrosine kinase are synthesized according to the procedure disclosed in U.S. Pat. No. 5,532,167 to Cantley, which is incorporated herein by way of reference. Accordingly a peptide Ala-Glu-Glu-Glu-Ile-Tyr-Gly-Glu-Phe-Glu-Ala-Lys-Lys-Lys-Lys is synthesized as an optimal substrate/antagonist for mutant Src tyrosine kinase. The kinetic studies are carried out as follows. Purified mutant kinase is immobilized on protein A beads and kinase reaction is performed in 20 μl of 50 mM Tris pH 7.0 buffer containing 50 mM NaCl, 10 mM MgCl 2 , 10 μM ATP 5 μCi [gamma- 32 P]-ATP (3000 mCi/mmol, NEN) and various dilutions of the peptide. For the experiment measuring the competitive inhibition of c-Src activity by the Src motif-containing peptide, 1 μM (final concentration) acid treated enolase (trans-phosphorylation) is included. After 2.5 minutes incubation, the supernatants are spotted on phosphocellulose paper, washed four times with 75 mM phosphoric acid, and radioactivity counted in a scintillation counter. For phosphorylation of enolase, the reaction is stopped by adding SDS loading buffer and the proteins are resolved on 10% SDS-PAGE gels. The Km and Vmax are calculated using a standard computer software. The peptide is a good substrate for pp60c-Src, with Km of 2 μM and Vmax of 0.9 μM/mg/min. The Src-substrate peptide is also an excellent competitive inhibitor of enolase phosphorylation by pp60c-Src (K 50% =5 μM).
In addition to peptides as antagonists of mutant pp60 Src various other compounds are identified based on the assay disclosed above. These include but are not limited to the antisense molecule, which is complimentary to the 5′ region of c-Src gene and blocks transcription via triplex formation. An exemplary sequence of the antisense molecule is as follows:
1
GCCCCGCAGG TGCCTACTGC CTCTCAGTGT CTGACTTCGA CAACGCCAAG GGCCTCAACG
(SEQ ID NO.7)
61
TGAAGCACTA CAAGATCCGC AAGCTGGACA GCGGCGGCTT CTACATCACC TCCCGCACCC
121
AGTTCAACAG CCTGCAGCAG CTGGTGGCCT ACTACTCCAG TGAG
This example is not limiting and one skilled in the art can select shorter oligonucleotide according to established procedures. For example, a series of methoxyethylamine 3′ end-cap oligodeoxynucleotides are prepared on a Biosearch 8750 DNA synthesizer, using standard H-phosphonate chemistry on controlled pore glass. The 15 or 18-base oligodeoxynucleotides are purified via DMT-on purification on a semi-prep Dynamax C-4 300A column. A secondary DMT-off purification is then performed on the same column. The oligomers are then desalted over a Pharmacia NAP-25 column, converted to the sodium form via Biorad AC 50W-X8 (Na+) 200-400 mesh polyprep column, and then passed over another NAP-25 column. The antisense oligos and their controls, which contained the same bases but in scrambled sequence, are in a similar manner. Lyophilized oligomers used in the following experiments are dissolved in PBS (1 mM stock) and sterile filtered with Millipore 0.2 micrometer disks. The sequence used for antisense inhibitory studies on SRC gene is a 27 base region of the corresponding mRNA spanning the AUG translation initiation codon. While the present invention is not limited to such sequences, antisense oligonucleotides directed against the initiation codon region of the mRNA are one type of antisense molecule believed to effectively inhibit translation of the resulting gene product. Other effective antisense molecules can be specifically targeted against the opposite end of the mRNA.
To selectively interfere with the expression of mutated SRC gene (SEQ ID NO. 3), 5 mice are injected once with 5 μg/g weight of antisense, phosphorothioated oligodeoxynucleotide prepared as above and which is complementary to the initiator AUG domain in SRC mRNA or with PBS for controls. Three weeks following the injection, liver biopsies are prepared from all of these mice. Each biopsy is frozen and then sliced into this slices and hybridized with isotope labeled SRC nucleic probes. Following 3 days of exposure to emulsion autoradiography, slides are developed to create silver grains over cells containing SRC mRNAs. Labeling and number of positive cells is decreased in liver specimens of mice treated with antisense phosphorothioated oligodeoxynucleotide demonstrating that antisense interfered with mutated SRC 531 expression. In contrast, in control mice, SRCmRNA levels per cell increased by about 20-fold. The decrease of mutated SRC 531 expression is also confirmed by Western Blot studies using antibodies obtained by methods disclosed in Example 6.10.
The methods of selecting, making, administering, and testing appropriate doses of an antisense molecule along with suitable modifications, adjuvants and molecules are well known in the art and can be found for example in U.S. Pat. Nos. 5,734,039, 5,583,032, 5,756,476, 5,856,103, and 5,677,289 which are incorporated herein by way of reference. In addition to classical antisense molecule targeting AUG sequence one skilled in the art will know to use other suitable approaches such as a non-coding sense sequence, ribosomal frameshifting, and a ribozyme sequence. The details for such approaches can be found for example, in U.S. Pat. Nos. 5,843,723, 5,759,829, 5,707,866, and 5,712,384 as incorporated herein by way of reference. Without limiting to above anti-sense approaches it is clear that other means are equally suitable such as compositions and methods for the treatment of SRC 531 transformed malignant cells by antisense nucleic acid molecules that can cause the apoptosis of said cells such as disclosed in U.S. Pat. Nos. 5,935,937, which is incorporated herein by way of reference.
Furthermore, equally suitable antagonists such as tyrphostin, pyrozolopyrimidine and their derivatives and salts are found as useful pharmaceutical compounds. The inhibitory activity of H-89, K252a, H-7, N-(9-acridinyl)maleimide, staurosporine, herbimycin A, isoflavones like genistein, daidzein, quercetin (as disclosed in U.S. Pat. Nos. 5,919,813 and 5,872,223), quinolymethylen-oxindole (as disclosed in U.S. Pat. No. 5,905,149), angelmicin, 2-iminochromene derivatives (as disclosed in U.S. Pat. No. 5,648,378), 5-aminopyrazoles (as disclosed in U.S. Pat. No. 5,922,741) sesquiterpene lactone (as disclosed in U.S. Pat. No. 5,905,089), various benzylidene-Z-indoline compounds (as disclosed in U.S. Pat. No. 5,880,141), urea- and thiourea-type compounds (as disclosed in U.S. Pat. No. 5,773,459), benzopyran compounds (as disclosed in U.S. Pat. No. 5,763,470), polyhydric phenol compounds (as disclosed in U.S. Pat. No. 5,780,008), resorcyclic acid lactones (as disclosed in U.S. Pat. No. 5,674,892), 4-aminopyrrolo[2,3-d]pyrimidines (as disclosed in U.S. Pat. No. 5,639,757), and miscellaneous other phosphotyrosine phosphatase inhibitors (as disclosed in U.S. Pat. No. 5,877,210) is also tested in the same assay system. It is thus clear that the screening assay using mutant pp60 is extremely useful assay in identifying antagonist compounds targeting this particular form of tyrosine kinase.
The utility of this approach is further confirmed by utilizing a Src-transformed fibroblast assay. In this assay the compounds identified above are used to inhibit the proliferation of fibroblasts. In addition to proliferation inhibition the expression of a mutant gene is also monitored by standard art accepted methods aimed at testing the gene expression.
6.10 Example
Production of Anti-mutant pp60 Monoclonal and Polyclonal Antibodies
A group of three Balb/c female mice (Charles River Breeding Laboratories, Wilmington, Mass.) are injected with 5 μg/dose of purified truncated C-terminal peptide of pp60c-Src in 100 μl Detox adjuvant (RIBI ImmunoChem Res Inc, Hamilton, Mo.) by intraperitoneal injection on days 0, 3, 7, 10, and 14. On day 17 the animals are sacrificed, their spleens are removed and the lymphocytes fused with the mouse myeloma line 653 using 50% polyethylene glycol 4000 by an established procedure (see U.S. Pat. Nos. 5,939,269, and 5,658,791 as incorporated herein by way of reference). The fused cells are plated into 96-well microtiter plates at a density of 2×10 5 cells/well followed by HAT selection on day 1 post-fusion. Immobilized hybridoma culture supernatants are then reacted with biotinylated mutant pp60 C-terminal peptide. The wells positive for anti-PC-1 antibodies are expanded for further study. These cultures remain stable when expanded and cell lines are cryopreserved. The parental cultures are isotyped and then assayed for their ability to capture and to specifically recognize mutant pp60.
Alternatively, polyclonal rabbit antisera is raised against purified mutant protein peptides Polyclonal antibodies against the C-terminal peptide are obtained by coupling such peptides to Keyhole Limpet Heamocyanin with 0.05% gluteraldehyde, emulsified in Freunds' complete adjuvant and injected intradermally at several sites. The animals are boosted four and seven weeks later with coupled peptide emulsified in Freunds' incomplete adjuvant and bled ten days after the last injection.
Antibodies prepared according to the above procedures are then used for identifying and/or diagnosing tumor cells that express SRC 531 mutation and/or for therapeutic approaches according to standard procedures known in the art, e.g., U.S. Pat. Nos. 5,601,989, 5,563,247, 5,610,276, and 5,405,941, as incorporated herein by way of reference. These same antibodies are used for monitoring expression of SRC 531, such as disclosed in Example 6.9.
6.11 Example
Transgenic Mice
According to the present invention, transgenic animals of any non-human species, including but not limited to mice, rats, rabbits, guinea pigs, pigs, or non-human primates can be produced using any technique known in the art, including but not limited to microinjection, electroporation, cell gun, cell fusion, or functional equivalents (see U.S. Pat. No. 5,550,316). In preferred embodiments of the invention, transgenic animals are generated according to the method disclosed hereinafter. Briefly, this method entails the following. Transgenic offspring are prepared by microinjecting a recombinant nucleic acid construct into fertilized eggs. For example, and not by way of limitation, fertilized mouse eggs can be collected from recently mated females with vaginal plugs, and then microinjected with construct DNA. Construct DNA, at a concentration of about 0.01-3 μg/ml, is microinjected into the male pronucleus of fertilized eggs, in an amount such that the volume of the pronucleus approximately doubles. The injected eggs are then transferred to female mice which had been mated the night before with vasectomized males. See also U.S. Pat. No. 4,873,191 by Wagner and Hoppe.
DNA clones for microinjection are cleaved with appropriate restriction enzymes, such as Sal1, Not1, etc., and the DNA fragments electrophoresed on 1% agarose gels in TBE buffer (U.S. Pat. No. 5,811,633). The DNA bands are visualized by staining with ethidium bromide, excised, and placed in dialysis bags containing 0.3M sodium acetate at pH 7.0. The DNA is then electroeluted into the dialysis bags, extracted with phenol-chloroform (1:1), and precipitated by two volumes of ethanol. The DNA is redissolved in 1 ml of low salt buffer (0.2M NaCl, 20 mM Tris, pH 7.4, and 1 mM EDTA) and purified on an Elutip-D column. The column is first primed with 3 ml of high salt buffer (1M NaCl, 20 mM Tris, pH 7.4, and 1 mM EDTA) followed by washing with 5 ml of low salt buffer. The DNA solutions are passed through the column for three times to bind DNA to the column matrix. After one wash with 3 ml of low salt buffer, the DNA is eluted with 0.4 ml of high salt buffer and precipitated by two volumes of ethanol. DNA concentrations are measured by absorption at 260 nm in a UV spectrophotometer. For microinjection, DNA concentrations are adjusted to about 3 μg/ml in 5 mM Tris, pH 7.4 and 0.1 mM EDTA. Other methods for purification of DNA for microinjection are also known. The purified inserts form pcSrc531RI plasmids are then microinjected into the pronuclei of fertilized (C57BL/6×CBA)F2 mouse embryos and surviving embryos are transferred into pseudopregnant females according to standard procedures such as disclosed in U.S. Pat. Nos. 5,877,397, 5,907,078, 5,849,993, 5,602,309, 5,387,742, which are incorporated herein by way of reference. SRC531 construct is operably linked to a suitable promoter, e.g., RSV long terminal repeat (LTR), glial fibrillary acidic protein (GFAP), or human beta-globin promoter (GF). Mice that developed from injected embryos are analyzed for the presence of transgene sequences by Southern blot analysis of mutant DNA. Transgene copy number is estimated by band intensity relative to control standards containing known quantities of cloned DNA. At 3 to 8 weeks of age, cells are isolated from these animals and assayed for the presence of transgene encoded SRC 531 mutation. All of the control non-transgenic mice tested negative for expression of SRC 531. Southern blot analysis indicates that many of these mice contain one or more copies of the transgene per somatic and/or germ cell. Some mice with high levels of Src expression developed abnormally, including edemas, head deformities, eye, axial system defects and usually these mice did not survive. Surviving transgenic mice exhibit malignant and/or benign transformation early in their life. Tumors include lymphomas, thymomas, fibrosarcomas, angiosarcomas, hemangiomas, neurofibrosarcomas, etc. These mice are useful as a model for studying SRC 531 mutants in vivo for testing, for example, drugs or SRC 531 antagonists.
Throughout this application, various publications and patents have been referenced. The disclosures in these publications or patents are incorporated herein by reference in order to more fully describe the state of the art.
From the foregoing, it will be evident that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention.
7
1
1611
DNA
Homo sapiens
misc_feature
(1)..(1611)
nucleotide sequence of normal c-Src oncogene
coding region
1
atg ggt agc aac aag agc aag ccc aag gat gcc agc cag cgg cgc cgc 48
Met Gly Ser Asn Lys Ser Lys Pro Lys Asp Ala Ser Gln Arg Arg Arg
1 5 10 15
agc ctg gag ccc gcc gag aac gtg cac ggc gct ggc ggg ggc gct ttc 96
Ser Leu Glu Pro Ala Glu Asn Val His Gly Ala Gly Gly Gly Ala Phe
20 25 30
ccc gcc tcg cag acc ccc agc aag cca gcc tcg gcc gac ggc cac cgc 144
Pro Ala Ser Gln Thr Pro Ser Lys Pro Ala Ser Ala Asp Gly His Arg
35 40 45
ggc ccc agc gcg gcc ttc gcc ccc gcg gcc gcc gag ccc aag ctg ttc 192
Gly Pro Ser Ala Ala Phe Ala Pro Ala Ala Ala Glu Pro Lys Leu Phe
50 55 60
gga ggc ttc aac tcc tcg gac acc gtc acc tcc ccg cag agg gcg ggc 240
Gly Gly Phe Asn Ser Ser Asp Thr Val Thr Ser Pro Gln Arg Ala Gly
65 70 75 80
ccg ctg gcc ggt gga gtg acc acc ttt gtg gcc ctc tat gac tat gag 288
Pro Leu Ala Gly Gly Val Thr Thr Phe Val Ala Leu Tyr Asp Tyr Glu
85 90 95
tct agg acg gag aca gac ctg tcc ttc aag aaa ggc gag cgg ctc cag 336
Ser Arg Thr Glu Thr Asp Leu Ser Phe Lys Lys Gly Glu Arg Leu Gln
100 105 110
att gtc aac aac acg gag gga gac tgg tgg ctg gcc cac tcg ctc agc 384
Ile Val Asn Asn Thr Glu Gly Asp Trp Trp Leu Ala His Ser Leu Ser
115 120 125
aca gga cag aca ggc tac atc ccc agc aac tac gtg gcg ccc tcc gac 432
Thr Gly Gln Thr Gly Tyr Ile Pro Ser Asn Tyr Val Ala Pro Ser Asp
130 135 140
tcc atc cag gct gag gag tgg tat ttt ggc aag atc acc aga cgg gag 480
Ser Ile Gln Ala Glu Glu Trp Tyr Phe Gly Lys Ile Thr Arg Arg Glu
145 150 155 160
tca gag cgg tta ctg ctc aat gca gag aac ccg aga ggg acc ttc ctc 528
Ser Glu Arg Leu Leu Leu Asn Ala Glu Asn Pro Arg Gly Thr Phe Leu
165 170 175
gtg cga gaa agt gag acc acg aaa ggt gcc tac tgc ctc tca gtg tct 576
Val Arg Glu Ser Glu Thr Thr Lys Gly Ala Tyr Cys Leu Ser Val Ser
180 185 190
gac ttc gac aac gcc aag ggc ctc aac gtg aag cac tac aag atc cgc 624
Asp Phe Asp Asn Ala Lys Gly Leu Asn Val Lys His Tyr Lys Ile Arg
195 200 205
aag ctg gac agc ggc ggc ttc tac atc acc tcc cgc acc cag ttc aac 672
Lys Leu Asp Ser Gly Gly Phe Tyr Ile Thr Ser Arg Thr Gln Phe Asn
210 215 220
agc ctg cag cag ctg gtg gcc tac tac tcc aaa cac gcc gat ggc ctg 720
Ser Leu Gln Gln Leu Val Ala Tyr Tyr Ser Lys His Ala Asp Gly Leu
225 230 235 240
tgc cac cgc ctc acc acc gtg tgc ccc acg tcc aag ccg cag act cag 768
Cys His Arg Leu Thr Thr Val Cys Pro Thr Ser Lys Pro Gln Thr Gln
245 250 255
ggc ctg gcc aag gat gcc tgg gag atc cct cgg gag tcg ctg cgg ctg 816
Gly Leu Ala Lys Asp Ala Trp Glu Ile Pro Arg Glu Ser Leu Arg Leu
260 265 270
gag gtc aag ctg ggc cag ggc tgc ttt ggc gag gtg tgg atg ggg acc 864
Glu Val Lys Leu Gly Gln Gly Cys Phe Gly Glu Val Trp Met Gly Thr
275 280 285
tgg aac ggt acc acc agg gtg gcc atc aaa acc ctg aag cct ggc acg 912
Trp Asn Gly Thr Thr Arg Val Ala Ile Lys Thr Leu Lys Pro Gly Thr
290 295 300
atg tct cca gag gcc ttc ctg cag gag gcc cag gtc atg aag aag ctg 960
Met Ser Pro Glu Ala Phe Leu Gln Glu Ala Gln Val Met Lys Lys Leu
305 310 315 320
agg cat gag aag ctg gtg cag ttg tat gct gtg gtt tca gag gag ccc 1008
Arg His Glu Lys Leu Val Gln Leu Tyr Ala Val Val Ser Glu Glu Pro
325 330 335
att tac atc gtc acg gag tac atg agc aag ggg agt ttg ctg gac ttt 1056
Ile Tyr Ile Val Thr Glu Tyr Met Ser Lys Gly Ser Leu Leu Asp Phe
340 345 350
ctc aag ggg gag aca ggc aag tac ctg cgg ctg cct cag ctg gtg gac 1104
Leu Lys Gly Glu Thr Gly Lys Tyr Leu Arg Leu Pro Gln Leu Val Asp
355 360 365
atg gct gct cag atc gcc tca ggc atg gcg tac gtg gag cgg atg aac 1152
Met Ala Ala Gln Ile Ala Ser Gly Met Ala Tyr Val Glu Arg Met Asn
370 375 380
tac gtc cac cgg gac ctt cgt gca gcc aac atc ctg gtg gga gag aac 1200
Tyr Val His Arg Asp Leu Arg Ala Ala Asn Ile Leu Val Gly Glu Asn
385 390 395 400
ctg gtg tgc aaa gtg gcc gac ttt ggg ctg gct cgg ctc att gaa gac 1248
Leu Val Cys Lys Val Ala Asp Phe Gly Leu Ala Arg Leu Ile Glu Asp
405 410 415
aat gag tac acg gcg cgg caa ggt gcc aaa ttc ccc atc aag tgg acg 1296
Asn Glu Tyr Thr Ala Arg Gln Gly Ala Lys Phe Pro Ile Lys Trp Thr
420 425 430
gct cca gaa gct gcc ctc tat ggc cgc ttc acc atc aag tcg gac gtg 1344
Ala Pro Glu Ala Ala Leu Tyr Gly Arg Phe Thr Ile Lys Ser Asp Val
435 440 445
tgg tcc ttc ggg atc ctg ctg act gag ctc acc aca aag gga cgg gtg 1392
Trp Ser Phe Gly Ile Leu Leu Thr Glu Leu Thr Thr Lys Gly Arg Val
450 455 460
ccc tac cct ggg atg gtg aac cgc gag gtg ctg gac cag gtg gag cgg 1440
Pro Tyr Pro Gly Met Val Asn Arg Glu Val Leu Asp Gln Val Glu Arg
465 470 475 480
ggc tac cgg atg ccc tgc ccg ccg gag tgt ccc gag tcc ctg cac gac 1488
Gly Tyr Arg Met Pro Cys Pro Pro Glu Cys Pro Glu Ser Leu His Asp
485 490 495
ctc atg tgc cag tgc tgg cgg aag gag cct gag gag cgg ccc acc ttc 1536
Leu Met Cys Gln Cys Trp Arg Lys Glu Pro Glu Glu Arg Pro Thr Phe
500 505 510
gag tac ctg cag gcc ttc ctg gag gac tac ttc acg tcc acc gag ccc 1584
Glu Tyr Leu Gln Ala Phe Leu Glu Asp Tyr Phe Thr Ser Thr Glu Pro
515 520 525
cag tac cag ccc ggg gag aac ctc tag 1611
Gln Tyr Gln Pro Gly Glu Asn Leu
530 535
2
536
PRT
Homo sapiens
MISC_FEATURE
(1)..(536)
amino acid sequence of non-receptor tyrosine
kinase encoded by the normal c-Src coding region
2
Met Gly Ser Asn Lys Ser Lys Pro Lys Asp Ala Ser Gln Arg Arg Arg
1 5 10 15
Ser Leu Glu Pro Ala Glu Asn Val His Gly Ala Gly Gly Gly Ala Phe
20 25 30
Pro Ala Ser Gln Thr Pro Ser Lys Pro Ala Ser Ala Asp Gly His Arg
35 40 45
Gly Pro Ser Ala Ala Phe Ala Pro Ala Ala Ala Glu Pro Lys Leu Phe
50 55 60
Gly Gly Phe Asn Ser Ser Asp Thr Val Thr Ser Pro Gln Arg Ala Gly
65 70 75 80
Pro Leu Ala Gly Gly Val Thr Thr Phe Val Ala Leu Tyr Asp Tyr Glu
85 90 95
Ser Arg Thr Glu Thr Asp Leu Ser Phe Lys Lys Gly Glu Arg Leu Gln
100 105 110
Ile Val Asn Asn Thr Glu Gly Asp Trp Trp Leu Ala His Ser Leu Ser
115 120 125
Thr Gly Gln Thr Gly Tyr Ile Pro Ser Asn Tyr Val Ala Pro Ser Asp
130 135 140
Ser Ile Gln Ala Glu Glu Trp Tyr Phe Gly Lys Ile Thr Arg Arg Glu
145 150 155 160
Ser Glu Arg Leu Leu Leu Asn Ala Glu Asn Pro Arg Gly Thr Phe Leu
165 170 175
Val Arg Glu Ser Glu Thr Thr Lys Gly Ala Tyr Cys Leu Ser Val Ser
180 185 190
Asp Phe Asp Asn Ala Lys Gly Leu Asn Val Lys His Tyr Lys Ile Arg
195 200 205
Lys Leu Asp Ser Gly Gly Phe Tyr Ile Thr Ser Arg Thr Gln Phe Asn
210 215 220
Ser Leu Gln Gln Leu Val Ala Tyr Tyr Ser Lys His Ala Asp Gly Leu
225 230 235 240
Cys His Arg Leu Thr Thr Val Cys Pro Thr Ser Lys Pro Gln Thr Gln
245 250 255
Gly Leu Ala Lys Asp Ala Trp Glu Ile Pro Arg Glu Ser Leu Arg Leu
260 265 270
Glu Val Lys Leu Gly Gln Gly Cys Phe Gly Glu Val Trp Met Gly Thr
275 280 285
Trp Asn Gly Thr Thr Arg Val Ala Ile Lys Thr Leu Lys Pro Gly Thr
290 295 300
Met Ser Pro Glu Ala Phe Leu Gln Glu Ala Gln Val Met Lys Lys Leu
305 310 315 320
Arg His Glu Lys Leu Val Gln Leu Tyr Ala Val Val Ser Glu Glu Pro
325 330 335
Ile Tyr Ile Val Thr Glu Tyr Met Ser Lys Gly Ser Leu Leu Asp Phe
340 345 350
Leu Lys Gly Glu Thr Gly Lys Tyr Leu Arg Leu Pro Gln Leu Val Asp
355 360 365
Met Ala Ala Gln Ile Ala Ser Gly Met Ala Tyr Val Glu Arg Met Asn
370 375 380
Tyr Val His Arg Asp Leu Arg Ala Ala Asn Ile Leu Val Gly Glu Asn
385 390 395 400
Leu Val Cys Lys Val Ala Asp Phe Gly Leu Ala Arg Leu Ile Glu Asp
405 410 415
Asn Glu Tyr Thr Ala Arg Gln Gly Ala Lys Phe Pro Ile Lys Trp Thr
420 425 430
Ala Pro Glu Ala Ala Leu Tyr Gly Arg Phe Thr Ile Lys Ser Asp Val
435 440 445
Trp Ser Phe Gly Ile Leu Leu Thr Glu Leu Thr Thr Lys Gly Arg Val
450 455 460
Pro Tyr Pro Gly Met Val Asn Arg Glu Val Leu Asp Gln Val Glu Arg
465 470 475 480
Gly Tyr Arg Met Pro Cys Pro Pro Glu Cys Pro Glu Ser Leu His Asp
485 490 495
Leu Met Cys Gln Cys Trp Arg Lys Glu Pro Glu Glu Arg Pro Thr Phe
500 505 510
Glu Tyr Leu Gln Ala Phe Leu Glu Asp Tyr Phe Thr Ser Thr Glu Pro
515 520 525
Gln Tyr Gln Pro Gly Glu Asn Leu
530 535
3
1611
DNA
Homo sapiens
misc_feature
(1)..(1593)
nucleotide sequence of mutant c-Src oncogene
coding region
3
atg ggt agc aac aag agc aag ccc aag gat gcc agc cag cgg cgc cgc 48
Met Gly Ser Asn Lys Ser Lys Pro Lys Asp Ala Ser Gln Arg Arg Arg
1 5 10 15
agc ctg gag ccc gcc gag aac gtg cac ggc gct ggc ggg ggc gct ttc 96
Ser Leu Glu Pro Ala Glu Asn Val His Gly Ala Gly Gly Gly Ala Phe
20 25 30
ccc gcc tcg cag acc ccc agc aag cca gcc tcg gcc gac ggc cac cgc 144
Pro Ala Ser Gln Thr Pro Ser Lys Pro Ala Ser Ala Asp Gly His Arg
35 40 45
ggc ccc agc gcg gcc ttc gcc ccc gcg gcc gcc gag ccc aag ctg ttc 192
Gly Pro Ser Ala Ala Phe Ala Pro Ala Ala Ala Glu Pro Lys Leu Phe
50 55 60
gga ggc ttc aac tcc tcg gac acc gtc acc tcc ccg cag agg gcg ggc 240
Gly Gly Phe Asn Ser Ser Asp Thr Val Thr Ser Pro Gln Arg Ala Gly
65 70 75 80
ccg ctg gcc ggt gga gtg acc acc ttt gtg gcc ctc tat gac tat gag 288
Pro Leu Ala Gly Gly Val Thr Thr Phe Val Ala Leu Tyr Asp Tyr Glu
85 90 95
tct agg acg gag aca gac ctg tcc ttc aag aaa ggc gag cgg ctc cag 336
Ser Arg Thr Glu Thr Asp Leu Ser Phe Lys Lys Gly Glu Arg Leu Gln
100 105 110
att gtc aac aac acg gag gga gac tgg tgg ctg gcc cac tcg ctc agc 384
Ile Val Asn Asn Thr Glu Gly Asp Trp Trp Leu Ala His Ser Leu Ser
115 120 125
aca gga cag aca ggc tac atc ccc agc aac tac gtg gcg ccc tcc gac 432
Thr Gly Gln Thr Gly Tyr Ile Pro Ser Asn Tyr Val Ala Pro Ser Asp
130 135 140
tcc atc cag gct gag gag tgg tat ttt ggc aag atc acc aga cgg gag 480
Ser Ile Gln Ala Glu Glu Trp Tyr Phe Gly Lys Ile Thr Arg Arg Glu
145 150 155 160
tca gag cgg tta ctg ctc aat gca gag aac ccg aga ggg acc ttc ctc 528
Ser Glu Arg Leu Leu Leu Asn Ala Glu Asn Pro Arg Gly Thr Phe Leu
165 170 175
gtg cga gaa agt gag acc acg aaa ggt gcc tac tgc ctc tca gtg tct 576
Val Arg Glu Ser Glu Thr Thr Lys Gly Ala Tyr Cys Leu Ser Val Ser
180 185 190
gac ttc gac aac gcc aag ggc ctc aac gtg aag cac tac aag atc cgc 624
Asp Phe Asp Asn Ala Lys Gly Leu Asn Val Lys His Tyr Lys Ile Arg
195 200 205
aag ctg gac agc ggc ggc ttc tac atc acc tcc cgc acc cag ttc aac 672
Lys Leu Asp Ser Gly Gly Phe Tyr Ile Thr Ser Arg Thr Gln Phe Asn
210 215 220
agc ctg cag cag ctg gtg gcc tac tac tcc aaa cac gcc gat ggc ctg 720
Ser Leu Gln Gln Leu Val Ala Tyr Tyr Ser Lys His Ala Asp Gly Leu
225 230 235 240
tgc cac cgc ctc acc acc gtg tgc ccc acg tcc aag ccg cag act cag 768
Cys His Arg Leu Thr Thr Val Cys Pro Thr Ser Lys Pro Gln Thr Gln
245 250 255
ggc ctg gcc aag gat gcc tgg gag atc cct cgg gag tcg ctg cgg ctg 816
Gly Leu Ala Lys Asp Ala Trp Glu Ile Pro Arg Glu Ser Leu Arg Leu
260 265 270
gag gtc aag ctg ggc cag ggc tgc ttt ggc gag gtg tgg atg ggg acc 864
Glu Val Lys Leu Gly Gln Gly Cys Phe Gly Glu Val Trp Met Gly Thr
275 280 285
tgg aac ggt acc acc agg gtg gcc atc aaa acc ctg aag cct ggc acg 912
Trp Asn Gly Thr Thr Arg Val Ala Ile Lys Thr Leu Lys Pro Gly Thr
290 295 300
atg tct cca gag gcc ttc ctg cag gag gcc cag gtc atg aag aag ctg 960
Met Ser Pro Glu Ala Phe Leu Gln Glu Ala Gln Val Met Lys Lys Leu
305 310 315 320
agg cat gag aag ctg gtg cag ttg tat gct gtg gtt tca gag gag ccc 1008
Arg His Glu Lys Leu Val Gln Leu Tyr Ala Val Val Ser Glu Glu Pro
325 330 335
att tac atc gtc acg gag tac atg agc aag ggg agt ttg ctg gac ttt 1056
Ile Tyr Ile Val Thr Glu Tyr Met Ser Lys Gly Ser Leu Leu Asp Phe
340 345 350
ctc aag ggg gag aca ggc aag tac ctg cgg ctg cct cag ctg gtg gac 1104
Leu Lys Gly Glu Thr Gly Lys Tyr Leu Arg Leu Pro Gln Leu Val Asp
355 360 365
atg gct gct cag atc gcc tca ggc atg gcg tac gtg gag cgg atg aac 1152
Met Ala Ala Gln Ile Ala Ser Gly Met Ala Tyr Val Glu Arg Met Asn
370 375 380
tac gtc cac cgg gac ctt cgt gca gcc aac atc ctg gtg gga gag aac 1200
Tyr Val His Arg Asp Leu Arg Ala Ala Asn Ile Leu Val Gly Glu Asn
385 390 395 400
ctg gtg tgc aaa gtg gcc gac ttt ggg ctg gct cgg ctc att gaa gac 1248
Leu Val Cys Lys Val Ala Asp Phe Gly Leu Ala Arg Leu Ile Glu Asp
405 410 415
aat gag tac acg gcg cgg caa ggt gcc aaa ttc ccc atc aag tgg acg 1296
Asn Glu Tyr Thr Ala Arg Gln Gly Ala Lys Phe Pro Ile Lys Trp Thr
420 425 430
gct cca gaa gct gcc ctc tat ggc cgc ttc acc atc aag tcg gac gtg 1344
Ala Pro Glu Ala Ala Leu Tyr Gly Arg Phe Thr Ile Lys Ser Asp Val
435 440 445
tgg tcc ttc ggg atc ctg ctg act gag ctc acc aca aag gga cgg gtg 1392
Trp Ser Phe Gly Ile Leu Leu Thr Glu Leu Thr Thr Lys Gly Arg Val
450 455 460
ccc tac cct ggg atg gtg aac cgc gag gtg ctg gac cag gtg gag cgg 1440
Pro Tyr Pro Gly Met Val Asn Arg Glu Val Leu Asp Gln Val Glu Arg
465 470 475 480
ggc tac cgg atg ccc tgc ccg ccg gag tgt ccc gag tcc ctg cac gac 1488
Gly Tyr Arg Met Pro Cys Pro Pro Glu Cys Pro Glu Ser Leu His Asp
485 490 495
ctc atg tgc cag tgc tgg cgg aag gag cct gag gag cgg ccc acc ttc 1536
Leu Met Cys Gln Cys Trp Arg Lys Glu Pro Glu Glu Arg Pro Thr Phe
500 505 510
gag tac ctg cag gcc ttc ctg gag gac tac ttc acg tcc acc gag ccc 1584
Glu Tyr Leu Gln Ala Phe Leu Glu Asp Tyr Phe Thr Ser Thr Glu Pro
515 520 525
cag tac tag cccggggaga acctctag 1611
Gln Tyr
530
4
530
PRT
Homo sapiens
MISC_FEATURE
(1)..(530)
amino acid sequence of the mutant c-Src
polypeptide encoded by the mutant c-Src coding region
4
Met Gly Ser Asn Lys Ser Lys Pro Lys Asp Ala Ser Gln Arg Arg Arg
1 5 10 15
Ser Leu Glu Pro Ala Glu Asn Val His Gly Ala Gly Gly Gly Ala Phe
20 25 30
Pro Ala Ser Gln Thr Pro Ser Lys Pro Ala Ser Ala Asp Gly His Arg
35 40 45
Gly Pro Ser Ala Ala Phe Ala Pro Ala Ala Ala Glu Pro Lys Leu Phe
50 55 60
Gly Gly Phe Asn Ser Ser Asp Thr Val Thr Ser Pro Gln Arg Ala Gly
65 70 75 80
Pro Leu Ala Gly Gly Val Thr Thr Phe Val Ala Leu Tyr Asp Tyr Glu
85 90 95
Ser Arg Thr Glu Thr Asp Leu Ser Phe Lys Lys Gly Glu Arg Leu Gln
100 105 110
Ile Val Asn Asn Thr Glu Gly Asp Trp Trp Leu Ala His Ser Leu Ser
115 120 125
Thr Gly Gln Thr Gly Tyr Ile Pro Ser Asn Tyr Val Ala Pro Ser Asp
130 135 140
Ser Ile Gln Ala Glu Glu Trp Tyr Phe Gly Lys Ile Thr Arg Arg Glu
145 150 155 160
Ser Glu Arg Leu Leu Leu Asn Ala Glu Asn Pro Arg Gly Thr Phe Leu
165 170 175
Val Arg Glu Ser Glu Thr Thr Lys Gly Ala Tyr Cys Leu Ser Val Ser
180 185 190
Asp Phe Asp Asn Ala Lys Gly Leu Asn Val Lys His Tyr Lys Ile Arg
195 200 205
Lys Leu Asp Ser Gly Gly Phe Tyr Ile Thr Ser Arg Thr Gln Phe Asn
210 215 220
Ser Leu Gln Gln Leu Val Ala Tyr Tyr Ser Lys His Ala Asp Gly Leu
225 230 235 240
Cys His Arg Leu Thr Thr Val Cys Pro Thr Ser Lys Pro Gln Thr Gln
245 250 255
Gly Leu Ala Lys Asp Ala Trp Glu Ile Pro Arg Glu Ser Leu Arg Leu
260 265 270
Glu Val Lys Leu Gly Gln Gly Cys Phe Gly Glu Val Trp Met Gly Thr
275 280 285
Trp Asn Gly Thr Thr Arg Val Ala Ile Lys Thr Leu Lys Pro Gly Thr
290 295 300
Met Ser Pro Glu Ala Phe Leu Gln Glu Ala Gln Val Met Lys Lys Leu
305 310 315 320
Arg His Glu Lys Leu Val Gln Leu Tyr Ala Val Val Ser Glu Glu Pro
325 330 335
Ile Tyr Ile Val Thr Glu Tyr Met Ser Lys Gly Ser Leu Leu Asp Phe
340 345 350
Leu Lys Gly Glu Thr Gly Lys Tyr Leu Arg Leu Pro Gln Leu Val Asp
355 360 365
Met Ala Ala Gln Ile Ala Ser Gly Met Ala Tyr Val Glu Arg Met Asn
370 375 380
Tyr Val His Arg Asp Leu Arg Ala Ala Asn Ile Leu Val Gly Glu Asn
385 390 395 400
Leu Val Cys Lys Val Ala Asp Phe Gly Leu Ala Arg Leu Ile Glu Asp
405 410 415
Asn Glu Tyr Thr Ala Arg Gln Gly Ala Lys Phe Pro Ile Lys Trp Thr
420 425 430
Ala Pro Glu Ala Ala Leu Tyr Gly Arg Phe Thr Ile Lys Ser Asp Val
435 440 445
Trp Ser Phe Gly Ile Leu Leu Thr Glu Leu Thr Thr Lys Gly Arg Val
450 455 460
Pro Tyr Pro Gly Met Val Asn Arg Glu Val Leu Asp Gln Val Glu Arg
465 470 475 480
Gly Tyr Arg Met Pro Cys Pro Pro Glu Cys Pro Glu Ser Leu His Asp
485 490 495
Leu Met Cys Gln Cys Trp Arg Lys Glu Pro Glu Glu Arg Pro Thr Phe
500 505 510
Glu Tyr Leu Gln Ala Phe Leu Glu Asp Tyr Phe Thr Ser Thr Glu Pro
515 520 525
Gln Tyr
530
5
20
DNA
Artificial Sequence
3′ mutant allele specific primer
5
tagaggttct ccccnggcta 20
6
20
DNA
Artificial Sequence
3′ wild-type allele specific primer
6
tagaggttct ccccgggctg 20
7
164
DNA
Artificial Sequence
Antisense sequence complementary to 5′ region
of c-Src gene
7
gccccgcagg tgcctactgc ctctcagtgt ctgacttcga caacgccaag ggcctcaacg 60
tgaagcacta caagatccgc aagctggaca gcggcggctt ctacatcacc tcccgcaccc 120
agttcaacag cctgcagcag ctggtggcct actactccag tgag 164 | The present invention provides a mutant oligonucleotide composition encoding a cellular c-Src tyrosine kinase oncogene. Methods for isolating, expressing and characterizing recombinant Src mutant polypeptide are also provided. The invention further relates to methods for utilizing such oligonucleotides, polypeptides, agonists and antagonists for applications, which relate to research, diagnostics, and clinical arts. More specifically, this invention provides methods of diagnosing, treating, immunizing, and creating transgenic animals based on use of such mutant Src. | 8 |
FIELD OF THE INVENTION
The present invention relates to a method for developing electrostatic latent images, and more particularly to a developing method in which a thin developer layer consisting of a two-component developer comprised of a toner and a carrier is formed on a developer transport carrier by using a layer thickness regulating member, this developer layer is transported on its surface keeping out of contact with the latent image carrier, to the developing region, and an electrostatic latent image formed on the latent image carrier is then developed by the developer, under application of an oscillating electric field.
BACKGROUND OF THE INVENTION
At present, for the formation of visible images from certain image information, those methods for image forming through electrostatic latent images as in the electrophotographic process, electrostatic recording process, electrostatic printing process, and the like, are commonly used.
As the developer for use in making electrostatic latent image development there are known two types, i.e., a two component type developer comprised of a mixture of a toner and a carrier, and a one component type developer comprised of a magnetic material containing magnetic toner to be used alone without being mixed with any carrier. In an electrostatic latent image developing method which uses the former two component type developer, the toner of the developer is frictionally chargeable by mechanically stirring the mixture of it with toner carrier, so that by making an appropriate selection of the properties of the carrier and stirring condition, the polarity of the toner by charging and the amount of charge can be controlled to a considerable degree, and the developer is excellent in the developability as well as in the fluidity, and, moreover, colors, when provided to the toner are widely selectable. In this respect, the electrostatic latent image developing method using a two component type developer is considered more advantageous than that of the latter using a one-component-type developer.
Conventionally known electrostatic image developing methods which use the two-component developer are classified into two types: (1) A contact-type developing method, in which development takes place with a developer layer in direct contact with the surface of the latent image carrier, and (2) a non contact type developing method, in which a developer layer is transported, whith its surface keeping out of contact with the latent image carrier, into a developing space, and an oscillating electric field is applied to the developer layer to perform development.
According to the latter non contact type developing method, the developer layer does not come into direct contact with the latent image carrier, so that it is advantageous particularly in the multicolor image formation. That is, after forming a first color toner image on the latent image carrier, with this toner image remaining intact without being transferred, charging/exposure and developing processes for a second color are carried out, whereby the second color toner image can be superposedly formed on the first color toner image. Accordingly, it is possible to form a multicolor image easily with no need of any complex construction such as a transfer drum.
As has been mentioned above, the developing method using a two-component developer in non-contact manner in an oscillating electric field has the advantage that the developer used is satisfactory in the fluidity as well as in the frictional chargeability and excellent in the developability, and besides the selectable range of colors applicable to the toner is so wide as suitable for color copying.
In the non contact type developing method, the developing is made by flying the toner of the developer layer toward the latent image carrier, so that an oscillating electric field strong enought to fly the toner is required in the developing gap d between the latent image carrier and the developing sleeve.
The strength E of such the oscillating electric field is normally from 500 to 10,000 V/mm: the oscillating electric field, if less than 500 V/mm, is too weak to fly toner, while if more than 10,000 V/mm, is to cause a dielectric breakdown. The oscillating electric field is formed by applying an AC voltage V to the gap d between the latent image carrier and the developing sleeve, and their relationship is expressed by the formula: E=V/d(mm). If the AC voltage V in the formula comes to excess, a leak discharge is prone to occur between the developing sleeve surface and peripheral devices, inviting danger, resulting in the damage of devices or fall of bias voltage. For this reason, the foregoing AC voltage V is conventionally less than 10 KV(p--p), the developing gap d in the above formula therefore is not more than 1 mm, and the thickness of the developer layer to be transported into the developing gap d is not more than 1 mm, and more preferably not more than 0.5 mm.
There have been a number of proposals for means to obtain such a thin developer layer. For example, Japanese Utility Model Publication Open to Public Inspection (hereinafter referred to as Japanese Utility Model O.P.I. Publication) Nos. 96455/1981, 104754/1981 and 112352/1982 and Japanese Patent Publication Open to Public Inspection (hereinafter referred to as Japanese Patent O.P.I. Publication) No. 143650/1979 disclose a thin layer forming member having a doctor blade provided close by the sleeve surface for regulating the developer layer, in which improvement is made on the doctor blade's form and arrangement in angle to the developing sleeve, material, and the like. Also, Japanese Utility Model O.P.I. Publication No. 57866/1983 and Japanese Patent 0.P.I. Publication No. 114561/1984 propose a thin layer forming member having a magnetic blade. Japanese Utility Model O.P.I. Publication No. 86654/1983 discloses one having a sponge press on the developing sleeve to regulate the thickness of the developer layer. And Japanese Patent O.P.I. Publication No. 126567/1984 describes the use of an elastic roll to press on the sleeve surface to regulate the thickness of the developer layer.
As has been explained, various types of thin layer forming member have been proposed to date, but the layer's thickness control is not easy, tending to cause uneven thickness, which has made it difficult to steadily obtain a uniform thickness-having thin developer layer. This problem is significant particularly in the case of using a two-component developer comprising a carrier and a toner, both being different in the particle size, configuration, fluidity and other physical properties.
We had earlier proposed in our Patent Application No. 192710/1987 (Japanese Patent O.P.I. Publication No. 52566/1987) a thin layer forming member having an elastic plate to press on the developing sleeve surface to form a thin two-component developer layer. This thin layer forming member, unlike those conventional ones utilizing a fixed narrow gap, allows a wide-range elastic regulation of the layer thickness, thus enabling not only to make a reasonable layer thickness regulating operation but also to obtain uniformly, stably an even thinner developer layer. This is advantageous especially in the case where a two-component developer is used; if the above-mentioned elastic plate is arranged so as to press against the sleeve surface with a pressure allowing the passage of about 1 to 3 carrier particles, then a so thin layer in the thickness range around the carrier particle size can be easily obtained. Furthermore this is advantageous in respect that it obstructs the passage of aggregates or foreign matter contained in the developer and allows the passage of the developer layer alone.
The (a) and (b) of FIG. 1 are drawings for explaining the particular construction of a thin layer forming member which uses an elastic plate, wherein 1 is a developing sleeve which rotates in the direction of arrow, 2 is a magnetic roll having a plurality of alternate N and S polarities, 3 is a thin layer forming member consisting of an elastic plate, and 4 is a support for supporting the elastic plate 3. When the planar elastic plate 3, with its tip end facing upstream the rotating direction of the developing sleeve, presses on the surface of developing sleeve 1, a wedge-shaped space 5 is formed between the tip end and the pressed contact point. When, under this condition, developing sleeve 1 is moved in a given direction, developer D that is retained on developing sleeve 1 due to the magnetic field of magnetic roll 2 is separated into two parts: one getting into wedge-shaped space 5 and the other having failed to get into wedge-shaped space 5 and sent away toward the reverse side of elastic plate 3 opposite to developing sleeve 1, and of these parts only the developer D that has entered the wedge-shaped space passes, due to the frictional force with developing sleeve 1, through the gap between developing sleeve 1 and elastic plate 3, and then is transported to the developing region. In this instance, the amount of the developer that is allowed to pass between developing sleeve 1 and elastic plate 3 corresponds to the gap ε, but is determined according to the height h of the opening of wedge-shaped space 5, free length 1, pressing force σ, and the like, and usually, the height h of the opening is from 0.08 to 0.3 mm, free length l is from 1 to 3 mm, and pressing force σ is from 1 to 6 g/mm.
Thus, the gap ε between developing sleeve 1 and elastic plate 3 allows the passage of an amount of one to several particles of carrier, resulting in the formation of a thin developer layer with a thickness of not more than 500 μm, and preferably 10 to 300 μm. By using the thin layer forming member having an elastic plate of the above construction, a thin two-component developer layer having a uniform thickness can be stably obtained. Therefore, this has the advantage that non-contact development with its carrier restrained from flying can be carried out and an image excellent in the resolution can be obtained. As a result of making the developer layer a thin layer as above-mentioned, the developing gap d is allowed to be small, thus making so much the smaller the oscillating electric field and AC voltage for forming the oscillating electric field, so that the development can be carried out with no dielectric breakdown, leak discharge, etc.
Incidentally, when non-contact development is made in the oscillating electric field, if the mass of the toner on the sleeve is regarded as M and the quantity of charge as Q, there is a tendency that the smaller the Q/M, the more easily does the development take place.
Since there is a nearly inversely proportional relation between the above Q/M and the particle size of the toner, relatively large particle sizes-having toner is much more consumed and smaller particle sizes-having toner remains: thus bringing about a phenomenon called `selective development`. Accordingly, when the non-contact development is repeatedly continued, smaller particle size toner is accumulated in the developer inside the developing device to cause the carrier surfce to have lots of small particle-size toner attached thereto, bringing about such troubles as 1) fatigue/deterioration of the carrier, 2) inadequate frictional charging of the toner, 3) lowering of image density, and 4) scattering of the toner. The reason why such troubles occur is considered due to the fact that the increase in the amount of the small particle-size toner increases the surface area of the toner, causing the toner's frictional charging amount to increase to make the toner strongly attach to the carrier surface to form a coat on the carrier, deteriorating the carrier to make the subsequent frictional charging of the toner inadequate, thus lowering the image density, scattering the toner, and so forth.
On the other hand, Japanese Patent O.P.I. Publication No. 140361/1985 has already proposed a developing method which uses a two-component developer whose toner has an weight average particle size of from 5 to 20 μm, and has such a particle size distribution that the more than double the weight average particle size part and the less than 1/3 of the weight average particle size part of the toner account for not more than 10% by weight of the whole toner.
According to this developing method, since the particle size distribution of the toner in the developer is limited to the above-mentioned range, the unevenness of the action of the oscillating electric field to the toner is lessened, so that the foregoing selective development phenomenon is improved.
Incidentally, according to our investigation, the selective development phenomenon is connected also with the thickness of the developer layer; the thinner the developer layer, the more significantly does the phenomenon tend to occur. That is, if the layer is thick, this phenomenon does not occur, which is considered due to the fact that the toner particles' mutual restraining action restrains the selective development.
As has been mentioned, in the case of forming a thin two-component developer layer, when the foregoing elastic plate is arranged to press on the sleeve surface, a developer layer as thin as not more than 500 μm, and preferably not more than 300 μm can be formed, and so much the higher resolution image can be obtained, but on the other hand, it has been found that the selective development occuring condition becomes so severe that it makes inadequate the developer as described in the foregoing Japanese Patent O.P.I. Publication No. 140361/1985 for its developing method.
SUMMARY OF THE INVENTION
The present invention has been made in view of the above-described circumstances. It is an object of the present invention to provide a method for developing electrostatic latent images in non-contact manner by use of a thin developer layer in an oscillating electric field, said method being capable of repeatedly making satisfactory development many times without bringing about any bias voltage fall due to dielectric breakdown, deterioration in image quality, selective development phenomenon, and the like.
The above object can be accomplished by a developing method in which during the course of transporting to the developing region a two-component developer comprised of toner particles powder and carrier beads powder by a developer transport carrier, the amount of the developer transported is regulated by a thin layer forming member consisting of a planar material arranged so as to elastically press on the said developer transport carrier to thereby form a thin developer layer, and the developer layer is transported, with its surface keeping out of contact with the latent image carrier, to the developing region, and an electrostatic latent image formed on the latent image carrier is then developed by the developer layer, being placed in an oscillating electric field,
in which method when the weight average toner particle size of said powdery toner particles is regarded as D 50 , the toner particles having particle sizes in the range of from 1/1.7 to 1.7 times the weight average particle size D 50 account for not less than 95% by weight of the whole toner particles powder.
In other words, the present invention relates to a method for developing an electrostatic latent image comprising,
a step of supplying a developer containing a carrier and a toner, said toner consisting of fine toner particles of which not less than 95% by weight have a particle size of from 1/1.7 to 1.7 times as large as the weight average size of the toner particles (D 50 ), to the outer circumfence of of a cylinder-shaped sleeve member of a developer transporting means which comprises said sleeve member and a plurality of magnets provided inside said sleeve member so that said magnets and said sleeve member are so arranged as to be rotatable in relation to each other around the center axis of said sleeve member,
a step of forming a thin layer of said developer on the surface of said sleeve member by the use of a layer thickness regulating member so that the maximum thickness of the developer layer is smaller than the minimum distance between the surface of said sleeve member and the surface of said electrostatic latent image carrying member, the layer thickness regulating member being disposed opposite to said developer transforming member, comprising a resilient plate and and being provided so that at least a part of said resilient plate is in pressure contact with said sleeve member,
a step of carrying said developer to close proximity of the image carrying member, and
a step of forming a toner image on said electrostatic latent image carrying member.
According to the preferred embodiment of the present invention, the weight average particle size D 50 is from 8 to 16 μm.
According to this invention, development is made by a very uniform and very thin two-component developer layer formed by using a thin layer forming member consisting of a planar material arranged so as to elastically press on the developer transport carrier, and in the toner particles powder constituting the two-component developer of the said developer layer, the toner particles' weight average particle size D 50 is specified to fall under a range as narrow as 8 to 16 μm, and the toner particles in the size range of 1/1.7 to 1.7 times the foregoing weight average particle size D 50 account for not less than 95% by weight of the whole toner particles powder, so that changes in the image quality due to dielectric breakdown and occurrence of the selective development phenomenon can be restrained, and satisfactory development can be repeatedly made a number of times.
Namely, a very narrow particle size distribution-having toner particles powder is used, so that the toner particles undergo uniformly the action of an oscillating electric field regardless of the particle size. Accordingly, there occurs no substantial difference in the adherence of the toner to an electrostatic image according to the particle size, and as a result, even when repeating the developing process many times, the particle size distribution of the toner particles inside the developing device is stably retained as in the initial condition.
Therefore, the amount of the toner's frictional charge can be steadily obtained enabling to stably form sufficient density-having images, and moreover, the surface stain of the carrier particles due to small-particle-size toner powder becomes reduced, the durability of the carrier particle is largely improved, and further, scattering of the toner particles is prevented, so that the developing process can be carried out without stain.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows sectional drawings for explaining a thin layer forming member.
FIG. 2 is a sectional view of a developing device for use in the developing method in an example of this invention.
In these drawings, 1 is a developing sleeve, 2 is a magnetic roll, 3 is a thin layer forming member or a layer thickness regulating member (elastic plate), 6 is a latent image carrier, 7 and 8 are stirring members, 11 is a toner T replenishing means, 12 is a toner replenishing roll, 13 is a developer (D) depository, 14 is a bias power supply, and 15 is a developing region.
DETAILED DESCRIPTION OF THE INVENTION
The toner particles powder constituting the two-component developer to be used in this invention is one which, if the weight average particle size of the toner particles of the said toner particles powder is regarded as D 50 , the toner particles having particle sizes in the range of from 1/1.7 to 1.7 times the weight average particle size D 50 account for not less than 95% by weight of the whole toner particles powder. The weight average particle size D 50 in the toner particles powder is a value measured by an instrument called `Coultercounter` (manufactured by Coulter Co.).
If a toner particles powder does not satisfy the above requirement, its particle size distribution is so wide that the selective development phenomenon occurs. Consequently, as the developing process is repeated, smaller-size toner particles become accumulated inside the developing device, thus increasing the amount of the toner's frictional charge to excess, whereby the image density is lowered, the carrier beads' surface is covered with small-particle-size toner particles, the toner's frictional chargeability is obstructed, and weakly charged or uncharged toner particles are scattered to bring about stain.
The weight average particle size D 50 of the toner particles in the toner particles powder is preferably from 8 to 16 μm. By using such the particle size-having toner particles powder, a high-quality image having a high resolution and excellent in the gradation reproducibility can be formed and the image formation can be carried out with no fogging trouble due to toner scattering.
The method for obtaining a specific particle size distribution-having toner particles powder as mentioned above, although not particularly restricted, is such that, for example, a crude powder obtained by kneading and finely pulverizing a toner material is classified an appropriate number of times to remove those small-diameter-side particles and large-diameter-side particles from the whole powder, whereby objective toner particles can be easily obtained.
A binder resin to be used for the toner is not particularly limited; any conventionally known resin may be used. Examples of the resin include polyester resins, styrene resins, acryl resins, styrene-acryl resins, and the like.
Coloring agents applicable to the toner include carbon black, nigrosine dyes, aniline blue, calco oil blue, chrome yellow, ultramarine blue, DuPont oil red, quinonline yellow, methylene blue chloride, phthalocyanine blue, malachite green oxalate, Lumpblack, Rosebengal, mixtures of some of these materials, and others.
To the toner may, if necessary, be added various additives, such as charge control agents, fixability improving agents, fluidity improving agents, abrasives, and the like. The fluidity improving agent and the abrasive are normally used in the manner of being added from the outside to and mixed with toner particles.
The carrier constituting the two-component developer to be used in this invention are desirable to be comprised substantially of spherical carrier particles, wherein the term `substantially spherical` implies that the value of the Wadell's practical sphericity w is not less than 0.65. The practical sphericity w is defined by the following formula: ##EQU1##
The measurement of the projected area of a particle may be carried out by using, e.g., `PAMIC-8800`.
The use of such the substantially spherical carrier beads-containing carrier powder results in sufficient toner-carrier frictional charging due to its high fluidity, thereby largely reducing the ratio of the carrier to weakly charged toner particles, and thus the toner-carrier electrostatic attraction causes the toner to be steadily retained on the developer carrier to thereby enable to prevent the toner or carrier from scattering, thus leading to prevention of the apparatus from being stained and of fogging trouble. The carrier creates no directivity in magnetization, so that it allows the formation of a thin, uniform thickness-having developer layer on the developer transport carrier, and consequently, due to the action of an oscillating electric field, the toner's adherence to an electrostatic latent image improves. Also, since a bias voltage is uniformly applied to the carrier particles, the applied effect of the bias voltage is sufficiently displayed.
The weight average particle diameter of the carrier is desirable to be not more than 50 μm. The use of such the particle diameter-having carrier makes possible to improve the image resolution as well as the gradation reproducibility. The weight average particle diameter of carrier herein is a value measured by means of a `Microtrack` (manufactured by Nikkiso Co.).
The resistivity of the carrier is preferably not less than 10 13 Ω.cm. The use of such the highly insulating carrier enables to prevent the occurrence of such phenomena as adherence of the carrier to the latent image carrier's surface as a result of the charge injection by the bias voltage, or vanishment of the charge for forming an electrostatic latent image. The resistivity of the carrier can be found in the following manner: a powder sample is put in a container having a sectional area of, e.g., 0.50 cm 2 , and, after tapping the container, a load of 1 kg/cm 2 is applied onto the sample particles contained to make its thickness about 1 mm, and the sample's resistivity can be found by measuring the value of an electric current which flows when applying an electric field of 10 2 to 10 5 V/cm to between the load and the bottom electrode.
The form of the carrier is not particularly limited. To be concrete, any of non-coated-type carrier, coated-type carrier beads powder, magnetic material-dispersed-type carrier, and the like, may be used.
The magnetic material to constitute the carrier can be any material without limitation as long as it is one strongly magnetizable by a magnetic field in its direction. Examples of such the material include ferromagnetic metals such as iron, nickel, cobalt, etc.; alloys containing these metals; ferromagnetic metal compounds such as ferrite, magnetite, etc.; alloys which do not contain any ferromagnetic elements but come to display ferromagneticity when subjected to appropriate thermal treatment, and which include those alloys called `Heusler alloys` such as, e.g., manganese-copper-aluminum, manganese-copper-tin, etc., and chromium dioxide, and the like.
The term `ferrite` herein is a general term for all magnetic oxides containing iron but not restricted to only those spinel-type ferrites which are represented by the formula: MO.Fe 2 O 3 (bivalent metals). By varying the ferrite's metal component composition, various magnetic characteristics can be obtained; particularly, a highly insulating carrier capable of exhibiting sufficient bias voltage application effect can be easily obtained.
Resins applicable to the coated-type carrier or magnetic material-dispersed-type carrier, although not particularly restricted, include styrene-type resins, acryl-type resins, styrene-acryl-type resins, vinyl-type resins, rosin denatured resins, polyamide resins, polyester resins, and the like.
The mixing ratio of the toner and the carrier is desirable to be determined so that about 5 to 30% of the surface of the carrier can be covered with the toner. This mixing ratio range is suitable for displaying even better developability by the action of an oscillating electric field.
In this invention, a developer layer comprised of the above-mentioned two-component developer is formed on the developing sleeve, this developer layer is transported, with its layer surface not contacted with the latent image carrier, to the developing region, and this developer layer, while being placed in an oscillating electric field, develops an electrostatic latent image on the electrostatic latent image carrier.
The foregoing oscillating electric field is from 500 to 7000 V/mm; the AC voltage (peak-to-peak value) required to form the oscillating electric field is about 0.5 to 5 kV; the voltage not to cause any leak discharge, dielectric breakdown, etc., is preferably about 1 to 3 kV: and an AC bias voltage of a frequency of from about 1 to 5 kHz may be used. This oscillating electric field is desirable to be formed between the developing sleeve and the latent image carrier, and particularly desired to be formed in the minimum gap (hereinafter may also be called `developing gap`) between the developing sleeve and the latent image carrier. Besides the above AC bias voltage, if necessary, a DC bias voltage may also be applied to the developing gap.
As the developing sleeve for use in transporting the developer layer to the developing region, although not particularly restricted, those similar in the construction to conventional, bias voltage-applicable ones may be used. The developing sleeve has thereinside a magnetic roll which comprises a plurality of alternately arranged N and S magnetic poles and which is fixed or rotatable either in the same direction as that of the sleeve or in the inverse direction. To be more concrete, as the magnetic roll, one having from 8 to 32 magnetic poles may be used, and when this is revolved, a fluctuating magnetic field can be formed on the developing sleeve.
Since the developer layer on the developing sleeve needs to be transported, with its surface not contacted with the latent image carrier, to the developing region, it is essential for the thickness of the layer to be smaller than the developing gap. To be concrete, the developer layer is desirable to be of a layer as thin as not more than 500 μm, and preferably from 10 to 300 μm. The developing gap needs to be larger than the thickness of the developing layer, but is preferred to be as much small as possible; preferably not more than 1000 μm, more preferably in the range of from 100 to 500 μm.
Where the developer layer is a so thin layer, the developing gap can be made so sufficiently small as to lower the voltage necessary for the formation of an oscillating electric field required for flying the toner in the developing region. Even the thus relatively low voltage is enough to form an adequate oscillating electric field, so it is advantageous also in respect that the toner scattering can be lessened, and at the same time, the occurrence of leak discharge from the developing sleeve can be prevented. Further, where the developing gap is so small, the electrostatic latent image formed on the latent image carrier causes the intensity of the electric field to be formed in the developing region to increase, thus making possible to develop satisfactorily even delicate changes in the gradation or fine pattern.
In order to make the developer layer a thin layer and yet to transport a sufficient amount of the toner to the developing region, it is desirable that the number of revolutions of the developing sleeve and, if necessary, the magnetic roll, be increased. However, in order to perform a non-directional, satisfactory development, the linear speed of the developing sleeve is desirable to be within ten times the linear speed of the latent image carrier.
As a meas for the formation of a thin developer layer on the developing sleeve, the `thin layer forming member arranged so as to elastically press on the surface of a developing sleeve` as described in the foregoing Japanese Patent O.P.I. Publication No. 52566/1987 may be used. In addition, the thickness of the developer layer can be found by using a device `Nikon Profile Projector` (manufactured by Nippon Kogaku Kogyo K.K.) and in comparison between the image of the developing sleeve projected onto a screen and the image of the developing sleeve with a developer layer formed thereon projected onto the screen.
The present invention will be illustrated in detail by the following examples, but the invention is not limited thereto.
EXAMPLE 1
Preparation of Toners
(1) Toner 1 (for the invention)
One hundred parts by weight of a polyester resin `UXK 120P` (product of Kao Co.), 6 parts by weight of polypropylene `Viscol 660P` (product of Sanyo Chemical Industry Co.) and 10 parts by weight of carbon black `Mogal L`(product of Cabot Co.) were mixed and then kneaded, cooled, roughly pulverized, further finely pulverized, and then classified, whereby a toner particles powder having the particle size distribution given in Table 1 was obtained. This was regarded as Toner 1.
(2) Toners 2 through 16 (for the invention)
Toners were prepared in the same manner as in Toner 1 except that the classification condition was varied, whereby 15 toner particles powders having different particle size distributions as shown in Table 1 were obtained. These were regarded as Toner 2 through Toner 16, respectively.
(3) Toners 17 through 32 (comparative)
Sixteen different toner powders were obtained as given in Table 1 by preparing in the same manner as in Toner 1 except that the classification condition was further varied otherwise. These were regarded as Toner 17 through Toner 32, respectively.
Preparation of Toner Carriers
(1) Carrier 1
The surface of ferrite particles (particle distribution range=5 to 60 μm, weight average particle size=49 μm) was coated with a methyl methacrylate-styrene copolymer resin (monomers ratio 6/4), whereby a coated-type carrier was obtained. This was regarded as Carrier 1.
This Carrier 1 had a weight average bead diameter of 50 μm, a practical sphericity w of 0.9 and a resistivity of 10 13 Ω.cm.
Preparation of Developers
The above-prepared Toners 1 through 32 each was combined with Carrier 1 to thereby prepare 10% by weight toner concentration-having developers which were regarded as Developers 1 through 32 corresponding to Toners 1 through 32, respectively.
Practical Copying Tests
These developers and a developing device as shown in FIG. 2 were used and the developing process were carried out in accordance with the developing condition that is hereinafter described.
In the developing device of FIG. 2, the same symbols are applied to the same portions as those of FIG. 1, wherein 3 is the thin layer forming member as shown in FIG. 1, 6 is a latent image carrier that revolves in the direction of arrow, 7 is a first stirring member and 8 is a second stirring member. And 9 and 10 are the revolving axes of the above stirring members 7 and 8, respectively, and 11 is a toner replenishing container, 12 is a toner replenishing roll, 13 is a developer depository, 14 is a bias power supply, 15 is a developing region, and T represents toner.
The developing operation of the developing device having the above-mentioned construction in FIG. 2 is as follows:
The developer D inside developer depository 13 is sufficiently mixed and stirred by the first stirring member 7 revolving in the direction of arrow and the second stirring member 8 revolving in the reverse direction overlappingly with the first stirring member 7, and is made adhere to the surface of developing sleeve 1 and transported by the transporting force of developing sleeve 1 revolving in the direction of arrow and magnetic roll 2 revolving counter thereto. The surface of developing sleeve 1 is pressed on by a part near the tip end of the foregoing thin layer forming member 3 held by a fixing member 4 extending from the housing, which member regulates the thickness of developer D that is transported as mentioned above. This developer layer, at the developing region 14, develops, in non-contact manner at an interval of the gap, the latent image on latent image carrier 6 which revolves in the direction of arrow, thereby forming a toner image.
At the time of the development, from power supply 14 a developing bias voltage containing both DC component and AC component on almost the same level as that of the electric potential in the non-exposed portion of the latent image carrier is applied to developing sleeve 1, and as a result, only the toner in the developer on developing sleeve 1 is selectively transferred onto and adheres to the plane of the foregoing latent image. In this instance, the measurement of the thickness of the developer layer was performed by the aforementioned method using the Nikon Profile Projector, manufactured by Nippon Kogaku Kogyo K.K.
Developing Conditions (Reversal Development)
Latent image carrier 6
A 140 mm diameter-having drum-type photoreceptor having an organic photoconductive photosensitive layer: A linear speed of 60 mm/s, non-image area's surface potential of -700 V, and image area's surface potential of -50 V.
Developing sleeve 1
A 20 mm diameter-having cylindrical sleeve: Its circumferentially moving direction was made the same at the developing gap as that of latent image carrier 6. A linear speed of 250 mm/s.
Magnetic roll 2
Having 8 magnetic poles and a revolving speed of 1000 rpm. Its revolving direction is counter to that of the developing sleeve.
Thin layer forming member 3
A 0.3 mm-thick elastic plate made of phosphor bronze, arranged so as to elastically press on the surface of the developing sleeve.
Developing gap
400 μm
Thickness of developer layer
300 μm (maximum)
DC bias voltage
-500 to -600 V DC voltaghe was applied to developing sleeve 1.
Oscillating electric field
An AC voltage having a frequency of 3 kHz and voltage (peak-to-peak value) of 2.0 kVp-p was applied to developing sleeve 1, and latent image carrier 6 was leveled with ground potential.
Under the above conditions, the 32 developer samples from No. 1 through No. 32 were used in turn, and copying operation was continually repeated 10,000 times per each developer, and the presence of selective development phenomenon at each of the stages of obtaining the 1000th copy, 2500th copy, 5000th copy, 7500th copy and 10,000th copy was checked paying attention to the degree of image density decline and toner scattering. Also, the image quality of the 10,000th copy obtained when each developer for this invention was used was evaluated with respect to the gradation and resolution, and rated `A` for excellent, `B` for somewhat poor, and `C` for inferior. The results are as shown in Table 2.
TABLE 1__________________________________________________________________________Characteristics Ratio of Ratio of Ratio of less than more than D.sub.50 × 1/1.7 D.sub.50 × 1/1.7 D.sub.50 × 1.7 to D.sub.50 × 1.7 D.sub.50 D.sub.50 × 1/1.7 D.sub.50 × 1.7 particles particles particlesToner No. (μm) (μm) (μm) (% by wt) (% by wt) (% by wt)__________________________________________________________________________1 5.0 2.9 8.5 2.3 2.2 95.52 5.0 2.9 8.5 1.4 1.9 97.33 7.6 4.5 12.9 2.2 1.8 96.0This 4 7.6 4.5 12.9 1.0 0.8 98.2Inven- 5 8.3 4.9 14.1 2.0 1.9 96.1tion 6 8.3 4.9 14.1 1.2 1.1 97.77 10.5 6.2 17.9 2.5 2.4 95.18 10.5 6.2 17.9 1.0 1.0 98.09 13.0 7.6 22.1 2.0 2.1 95.910 13.0 7.6 22.1 1.1 1.1 97.811 15.8 9.3 26.9 2.2 2.3 95.512 15.8 9.3 26.9 0.8 0.9 98.313 16.2 9.5 27.5 2.2 2.4 95.414 16.2 9.5 27.5 0.8 1.1 98.115 20.0 11.8 34.0 2.3 2.6 95.116 20.0 11.8 34.0 1.2 1.1 97.217 5.2 3.1 8.8 2.8 2.5 94.718 5.2 3.1 8.8 4.0 4.5 91.519 7.8 4.6 13.3 2.8 2.6 94.6Compa- 20 7.8 4.6 13.3 5.0 4.8 90.2rative 21 8.1 4.8 13.8 3.2 2.8 94.0Exam- 22 8.1 4.8 13.8 3.7 3.8 92.5ple 23 10.3 6.1 17.5 2.5 2.4 94.124 10.3 6.1 17.5 4.3 4.3 91.425 12.9 7.6 21.9 2.8 2.9 94.326 12.9 7.6 21.9 4.8 4.9 90.327 15.6 9.2 26.5 3.0 3.1 93.928 15.6 9.2 26.5 5.0 5.2 89.829 16.3 9.6 27.7 3.0 3.2 93.830 16.3 9.6 27.7 4.2 4.5 91.331 21.0 12.4 35.7 2.8 3.0 94.432 21.0 12.4 35.7 4.3 4.7 91.0__________________________________________________________________________
TABLE 2__________________________________________________________________________Characteristics Final image Ratio of quality D.sub.50 × 1/1.7 (grada- to D.sub.50 × 1.7 tion,Toner D.sub.50 particles resolu-No. (μm) (% by wt) 1000th 2500th 5000th 7500th 10000th tion)__________________________________________________________________________1 5.0 95.5 DD B2 5.0 97.3 " B3 7.6 96.0 " B4 7.6 98.2 " BThis 5 8.3 96.1 with-Inven- out SD Ation 6 8.3 97.7 " A7 10.5 95.1 " A8 10.5 98.0 " A9 13.0 95.9 " A10 13.0 97.8 " A11 15.8 95.5 " A12 15.8 98.3 " A13 16.2 95.4 " B14 16.2 98.1 " B15 20.0 95.1 " C16 20.0 97.2 " C17 5.2 94.7 DD, TS -- -- --18 5.2 91.5 " -- -- --19 7.8 94.6 DD TS -- -- --Compa- 20 7.8 90.2 DD, TS -- -- --rative 21 8.1 94.0 DD, TS -- -- --Exam- 22 8.1 92.5 " -- -- --ple 23 10.3 94.1 " -- -- --24 10.3 91.4 " -- -- --25 12.9 94.3 " -- -- --26 12.9 90.3 " -- -- --27 15.6 93.9 " -- -- --28 15.6 89.8 " -- -- --29 16.3 93.8 DD TS -- -- --30 16.3 91.3 " " -- -- --31 21.0 94.4 " " -- -- --32 21.0 91.0 " " -- -- --__________________________________________________________________________ Note: DD . . . Density Decrease TS . . . Toner Scattering SD . . . Selective Development
As is apparent from Table 2, unlike the comparative samples, the samples for this invention bring about no selective development phenomenon which is to appear at the time of image density decline, toner scattering, etc., and thus the invention is suitable for repetitive image forming operation or a large number of copies making operation. Also, it is understood that in respect of image quality, the weight average particle size range of from 8 to 16 μm is particularly excellent. | A method for developing an electrostatic latent image comprising, a step of supplying a developer containing a carrier and a toner, said toner consisting of fine toner particles of which not less than 95% by weight have a particle size of from 1/1.7 to 1.7 times as large as the weight average size of the toner particles (D 50 ), to the outer circumfence of a cylinder-shaped sleeve member of a developer transporting means, a step of forming a thin layer of said developer on the surface of said sleeve member by the use of a layer thickness regulating member so that the maximum thickness of the developer layer is smaller than the minimum distance between the surface of said sleeve member and the surface of said electrostatic latent image carrying member, a step of carrying said developer to close proximity of the electrostatic latent image formed on said electrostatic larent image carrying member, and a step of forming a toner image on said electrostatic latent image carrying member is disclosed. | 6 |
FIELD
[0001] The present application relates to films that are prepared by the sol-gel method made with lanthanide doped nanoparticles. The films can comprise silica, zirconia or alumina. The nanoparticles can be tuned to produce visible, including white and near-infrared light. More specifically, the application relates to pumping near infrared light into sol-gel derived thin film made with Ln 3+ doped LaF 3 nanoparticles to produce bright white light.
BACKGROUND
[0002] The sol-gel process is one of the most widely used methods for the preparation of bulk materials and thin films used in integrated optics (IO) circuits. 1 The major advantages of the process are its simplicity and its ability to control the purity and homogeneity of the final material on a molecular level. The method offers the possibility of modifying the refractive index, phonon energy, and transparency of a material by choosing suitable matrices like SiO 2 , TiO 2 , ZrO 2 , Al 2 O 3 , GeO 2 , etc., 2-6 either individually or in combination. Such matrices are potential candidates for making planar waveguides, fiber amplifiers, and up-conversion devices, when doped with trivalent lanthanide (also known as rare earth) ions. 7-9 Preparation of these matrices involves the direct doping of the materials with Ln 3+ ions. The most commonly used lanthanide ion for these applications is Er 3+ , as it provides amplification in the 1550 nm communication window, through its 4 I 13/2 → 4 I 15/2 transition. Improvements are still needed to optimize performance.
[0003] It is desirable to have a high quantum yield and an increased line width for this transition, to enable those materials to be used for broad-band near-infrared amplification. The three main factors that decide the performance characteristics of such lanthanide ion containing materials are the phonon energy of the host in which the lanthanide ions are incorporated, the proximity of the OH groups present in the matrix to the lanthanide ions, and clustering of lanthanide ions. For example in Er 3+ incorporated materials, high phonon energy of the host matrix favors the non-radiative relaxation of the 4 I 13/2 excited state, thereby reducing its life time and quantum yield of the 4 I 13/2 → 4 I 15/2 transition. Because the OH groups, an inherent result of sol-gel process, quench the excited state of the lanthanide ions by dipole-dipole interaction, the proximity of the OH groups to the lanthanide ions, results in a much higher extent of quenching. Finally, clustering of the lanthanide ions reduce the excited state lifetime by concentration quenching. 10-11 Several reports are available regarding ways to improve the luminescence characteristics of such materials. These mainly include the works of Biswas et al 12-13 and Tanabe et al, 14 on the sol-gel glasses and glass ceramics containing Er 3+ ions.
[0004] Glass-ceramics are usually made by a two step procedure involving the formation of the glass by melting the reagents together at high temperature and quenching, followed by a programmed heat treatment. During the heat treatment, separation of the LaF 3 or lanthanide ion doped LaF 3 takes place. This method is also not readily applicable to the formation of thin films. Furthermore, these materials have only limited applications as they need to be melted at higher temperature to draw them into fibers. Fiber amplifiers are less convenient for integrated optics because of their increased length and extensive research is going on to replace them with planar waveguide amplifiers. 15 A lifetime of 17 ms for the 4 I 13/2 of Er 3+ was reported by Slooff et al. 16 for Er 3+ ion implanted silica colloidal particles having sizes in the range of 240-360 nm and annealed over the temperature range of 700-900° C. This was attributed to the decreased OH concentration in these materials. The disadvantage of this method is that the ion implantation is a small area, low throughput procedure.
[0005] Lanthanide ions like Er 3+ , Nd 3+ , etc., have been demonstrated to undergo clustering when incorporated in a silica matrix. Clustered rare earth ions have shorter lifetime compared to the non-clustered ones.
[0006] In some matrices some Ln 3+ ions are not emissive. For instance, Ho 3+ directly doped into SiO 2 does not emit light, but via the Ho 3+ doped LaF 3 nanoparticles they do.
[0007] A general method, from readily available starting materials, that combines the advantage of the improved luminescent properties of Ln 3+ -doped LaF 3 nanoparticles and the simplicity of making thin films using sol-gel method, is thus highly desirable.
[0008] There is a large interest in cheap efficient generation of (white) light for a variety of purposes such as displays, LCD back light and general lighting appliances. In particular, there is an interest in replacing the incandescent light bulb. 17-19 There are three basic approaches to the attainment of white light: i) the conversion of electricity; ii) the conversion of light, either by down-conversion or up-conversion; and iii) thermal radiation in the incandescent lamb to achieve white light.
[0009] Electricity is used in light-emitting diodes. There have been some major advances over the last few years in organic light-emitting diodes (OLEDs) 20-23 and polymer light-emitting diodes (PLEDs). 24-26 However, the generation of white light from OLEDs and PLEDs has proven to be challenging because: 1) blue and white light emitters are not as efficient as green and red emitters; 27,28 2) energy down conversion in the case of multilayer devices, i.e blue light can easily be absorbed by green chromophore and green light can be absorbed by red chromophore which results in one colour emission that depends on their efficiency; 3) bias dependant colour variation i.e. recombination zone of hole and electron is shifted at different bias which leads to different mobility of the charge carriers; 29 4) many layers are involved in the multilayer devices which leads to high manufacturing cost; 30 and 5) long term stability of emitters such as N-N′-diphenyl-N,N′-bis(3-methyl phenyl)-1,1′-biphenyl-4,4′-diamine (TPD), tris(8-quinolinotato) aluminum (Alq 3 ). 31
[0010] Down conversion is the conversion of higher energy UV light into visible light and is widely exploited in phosphors. 32 The short-wavelength emitting light sources can be used as efficient pumps to excite organic and inorganic luminescent matrices for subsequent photon emission at lower energies. The main challenge of this process is the degradation of the emitting material, especially in the organic emitting materials, over time because of photodecomposition and other means, as would be known to one skilled in the art.
[0011] One of the oldest devices for the production of white light is an incandescent light bulb. An incandescent light bulb produces light by heating a small filament of tungsten to about 2500° C. Despite many years of use, the efficiency (10-12%) is very low. 33
[0012] Up-conversion converts cheap near infrared photons via multiphoton processes into visible photons 34 Up-conversion is based on sequential absorption and energy transfer steps involving real metastable excited state that is intermediate in energy between the ground state and the emitting state of the ion. This process requires the absorption of at least two photons to provide sufficient energy for the up-converted emission to occur. This process is different from multiphoton absorption process which occurs through the simultaneous absorption of two or more photons via a non-stationary virtual quantum mechanical state in a medium, requiring high excitation densities.
[0013] Lanthanide ions are suitable candidates for up-conversion processes because of their crystal field-split (stark) level structure that provides many intermediate levels with favorable spacing and their long-lived excited states. Moreover, cheap NIR diode continuous wave (CW) laser can be used as excitation source.
[0014] In order to achieve an efficient, cost effective and durable white light source, the following points may be considered: i) stable photocycle of the emitting species; ii) one cheap excitation source (e.g. 980 nm CW laser) and efficient absorption; iii) easy control over the luminescence intensity of red, green, and blue emission; and iv) easy and cost effective fabrication of the device. It is an object of the invention to overcome the deficiencies in the prior art.
SUMMARY
[0015] A method of preparing a lanthanide-doped product nanoparticle sol-gel matrix film is provided. The method comprises preparing precursor nanoparticles; stabilizing the nanoparticles with ligands operative to stabilize the nanoparticles in an aqueous solution and selected to be substantially removed from the sol-gel matrix film during synthesis;
[0000] incorporating the stabilized nanoparticles into a sol-gel matrix, and heating the lanthanide doped nanoparticle sol-gel matrix to a temperature suitably selected to increase the signal to noise ratio by substantially removing the low molecular weight organic molecules water and hydroxyl groups thereby preparing a lanthanide-doped product nanoparticle sol-gel matrix film.
[0016] In one aspect of the invention the ligands are with low molecular weight organic molecules.
[0017] In another aspect of the invention, the low molecular weight organic molecules comprise at least one negatively charged group.
[0018] In one aspect of the invention, the low molecular weight organic molecules are carboxylates.
[0019] In another aspect of the invention, the carboxylate is citrate.
[0020] In another aspect of the invention, the temperature is in the range of 400-1200 C.
[0021] In another aspect of the invention, the temperature is in the range of 600-1200 C.
[0022] In another aspect of the invention, the temperature is approximately 800 C.
[0023] In another aspect of the invention, the method further comprises spin coating the sol-gel.
[0024] In another aspect of the invention, the sol-gel matrix comprises at least one of silica, alumina, zirconia, titania, hafnia, tantalum pentoxide, niobium pentoxide, germanium dioxide, yttria (Y 2 O 3 ), and gadolinia (Gd 2 O 3 ).
[0025] In another aspect of the invention, the precursor nanoparticles are selected from the group consisting of LaF 3 :Ln (Ln=Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb).
[0026] In another aspect of the invention the precursor nanoparticles are selected from the group consisting of La 0.75 Yb 0.2 Ho 0.05 F 3 , La 0.45 Yb 0.5 Er 0.05 F 3 for the production of green and red light, La 0.75 Yb 0.2 Tm 0.05 F 3 for the production of blue light, Yb 0.75 La 0.20 Eu 0.05 F 3 for the production of red light, Yb 0.75 La 0.20 Tb 0.05 F 3 for the production of green, La 0.45 Yb 0.5 Er 0.05 F 3 for the production of green and red, La 0.75 Yb 0.2 Ho 0.05 F 3 for the production of green and red, Yb 0.75 La 0.20 Tb 0.05 F 3 for the production of green and some orangey red, Yb 0.75 La 0.20 Eu 0.05 F 3 for the production of red and La 0.75 Yb 0.2 Tm 0.05 F 3 for the production of blue.
[0027] In another aspect of the invention the precursor nanoparticles are selected from the group consisting of LaF 3 :Ln (Ln=Yb 3+ Eu 3+ Er 3+ Tm 3+ Ho 3+ Tb 3+ ) and combinations thereof.
[0028] In another aspect of the invention the nanoparticles are synthesized in a ratio of about 150 La 0.75 Yb 0.2 Tm 0.05 F 3 to 0.5 La 0.45 Yb 0.5 Er 0.05 F 3 to 0.5 La 0.75 Yb 0.2 Ho 0.05 F 3 or 100 La 0.75 Yb 0.2 Tm 0.05 F 3 , to 0.5 La 0.45 Yb 0.5 Er 0.05 F 3 to 100 La 0.20 Yb 0.75 Tb 0.05 F 3 or 100 La 0.75 Yb 0.2 Tm 0.05 F 3 , to 80 Yb 0.75 La 0.2 Eu 0.05 F 3 to 80 La 0.20 Yb 0.75 Tb 0.05 F 3 or 150La 0.75 Yb 0.2 Tm 0.05 F 3 , to 1 La 0.20 Yb 0.75 Er 0.05 F 3 .
[0029] In another aspect of the invention, the precursor nanoparticles are core-shell nanoparticles.
[0030] In another aspect of the invention, the shell comprises LaF 3 .
[0031] Another embodiment of the invention provides a lanthanide doped nanoparticle sol-gel film prepared by any of the above methods.
[0032] Another embodiment of the invention provides a lanthanide-doped nanoparticle sol-gel film comprising a nanoparticle selected from the group consisting of LaF 3 :Ln (Ln=Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb).
[0033] In another aspect of the invention, the sol-gel film is stabilized with ligands operative to stabilize the nanoparticles in an aqueous solution and selected to be substantially removed from the sol-gel matrix during synthesis.
[0034] In another aspect of the invention, the lanthanide-doped nanoparticle sol-gel film comprises silica, alumina, zirconia, titania, hafnia, tantalum pentoxide, niobium pentoxide or germanium dioxide.
[0035] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the nanoparticle comprises a metal halide salt.
[0036] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the nanoparticle comprises a metal fluoride salt.
[0037] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the nanoparticle comprises MF 3 :Ln (M=La, Gd, Lu, Y, Sc; Ln=Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb).
[0038] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the nanoparticle comprises M 1 M 2 F 4 :Ln (M 1 =Li, Na, K, Rb, Cs; M 2 =La, Gd, Lu, Y, Sc; Ln=Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb).
[0039] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the nanoparticle comprises MF 2 :Ln (M=Be, Mg, Ca, Sr, Ba; Ln=Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb).
[0040] In another embodiment of the invention, a lanthanide-doped core-shell nanoparticle sol-gel film is provided comprising;
[0000] a nanoparticle selected from the group consisting of LaF 3 :Ln (Ln=Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb) and
a sol-gel matrix comprising silica or alumina.
[0041] In another aspect of the invention, the nanoparticle comprises LaF 3 :Ln (Ln=Er) and the sol-gel film comprises silica.
[0042] A method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, for the production of light is provided. The method comprises, selecting lanthanides for the production of at least one of green, red and blue light when excited with near infrared light, preparing nanoparticles comprising the selected lanthanides, stabilizing the nanoparticles with ligands operative to stabilize the nanoparticles in an aqueous solution and selected to be substantially removed from the sol-gel matrix film during synthesis, incorporating the stabilized nanoparticles into a sol-gel matrix and heating to increase the signal to noise ratio of the luminescence by substantially removing the low molecular weight organic molecules.
[0043] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the ligands are low molecular weight organic molecules.
[0044] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the low molecular weight molecules comprise at least one negatively charged group.
[0045] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the low molecular weight organic molecules are carboxylates.
[0046] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the carboxylate is citrate.
[0047] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the temperature is in the range of 400-1200 C.
[0048] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the temperature is in the range of 600-1200 C.
[0049] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the temperature is approximately 800 C.
[0050] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the invention further comprises spin coating the sot-gel.
[0051] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the sol-gel comprises silica, alumina, zirconia, titania, hafnia, tantalum pentoxide, niobium pentoxide, gadolinium oxide, yttria or germanium dioxide.
[0052] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the sol-gel comprises silica.
[0053] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the sol-gel comprises zirconia.
[0054] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the nanoparticles are selected from the group consisting of LaF 3 :Ln (Ln=Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, and Yb).
[0055] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the nanoparticles are selected from the group consisting of La 0.75 Yb 0.2 Ho 0.05 F 3 , for the production of green and red light, La 0.75 Yb 0.2 Tm 0.05 F 3 , for the production of blue light, La 0.45 Yb 0.5 Er 0.05 F 3 for the production of green and red light.
[0056] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the nanoparticles are selected from the group consisting of Yb 3+ Eu 3+ Er 3+ Tm 3+ and La 3+ .
[0057] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the nanoparticles are synthesized in a ratio of about 1 La 0.45 Yb 0.5 Er 0.05 F 3 , to 100 La 0.75 Yb 0.2 Tm 0.05 F 3 , to 150 Yb 0.75 La 0.2 Eu 0.05 F 3 .
[0058] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the nanoparticles are core-shell nanoparticles.
[0059] In another aspect of the method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, the shell comprises LaF 3 .
[0060] In one embodiment, a white light emitting lanthanide doped nanoparticle sol-gel film is provided.
[0061] In another embodiment, a sol-gel film made with lanthanide doped nanoparticles, the nanoparticles comprising a ratio of about 1 La 0.45 Yb 0.5 Er 0.05 F 3 , to 100 La 0.75 Yb 0.2 Tm 0.05 F 3 , to 150 Yb 0.75 La 0.2 Eu 0.05 F 3 is provided.
[0062] In another embodiment, the lanthanide-doped nanoparticle sol-gel film is stabilized with ligands operative to stabilize the nanoparticles in an aqueous solution and selected to be substantially removed from the sol-gel matrix film during synthesis.
[0063] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the ligands are low molecular weight organic molecules.
[0064] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the low molecular weight molecules comprise at least one negatively charged group.
[0065] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the sol-gel comprises silica, alumina, zirconia, titania, hafnia, tantalum pentoxide, niobium pentoxide, gadolinium oxide, yttria or germanium dioxide.
[0066] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the sol-gel comprises silica.
[0067] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the sol-gel comprises zirconia.
[0068] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the nanoparticle is a core-shell nanoparticle.
[0069] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the shell comprises a metal halide salt.
[0070] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the shell comprises a metal fluoride salt.
[0071] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the shell comprises MF 3 (M=La, Gd, Lu, Y, Sc).
[0072] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the shell comprises M 1 M 2 F 4 (M 1 =Li, Na, K, Rb, Cs; M 2 =La, Gd, Lu, Y, Sc).
[0073] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the shell comprises MF 2 (M=Be, Mg, Ca, Sr, Ba).
[0074] In another aspect of the lanthanide-doped nanoparticle sol-gel film of one embodiment, the shell comprises LaF 3 .
[0075] In another embodiment, a white light emitting lanthanide-doped core-shell nanoparticle is provided. The sol-gel film comprises:
[0076] a nanoparticle made from La 0.45 Yb 0.5 Er 0.5 F 3 , La 0.75 Yb 0.2 Tm 0.05 F 3 , and Yb 0.75 La 0.2 Eu 0.05 F 3 ; and
[0077] a sol-gel matrix comprising silica.
[0078] In another aspect of the white light emitting lanthanide-doped core-shell nanoparticle sol-gel film of one embodiment, the sot-gel matrix comprises silica.
[0079] In another aspect of the white light emitting lanthanide-doped core-shell nanoparticle sol-gel film of one embodiment, the sot-gel matrix comprises zirconia.
[0080] In another embodiment, a method for the production of light is provided.
The Method Comprises:
[0081] selecting lanthanides for the production of at least one of green, red and blue light when excited with near infrared light preparing nanoparticles comprising the selected lanthanides;
[0082] stabilizing the nanoparticles with ligands operative to stabilize the nanoparticles in an aqueous solution and selected to be substantially removed from the sol-gel matrix film during synthesis;
[0083] preparing a sol-gel matrix made with the nanoparticles;
[0000] heating the sol-gel matrix to a temperature suitably selected to increase the signal to noise ratio of the luminescence by substantially removing the low molecular weight organic molecules; and
[0084] exciting the light emitting lanthanide doped nanoparticle sol-gel films with near infrared light.
[0085] In another aspect of the method for the production of white light, the infrared light excites Yb 3+ .
[0086] In another aspect of the method for the production of white light, the infrared light is 980 nm.
[0087] In another aspect of the method for the production of white light, the ligands are low molecular weight organic molecules.
[0088] In another aspect of the method for the production of white light, the low molecular weight molecules comprise at least one negatively charged group.
[0089] In another aspect of the method for the production of white light, the low molecular weight organic molecules are carboxylates.
[0090] In another aspect of the method for the production of white light, the carboxylate is citrate.
[0091] In another aspect of the method for the production of white light, the temperature is in the range of 400-1200 C.
[0092] In another aspect of the method for the production of white light, the temperature is in the range of 600-1200 C.
[0093] In another aspect of the method for the production of white light, the temperature is approximately 800 C.
[0094] In another aspect of the method for the production of white light, one embodiment further comprises spin coating said sol-gel.
[0095] In another aspect of the method for the production of white light, the sol-gel comprises silica, alumina zirconia, titania, hafnia, tantalum pentoxide, niobium pentoxide, gadolinium oxide, yttria or germanium dioxide.
[0096] In another aspect of the method for the production of white light, the sol-gel comprises silica.
[0097] In another aspect of the method for the production of white light, the sol-gel comprises zirconia.
[0098] In another aspect of the method for the production of white light, the nanoparticles are selected from the group consisting of LaF 3 :Ln (Ln=Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb).
[0099] In another aspect of the method for the production of white light, the nanoparticles are selected from the group consisting of La 0.75 Yb 0.2 Ho 0.05 F 3 , for the production of green and red light, La 0.75 Yb 0.2 Tm 0.5 F 3 for the production of blue light, La 0.45 Yb 0.5 Er 0.05 F 3 for the production of green and red light.
[0100] In another aspect of the method for the production of white light, the nanoparticles are selected from the group consisting of Yb 3+ Eu 3+ Er 3+ Tm 3+ and La 3+ .
[0101] In another aspect of the method for the production of white light, the nanoparticles are used in a ratio of about 1 La 0.45 Yb 0.5 Er 0.05 F 3 , to 100 La 0.75 Yb 0.2 Tm 0.05 F 3 , to 150 Yb 0.75 La 0.2 Eu 0.05 F 3 .
[0102] In another aspect of the method for the production of white light, the nanoparticles are core-shell nanoparticles.
[0103] In another aspect of the method for the production of white light, the shell comprises LaF 3 .
[0104] In another embodiment, white light is emitted.
FIGURES
[0105] FIG. 1 . 1 H NMR of LaF 3 :Er-citrate particles in accordance with the invention. The peaks around 1.2 ppm and 3.6 ppm are due to ethanol and the one around 4.9 ppm arises due to water. δ (D 2 O): 2.45-2.60 (broad, C H 2 COOH—C H OH(COOH)—C H 2 COOH).
[0106] AFM images were recorded in the contact mode using a Thermo microscope AFM scanner having a silicon nitride tip (model MLCT-EXMT-A) supplied by Veeco Instruments. The particles were dissolved in water and a drop of the solution was put on a mica sheet (5×5 mm 2 ) and allowed to dry before mounting the sheet on the sample holder. The measurements were done with a resolution of 500×500 pixels per image and an image dimension of both 5×5 μm 2 . The average particle height was determined by measuring the individual particle heights for over 100 particles.
[0107] FIGS. 2A-2B . AFM image ( FIG. 2A ) and histogram ( FIG. 2B ) of LaF 3 :Er-citrate particle in accordance with the invention.
[0108] FIG. 3 ( a ) Emission spectra of LaF 3 :Er-citrate particles dissolved in D 2 O (b) Decay curve corresponding to the 4 I 13/2 level of Er 3+ in the sample. The sample was excited at 488 nm and the emission monitored at 1530 nm.
[0109] FIG. 4 . Emission spectra and decay curves for silica films containing LaF 3 :Er nanoparticles (left) and bare Er 3+ ion (right) with Er/Si=1×10 −3 and heated for 12 h at (a and d) 400, (b and e) 600, and (c and t) 800° C. The samples were excited at 488 nm and emission monitored at 1532 nm. Peak marked “*” is an artifact.
[0110] FIG. 5 . The emission spectra and decay curves for 800° C. heated (12 h) silica films containing LaF 3 :Nd nanoparticles (left) and bare Nd 3+ ions (right), with Nd/Si ratio is 0.9×10 −3 . The samples were excited at 514 nm and emission monitored at 1064 nm. The inset of the decay curve in the right shows an expansion of the fast decay component.
[0111] FIG. 6 . Emission spectrum and decay curve (left) for silica films containing LaF 3 :Ho nanoparticles heated in air at 800° C. for 12 h. The samples were excited at 448 nm with emission monitored at 1180 nm. In the right, emission spectrum of LaF 3 :Eu nanoparticle incorporated silica film heated at 800° C. in air for 12 h, (c), along with that of LaF 3 :Eu-citrate nanoparticles dissolved in water (d) are shown. (The insets show the emission spectrum collected with a resolution of 0.2 nm in the region corresponding to 5 D 0 → 7 F 0 transition). The samples were excited at 464 nm.
[0112] FIG. 7 . XRD pattern (Rietveld refinement plot) of a 25 weight % of LaF 3 :Fu (5%) nanoparticles incorporated silica film heated at 800° C. for 12 h in air. Diamonds—observed pattern, solid line—calculated pattern, solid lines below—calculated patterns of individual phases (selected peaks shown for Cr—cristobalite, LaF 3 — LaF 3 phase, LaSil—La 9.31 Si 6.24 O 26 phase), solid line bottom—difference pattern. The broad peak around 22 degrees is attributed to amorphous silica.
[0113] FIG. 8 . Emission spectrum (a) and decay curve (b) for Al 2 O 3 films incorporated with LaF 3 :Er (5%) nanoparticles and heated at 800° C. in air for 12 h. The emission spectrum and decay curve for Er 3+ incorporated Al 2 O 3 films with the same Fr/Al ratio (−1.5×10 −3 ) and subjected to the same heat treatment is shown in FIGS. 5 ( c ) and ( d ) respectively. The samples were excited at 488 nm and the emission, monitored at 1532 nm.
[0114] FIG. 9 . Up-conversion spectra, after excitation at 980 nm, of a silica film made with La 0.45 Yb 0.5 Er 0.05 F 3 . La 0.75 Yb 0.2 Tm 0.2 F 3 , and Yb 0.75 La 0.2 Eu 0.05 F 3 nanoparticles, heated at 800° C. (the inset show the CIE colour coordinates of resulting white light) in accordance with the invention.
[0115] FIG. 10 . Up-conversion emission spectra Ln 3+ (Er 3+ . Tm 3+ and Eu 3+ ) with Yb 3+ ions directly incorporated in silica film and heated at 800° C. as control sample under 980 nm laser excitation.
[0116] FIG. 11 . Up-conversion emission spectra of a silica film made with La 0.75 Yb 0.2 Ho 0.05 F 3 nanoparticles (heated at 800° C.) under 980 nm laser excitation.
[0117] FIG. 12 . Energy level of Ho 3+ , Tm 3+ , Er 3+ , and Yb 3+ ions as well as possible up-conversion mechanisms.
[0118] FIG. 13 Energy level of Eu 3+ and Yb 3+ ions as well as possible up-conversion mechanisms.
[0119] FIG. 14 . Dependence of the up-conversion emission intensity on the excitation power in different silica films individually made with a) La 0.75 Yb 0.2 Ho 0.05 F 3 , b) La 0.75 Yb 0.2 Tm 0.05 F 3 and c) La 0.45 Yb 0.5 Er 0.5 F 3 , heated at 800° C. under 980 nm laser excitation.
[0120] FIG. 15 . Up-conversion emission spectra of ZrO 2 thin film prepared at 800° C. made with La 0.45 Yb 0.5 Er 0.05 F 3 , La 0.75 Yb 0.2 Tm 0.05 F 3 , and Yb 0.75 La 0.2 Eu 0.05 F 3 nanoparticles under 300 mW 980 nm CW laser excitation (the insets show the CIE colour coordinates of the resulting white light). * The origin of the emission at 630 nm is not clear.
[0121] FIG. 16 . XRD pattern (Rietveld refinement plot) of a silica film prepared at 800° C. made with 25 weight % of La 0.45 Yb 0.52 Er 0.05 F 3 nanoparticles. Green lines: La 2 Zr 2 O 7 phase, Violet lines: ZrO 2 Baddeleyite phase, Red lines: ZrO 2 Zirconia phase.
[0122] FIG. 17 . shows the digital image of bright white light emission from silica thin film made with nanoparticles of combination 1 under 980 nm CW laser excitation.
[0123] FIG. 18 . Up-conversion emission spectra of silica thin film prepared at 800° C. made with nanoparticles of a) combination 1 (Yb/Tm, Yb/Ho and Yb/Er) b) combination 2 nanoparticles (Yb/Tm and Yb/Er) under 300 mW 980 nm CW laser excitation.
[0124] FIG. 19 . Up-conversion emission spectra of silica thin film prepared at 800° C. made with nanoparticles of combination 3 (Yb/Tm, Yb/Tb and Yb/Er) under 300 mW 980 nm CW laser excitation.
[0125] FIG. 20 . Up-conversion emission spectra of silica thin film prepared at 800° C. made with nanoparticles of combination 4 (Yb/Tm, Yb/Tb and Yb/Eu) under 300 mW 980 nm CW laser excitation.
[0126] FIG. 21 . Energy level of Ho 3+ , Tm 3+ , Er 3+ , Eu 3 +3 Tb 3+ and Yb 3+ ions as well as the up-conversion mechanisms based on Phys. Rev. B 1970, 1, 4208.
[0127] FIG. 22 . a) Decay curve for a) La 0.45 Yb 0.5 Y 0.05 F 3 , b) La 0.45 Yb 0.5 Er 0.05 F 3 nanoparticles individually incorporated in silica film and heated at 800° C. (λ ex =940 nm, λ em =980 nm, excitation source—OPO)
[0128] FIG. 23 . Dependence of the up-conversion emission intensity on the excitation power in La 0.75 Yb 0.21 Ho 0.05 F 3 nanoparticles individually incorporated in silica films and heated at 800° C. under 980 nm laser excitation.
[0129] FIG. 24 . Up-conversion emission spectra of ZrO 2 thin film prepared at 800° C. made with nanoparticles of combination 1 (Yb/Tm Yb/Ho and Yb/Er) under 300 mW 980 nm CW laser excitation.
[0130] FIG. 25 . Up-conversion emission spectra of ZrO 2 thin film prepared at 800° C. made with nanoparticles of combination 2 (Yb/Tm and Yb/Er) under 300 mW 980 nm CW laser excitation.
[0131] FIG. 26 . Up-conversion emission spectra of ZrO 2 thin film prepared at 800° C. made with nanoparticles of combination 3 (Yb/Tm, Yb/Tb and Yb/Er) under 300 mW 980 nm CW laser excitation.
DETAILED DESCRIPTION
Definitions
[0132] Precursor nanoparticle: A nanoparticle that is used for making doped nanoparticle sol-gel films. The resulting doped nanoparticle sol-gel may or may not be comprised of the precursor nanoparticle.
[0133] Product nanoparticle: A doped nanoparticle sol-gel comprises product nanoparticle. The product nanoparticle may or may not comprise precursor nanoparticle. The product nanoparticle can be a core-shell nanoparticle or it may only comprise the core.
[0134] Temperature Ranges: The temperature at which the sol-gel films are made range from approximately about 400-1200 C, preferably approximately about 600-1200 C, and more preferably approximately about 800 C.
EXAMPLE 1
Overview
[0135] Silica films with Ln 3+ -doped LaF 3 nanoparticles were prepared by the sol-gel method and their luminescent properties were studied as a function of temperature. Significant improvements in the luminescent properties, in terms of the lifetime for the 4 I 13/2 level of Er 3+ (˜10.9 ms), the 4 F 3/2 level of Nd 3+ (˜171 μs) and the 5 F 3 level of Ho 3+ (˜6 μs) were obtained when corresponding nanoparticles were incorporated in silica films rather than the bare ions. Life time values could be further improved by incorporating core-shell particles (the doped LaF 3 core is surrounded by an undoped shell of LaF 3 ) in the silica matrix, as a result of further reduction of the non-radiative pathways.
[0136] LaF 3 :Er (5%) nanoparticles stabilized with citrate ligands were prepared and incorporated in silica films made by the sol-gel method. The luminescent aspects of these films were studied as a function of the annealing temperature from 400 to 800° C. The results were compared with that of silica films doped directly with Er 3+ ions having the same Er/Si ratio as that of nanoparticle incorporated films. The procedure was extended to other lanthanide ions like Nd 3+ and Ho 3+ and also to another sol-gel matrix (Al 2 O 3 ), showing the generality of the method.
Preparation of Nanoparticles:
[0137] LaF 3 :Er, LaF 3 :Eu, LaF 3 :Nd and LaF 3 :Ho nanoparticles, (all doped at 5 atom % with respect to the total amount of lanthanide ions), stabilized with citrate ligand were prepared by the co-precipitation technique in aqueous solution in presence of citrate ions. Around 2 g of citric acid and 0.126 g NaF was dissolved in 40 ml of water. The pH of the solution was adjusted to 6 by adding NH 4 OH and the solution was heated to 75° C. Stoichiometric amounts of the nitrate salts of lanthanide ions were dissolved in 2 ml water (for Er 34 and Eu 3+ ions) or 2 ml of methanol (for Nd 3+ and Ho 3+ ions), and added drop wise. A clear solution was obtained and after two hours of reaction, the resulting solution was mixed with 150 ml of ethanol to precipitate the nanoparticles. These particles were collected by centrifugation, washed with ethanol, and dried under vacuum. Formation of citrate-stabilized nanoparticles was confirmed from 1 H NMR and AFM studies ( FIGS. 1 and 2 ). For the preparation of core-shell nanoparticles having a doped core covered by an undoped shell, the procedure was slightly modified.
Preparation of Core-Shell Nanoparticles:
[0138] Approximately 3 g of citric acid was dissolved in 35 ml of water and neutralized with NH 4 OH till the pH reaches around 6 and this solution was then heated to 75° C. La(NO 3 ) 3 .6H 2 O and Nd(NO 3 ) 3 .6H 2 O or Ho(NO 3 ) 3 .5H 2 O (1.33 mmol total) were dissolved in 3 ml of methanol and added to this followed by the dropwise addition of 3 ml water containing 0.266 g NaF. After 10 minutes, 3 ml of a methanolic solution containing 0.6 g of La(NO 3 ) 3 .6H 2 O was added drop-wise to the reaction mixture while stirring, for the formation of shell around the core particles. The reaction was allowed to continue for two hours and finally the nanoparticles were precipitated by the addition of excess of ethanol to the reaction mixture.
[0139] Formation of particles having a core-shell geometry by this procedure was confirmed from the luminescent studies of citrate stabilized LaF 3 :Eu—LaF 3 core-shell nanoparticles, prepared by the same procedure. The details of the luminescent properties of core shell particles have been reported elsewhere (J. W. Stouwdam and F. C. J. M. van Veggel, Langmuir 20, 11763 (2004)).
[0140] Approximately 50-60 mg of these nanoparticles was dissolved in 1.5 ml water, which was then mixed with 3 ml of tetraethoxysilane (TEOS) and 7.8 ml of ethanol. The pH of the solution was adjusted to 2 by adding few drops of 0.1 N HCl and the solution was stirred for 24 hours to get a clear sol. The sol was then spin coated on a quartz substrate at 2500 rpm and heated at different temperatures under ambient environment. The films were transparent to visible light and no cracks were observed.
[0141] Emission spectra and decay curves from the samples were measured using a pulsed Nd—YAG (Nd—YAG stands for Nd 3+ doped yttrium aluminium garnet) laser source attached with an optical parametric oscillator (OPO). The pulse duration was 5 ns with a repetition frequency of 10 Hz. Emission spectrum of LaF 3 :Er nanoparticles dispersed in D 2 O obtained after exciting the sample at 488 nm, was characterized by a broad peak around 1530 nm (full width at half maximum (FWHM)=69 nm), corresponding to the 4 I 13/2 → 4 I 15/2 transition. The decay curve corresponding to the 4 I 13/2 level in the sample was fitted bi-exponentially with decay times 200 μs (82%) and 58 μs (18%) respectively ( FIG. 3 ).
[0142] FIG. 4 shows the emission spectra and decay curves for the LaF 3 :Er and Er 3+ incorporated silica films with Er/Si ratio ˜1.0×10 −3 and heated in air at 400, 600, and 800° C. for 12 hours. There was significantly improved signal to noise ratio in the emission spectrum for the particles incorporated films heated at all the temperatures. Furthermore, the full width at half maximum (FWHM) for particle-incorporated films were almost comparable for all the heat treatment temperatures. However, for silica films directly incorporated with Er 3+ ions, the signal to noise ratio was poor, particularly for low temperature heat-treated films. The line width drastically decreased with increased heat treatment temperatures. The lifetime values corresponding to the 4 I 13/2 level of Er 3+ from the 800° C. heated samples are shown in Table 1. (Corresponding values for the low temperature heated films are shown in Table 2). For silica films incorporated with LaF 3 :Er nanoparticles, life time values were much higher at all the heat treatment temperatures compared to the directly Er 3+ incorporated silica films, as can be seen from FIG. 4 and Table 1. For nanoparticle incorporated films heated at 800° C., the 1 I 13/2 life time was found to be 10.9 ms. In the case of silica film incorporated with bare Er 3+ ions and heated at 800° C., there was a fast decay component followed by a slow decay component. The observed fast decay component for the 800° C. heated film was attributed to the aggregation of Er 3+ ions in the silica matrix. However, for silica films incorporated with LaF 3 :Er nanoparticles, no fast decay component was observed particularly for the ones heated at 600 and 800° C. Thus, the particle-incorporated silica films offer a clear advantage in terms of the improved lifetime and absence of clustering of lanthanide ions when compared with silica films directly incorporated with the bare Er 3+ ion.
[0143] Similar experiments were carried out for Nd 3+ - and Ho 3+ -incorporated samples. The citrate-stabilized nanoparticles of LaF 3 :Nd and LaF 3 :Ho were incorporated in a silica matrix by the same procedure employed for the LaF 3 :Er nanoparticles. FIG. 5 shows the emission spectra and corresponding decay curves for silica films incorporated with LaF 3 :Nd nanoparticle and Nd 3+ ion, respectively, with a Nd/Si ratio 0.9×10 −3 and heated at 800° C. for 12 h. For silica films doped with LaF 3 :Nd nanoparticles, decay corresponding to 4 F 3/2 level was multi-exponential with a major component of ˜171 μs (72%) and a faster component of 56 μs (28%). For Nd 3+ ions directly doped in silica films with the same Nd/Si ratio, the corresponding decay curve was characterized by a fast decay component (−2.0 μs, 48%) as can be seen from the inset of FIG. 5 (bottom right), and a slow decay component (130 μs, 52%). The fast component is attributed to the clusters of Nd 3+ ions formed in the silica matrix. 35 A comparison of the life time values shown in Table 1 and the decay curves shown in FIG. 5 clearly reveals that there is an improvement of the luminescent properties, in terms of improved life time and absence of lanthanide ion clustering, when the nanoparticles are incorporated in the silica films rather than the bare ions.
[0144] For silica films incorporated with LaF 3 :Ho nanoparticles with a Ho/Si ratio around 1.5×10 −3 and heated at 800° C., luminescence was observed both in the visible and near-infrared region. The emission spectrum in the NIR region along with the decay curve corresponding to the 5 F 3 level of Ho 3+ from this sample are shown in FIG. 6 (left). The lifetime value of 5 F 3 level was found to be 6 μs (75%) and 12 μs (25%), with no faster decay component, indicating the absence of Ho 3+ clustering in the sample. In contrast to this, when Ho 3+ ions are directly doped in silica films with the same Ho/Si ratio, no emission was observed in the visible and near-infrared region.
[0145] LaF 3 :Eu nanoparticle stabilized with citrate ions were prepared, incorporated in silica matrix and subjected to heat treatments at different temperatures. FIG. 6 (right) show the emission spectra of the LaF 3 :Eu incorporated silica film heated at 800° C. in air. The intensity of the 5 D 0 → 7 F 2 emission peak (˜615 nm) for this sample was found to be significantly larger than that of the 5 D 0 → 7 F 1 emission peak (591 nm). which is characteristic of Eu 3+ surrounded by oxygen ions. As both 5 D 0 and 7 F 0 levels are non-degenerate, the transition between the levels can be used as a probe to understand the environment around the Eu 3+ ions in the lattice. The high resolution emission spectrum corresponding to the 5 D 0 → 7 F 0 transition for LaF 3 :Eu nanoparticles incorporated silica films (shown as inset of FIG. 6 c ) clearly shows an asymmetric peak which could be deconvoluted into two Gaussians centered around 576.9 and 578.2 nm, respectively, indicating that more than one type of Eu 3+ is present in the films. For LaF 3 :Eu nanoparticles relatively sharper and a more symmetric peak around 578 nm was observed corresponding to the 5 D 0 - 7 F 0 transition (inset of FIG. 6 d ). Comparing the spectra in FIG. 6 (c and d), it is clear that Eu 3+ is existing in more than one crystallographic phase in LaF 3 :Eu incorporated silica films. X-ray diffraction studies carried out on a sample of silica film incorporated with 25 wt % of LaF 3 :Eu nanoparticles and heated at 800° C., revealed the presence of a non-stoichiometric lanthanum silicate phase, (La 9.31 Si 6.24 O 26 ), along with the LaF 3 phase as can be seen from FIG. 7 , roughly in a 1:1 ratio. The Eu 3+ thus occurs in two different phases, which confirmed the luminescence data. It is likely that the surface of the LaF 3 :Eu nanoparticles reacted with the silanol groups of the matrix to form the Eu 3+ -doped lanthanum silicate surrounding a core of unreacted LaF 3 :Eu. One skilled in the art would conclude that the same occurs for all LaF 3 :Ln (Ln—Er, Nd, and Ho) doped SiO 2 films in this study. The life time values of the lanthanide ion containing silica films can be further improved by incorporating the core-shelf nanoparticles having a doped core covered by an undoped shell. (Core-shell nanoparticles doped with Er 3+ ions in the core were found to be less soluble in water and hence good quality sol-gel films could not be obtained). The life time values observed for 4 F 3/2 level of Nd 3+ and 5 F 3 level of Ho 3+ in LaF 3 :Nd—LaF 3 and LaF 3 :Ho—LaF 3 core-shell nanoparticle incorporated films are shown in Table 1. There was an improvement in the life time of the core-shell particles incorporated films compared to the core particle incorporated films.
Incorporation of Nanoparticles in Al 2 O 3 Matrix:
[0146] In order to further substantiate the generality of the method, the above experiments were repeated by taking Al 2 O 3 as the sol-gel matrix. Al 2 O 3 sols were prepared based on the procedure similar to that of Ishizaka et al. 36 Hydrous aluminum hydroxide was precipitated by adding aqueous 6M NH 3 solution to a 0.2 M Al(NO 3 ) 3 .9H 2 O solution drop wise under stirring. The precipitated hydroxide was aged for 12 h without stirring, then centrifuged and washed with water. This was then mixed with glacial acetic acid and heated at 80° C. for 8 h. The viscous sol obtained thus was mixed with around 3.5 mg of Er(NO 3 ) 3 .5H 2 O or around 30 mg LaF 3 :Er nanoparticles stabilized with citrate ligand and stirred for 24. The sot was then transferred to a Petri dish and dried under ambient conditions followed by heating at 800° C. for 8 hours.
[0147] Similar to SiO 2 matrix, significant improvement in the life time values were observed when LaF 3 :Er nanoparticles were incorporated in the films compared to the bare Er 3+ incorporated films ( FIG. 8 ).
[0148] In conclusion, a general method, from readily available and cheap starting materials, that combines the advantages of both nanoparticles and the sol-gel method, has been demonstrated for making silica and alumina films containing highly luminescent lanthanide ions. The improved luminescent properties of nanoparticle incorporated films have been attributed to the effective isolation of lanthanide ions from the high phonon energy matrix, residual OH groups, and absence of lanthanide ion clustering.
EXAMPLE 2
Overview
[0149] White light was generated from a silica or zirconia thin film made with Yb 0.75 La 0.2 Eu 0.05 F 3 , La 0.45 Yb 0.5 Er 0.05 F 3 , and La 0.75 Yb 0.2 Tm 0.05 F 3 nanoparticles by exciting with a single source near infrared light (980 nm CW diode laser). Eu 3+ and Tm 3+ ions are responsible for red and blue emission respectively. Er 3+ ion is responsible for green as well as red emission. The Commission Internationale de l'Eclairage (CIE) coordinates of the resulting light were easily adjusted by controlling the concentration of lanthanide ions in the nanoparticles 27-31 as well as the concentration of nanoparticles (Ln 3+ doped) in the sol-gel thin layer.
[0150] More specifically, there is spatial isolation of the three pairs of precursor Ln 3+ ions (i.e. Tm 3+ /Yb 3+ , Er 3+ /Yb 3+ , and Eu 3+ /Yb 3+ ) that generate blue, green plus red, and red emission, respectively.
[0151] Silica thin film made with La 0.75 Yb 0.2 Ho 0.05 F 3 nanoparticles produced bright green light by exciting with near infrared light (980 nm CW diode laser) which can be also used in the generation of white light.
[0152] In the case of ZrO 2 as the sol-gel matrix we see La 2 Zr 2 O 7 as phase, which is a low-phonon matrix. This has the advantage of leading to less quenching than would occur in high-phonon matrices.
Synthesis of Citrate Stabilized Lanthanide Doped Nanoparticles
[0153] La 0.45 Yb 0.5 Er 0.05 F 3 , La 0.75 Yb 0.2 Tm 0.05 F 3 , La 0.75 Yb 0.2 Ho 0.05 F 3 , and Yb 0.75 La 0.2 Eu 0.50 F 3 nanoparticles, stabilized with citrate ligand were prepared by the co-precipitation technique in aqueous solution in presence of citrate ions. Around 2 g of citric acid and 0.126 g NaF was dissolved in 40 ml of water. The pH of the solution was adjusted to 6 by adding NH 4 OH and the solution was heated to 75° C. Stoichiometric amounts of the nitrate salts of lanthanide ions were dissolved in 2 ml of methanol and added drop wise. A clear solution was obtained and after two hours of reaction, the resulting solution was mixed with 70 ml of ethanol to precipitate the nanoparticles. These particles were collected by centrifugation at 3000 rpm, washed with ethanol, and dried under vacuum. After drying the particles can easily be dispersed in water. Formation of citrate stabilized nanoparticles was confirmed from 1 H NMR and AFM studies (van Veggel c.s. Chem. Mater. 2005, 17, 4736).
Preparation of Sol-Gel Thin Films
[0154] 50 mg of Ln 3+ doped LaF 3 nanoparticles were dissolved in 2 ml water, which was then mixed with 3 ml of tetraethoxyorthosilane (TEOS) and 7.8 ml of ethanol. The pH of the solution was adjusted to 2 by adding a few drops of 0.1 N HCl and the solution was stirred for 24 hours to get a clear sol. The sol was then spin coated on a quartz substrate at 2500 rpm and heated to 400° C. from 25° C. in 1.40 hr, staying at 400° C. for 30 min and then heated to 800° C. in 2 hr and staying at 800° C. for 12 hr under ambient environment. 1 mg of La 0.45 Yb 0.5 Er 0.05 F 3 , 100 mg of La 0.75 Yb 0.2 Tm 0.05 F 3 , and 150 mg of Yb 0.75 La 0.2 Eu 0.05 F 3 in 4 ml water were used for the material which gave white light emission. Up-conversion emission spectra from the samples were measured using a 980 nm CW semiconductor laser source.
Results
[0155] FIG. 9 shows the up-conversion emission spectra of silica films made with La 0.45 Yb 0.5 Er 0.05 F 3 , La 0.75 Yb 0.2 Tm 0.05 F 3 , and Yb 0.75 La 0.2 Eu 0.05 F 3 nanoparticles. Emission peaks at red, green and blue region can be seen. The calculated colour coordinates are 0.37 and 0.32. 35 These values fall within the white region of 1931 Commission Internationale de l'Eclairage (CIE) diagram. 37 This white light was bright and can been seen by the naked eye even at a laser pump power of only 200 mW. There is no virtually change in the colour coordinates of the white light with a change in the excitation power. The weak emissions at region 590 and 612 nm from Eu 3+ ions help keep the colour coordinates from moving slightly towards green region (0.3, 0.41). In order to show that using three different Ln 3+ /Yb 3+ pairs in a silica thin film does not lead to a thin film capable of emitting white light, a thin film was prepared with the same concentrations of La 3+ Er 3+ , Tm 3+ , and Eu 3+ ions with Yb 3+ ions by direct incorporation and subjected to the same heat treatment. The results show only green and red emission from Er 3+ ions and no blue and red emission from Tm 3+ ions and Eu 3+ ions respectively ( FIG. 10 ).
[0156] The emission band around 470 nm is assigned to the 1 G 4 to 3 H 6 transition of Tm 3+ ions. An emission band of Tm 3+ ions at 790 nm ( 3 H 4 to 3 H 6 transition) was also observed. Er 3+ gave emission peaks around 515, 540 nm and 645 nm which are assigned to the 2 H 11/2 to 4 I1 15/2 , 4 S 3/2 to 4 I1 15/2 , 4 F 9/2 to 4 I1 15/2 transitions, respectively. The intensity ratio of red to green emission from Er 3+ ions can be tuned by changing the concentration of Yb 3+ ions in the Gd 2 O 3 nanoparticle (Guo, H.; Dong, N.; Yin, M.; Zhang, W.; Lou, L.; Xia, S. J. Phys. Chem. 2004, 108, 19205).
[0157] We also found similar green to red ratio dependence by changing the Yb 3+ concentration in the nanoparticle. The emission bands around 590 nm and 612 nm are assigned to the 5 D 0 to 7 F 1 and 5 D 0 to 7 F 2 transitions of Eu 3+ ions, respectively.
[0158] FIG. 11 shows the up-conversion spectra of La 0.75 Yb 0.2 Ho 0.05 F 3 incorporated in silica film under 980 nm CW laser excitation. Ho 3+ ions gave two emission bands at approximately 540 nm and 640 nm, which are assigned to the 5 S 2 to 5 I 8 and 5 F 5 to 5 I 8 transitions, respectively. The green luminescence intensity is very high when compared with the red emission and can easily be seen with the naked eye at laser pump power of only 200 mW. This can be also used as green and red light source of the white light combination. Lifetime of 5 S 2 level is 250 μs which indirectly shows that the up-conversion process is efficient. To our knowledge, no such studies have been reported regarding up-converted green and red emission from Ho 3+ ions in sol-gel derived oxide nanoparticles by exciting Yb 3+ ions. Ln 3+ (Ho 3+ , Tm 3+ , Eu 3+ ) ions with the Yb 3+ ions individually incorporated in silica thin film and subjected to same heat treatment didn't show any up-conversion. This clearly demonstrates the advantage of nanoparticles used in silica thin film rather than direct doping with lanthanide ions. The up-conversion luminescence can be improved by using LaF 3 :Ln 3+ core-shell nanoparticles (the doped LaF 3 core is surrounded by an undoped shell of LaF 3 ) in the silica matrix and then used as precursor nanoparticles in the thin film formation.
[0159] Possible mechanisms for the up-conversion processes are, photoavalanche (PA), excited state absorption (ESA), energy transfer (ET). A schematic diagram showing the energy level of Ho 3+ , Tm 3+ , Er 3+ , Eu 3+ and Yb 3+ as well as possible up-conversion mechanisms for the blue, green, and red emissions under 980 nm excitation are shown in FIGS. 12 and 13 . FIG. 14 shows the dependence of the up-conversion emission intensity on the excitation power in different samples a) La 0.75 Yb 0.2 Ho 0.05 F 3 , b) La 0.75 Yb 0.2 Tm 0.05 F 3 c) La 0.45 Yb 0.5 Er 0.05 F 3 nanoparticles individually incorporated in silica film. Blue emission from Tm 3+ ions is three photon process. Green and red emission from Er 3+ and Ho 3+ ions are two photon processes. Power dependence graphs ( FIG. 14 ) show a slight decrease in the slope when the laser power is increased. This can be attributed to a ground state depletion caused by the population build-up of the Yb 3+ excited level and in turn in the saturation of corresponding levels in the lanthanide ions.
[0160] When the ZrO 2 films were made with La 0.45 Yb 0.5 Er 0.05 F 3 , La 0.75 Yb 0.2 Tm 0.05 F 3 , and Yb 0.75 La 0.2 Eu 0.05 F 3 nanoparticles white light was observed with the coordinates of 0.37, 0.31 ( FIG. 15 ). A ZrO 2 thin film prepared with the same concentrations of La 3+ , Er 3+ , Tm 3+ , and Eu 3+ ions with Yb 3+ ions by direct incorporation only showed green and red emission from Er 3+ ions and no blue and red emission from Tm 3+ ions and Eu 3+ ions, respectively, which substantiates the importance of the role of three different nanoparticles. Our recent report showed the presence of a non-stoichiometric lanthanum silicate phase (La 9.31 Si 6.24 O 26 ) along with the expected LaF 3 phase from X-ray diffraction (XRD) studies carried out on a silica thin film sample (van Veggel c.s. Chem. Mater. 2005, 17, 4736).
[0161] XRD studies carried out on ZrO 2 thin films made with nanoparticles showed the presence of lanthanum zirconate (La 2 Zr 2 O 7 ), but little or no LaF 3 ( FIG. 16 ). We conclude that the nanoparticles have reacted with OH groups present in ZrO 2 sol-gel to form Ln 3+ doped lanthanum zirconate. In spite of the formation of lanthanum zirconate, the three pairs of Ln 3+ ions are spatially isolated in the sol-gel layer made with nanoparticles. Accordingly, the pairs of Ln 3+ ions are still effectively in a nanoparticle that has very low phonon energy (perhaps in the range of ˜300 cm −1 ).
[0000]
TABLE 1
The life times in ms of Er 3+ ( 4 I 13/2 ), Nd 3+ ( 4 F 3/2 ) and Ho 3+ ( 5 F 3 )
ions in silica films when incorporated as nanoparticles and bare ions.
All the samples were heated at 800° C. and the numbers in brackets
indicate the relative percentages of the different life time components.
LaF 3 :Ln—SiO 2 films a
Core
Core-shell
Ln—SiO 2 films a
Ln 3+
τ 1
τ 2
τ 1
τ 2
τ 1
τ 2
Er 3+
10.9 (95)
3.9 (5)
b
b
6.0
1.2
(70)
(30)
Nd 3+
0.171 (72)
0.056 (28)
0.325 (76)
0.087 (24)
0.130
0.002
(52)
(48)
Ho 3+
0.006 (75)
0.012 (25)
0.007 (65)
0.015 (35)
c
c
a Er/Si = 1.0 × 10 −3 , Nd/Si = 0.9 × 10 −3 and Ho/Si = 1.6 × 10 −3 ,
b measurements could not be done as the films were of poor quality.
c no emission observed.
[0000]
TABLE 2
Life time values of Er 3+ ( 4 I 13/2 ) ions in silica films when incorporated as
nanoparticles and bare ions and heated at different temperatures. The
numbers in brackets gives the relative percentages of the two life
time components.
LaF 3 :Er—SiO 2 films
Er 3+ —SiO 2 films
Er/Si = 1 × 10 −3
Er/Si = 1 × 10 −3
Temperature
τ 1 ms (%)
τ 2 ms (%)
τ 1 ms (%)
τ 2 ms (%)
400° C.
2.6 (70%)
0.6 (30%)
A
a
600° C.
7.4 (69%)
0.9 (31%)
0.98 (35%)
0.27(65%)
a No emission observed
EXAMPLE 3
Overview
[0162] Bright white light was generated from SiO 2 and ZrO 2 sol-gel thin film made with four different combinations of lanthanide-doped nanoparticles. A 33-fold increase in the white light emission intensity was observed with the Commission Internationale de l'Eclairage (CIE) co-ordinates of 0.39, 0.31 from silica thin film made with Combination 2 (Yb/Tm and Yb/Er) nanoparticles when compared to our previous thin film of Example 2. We have estimated the efficiency of production of the resulting white light as 25% based on the efficiency of energy transfer and quantum yield of the Ln 3 f emissions. Similarly, silica thin film made with combination 1 (Yb/Tm, Yb/Ho, and Yb/Er), combination 3 (Yb/Tm, Yb/Tb, and Yb/Er), and combination 4 (Yb/Tm, Yb/Tb, and Yb/Eu) nanoparticles also produced white light with higher efficiency when compared to our previous thin films of Example 2 (26, 11, 2 times, respectively). ZrO 2 thin films made with these new combinations of nanoparticles also showed similar increases in the efficiency of white light.
[0163] The combinations of Ln 3+ -doped LaF 3 nanoparticles, stabilized by citrate ligands, incorporated in sol-gel thin films used to achieve the white light are given in Table 3. The films were transparent to visible light and no cracks were observed under an optical microscope. Film formation characteristics have been reported by us. 38 FIG. 17 shows the digital image of bright white light emission from silica thin film made with nanoparticles of combination 1 under 980 nm CW laser excitation. Bright white light can be seen very clearly from the thin film even at a laser pump power of only 300 mW.
[0164] FIG. 18 a shows the up-conversion emission spectra of silica thin film made with nanoparticles of combination 1. Emission peaks at red, green and blue region can clearly be seen in FIG. 18 a . The calculated CIE colour coordinates of the combination 1 are 0.39 and 0.31. These values fall within the white region of 1931 Commission Internationale de l'Eclairage (CIE) diagram. A 26-fold increase in the efficiency of generation of white light was observed when compared to our earlier thin film of Example 1. In this new combination red emission at 640 nm from Ho 3+ ions compensates for the absence of red emission from Eu 3+ ions and keeps the colour co-ordinates in the white light region. In addition, the energy transfer from Yb 3+ ions to Ho 3+ ions is very efficient when compared to co-operative up-conversion of Yb 3+ ions to Eu 3+ ions which makes our new combination overall more efficient. Like our previous thin film, there is virtually no change in the CIE colour coordinates of the white light with a change in the excitation power.
[0000]
TABLE 3
Silica thin film made with different combination of nanoparticles (see
Table 4 for amount of nanoparticle used.)
Combi-
Yb 3+ ion
Relative
nation
Ln 3+ ions
(mg)
Efficiency a
CIE
1
Yb/Tm, Yb/Ho, Yb/Er
7.58
26
0.39, 0.31
2
Yb/Tm, Yb/Er
7.68
33
0.30, 0.34
3
Yb/Tm, Yb/Tb, Yb/Er
23.8
11
0.29, 0.30
4
Yb/Tm, Yb/Tb, Yb/Eu
48.13
2
0.39, 030
example 2
Yb/Tm, Yb/Er, Yb/Eu
66.35
1
0.37, 0.32
a relative to the total amount of Yb 3+ in example 2
[0000] TABLE 4 Amount of nanoparticles used for making thin films Combination Amount of nanoparticles used 1 La 0.75 Yb 0.20 Tm 0.05 F 3 (150 mg), La 0.75 Yb 0.20 Ho 0.05 F 3 (0.5 mg) and La 0.45 Yb 0.50 Er 0.05 F 3 (0.5 mg) 2 La 0.75 Yb 0.20 Tm 0.05 F 3 (150 mg) and Yb 0.75 La 0.20 Er 0.05 (1 mg) 3 La 0.75 Yb 0.20 Tm 0.05 F 3 (100 mg) La 0.45 Yb 0.5 Er 0.05 F 3 (0.5 mg) and Yb 0.75 La 0.20 Tb 0.05 (100 mg) 4 La 0.75 Yb 0.20 Tm 0.05 F 3 (100 mg) Yb 0.75 La 0.20 Tb 0.05 (80 mg) and Yb 0.75 La 0.20 Eu 0.05 (150 mg)
Silica and zirconia thin films were made with 6 mL of TEOS and 4 mL of zirconium propoxide, respectively.
[0165] The emission band around 470 nm is assigned to the 1 G 4 to 3 H 6 transition of Tm 3+ ions. Both Er 3+ and Ho 3+ ions are responsible for green and red emission. Er 3+ ions gave emission peaks around 515, 540, and 665 nm, which are assigned to the 2 H 11/2 to 4 I 15/2 , 4 S 3/2 to 4 I 15/2 , 4 F 9/2 to 4 I 15/2 transitions, respectively. Ho 3+ ions gave two emission bands at approximately 540 nm and 640 nm, which are assigned to the 5S 2 to 5 I 8 and 5 F 5 to 5 I 8 transitions, respectively. A control silica thin film was made with the sane concentration of La 3+ , Er 3+ , Ho 3+ , Tm 3+ , and Yb 3+ ions by direct incorporation only showed green and red emission from Er 3+ ions, consistent with earlier observations. Silica thin films with Ho 3+ /Yb 3+ or Tm 3+ /Yb 3+ ions didn't show any up-conversion which also clearly demonstrates that different nanoparticles are necessary to produce white light.
[0166] FIG. 18 b shows the up-conversion emission spectrum of silica thin film made with nanoparticles of combination 2. A 33-fold increase in the efficiency of white light generation was observed. The calculated CIE colour coordinates are 0.30 and 0.34. The efficiency generation of white light from combination 2 has been improved here in a different way than in combination 1 by increasing the red to green emission ratio from Er 3+ ions. The increase in the red to green emission ratio has been achieved by increasing the concentration of Yb 3+ in the nanoparticle. Zhang and co-workers 39 and Capobianco and co-workers 40 have also investigated this dependence of red to green ratio on Yb 3+ concentration in matrices like Gd 2 O 3 and Y 2 O 3 , respectively.
[0167] An 11-fold and 2-fold increase in the efficiency of generation of white light has been achieved from combination 3 ( FIG. 19 ) and combination 4 ( FIG. 20 ), respectively. The emission peaks at 542, 586 and 623 nm are assigned to 5 D 4 to 7 F 5 , 7 F 4 and 7 F 3 transitions of Tb 3+ ion, respectively. The co-operative up-conversion of Yb—Tb ions is more efficient than Yb—Eu ions because energy transfer can happen relatively easily from the virtual state (−490 nm) of two excited Yb 3 ions to the 5 D 4 level (490 nm) of Tb 3+ ions, where these two levels are resonant in energy. In the case of Yb—Eu up-conversion process some energy has to be dumped into the matrix during the energy transfer from the Yb 3+ ions to the 5 D 1 level (520 nm) of Eu ions. Gudel and co-workers 41 have reported co-operative up-converted emission mechanism in Cs 3 Tb 2 Br 9 :Yb 3+ single crystal.
[0168] Preliminary results into the mechanism of the up-conversion process suggests that it is occurring via energy transfer (ET) rather than an excited state absorption (ESA). Up-conversion from Tm 3+ and Eu 3+ ions are due to energy transfer processes, because both ions have no ground or excited state absorption that matches the 980 nm photon. Green and red emission from Er 3+ ions are predominantly due to energy transfer processes and may be due to a photoavalanche (PA) process and little contribution is from Er 3+ excited state absorption, as can be seen from a silica thin film made with La 0.45 Yb 0.5 Er 0.05 F 3 nanoparticles that showed intense luminescence when compared to a silica thin film made with La 0.95 Er 0.05 F 3 nanoparticles. The energy level of Ho 3+ , Tm 3+ , Er 3+ , Tb 3+ , Eu 3+ and Yb 3+ as well as possible up-conversion mechanisms for the blue, green, and red emissions under 980 nm excitation are given in the FIG. 21 . We can calculate the efficiency of energy transfer (η τ ) from Yb 3+ to Ln 3+ ions from η τ =1−(τ DA /τ D ), Where, τ DA is lifetime of donor in the presence of acceptor and τ D is the lifetime of donor in the absence of acceptor.
[0169] The effective lifetime of the 2 F 5/2 level of Yb 3+ ions in the silica thin film incorporated with La 0.45 Yb 0.50 Y 0.05 nanoparticles is 1.1 ms ( FIG. 22 a ). Lifetime of Yb 3+ when it is co-doped with Er 3+ ( FIG. 22 b ), Ho 3+ and Tm 3+ are 428 μs, 475 μs, and 600 μs, respectively. Thus, the efficiency of energy transfer to Er 3 , Ho 3+ and Tm 3+ were determined to be 0.6, 0.6 and 0.5, respectively. The effective lifetime 1 G 4 level of Tm 3+ ions and 5 S 2 level of Ho 3+ ions in the sample was found to be 300 μs (τ R =837 μs 42 and 378 μs, (τ R =489 μs 42 , respectively. The effective lifetime of 4 S 3/2 level and 4 F 9/2 level of Er 3+ ions was found to be 525 μs (τ R =778 μs |17| ) and 418 μs, (τ R =1.4 ms 43 ) respectively. The effective lifetime of 5 D 0 level of Eu 3+ and 5 D 4 level of Tb 3+ ions was found to be 2.8 ms (τ R =6.7 ms 44 ) and 3.8 ms, (τ R =4.9 ms 45 ), respectively. The effective lifetimes and radiative lifetimes (τ R ) of above lanthanide ions suggest that the estimated quantum yield (QY=τ eff /τ R ) of resulting white light is on the order of 50%. Thus, the efficiency of the resulting white light is on the order of 25%. The power dependence of the up-conversion emission intensity of silica film individually made with La 0.75 Yb 0.2 Ho 0.05 F 3 nanoparticles was measured ( FIG. 23 ), showing that the green and red emission from Ho 3+ ions are two-photon processes. The power dependence graphs show a slight decrease in the slope when the laser power is increased. This can be attributed to a ground state depletion caused by the population build-up of the Yb 3+ excited level and in turn to the saturation of corresponding levels in the lanthanide ions. The green and red emission from Er 3+ ions are two-photon processes and the blue emission from Tm 3+ ions is a three-photon process.
[0170] In order to substantiate further the generality of the method, above experiments were repeated by taking ZrO 2 as the sol-gel matrix. Similar to SiO 2 matrix, white light was observed with the ZrO 2 films made with combination 1 ( FIG. 24 ), combination 2 ( FIG. 25 ), and combination 3 ( FIG. 26 ) nanoparticles. ZrO 2 thin films made with these combinations of nanoparticles also showed similar increase in the efficiency of white light like silica thin film. The calculated CIE colour co-ordinates for combination 1 and combination 2 are 0.37, 0.40 and 0.34, 0.29 respectively. The calculated CIE colour co-ordinates for combination 3 are 0.34 and 0.37. A ZrO 2 thin film prepared with the same concentrations of La 3+ , Er 3+ , Tm 31 , and Ho 3+ ions with Yb 3+ ions by direct incorporation only showed green and red emission from Er 3+ ions and no emission from Tm 3+ ions and Ho 3+ ions was observed. Similarly, ZrO 2 thin film prepared with the same concentrations of La 3+ , Tb 3+ , Tm 3+ , and Er 3+ ions with Yb 3+ ions showed green and red emission which is from Er 3+ ions. This again substantiates the importance of the role of three different nanoparticles to produce white light.
[0171] In conclusion, up to a 33-fold increase in the efficiency of the conversion of 980 nm light into white light has been achieved in sol-gel derived thin films by a judicious choice of upconverting Ln 3+ -doped nanoparticles that were co-doped with Yb 3+ .
[0000] Experimental: For nanoparticles amounts see Table 4. Effective lifetimes were calculated using Origin 7 software based on the following equation,
[0000]
τ
eff
=
∫
O
∞
tI
(
t
)
t
∫
O
∞
I
(
t
)
t
[0172] All the calculations were done based on duplicate measurements and the values have estimated errors of 5%.
[0173] The foregoing is a description of embodiments of the invention. As would be known to one skilled in the art, variations would be contemplated that would not alter the scope of the invention. For example, this method can be extended to other luminescent Ln 3 ions, i.e. Ce, Pr, Sm, Gd, Tb, Dy, Tm, or Yb, other nanoparticles, and to other matrices for example, but not limited to TiO 2 , ZrO 2 , HfO 2 , Ta 2 O 5 , Nb 2 O 5 , GeO 2 , Y 2 O 3 , and Gd 2 O 3 . Further, other carboxylates can be employed, provided that they are substantially removed during heating of the sol-gel, as can some neutral molecules. White light can easily be generated by incorporating Ln 3+ doped nanoparticles in sol-gel thin films other than SiO 2 and ZrO 2 for example, but not to be limiting, Y 2 O 3 , Gd 2 O 3 TiO 2 , Al 2 O 3 , GeO 2 , HfO 2 , Nb 2 O 5 , Ta 2 O 5 either individually or in combination. Additionally, other core-shell nanoparticles could be used comprising lanthanides suitable for the production of core-shell nanoparticles. In general, other nanoparticles, such as oxides, could be used as well. Additionally, the foregoing methods and products can be used to produce individual colors of light. For example, but not limited to, green and some red via nanoparticles as shown in FIG. 14 a , blue via nanoparticles as shown in FIG. 14 b , and red and some green via nanoparticles as shown in FIG. 14 c.
[0174] Yb 3+ /Eu 3+ /Er 3+ /Tm 3+ /La 3+ in SiO 2 or ZrO 2 produces green and red from Er 3+ . The fact that there is no light generate from Eu 3+ and Tm 3+ could be a result of energy transfer to Er 3+ and/or quenching of the excited Eu 3+ and Tm 3+ , leading to non-radiative decay, when not introduced via the precursor nanoparticles.
5. REFERENCE
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45 K. Binnemans, R. Van Deun, C. Gorller-Walrand, J. L. Adam, J. Non - Cryst. Solids, 1998, 238, 11. | A method of preparing a lanthanide-doped nanoparticle sol-gel matrix film having a high signal to noise ratio is provided. The sol-gels are also provided. A method of preparing light emitting sol-gel films made with lanthanide doped nanoparticles, for the production of white light is also provided. The method comprises selecting lanthanides for the production of at least one of green, red and blue light when excited with near infrared light, preparing nanoparticles comprising the selected lanthanides, stabilizing the nanoparticles with ligands operative to stabilize the nanoparticles in an aqueous solution and selected to be substantially removed from the sol-gel matrix film during synthesis, incorporating the stabilized nanoparticles into a sol-gel matrix and heating to increase the signal to noise ratio of the luminescence by substantially removing the low molecular weight organic molecules. Additionally, light emitting sol-gel films made with lanthanide doped nanoparticles are provided. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an attachment element having at least one engagement member insertable in a mounting opening of a hollow body in its first position and engaging holding projections provided on the hollow body in its second position, at least one stop for engaging outer end sides of rims of longitudinal sides of the hollow body which limit the mounting opening, and at least one fastening element which displaces, upon being actuated, the at least one engagement member from its first position to its second position.
2. Description of the Prior Art
Attachment elements of the type described above are used for securing objects, e.g., on a C-shaped mounting rail that can, e.g., be secured on a constructional component. The attachment element is inserted in a mounting opening and, e.g., is pivoted by 90° so that the engagement member of the attachment element engages holding projections provided on the mounting rail. With this preliminary attachment, the attachment element can be displaced in the longitudinal direction of the mounting rail for adjusting the attachment element. In order to finally secure the attachment element on the mounting rail, the engagement member is secured to a stop, e.g., with a threaded rod so that it is clamped to the projections. This type of attachment element is suitable, e.g., for securing elongate objects or a bunch of conduits such as pipes and the like.
From the state of the art, different embodiments of so-called rail nuts are known. E.g., German Publication DE 38 11 974 A1 discloses a spring-biased rail nut having longitudinal grooves in which the rim webs of a C-shaped rail engage in the pivotal position of the nut.
German Publication DE 196 35 632 A1 discloses a rail nut the transverse extension of which is inserted in a slot-shaped opening in a C-shaped profile rail, and the longitudinal extension of which is greater that the inner dimension of the slot-shaped opening so that upon rotation of the nut the nut engages from behind the rims of the slot-shaped opening.
German Patent DE 196 17 750 C1 also discloses a rail nut which is inserted in a mounting opening in a C-shape mounting rail and is the rotated. During a setting process of the nut, it is aligned for engagement from behind the longitudinal edges of the mounting opening by a release member.
German Publication DE 100 52 534A discloses an attachment element insertable in a mounting opening of a hollow body and having a rotatable engagement member for engaging from behind longitudinal edges or rims of the mounting opening. With this attachment element e.g., angles for connecting two mounting rails can be secured on the mounting rails.
The drawback of the known solutions consists in that the length of the contact surface of the engagement member is limited by the slot width of the mounting rail. Thereby, only a limited value of transverse forces can be absorbed by conventional attachment elements. With inclined or vertically extending conduit strands or with axially loaded conduit strands, and in devices for connecting two mounting rails, substantial transverse forces act on the attachment element.
Accordingly, an object of the present invention is to provide an attachment element that insures a reliable connection under action of significant transverse forces.
Another object of the present invention is to provide an attachment member that can be easily inserted in amounting opening of a hollow body at any arbitrary selected location along the longitudinal axis of the hollow body.
SUMMARY OF THE INVENTION
These and other objects of the present invention, which will become apparent hereinafter, are achieved by providing an attachment element including at least one engagement member insertable in a mounting opening of a hollow body in its first position and engaging holding projections provided on the hollow body in its second position, at least one stop for engaging outer end side rims of the longitudinal sides of the hollow body which limit the mounting opening, and at least one fastening element which displaces, upon being actuated, the at least one engagement member from its first position to its second position. The at least one engagement member has at least two strip sections each of which is displaceably supported on the at least one stop. The fastening element has an expansion body for laterally displacing the at least one engagement member from its first position to its second position.
The length of the strip sections can be determined dependent on to-be-absorbed transverse forces. Thus, the length of the strip sections is not determined based on the inner width of the mounting opening of a hollow body, as is the case with conventional attachment elements. In its first position, the at least one engagement member has a width which is smaller than the inner width of the mounting opening of the hollow body. Upon actuation of the fastening element, its expansion body presses the strip sections laterally away from each other in a direction of the holding projections provided in the interior of the hollow body, so that the strip sections engage the holding projections from behind. The inventive attachment element can be displaced along the mounting opening until it reaches a predetermined position before it is secured. After it reaches the predetermined or desired position, the attachment element is secured on the hollow body.
The attachment element can be provided on e.g., a C-shaped mounting rail the rims of which are bent down inward in the region of the mounting opening and form the holding projections for the engagement member. The inventive attachment element can also be arranged on al box-shaped or even plate-shaped component having a suitable mounting opening through which the engagement member can be inserted. The rim regions of the mounting opening are engaged, in the second position of the at least one engagement member, by the strip sections.
At high transverse forces, preferably, two or more strip sections are provided on each side of the engagement member. The attachment element is so formed that either a plurality of strip sections can be laterally displaced, or a plurality of fastening elements is provided on the stop, with each fastening element displacing, upon its actuation, respective two diametrically opposite strip sections from the first position to the second position.
Advantageously, each strip section is pivotally supported on the stop. In this case, the strip sections are brought from their first position to the second position by a pivotal movement of the engagement member. In addition, the strip sections can be supported on the stop with a possibility of lateral displacement.
Advantageously, the at least two strip sections of the engagement member have each a spacing section and an angular section having, optionally, a profile for an improved engagement of the holding-projections in the interior of the hollow body, e.g., of the rim regions. The spacing section of the strip section has an extent that corresponds to the extent of the holding projection, e.g., to the corresponding wall dimension in the setting direction of the attachment element. The angular section serves for engaging, from behind holding projections, e.g., rim regions of the body. The angular section extends at an angle relative to spacing section and in a direction of the engageable holding projections, e.g., engageable rim regions. Preferably, the angle, which is formed by the spacing and angular sections is so selected that the contact surface of the angular sections with the holding projections, e.g., a rim regions, extends in the second position of the strip sections, substantially parallel to the contact surface of the free edges of the holding projections, e.g., rim region.
For a better engagement of the angular section with the holding projection, e.g., with the rim region, the contact surface of the angular section is provided with a special profile, e.g., knurling. Advantageously, the free rim of the holding projection, e.g., the edge region is likewise provided with an appropriate profile, e.g., knurling, so that the knurling of holding projection, e.g., of the rim region, can cooperate with knurling of the angular section. For an optimal engagement of the engagement member with the holding projections, e.g., with the rim regions, the knurling, which is provided on the angular sections, is matched with the knurling on the holding projections, e.g., on the rim regions.
Advantageously, the spacing section has a shorter longitudinal extent than the angular section. In this case, the strip section has, in side view, a substantially T-shaped profile, with the horizontal section of the T-shaped profile forming the angular section and the vertical section of the T-shaped profile forming the spacing section. The free end of the spacing section is displaceably supported on the at least one stop. With such strip sections, the engagement member can be displaced from its first position to its second position by the fastening element, while providing an adequate bearing surface on the angular sections for engaging the holding projections, e.g., rim regions of the hollow body, which permits the attachment element, which is secured on the hollow body, to absorb correspondingly larger transverse forces.
Preferably, the at least two strip sections of the at least one engagement member are held in the first position by a spring member. The spring member can be formed as an annular ring or as a rubber band. The spring member serves, on one hand, as transportation and positioning means that holds the engagement member of the inventive attachment element in the first position in which the engagement member is inserted in the mounting opening of the hollow body. On the other hand, in the second position of the engagement member, the spring member applies a biasing force to the strip sections and which, upon loosening of the fastening element, presses the strip sections toward the expansion body of the fastening element, facilitating repositioning of the inventive attachment element along the mounting opening. Further, the dismounting of the inventive attachment element is facilitated because upon release of the attachment element, the strip sections are urged from the second position to the first position. Advantageously, the biasing force of the spring member is so selected that the strip sections of the engagement member can be easily displaced form the first position to the second position, so that the setting process of the inventive attachment element is not unduly aggravated by a need to overcome a heavy force.
Advantageously, the expansion body of the fastening element has a substantially rectangular cross-section, with at least two diametrically opposite sides of the expansion body being provided with a control profile in the form of an arched surface. The expansion body is formed substantially as an eccentric that laterally displaces the strip sections of the engagement member. When the strip sections are pivotally supported on at least one stop, they are pivoted, upon actuation of the fastening element, relative to the holding projections of the hollow body, with the angular sections being pivoted under the holding projections.
The large initial path of the strip sections of the engagement member is bridged by a traverse extension of the flat cross-sectional profile of the expansion body. Under the action of the arched surfaces of the control profile on the strip sections, a secure seating is achieved by further rotation of the fastening element. The arched surface of the control profile, preferably, does not extend over the entire length of the corresponding side of the cross-sectional profile. By selecting the angle, at which the angular section extends toward the spacing section of the strip section and by appropriately forming the arched surface of the control profile, the tolerances between separate parts of the inventive attachment element and/or of the hollow body can be compensated.
Advantageously, the expansion body of the fastening element has an enlargement of its cross-section at its setting direction end. The enlargement of the expansion body is advantageously formed by a circumferential band. Advantageously, the transition region from the expansion body to its enlargement is formed as, e.g., a cone, preferably, as a truncated cone. With the enlargement portion, the angular sections of the strip sections, upon tightening of the attachment element, are pressed against the free ends of the holding projections, e.g., against the rim regions. Further, the enlargement contributes to the compensation of tolerances of the connection between the attachment element and the hollow body and provides for transmission of additional axial forces to the engagement member and for displaceable support of the strip sections at the at least one stop.
Preferably, the attachment element has, at its end facing in the direction opposite the setting direction, torque transmitting means, e.g., a hexagon. With the torque transmitting means, the attachment element can be easily operated with a simple tool or manually. Advantageously, the hexagon is formed based on metric or inch system. The fastening element can be formed of two parts, with the expansion body being provided at its end facing in a direction opposite the setting direction with an outer thread on which a nut, e.g., a conventional hexagon nut, can be arranged. Thereby, the connection between the inventive attachment element and the hollow body can be additionally axially tighten after a lateral displacement of the strip sections of the engagement member. The nut is secured in its initial position against rotation with a securing lacquer or by being upset. In the first step, upon rotation of the nut, the expansion body also rotates, widening the engagement member. This provides for a preliminary fixing of the attachment element. Upon further rotation of the nut, the connection of the nut with the expansion body is released, and the inventive attachment element is tightened against the hollow body as a result of an axial displacement of the expansion body.
Advantageously, the fastening element is provided with a setting mark, e.g., an optical mark. The setting mark insures a reliable assembly and control of the connection by the user and/or a quality inspector. Advantageously, an optical mark is provided, e.g., on the torque transmitting means at a location visible from outside, e.g., on a bolt end. As an optical mark, e.g., a notch, an engraving, etching, or a color marking in a form of line, circle, or arrow can be used. The user can evaluate a correct alignment of the attachment element by a change in the position of the optical setting mark, e.g., by a change of the original position of the mark by rotating it to 90°, with the changed position corresponding to the position of the inventive fastening element in which it can absorb the loads acting thereon.
Advantageously, the stop is formed as an angle. An angle provides for connection of two hollow bodies, e.g., two C-shaped mounting rails, with one mounting rail being arranged, with its end surface, at an arbitrary location along the mounting opening of the other mounting rail. Advantageously, the angle, as a construction component, is provided with all of the other parts of the attachment element at the working site. With a two-leg angle, e.g., a fastening element with a respective engagement member, which is operated by this fastening element, is provided on each of the legs of the angle.
At least some of parts of the attachment element advantageously are formed of sheet metal by a stamping/bending process. Also, use of plastic materials having suitable properties for forming at least some of the parts of the attachment element is also possible.
The novel features of the present invention, which are considered as characteristic for the invention, are set forth in the appended claims. The invention itself, however both as to its construction and its mode of operation, together with additional advantages and objects thereof, will be best understood from the following detailed description of preferred embodiments, when read with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings show:
FIG. 1 a a cross-sectional view of a first embodiment of an attachment element according to the present invention in the first position of the engagement member;
FIG. 1 b a cross-sectional view of a first embodiment of an attachment element according to the present invention in the intermediate position of the engagement member;
FIG. 1 c a cross-sectional view of a first embodiment of an attachment element according to the present invention in the second position of the engagement member;
FIG. 2 a a horizontal, with reference to FIG. 1 a , cross-sectional view of a first embodiment of an attachment element according to the present invention in the first position of the engagement member;
FIG. 2 b a horizontal, with reference to FIG. 1 b , cross-sectional view of a first embodiment of an attachment element according to the present invention in the intermediate position of the engagement member;
FIG. 2 c a horizontal, with reference to FIG. 1 c , cross-sectional view of a first embodiment of an attachment element according to the present invention in the second position of the engagement member;
FIG. 3 a a cross-sectional view of a second embodiment of an attachment element according to the present invention in the first position of the engagement member;
FIG. 3 b a cross-sectional view of a second embodiment of an attachment element according to the present invention in the second position of the engagement member;
FIG. 4 a a cross-sectional view of a third embodiment of an attachment element according to the present invention in the first position of the engagement member;
FIG. 4 b a cross-sectional view of a third embodiment of an attachment element according to the present invention in the second position of the engagement member; and
FIG. 5 a cross-sectional view along line V—V in FIG. 4 a.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As discussed above, FIG. 1 a shows a cross-sectional view of a first embodiment of an attachment element according to the present invention in a first position of the engagement member, and FIG. 2 a shows a horizontal cross-sectional view of the inventive attachment element shown in FIG. 1 a in the first position of the engagement member. The inventive attachment element 1 is used for connecting two C-shaped mounting rails 2 . 1 and 2 . 2 . The mounting rails 2 . 1 and 2 . 2 each has a respective mounting opening 3 . 1 , 3 . 2 provided in a longitudinal outer side of the respective rail 2 . 1 , 2 . 2 and extending along the longitudinal axis of the respective mounting rail 2 . 1 , 2 . 2 .
The attachment element 1 has a two-leg angle 6 which serves as a stop for engaging outer end sides of rims of the C-shaped mounting rails 2 . 1 , 2 . 2 and which limit the respective mounting openings 3 . 1 , 3 . 2 . On each leg of the angle 6 , there is arranged a respective engagement member, e.g., 7 . 1 and a respective eccentric bolt 8 . 1 , 8 . 2 for operating the respective engagement member, e.g., 7 . 1 . The engagement members are pivotally arranged on respective legs of the angle 6 .
Below, the construction and the function of the engagement members and eccentric bolts of the attachment element 1 will be discussed with reference to the engagement member 7 . 1 and the corresponding eccentric bolt 8 . 1 . The second engagement member and the second eccentric bolt 8 . 2 , which are arranged on the second leg of the angle 6 , have analogous construction and function. The engagement member has two strip sections 9 . 1 , 9 . 2 . The strip sections 9 . 1 , 9 . 2 each has an angular section 10 . 1 , 10 . 2 and a spacing section 11 . 1 , 11 . 2 The angular sections 10 . 1 , 10 . 2 each forms with a respective spacing section 11 . 1 , 11 . 2 an obtuse angle. The free ends of the spacing sections 11 . 1 , 11 . 2 are inserted in respective openings (e.g., in opening 12 ) in the angle 6 and pivot about a point of their contact with the rim limiting a respective opening. The length of the spacing sections 11 . 1 , 11 . 2 is so selected that the angular sections 10 . 1 , 10 . 2 , connected therewith, pivot below the free rims 4 . 1 and 4 . 2 of the mounting rail 2 . 1 and are capable of engaging the same.
The surface of the angular sections 10 . 1 , 10 . 2 , which engages the free rims 4 . 1 and 4 . 2 of the mounting rail 2 . 1 upon tightening of the attachment element 1 , is provided with knurling. In order to insure that the connection between the engaging member 7 . 1 and the free rims 4 . 1 , 4 . 2 of the mounting rail 2 . 1 is able to withstand high loads, the free rims 4 . 1 , 4 . 2 are likewise provided with knurling. Advantageously, both knurling, which engage each other, are adapted to each other.
The bolt head of the eccentric bolt 8 ; 2 and the bolt head of the eccentric bolt 8 . 1 (not shown in detail) is provided with a setting mark in form of a notch 13 . 2 that would indicate to the user that the respective engagement member 7 . 2 or 7 . 1 is located in the first, so-called insertion position. The engagement member 7 . 1 is held in the insertion position in which the attachment element 1 is inserted in the mounting rails 2 . 1 and 2 . 2 with an annular spring member 14 .
The eccentric bolt 8 . 1 has an expansion body 16 . 1 which is provided at its end facing in the setting direction with a conical enlargement 17 . 1 . The enlargement 17 . 1 surrounds the entire expansion body 16 . 1 and engages from behind the angular sections 10 . 1 and 10 . 2 in each position of the eccentric bolt 8 . 2 . In the insertion position, the spacing sections 11 . 1 and 11 . 2 of the strip sections 9 . 1 and 9 . 2 lie on flat cross-sectional profiles 18 . 1 and 18 . 2 of the expansion body 16 . 1 .
As discussed above, FIGS. 1 b and 2 b show, respectively, a cross-sectional view of the first embodiment of the attachment element in the intermediate position of the engagement member and a horizontal cross-sectional view of the element 1 in the intermediate position of the engagement member. By rotation of eccentric bolt 8 . 1 , e.g., in the clockwise direction (in direction of the arrow 21 ), the angular sections 10 . 1 and 10 . 2 are brought into engagement with the free rims 4 . 1 and 4 . 2 of the mounting rail 2 . 1 . This leads to expansion of the spring member 14 . The resulting biasing force, which is applied to the strip sections 9 . 1 and 9 . 2 provides for repositioning of the attachment element 1 after it has been released.
The large initial path of the lateral displacement of the engaging member 7 . 1 is bridged over by a side turn of the flat cross-sectional profiles 18 . 1 and 18 . 2 of the expansion body 16 . 1 . By a further rotation of the eccentric bolt 8 . 1 in the direction of the arrow 21 and as a result of action of eccentric arcs 22 . 1 and 22 . 2 on the strip sections 9 . 1 . and 9 . 2 , respectively, a fixed seating of the engagement member is achieved.
As discussed above, FIGS. 1 c and 2 c show, respectively, a cross-sectional view of the first embodiment of the attachment element in the second position of the engagement member and a horizontal cross-sectional view of the attachment element in the second position of the engagement member. In the second position, the angular sections 10 . 1 and 10 . 2 of the engagement member 7 . 1 are aligned for engagement with the free rims 4 . 1 and 4 . 2 of the mounting rail 2 . 1 . The angular sections 10 . 1 and 10 . 2 are pressed against the free rims 4 . 1 and 4 . 2 by the conical enlargement 17 . 1 . Based on the alignment of the notch 13 . 2 of the eccentric bolt, the user can determine whether the attachment element 1 is securely mounted on the mounting rail 2 . 1 and 2 . 2 :
The eccentric arcs 22 . 1 and 22 . 2 do not extend over the entire short cross-sectional length of the expansion body 16 . 1 . The surfaces 23 . 1 and 23 . 2 , which adjoin the respective eccentric arcs 22 . 1 and 22 . 2 , act as stop and means for preventing over-rotation of the expansion body 16 . 1 . This prevents over-rotation of the eccentric bolt 8 . 1 and insures the reliability of the attachment element 1 .
FIG. 3 a shows a cross-sectional view of a second embodiment of an attachment element 31 according to the present invention in the first position of the engagement member, and FIG. 3 b shows a cross-sectional view of a second embodiment of the attachment element 31 according to the present invention in the second position of the engagement member. The attachment element 31 , which is shown in FIGS. 3 a – 3 b , is substantially analogous to the attachment element 1 . The eccentric bolts 32 . 1 and 32 . 2 are formed of two parts. The eccentric bolt 32 . 1 has an expansion body 33 . 1 provided at its end facing in a direction opposite the setting direction, with an outer thread 35 . 1 . A nut 36 . 1 is screwed on the outer thread 35 . 1 . For rotation of the expansion body 33 . 1 , the nut 36 . 1 is secured in the initial position with a securing lacquer. On a surface which is provided on the free end of the eccentric bolt 32 . 2 and which is adjacent to the user, there is provided a setting mark in form of an arrow 37 . 2
By operating the second nut 36 . 1 , the engagement member 38 . 1 is pivoted from its first position to its second position. As soon as angular sections 39 . 1 and 39 . 2 are aligned for engagement with free rims 40 . 1 and 40 . 2 of the mounting rail 41 . 1 ; the cross-section of the expansion body 33 . 1 , which is analogous to that of the expansion body 16 . 1 of the eccentric bolt 8 . 1 which was described above, prevents further rotation of the eccentric bolt 32 . 1 . This position of the eccentric bolt 32 . 1 is clearly visible to the user due to the position or alignment of the setting mark, the arrow 37 . 2 of the eccentric bolt 32 . 1 .
By further rotation of the nut 36 . 1 in the initial locking direction of the eccentric bolt 32 . 1 , e.g., in the direction of arrow 42 , the connection between the nut 36 . 1 and the expansion body 33 . 1 is released, and the expansion body 33 . 1 is lifted in a direction opposite the setting direction of the eccentric bolt 32 . 1 and shown with arrow 43 . With lifting of the expansion body 33 . 1 , the angular sections 39 . 1 and 39 . 2 are pressed, additionally to the already obtained locking connection, against the free edges 40 . 1 and 40 . 2 of the mounting rail 41 . 1 with an enlargement 34 . 1 .
FIG. 4 a shows a cross-sectional view of a third embodiment of a attachment element 51 according to the present invention in the first position of the engagement member, and FIG. 4 b shows a cross-sectional view of a second embodiment of the attachment element 51 according to the present invention in the second position of the engagement member. The attachment element 51 , which is shown in FIGS. 4 a – 4 b , has, instead of an angle, a plate 52 for engaging end surfaces of the rims which limit a mounting opening 53 of the mounting rail 54 . The attachment element 51 can serve, e.g., for securing a bunch of conduits-shells on, e.g., the mounting rail 54 which is attached to a constructional component.
The engagement member 55 has two strip sections 56 . 1 and 56 . 2 which are supported laterally against the plate 52 and are capable of being displaced laterally relative thereto. By operating a hexagon 58 provided on an eccentric bolt 57 , the expansion body 59 is rotated, and the strip sections 56 . 1 and 56 . 2 are displaced from the first position to the second position in the direction of free rims 60 . 1 , 60 . 2 which limit the mounting opening 53 .
FIG. 5 shows a cross-sectional view of a strip section 56 . 2 of the engagement member 55 along line V—V in FIG. 4 a . The strip section 56 . 2 has a substantially T-shape in front view and a substantially C-shaped cross-section. The horizontal section of the T-shape is formed by an angular section 62 . 2 , and the vertical section of the T-shape is formed by a spacing section 61 . 2 , with the spacing section 61 . 2 having a smaller longitudinal extent that the angular section 62 . 2 . With reference to the C-shaped cross-section, as shown in FIGS. 4 a – 4 b , the leg 63 . 2 which is located opposite the angular section 62 . 2 , of the strip section 56 . 2 serves for positioning and guiding the strip section 56 . 2 during its lateral displacement form the first position to the second position.
In summary, there is provided an attachment element which insures a reliable connection even when the attachment element is subjected to transverse load. The inventive attachment element can be inserted at any location of the mounting opening of a hollow body, repositioned along the mounting opening, and secured on the hollow body.
Though the present invention was shown and described with references to the preferred embodiments, such are merely illustrative of the present invention and are not to be construed as a limitation thereof and various modifications of the present invention will be apparent to those skilled in the art. It is therefore not intended that the present invention be limited to the disclosed embodiments or details thereof, and the present invention includes all variations and/or alternative embodiments within the spirit and scope of the present invention as defined by the appended claims. | An attachment element ( 1; 31; 51 ), includes at least one engagement member ( 7.1; 7.2; 38.1; 55 ) insertable in a mounting opening ( 3.1; 3.2; 53 ) of a hollow body ( 2.1; 2.2; 41.1; 54 ) in its first position and engaging holding projections ( 4.1; 4.2; 40.1; 40.2; 60.1; 60.2 ) provided on the hollow body ( 2.1; 2.2; 41.1; 54 ) in its second position, at least one stop ( 6; 52 ) for engaging outer end sides of hollow body rims which limit the mounting opening ( 3.1; 3.2; 53 ), and at least one fastening element ( 8.1; 8.2; 32.1; 32.2; 57 ) having an expansion body ( 16.1; 33.1; 59 ) for laterally displacing the at least one engagement member ( 7.1; 7.2; 38.1; 55 ) from the first position thereof to the second position. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a novel physiologically active peptide and salts thereof, and to antiallergic agents containing the same as an active ingredient. Furthermore, it is concerned with a method for the prevention or therapy of allergies.
2. Description of Prior Art
A variety of drugs have been proposed and developed for the prevention or therapy of various allergic diseases. Some of them have already been placed on the market.
Among the allergic symptoms, immediate-type allergic reactions such as bronchial asthma, urticaria and allergic rhinitis are classified as type I-allergic reaction. The type I-allergic reaction is in general believed on the basis of onset of the symptoms and action mechanism of the antiallergic agent to involve the following three stages: against an extraneous antigen which has entered the body produces IgE antibody, which is fixed to the Fc receptor in tissue mast cells or blood basophils thereby producing sensitization (this process is at the first stage); next, when the extraneous antigen again enters the body, the IgE antibody fixed to the Fc receptor in the cells and the extraneous antigen are bonded to cause antigen-antibody reaction which triggers such reactions as activation of the cell membrane enzymes and inflow of calcium ions into cells thereby producing biochemical changes such as enzymatic reactions and histological changes such as degranulation with a result that chemical mediators such as histamine and SRS-A are released outside the cells (this process is at the second stage); the chemical mediators released outside the cells as mentioned above have such actions as contraction of smooth muscles and accentuation of permeability and promotion of excretion of the capillary blood vessels and cause various allergic symptoms (this process is at the third stage).
Among heretofore known antiallergic agents, nonspecific hyposensitization therapeutic agents and antibody production inhibitory agents are drugs acting on the first stage. None of the drugs specifically acting on the first stage has been placed on the market. As drugs acting on the second stage are known chemical mediator-inhibitory agents such as disodium cromoglycate (DSCG) and Tranilast. Antihistaminics and bronchodilators are drugs acting on the third stage. Japanse Patent Publication Sho No. 60-2318 discloses peptide antiallergic agents though not placed on the market. Whereas the peptide has not yet been demonstrated for inhibition of the IgE antibody production at the first stage, it blocks allergic reaction by inhibiting bond of the IgE antibody with mast cells which first occurs at the second stage, as well as by simultaneously substituting the IgE antibody already bonded at the second stage. It is composed of five amino acid residues in Fc region of IgE antibody and, as shown below by the primary structure, is a pentapeptide of IgE antibody origin.
Asp-Ser-Asp-Pro-Arg
Although the peptide is under investigation and development as a pharmaceutical preparation, its level of the activity is not clear.
Based on the mechanism of the onset of allergic symptoms in the type I-allergic reaction, development of antiallergic agents has heretofore been directed to a drug acting on one of the three stages for the onset of allergic symptoms. Studies were made of prevention of onset or therapeutic treatment of allergic symptoms by blocking at any one stage in the chain of the three stages. Therapy which is expected to produce some efficacy has been developed by the development of drugs acting on one of the three stages in the onset of allergic symptoms.
These chemotherapeutic agents, however, cannot completely block the chain of the above-mentioned three stages. Thus, use of a combination of several drugs has been adopted based on an idea of realizing complete blocking of the chain by combined use of a drug acting on one of the three stages with a drug acting on another, but the results are not as expected.
Then, it is expected that development of a drug acting on plural stages of the three stages in the onset of allergic symptoms would drastically improve the effects as an antiallergic agent, and development of such drugs is desirable.
It is also conceivable on the basis of mechanism of the onset of allergic symptoms that superior antiallergic agents would become available if a peptide of IgE antibody origin or a peptide analogous to such peptide is developed. Development of novel peptides by the above-mentioned approach is also expected.
SUMMARY OF THE INVENTION
Under such circumstances, an attempt was made by us of a new design of derivatives related to pentapeptides of IgE antibody origin for the development of pentapeptides with a higher activity.
We designed a new pentapeptide having the primary structure
Asp-Ser-Asp-Gly-Lys
and made investigations of its inhibitory activities on the release of chemical transmitters. As a result, we have found that the pentapeptide exerts an activity higher than that of the pentapeptide of IgE antibody origin specifically in inhibition of histamine release.
Surprisingly, the novel pentapeptide also possesses an activity of inhibiting IgE antibody production in addition to the above-mentioned activity of inhibiting histamine release.
The present invention accordingly relates to a novel physiologically active peptide having the primary structure
Asp-Ser-Asp-Gly-Lys
and pharmaceutically acceptable salts thereof which have an activity of inhibiting the IgE antibody production simultaneously with an activity of inhibiting the histamine release, as well as antiallergic agents containing the same as an active ingredient.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 indicates results of an analysis by high performance liquid chromatography of the novel peptide of the invention in which the vertical axis represents the intensity of ultraviolet absorption at 210 nm and the horizontal axis represents the elution time (minute).
FIG. 2 indicates an infrared absorption spectrum of the present compound.
FIG. 3 is a graph indicating the ratio of histamine release (%) caused by the present compound, in which the vertical axis represents the ratio of histamine release (%) and the horizontal axis represents the molar concentration of the present compound or a control substance.
FIG. 4 is a graph indicating the activity of IgE antibody produced by pretreatment with the present compound.
FIG. 5 is a graph indicating the activity of IgE antibody produced when administered during duration of IgE antibody production.
In FIG. 5 the portion with slashed lines indicates the antibody titer in heat-treated serum. In FIGS. 4 and 5 the vertical axis respectively represents the antibody titer and the horizontal axis represents dose (mg/kg) of the present compound and the control.
DETAILED DESCRIPTION OF THE INVENTION
According to the present invention there are provided a novel peptide having the primary structure
Asp-Ser-Asp-Gly-Lys
or pharmaceutically acceptable salts thereof.
Further, according to the invention there are provided antiallergic agents containing as an active ingredient the above-mentioned peptide or a pharmaceutically acceptable salt thereof.
The invention also provides a method for the prevention or therapy of allergies which comprises administering to patients with allergic diseases an effective dose of the above-mentioned peptide or a pharmaceutically acceptable salt thereof.
The present invention covers pharmaceutical preparations comprising the present compound or a medicinally acceptable salt thereof together with pharmaceutically acceptable carriers or diluents. Preferable examples of the salts include salts with an alkali metal such as sodium or potassium and salts with a metal such as an alkali earth metal, for example, calcium or magnesium, ammonium salts, salts with an organic base, salts with an organic acid and salts with an inorganic acid. The present preparations may be formulated so that the active ingredient is released rapidly, continuously or sustainedly following administration to patients.
The antiallergic agents according to the invention may appropriately be in the form either for oral administration or for parenteral administration. They can be administered by various routes typical of which are oral, rectal, cutaneous, subcutaneous, intravenous, intramuscular, inhalative and nasal ones.
The antiallergic agents of the invention can be administered in various forms of pharmaceutical preparations by the various routes. As these pharmaceutical preparations are mentioned tablet, hard capsule, soft capsule, granule, powder, troche, suppository, syrup, cream, ointment, cataplasma, injection, suspension, inhalation, aerosol and the like. They may also be formed into bilayer tablet or multilayer tablet together with other antiallergic agents and drugs. The tablet can further be coated, as needed, by a conventional method to prepare sugar coated tablet or enteric coating tablet, for example.
In forming solid preparations such as tablet, granule and powder, known additives such as lactose, sucrose, glucose, crystalline cellulose, corn starch, calcium phosphate, sorbitol, glycin, carboxymethylcellulose, hydroxypropylcellulose, gum arabic, polyvinylpyrrolidone, polyethylene glycol, magnesium stearate and talc may be added.
In producing semi-solid preparations such materials as vegetable wax, microcrystalline wax and fat, for example, tallow or lanolin may be added.
In preparing liquid preparations such materials as sodium chloride, sorbitol, glycerin, olive oil, armond oil, propylene glycol, and ethylene glycol may be added.
Dosage of the present compound is 0.01-10 mg/kg/day in oral administration, 0.1-100 mg per shot in nasal administration and 10-1,000 μg/kg/day in parenteral administration, although it may appropriately be increased on decreased depending upon age, bodyweight and symptom of the patient.
The substance of the invention which is a novel peptide having a primary structure
Asp-Ser-Asp-Gly-Lys
was newly designed by the reasons given below. First, Pro of the C terminal Pro-Arg of the above-mentioned Asp-Ser-Asp-Pro-Arg was substituted with Gly which is a neutral amino acid in the same category. Then, the basic amino acid Arg was replaced by Lys which is a most homologous one.
The substance of the invention produces a single peak by reverse phase HPLC (ODS column, YMA-D-ODS, 20 mm×250 mm) with solvents of the gradient 0.1% TFA→70% CH 3 CN. The composition is confirmed by the peptide map after enzymatic degradation and the analysis of amino acid after hydrolysis.
The present substance can be prepared either in solid phase or in liquid phase by a conventional method. For example, according to a solid phase technique generally called the Merrifield method, the preparation can be effected as described below by means of the synthesizer Model 990B manufactured by Beckman.
First, a C terminal amino acid of the present substance protected with tertiary butoxycarbonyl group (called Boc for short) at the N terminal is fixed on a chloromethyl resin carrier through an amide bond or an ester bond. More particularly, for example, chloromethyl resin is coupled with Boc-Lys[Z(2Cl)], Boc-Gly, Boc-Asp(OBzl) or Boc-Ser(Bzl). The Boc is then eliminated with an acid. The resin is coupled with an amino acid second to the C terminal in which the N terminal and, if necessary, a functional group of the side chain of the amino acid have in advance been protected to form a peptide. In this reaction, the protected amino acid employed is in an amount of 3-5 times of the theoretical amount, and dicyclohexylcarbodiimide (called DCC for short) is used as a coupling reagent. End point of the reaction is confirmed when reaction of the amino group with ninhydrin becomes negative. Amino acids in which N terminal and, if necessary, a functional group of the side chain of the amino acids are protected are successively reacted in the order of amino acid sequence in the primary structure of the present substance finally to give the present substance with functional groups and N terminal protected. Finally, the resulting substance is treated with hydrofluoric acid to eliminate the protective group and to be released from the resin. In order to prevent side reactions anisole is added in the final treatment. The crude product obtained by removing the hydrofluoric acid may be purified by ion exchange column chromatography. Purity is confirmed by high performance liquid chromatography. If necessary, further purification by preparative high performance liquid chromatography can produce the present substance in pure form. Confirmation of the structure and purity of the present substance could be carried out by means of high performance liquid chromatography, peptide map, amino acid analysis and others.
The present invention is directed to a novel pentapeptide derived from the pentapeptide corresponding to Fc region of IgE antibody, which specifically inhibits the histamine release on the basis of IgE antibody. The novel pentapeptide also inhibits production of the IgE antibody, a factor causing allergy. It is therefore expected that the novel pentapeptide is useful as a therapeutic agent for preventing or curing allergic diseases caused not only by release of chemical transmitters such as histamine but also by increase in the IgE antibody. These two aspects of action possessed by the novel pentapeptide may result in blocking two of the three stages of the chain in the onset of type I-allergic reactions without combined use of plural drugs. Since components of the novel pentapeptide is natural amino acids, the product will easily be metabolized in the body with high safety associated.
The present invention will be described in particulars with reference to an example given below.
EXAMPLE
In the reaction tank of a peptide synthesizer Model 990B manufactured by Beckman is placed 1.50 g of Boc-Lys[Z(2Cl)]-chloromethyl resin [containing 0.33 mmol/g of Boc-Lys[Z(2Cl)], manufactured by Vaga Boichem], which is stirred in CH 2 Cl 2 for 2 hours to swell.
Then, the next component Boc-Gly is reacted by stepwise procedures as set forth below.
(1) Wash with 20 ml of CH 2 Cl 2 for 2 min./three times.
(2) Wash with 20 ml of MeOH for 2 min./three times.
(3) Wash with 20 ml of CH 2 Cl 2 for 2 min./three times.
(4) Wash with 20 ml of 45% TFA and CH 2 Cl 2 for 5 min./once.
(5) Wash with 20 ml of 45% TFA and CH 2 Cl 2 for 15 min./once.
(6) Wash with 20 ml of CH 2 Cl 2 for 2 min./three times.
(7) Wash with 20 ml of MeOH for 2 min./three times.
(8) Wash with 20 ml of CH 2 Cl 2 for 2 min./three times.
At this point, positive amino group reaction is confirmed with ninhydrin.
(9) Wash with 20 ml of 10% TFA and CH 2 Cl 2 for 2 min./once.
(10) Wash with 20 ml of CH 2 Cl 2 for 2 min./three times.
(11) Dissolve 4 equivalents of a Boc-protected amino acid and 10 ml of CH 2 Cl 2 in a mixed solution of 2 equivalents of DCC and 5 ml of CH 2 Cl 2 , add the solution and then shake in ice water for 20 min. to effect the reaction. Dry precipitates thus produced followed by suction filtration on a glass filter to obtain a Boc-amino acid anhydride.
(12) Wash with 20 ml of CH 2 Cl 2 for 2 min./three times and confirm negative amino group reaction with ninhydrin.
(13) Wash with 20 ml of MeOH for 2 min./three times.
(14) Wash with 20 ml of CH 2 Cl 2 for 2 min./three times.
Introduction of Boc-Gly is completed by the above procedures.
Subsequently, the steps (1) to (14) are repeated successively for Gly through the N terminal. The protected amino acids are added in the order shown below.
Boc-Asp(OBzl): 1.50 g,
Boc-Ser(OBzl): 1.50 g,
Boc-Asp(OBzl): 1.50 g.
Completion of the above procedures results in synthesis of the protected peptide
Boc-Asp(OBzl)-Ser(Bzl)-Asp(OBzl)-Gly-Lys[Z(2Cl)]-resin.
The protected peptide on the resin is filtered off after the above-described steps (1)-(14) conducted and dried overnight in a desiccator. There is obtained 1.94 g of the dried protected peptide-resin. It is treated with 30 ml of hydrofluoric acid in the presence of 2 ml of anisole and 0.5 ml of DMS at 0° C. for 1 hour. The hydrofluoric acid is distilled off, and the residue is washed with anhydrous ether-n-hexane (1:1) mixture and then with anhydrous ether alone and thoroughly dried. The peptide is dissolved in 50 ml of 10% acetic acid, and undissolved resin is filtered off.
The solution thus obtained is placed on a Dowex I-X2 column (1×15 cm) followed by elution with 2N acetic acid. The solution thus produced is filtered through a 0.22μ milipore filter and freeze dried. There is obtained 360 mg of a crude peptide. It is further subjected to high performance liquid chromatography under the conditions:
Column: YMC-D-ODS 20 mm×250 mm
Solvent: Solvent composed of 0.1% TFA and CH 3 CN mixed in a proportion with a gradient from 0% to 70%
Flow rate: 1.0 ml/min.
By said high performance liquid chromatography is produced 46.8 mg of a pure peptide with a purity of 97%. This corresponds to a yield of 13%. The pure peptide thus obtained are measured for peptide map and amino acid analytical value and are confirmed to be the present substance. Codes for the description are:
Z(2Cl): 2-chlorobenzyloxycarbonyl
Bzl: Benzyl.
Results of analysis of high performance liquid chromatography carried out for the novel peptide of the invention under separation conditions given below are shown in FIG. 1.
Eluent: 0.1% TFA-H 2 O
Flow rate: 1 ml/min.
Detection: 210 nm
Column: YMC R-ODS (4.6 mm×250 mm).
The infrared absorption spectrum is shown in FIG. 2.
The novel peptide of the invention has characteristic physical properties:
Hydrophobity (Hφ): 1.86
Molecular weight: 520.6
Isoelectric point: 3.7
Results of amino acid analysis carried out for the product of the example are shown below for reference.
After a hydrolysis reaction in 6N HCl (containing 0.1% phenol) at 110° C. for 24 hours, analysis was made using a Hitachi amino acid analyzer model 835. As shown below experimental values well corresponded to the theoretical values to establish that the produce was the desired substance according to the invention.
______________________________________Amino acid Theoretical value Experimental value______________________________________Asp 2.0 2.0Ser 1.0 1.0Gly 1.0 1.1Lys 1.0 1.0______________________________________
Effect of the invention will be shown below with reference to test examples.
TEST EXAMPLE 1
Inhibitory activity on histamine release from mast cells was tested to investigate antiallergic action of the compound of the invention.
Method
Male Wistar rats weighing 300-350 g were passively sensitized, intraperitoneal mast cells of which were then employed. Rat antiserum for use in the passive sensitization were prepared in accordance with the method of Mota [Immunology, 7 p. 681 (1964)] and the method of Hamaoka [J. Immunology, 113, p. 958 (1974)]. Male Wistar rats (weighing 200-250 g) were each injected with eggwhite albumin (10 mg/kg) intramuscularly on the both thighs in a volume of 5 ml/kg simultaneously with intraperitoneal administration of 2×10 10 cells of killed Bordetella pertussis for immunization. Blood was drawn from the abdominal aorta under ether anesthesia on the 12th day of the initial sensitization, and antiserum was separated. The antiserum was lyophilized and stored at -20° C. Titer of the antiserum was measured by the 48 hr. rate PCA reaction. The antiserum with a titer multiplied 128-256 fold was placed for the experiment. The eggwhite albumin rat IgE serum was diluted two fold, and 1 ml of the diluted serum was intraperitoneally administered for sensitization. The rat was blooded to death 48 hrs. after the sensitization, and 15 ml of a phosphate buffer solution (8 g of NaCl, 0.2 g of KCl, 2.88 g of Na 2 HPO 4 .12H 2 O, 0.2 g of KH 2 PO 4 , 0.2 g of EDTA 2 Na and 1 g of bovine serum albumin dissolved in purified water to 1 lit., pH 7.4, called PBS (-) for short hereinbelow) was intraperitoneally injected. The rat was then given light abdominal massage for ca. 2 min. and subjected to laparotomy to collect cells in the abdominal cavity. The cell suspension was centrifuged (1,000 rpm, 10 min.) and then resuspended in BPS (-). The BPS (-) suspension was overlayered upon gum arabic density (specific gravity 1.075) followed by centrifugal separation (2,500 rpm, 10 min.). Deposited cells were washed twice with BPS (-) and suspended in fresh PBS [solution in which the EDTA 2 Na in PBS (-) is replaced by 0.1 g of CaCl 2 , called BPS (+) for short] and adjusted to 1×10 5 cells/ml. The cell suspension was divided in a volume of 0.8 ml per tube into silicon-treated test tubes, which were then preincubated at 37° C. for 10 min. In the test tube containing the cell suspension was placed 0.1 ml of the test solution with a concentration adjusted with PBS (+) followed by incubation at 37° C for 15 min. To the test tube was then added 0.1 ml of a mixed solution of eggwhite albumin antigen (final concentration 1 mg/ml) and phosphatidyl-L-serine (final concentration 100 μg/ml) followed by incubation for additional 15 min. to suspend the histamine from mast cells. DSCG was added 30 sec. prior to the addition of antigen. After addition of the antigen, incubation was made for additional 15 min. Then, 1 ml of ice-cooled PBS (+) was added to terminate the reaction followed by centrifugal separation at 2,500 rpm for 10 min. To 2 ml of the supernatant was added 1 ml of 4% solution of perchloric acid for use as the sample for the determination of free histamine. For total histamine, 0.8 ml of an untreated mast cell suspension (1×10 5 cells/ml) was placed in boiling water for 10 min. followed by addition of 4% perchloric acid to prepare the sample for the determination of total histamine.
Histamine in each sample was measured by fluorimetry, and ratio of histamine release (%) was calculated by the following equation: ##EQU1##
Results
Ratio of histamine release (%) at each concentration of the present compound was shown in FIG. 3 of the attached drawing. As clearly seen from FIG. 3, the present compound exerted an inhibitory action on histamine release at a concentration of 10 -6 M. The potency was approximately equal to or higher than that of DSCG.
TEST EXAMPLE 2
Inhibitory activity on IgE antibody production was tested in mice in order to investigate antiallergic action of the present compound.
Method
Groups of five male BALB/c mice (20-25 g) were used as the immunized animal. An antigen, 10 μg of DNP-BSA was adsorbed on 4 mg of aluminum hydroxide gel, an immunoenhancer. Experiments were carried out by the method described below.
In Test 2-1, 1 mg and 10 mg of the present compound respectively were intraperitoneally given, 30 min. later the DNP-BSA was intraperitoneally administered and on the 14th day blood was drawn to obtain serum.
In Test 2-2, the DNP-BSA was intraperitoneally administered and on the 13th day, 1 mg and 10 mg of the present compound respectively were intraperitoneally given. On the next day the animal was again immunized with the DNP-BSA, and on the 14th day of the immunization blood was drawn to obtain serum.
Antibody titer was measured by the rat 48 hr. PCA reaction for the serum obtained in Tests 2-1 and 2-2.
In particulars, male Wistar rats (200-250 g) were sensitized with the serum subcutaneously on the back, and 48 hrs. later DNP-BSA solution containing 0.5% Evans blue was intravenously injected on the tail. Antibody titer was measured after 30 min. by developed pigment spot. In order to confirm that the antibody titer as obtained by the PCA reaction is for IgE, the serum was heat-treated at 56° C. for 3 hrs., in addition to the untreated run, and antibody titer was measured by the PCA reaction.
Results
IgE antibody production at each concentration of the present compound was shown in FIG. 4 and FIG. 5 of the attached drawing in terms of the antibody titer determined by the PCA reaction. As clearly seen from FIG. 4 and FIG. 5, the present compound strongly inhibited IgE antibody production at concentrations of 1 mg and 10 mg, respectively. The antibody titer of the heat-treated serum was 0 for the serum in Test 2-1 (FIG. 4) but was slightly positive for the serum in Test 2-2 as shown in FIG. 5 (slashed lines). | Novel peptide having the primary structure Asp-Ser-Asp-Gly-Lys or pharmaceutically acceptable salts thereof.
The present peptide possesses activity of inhibiting histamine release and IgE antibody production in the onset of type I-allergy and is effective in the prevention or therapy of type I-allergias such as bronchial asthma, urticaria and allergic rhinitis. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to a rotor shroud assembly in a gas turbine engine. In particular, it concerns the control of the clearance between the tips of the rotor blades of a turbine rotor and the encircling shroud assembly.
The radial growth of a bladed turbine rotor disc at any point in an engine operating cycle is governed by three factors namely:
The thermal growth of the rotor disc, which is influenced by the temperature of the high pressure compressor delivery cooling air;
The thermal growth of the turbine blades, which is influenced by the temperature of the combustion gases; and
The centrifugal growth of a complete bladed rotor disc.
As a result of engine accelerations, blade thermal growth and bladed rotor disc growth factors respond very quickly. The disc thermal growth factor responds more slowly because of the greater bulk of the disc relative to that of the rotor blades.
These various growth changes affect the clearance between the tips of the rotor blades and the shroud surrounding those blades, and it is important for the purpose of engine operating efficiency that this clearance be controlled at all stages of engine operation.
It is conventional practice to surround the bladed rotor disc with a segmented shroud liner ring having an internal diameter slightly larger than the outside diameter of the blades of the disc so that a small clearance exists between the liner ring and the blade tips. The shroud liner ring comprises a number of segments each of which may change its radial position relative to the adjacent segments. When the engine is running, the liner segment is subject to the same high temperature exhaust gases as pass over the turbine blades so, as the blades change their length, and thus the diameter of the rotor changes, the ring of liner segments also changes its diameter.
It is relatively easy to control the turbine shroud liner segments by means of a control ring so that the shroud liner segments closely follow rotor disc growth at engine steady state conditions. As the major part of the bladed rotor growth is attributed to disc thermal expansion, the control ring is required to have a similarly slow response. However, having matched the control ring with the bladed rotor, problems arise when rapid acceleration and deceleration take place. To follow, as closely as possible, bladed rotor tip movement, the control ring growth must be boosted at the early stages of the acceleration cycle and attenuated at the early stages of the deceleration cycle.
SUMMARY OF THE INVENTION
According to one aspect of the invention, there is provided a gas turbine engine rotor seal for surrounding a rotor assembly of circumferentially spaced blades, each having a radial tip, comprising:
a plurality of arcuate shroud liner segments encircling the rotor assembly, each segment being mounted for radial movement and has a radially inner surface spaced from the tips of the blades by a pre-determined clearance,
a first control ring having a relatively rapid radial response to thermal change,
a second control ring having a relatively slow radial response to thermal change,
a mounting device coupled with the first and second control rings and supporting each of the shroud segments such that the radial position of each segment is continuously controlled by the thermal expansion of the first and second control rings in combination.
In a preferred arrangement, the coupling device comprises a rod extending through spherical bearings carried in the first and second control rings, and the mounting device comprises a spherical bearing in the shroud liner the spherical bearing supporting the rod between the spherical bearings in the first and second control rings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example, with reference to the accompanying drawings in which:
FIG. 1 shows a sectional side view of a control ring arrangement used in co-operation with a turbine bladed rotor disc,
FIG. 2 shows a cross-section along the line 2--2 of the control ring arrangement shown in FIG. 1,
FIG. 3 is a view in the direction of arrow X in FIG. 2, and
FIG. 4 illustrates thermal growth against time of the rotor disc.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, a turbine rotor blade 1 is shown located between a pair of guide vanes 2,3 and is secured to a central mounting disc 4 in a known manner, not shown. The blade 1 is one of an array of blades mounted for rotation within a duct 5 that comprises a forward cylindrical part 6 and a rearward diffuser duct member 7. The part 6 and member 7 are spaced apart to receive a shroud liner segment 8 having forward and rearward outwardly extending flanges 9,10 respectively. Flange 9 is engaged by a sealing ring 12 positioned within a recess 13 in the rear end of cylindrical part 6, whilst flange 10, which is longer than flange 9, engages a sealing ring 14 positioned within a recess 15 in a diaphragm 16 at the forward end of the diffuser duct 7.
A locating ring 17 extends forwardly from the diaphragm 16 and carries an annular flange 18 at its forward end to which a control ring member 19 is secured. Control ring member 19 includes a radially outer mounting ring 21, a central web portion 22 to which is secured a mass of thermal insulation material 23 enclosed within shield members 24,25, a forwardly directed flange 26 and an inwardly directed flange 27. The ring member 19 is heavily insulated such that it has a response rate to temperature change matched to that of the rotor disc. The radially inner flange 27, ata plurality of locations spaced apart circumferentially, is adapted to carry a suspension member 29. There are as many locations and members 29 as there are liner segments 8, and each member 29 supports a liner segment8. In the illustrated example the member 29 consists of an actuation rod one end of which is located in the flange 27 of ring 19 by means of a spherical bearing.
A second control ring 35 is also secured to the annular flange 18 by means of a resilient, annular member 32. This member 32 consists of inner and outer mounting rings 31,33 and an interconnecting annular web 34 of zig-zag radial section. The outer ring 33 is secured to the annular flange18, together with the outer mounting ring 21 of the first control ring 19. The zig-zag section web 34 depends from the ring 33 and suspends the innermounting ring 31 which carries the second control ring 35.
The ring 35 is of lightweight construction, it is of relatively thin gauge,is uninsulated and is pierced by a multiplicity of apertures 40,41 through which air bled from the engine compressor may pass. It is normal to bleed this air from the high pressure (HP) compressor for internal cooling purposes. Thus, it serves a dual purpose in the invention: first to warm or cool, as appropriate, the tip clearance control rings and second to fulfil its conventional air cooling function.
The second control ring 35 is provided with annular stiffening flanges 36,37 spaced apart in a radial direction. Around its radially inner circumference it is adapted to carry the plurality of suspension members 29 at locations spaced apart circumferentially. As mentioned above, in connection with the first control ring 19, the member 29 consists of an actuation rod one end of which is located in the first ring flange 27 by aspherical bearing. The opposite end of rod 29 is also located by means of asecond spherical bearing in the second control ring 35. Thus, the actuationrods 29 are mounted at opposite ends between two control rings 19,35, whichexpand and contract at different rates in response to changes in their thermal conditions.
Each shroud liner segment 8, as can be seen in FIGS. 1 and 2, is supported by a backing plate 44 formed with an upstanding pillar 43 located in a circumferential direction towards one end of a segment and mid-way betweenits upstream and downstream. Backing plate 44 spans the distance between the flanges 9,10 of the shroud liner 8. Alternatively, the plate 44 may beomitted and the pillar formed integrally with a liner segment substrate. Each liner segment 8 is suspended from the actuation rod 29 by means of a spherical bearing 42 carried in pillar 43. A spigot 47 extends from the pillar 43 and is located in a recess in the flange 26 in order to control the pitch attitude of the shroud liner 8. The plate 44 may have recesses in its edges that abut flanges 9 and 10 to enable the passage of air between the radially outer and radially inner surfaces of the plate. As can be seen in FIG. 2, the shroud liner 8 comprises a number of segments pinned together by means of pin and slot connections 45,46 to allow for expansion and contraction of the annulus formed by the segments. The suspension bearing is located towards one end of a liner segment, in a circumferential direction. The opposite end of the segment backing member is stepped and overlapped with the adjacent edge of a neighboring segment for support. This end is this close to the suspension point of the neighboring segment.
The turbine section liner 6 together with engine casing 48 defines a passageway 50 which is blanked-off by diaphragm 16. HP compressor air is fed into the passageway at an upstream location, not shown in the drawings. A metered proportion of this air is allowed to escape as film cooling air through a multiplicity of cooling holes 52 circumferentially spaced apart around the upstream edge of the shroud annulus. Further film cooling air is permitted to escape in a controlled way through gaps 54 at the downstream edge of the shroud segments 8. Thereby a governed flow of compressor bleed air is established through the passageway 50 in which is housed the tip clearance control rings 19,35, controlling the radial position of the shroud liner segments 8. Since the pressure to which a gasis raised by a compressor is a function of engine speed, then the temperature of the gas is also a function of speed. Thus, the temperature of the gas flowing through the passageway 50 is dependent upon the operating speed of the engine.
The control ring arrangement used to control the blade tip clearance comprises two separate control rings 19 and 35. The ring 19 is heavily slugged with heat insulating material, is therefore slow to response and duplicates the thermal expansion of the turbine disc. The ring 35 in contrast is lightly constructed, is therefore quick to respond and duplicates the centrifugal expansion of the turbine disc and the thermal expansion of the turbine blades. The individual segments 8 forming the shroud liner ring are individually suspended by a member coupled to both control rings 19 and 35. In operation, therefore, the radial position of the liner segment 8 is determined by radial positions of the spherical bearings 42 on actuation rods 29. Because opposite ends of the rods 29 arecarried by the fast and slow control rings 35,19 and the bearings 42 are mid-way between the rod ends their positions are always the average of thepositions of the ends. The contributions of the two control rings are equally weighted. However, these weightings may be altered so that one or the other of the control rings exerts greater influence on the segment positions by displacing the suspension bearing 42 towards the corresponding control ring.
A still further arrangement may be envisaged wherein the actuation member 29 is cantilevered from the control rings and carries the segment suspending bearing 42 towards one end. The member 29 may be journalled at a mid-portion in the slow control ring 19 with the first control ring 35 disposed at the opposite end of the member. The ratio of the distances between the segment bearing 42 and the two control rings again determines their respective influences.
The phases of rotor assembly expansion, and in reverse contraction, is illustrated in FIG. 4. When the engine is accelerated the turbine tips move rapidly outwards due to both the rapid thermal growth of the blades and the centrifugally generated growth of the turbine disc. This happens within a few seconds. Simultaneously the shroud liner 8 expands rapidly asthe segments are pulled out by the thermal expansion of the control ring 35. Thereafter, the blade tips move slowly outward due to thermal expansion of the turbine disc while the shroud liner segments are slowly pulled out by the thermal expansion of the heavily insulated control ring 19. This happens much more slowly over a period of several minutes. The reverse happens when the engine is decelerated.
The arrangement described provides continuously variable control of the clearance between the turbine blade tips and the shroud liner to be maintained at a reduced level thereby providing an increase in engine efficiency. The manner in which each of the control rings contributes to the control of the tip clearance gap can be tailored to suit requirements.The thermal response of both control rings may be adapted as needed. The response of the slow response ring may be varied by altering the properties of the insulation and the thermal expansion properties of the material of the ring itself. Similarly the fast response ring may be altered by choice of material and design to follow the temperature of the HP air more, or less, closely. Also, as mentioned above, the degree to which each control ring influences the position of each shroud liner segment is determined by the spacing between the bearings carried by the control rings and the segment supports. | In a gas turbine engine tip clearance between rotor blades and an encircling shroud liner is controlled by moving the shroud liner radially to match the thermal and centrifugal growth of the rotor assembly. The shroud liner segments are suspended between two axially displaced control rings located in a passageway carrying air ducted from the compressor. One control ring responds very quickly to changes in gas temperature corresponding to centrifugal growth and blade thermal growth. The other ring responds very much more slowly and corresponds to the thermal growth of the disc. The shroud liner segments are suspended from the control rings to adopt a position that constitutes the average between the growth positions of the two control rings. | 5 |
PRIORITY INFORMATION
[0001] This patent application is a divisional of co-pending U.S. application Ser. No. 11/587,070 filed Dec. 18, 2006.
BACKGROUND INFORMATION
[0002] This invention relates to the field of gas sensors and in particular to sensors that detect reducing gases, alcohols or hydrocarbons.
[0003] Carbon monoxide (CO) is an odorless, toxic, and explosive gas, arising during incomplete combustion of carbon or its compounds. The amounts of CO formed depend on the degree of oxygen deficit during the combustion and may reach the range of several volume percent. There is thus a great need for CO alarms that are triggered when a given maximum workplace concentration (MWC) value is exceeded. This value, for example, will be MWC=30 vpm. Typical applications occur in monitoring the air in buildings where CO can occur due to incomplete combustion, such as in underground garages, multistory parking garages, street tunnels, apartments with furnace units, or industrial environments.
[0004] Since CO is also generally formed in fires, the detection of an elevated concentration can also be used as a fire alarm. Another very important application is in automotive air quality sensors, which measure the quality of the outside air and switch the passenger compartment ventilation to recirculated air when the air quality becomes substantially impaired due to other vehicles in the area. In this case, the exhaust gases of internal combustion engines are detected in terms of CO as the monitor gas in the range of several ppm.
[0005] Many applications require economical sensors which, while they typically only detect threshold values of CO concentration, must nonetheless be very reliable. At the same time, they should have a long lifetime, minimal maintenance expense, and a low power requirement. The power requirement should be so low as to allow several months of battery operation or direct connection, without auxiliary power, to data bus lines.
[0006] Due to the need for safety and the broad applicability of CO measurement, a large number of different measurement systems are already in use today. For highest demands, expensive nondispersive infrared (NDIR) devices are used. More economical are CO sensitive electrochemical cells. However, for many applications the price of these cells is still too high and sensor systems built from them require a high maintenance expense, since the lifetime of the individual sensors is relatively short. In the lower price range are the metal oxide sensors, especially those based on SnO 2 or Ga 2 O 3 , whose gas reaction can be read off in terms of their change in conductance. These sensors, however, are operated at relatively high temperatures; for example, SnO 2 sensors at >300° C. or Ga 2 O 3 sensors at >600° C. A high power consumption is therefore needed to reach the operating temperature. Also, these sensors are not suitable for many applications, such as fire protection, due to the need for battery operation or a direct connection, generally without auxiliary power, to the data bus.
[0007] For this reason, CO sensors are used only when required by law and therefore one must incur the necessary expenditures such as high sensor costs and furnishing the required operating power to the sensors. Outside of mandatory use, CO sensors are only employed when indispensable, e.g., for the regulating of devices and systems, and the operating power is available without additional expense, such as in motor vehicles or small furnace units. As soon as these conditions are lacking, the use of CO sensors is abandoned, even if they would be desirable for safety reasons.
[0008] Gas sensors, which use the change in the electronic work function of materials when interacting with gases as the measurement sensing technique, are suitable in theory for operating at relatively low temperatures and therefore with a low power requirement. One takes advantage of the possibility of feeding the change in work function of gas-sensitive materials to a field-effect transistor (GasFET), thereby measuring the change in work function as a change in current between the source and drain of the transistor. Typical designs are known from German Patent DE 42 39 319. The relevant technology for constructing these sensors is specified in German Patent DE 19956744.
[0009] Measurement of ethanol in the gas phase is used, for example, to deduce from the concentration of alcohol vapor in exhaled air the corresponding concentration in the blood. This is where small mobile devices are of interest, for example those which can operate with batteries or storage cells.
[0010] What is needed is a sensor for the detection, in particular, of reducing gas or gaseous alcohol, using the least possible amount of power for operation, as well as a method of fabrication and operation thereof.
SUMMARY OF THE INVENTION
[0011] Briefly, according to one aspect of the invention, an FET-based gas sensor includes at least one field-effect transistor and at least one gas-sensitive layer and a reference layer. Any changes in work function occurring when materials of the layers are exposed to a gas are used to trigger the field-effect structure. The gas-sensitive layer comprises a metal oxide having an oxidation catalyst on its surface and accessible to the measured gas.
[0012] The present invention provides a number of advantages, including: operation with low power consumption, battery operation, or direct connection to data bus lines; small geometrical size, facilitating the creation of sensor arrays; possibility of monolithic integration of the electronics into the sensor chip; and use of sophisticated, economical methods of semiconductor fabrication.
[0013] The following two types of transistors are of special interest: suspended gate field effect transistor (SGFET); and capacitively controlled field effect transistor (CCFET). Both types are characterized by their hybrid construction, i.e., the gas-sensitive gate and the actual transistor are made separately and joined together by a suitable technology. In this way, it is possible to introduce many materials into the transistor, whose fabrication conditions are not compatible with those of silicon technology. This applies, in particular, to metal oxides, which can be laid down by thick or thin layer technology.
[0014] The invention as it applies to reducing gases, such as CO or H 2 , and to alcohols or hydrocarbons, is designed to use, in an FET-based construction, a sensitive material consisting of a metal oxide, as well as an oxidation catalyst situated on the surface thereof which is accessible to the measured gas. Usually, fine dispersions of the catalyst are used.
[0015] Such systems exhibit a sudden and reversible change in their electronic work function when exposed to reducing gases in humid air and at typical operating temperatures between room temperature and 150° C. An example discussed further below is illustrated in FIG. 1 . The change in the electronic work function for the relevant gas concentration range of the aforesaid applications is approximately 10-100 mV and thus is large enough to be detected with hybrid technology FET gas sensors.
[0016] The mode of functioning of these layers is based on charged adsorption of the molecules being detected on the metal oxide. The catalyst material applied serves essentially to allow these reactions to occur already in the aforesaid temperature range.
[0017] These and other objects, features and advantages of the present invention will become more apparent in light of the following detailed description of preferred embodiments thereof, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a graph that illustrates the change in work function of a sensitive layer based on SnO 2 with Pd as the catalyst, when exposed to CO in humid air, at room temperature;
[0019] FIG. 2 is a graph that illustrates a Kelvin measurement of a Ga 2 O 3 thin layer, provided with a catalyst made of finely divided platinum, the sensor temperatures lying between approximately 120° C. at 2.5 V heating voltage and approximately 220° C. at 4 V heating voltage; and
[0020] FIG. 3 is a graph that illustrates a reaction of a Pd-activated SnO 2 layer to ethanol at various temperatures.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Oxides such as SnO 2 , Ga 2 O 3 or CoO have proven to be especially suitable metal oxides for the detection of CO and other reducing gases. These oxides have very high stability under various environmental conditions. One can also use mixtures of different metal oxides, preferably with a fraction of one of the mentioned materials.
[0022] These materials are prepared as layers, for which one can use either cathode sputtering, silk screen methods, or CVD methods. Typical layer thicknesses lie between 1 and 3 μm. It is especially advantageous to produce a porous, e.g., an open-pore, layer of the metal oxide.
[0023] The reactivity of metal oxides at low temperatures is supported by the application of catalysts, such as oxidation-active catalysts, preferably from the group of the platinum metals or silver. The preferred metals are Pt or Pd, Rh or mixtures of these materials. The metals should preferably be present in the form of small particles, “catalyst dispersion” or “catalyst clusters,” with typical dimensions of 1-30 nm. As a result, the catalytically active metals can very often influence, i.e., increase the gas reactivity of, the metal oxides beyond the three-phase boundary (metal/metal oxide/gas).
[0024] The catalyst clusters are preferably deposited by an impregnation method, in which a salt of the precious metal is dissolved in a solvent wetting the surface of the metal oxide and this solution is applied to the surface of the prepared metal oxide. After drying, the salt is now chemically decomposed and the metallic catalyst cluster is formed. As an alternative, one can use a PVD method (e.g., cathode sputtering) to deposit a very thin (<30 nm) whole-surface layer of the catalyst. In a subsequent tempering step in the range of 600-1000° C., the whole-surface layer breaks down and once again the catalyst clusters result in the required size.
[0025] Economical CO sensors with a low power requirement are available for applications not heretofore served, for lack of the appropriate sensors.
[0026] For the first time, a sensitive layer exists with which, on the basis of or in combination with FET sensor engineering, sensors are available for reducing gases that have very low operating temperatures and operating powers.
[0027] Measurements with the Kelvin method have been performed to confirm the stability of the sensor signal, showing a CO detection at temperatures distinctly below the operating temperatures of SnO 2 and Ga 2 O3 conductance sensors. The measurements are done on Pt and Pd activated thick and thin layers, by measuring the work function.
Sensor Preparation/Preparation of Sensitive Layers
EXAMPLE 1
[0028] The foundation is a sputtered Ga 2 O 3 thin layer with 2 μm thickness on sputtered platinum as the backside contact. Catalytic activation is done with a Pt dispersion, produced by thermal decomposition (at 600° C.) of a wet chemistry solution of a water-soluble platinum complex. The work function is measured at temperatures between approximately 220° C. and 120° C. in moist synthetic air when exposed to CO (1 vol. %), H 2 (1 vol. %), and CH 4 (1000 vpm). The result is illustrated in FIG. 2 . The temperature range of the measurement lies well below the operating temperature of Ga 2 O 3 conductance sensors (T>600° C.) and shows that CO detection is possible with low heating power.
EXAMPLE 2
[0029] A Kelvin probe is produced based on an open-pore SnO 2 thick layer, baked at 600° C. The catalytic activation was done for an aqueous solution of a Pd complex, which is thermally decomposed to form Pd at temperatures between 100° C. and 250° C.
[0030] The Kelvin measurements are carried out at room temperature up to approximately 110° C. in humid synthetic air. FIG. 1 illustrates the Kelvin signal at room temperature at CO concentrations between 2 and 30 vpm CO. The measurement shows that CO can be detected with high sensitivity at low temperatures with this sensitive layer.
[0031] The sensitivity of the same sensitive layer to ethanol is illustrated in FIG. 3 as an example of yet another reducing gas. FIG. 3 illustrates a reaction of a Pd-activated SnO 2 layer to ethanol at various temperatures.
Activation and Reactivation of Gas-Sensitive Layers:
[0032] The gas-sensitive layers have a tendency, when operated continuously for several weeks, to lose their high sensitivity to the target gases at room temperature. This becomes evident by a decrease in signal height, as well as an increase in response time. A remedy is possible by “reactivation” of the layer at regular intervals (e.g., every 4-5 days). The “reactivation” of the layer is done by heating the layer in humid surrounding air to temperatures between 180 and 250° C. for a period of a few minutes to no more than one hour. No other requirements, such as the presence of the target gases or the like, need be met.
[0033] Systems for detection of ethanol by means of a gas-sensitive field-effect transistor in humid air have typical values, such as operating temperature between room temperature and 100° C., as well as sudden and reversible change in electronic work function. The signal level is large enough to perform measurements. When the thickness of the tin oxide layer is uniform, a uniform air gap exists and constant signal levels are obtained.
[0034] Tin oxide and gallium oxide are especially well suited for the detection of ethanol. These oxides have very high stability under various environmental conditions. One can also use mixtures, in which at least one fraction of the aforesaid materials is contained.
[0035] A layer preparation, for example, by cathode sputtering, silk screen method, or CVD method, should produce layer thicknesses of 15 to 20 μm. Porous, especially open-pore, layers of metal oxide are advantageous. The catalyst clusters are produced by depositing a dispersion, followed by moderate tempering of the layer. As an alternative, sputtering techniques can be used for thin films, in which case tempering is again necessary. Pt or Pd can be considered as the catalyst material.
[0036] Although the present invention has been illustrated and described with respect to several preferred embodiments thereof, various changes, omissions and additions to the form and detail thereof, may be made therein, without departing from the spirit and scope of the invention. | An FET-based gas sensor includes at least one field-effect transistor and at least one gas-sensitive layer and a reference layer. Any changes in work function occurring when materials of the layers are exposed to a gas are used to trigger the field-effect structures. The gas-sensitive layer includes a metal oxide having an oxidation catalyst on its surface and accessible to the measured gas. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present invention claims a priority from Japanese Patent Application No. 2007-288077, which was filed on Nov. 6, 2007, the disclosure of which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a water-based infrared absorptive ink for ink-jet recording capable of producing images that absorb infrared light, to an ink-jet recording method using the ink, and to an ink-jet recording apparatus for implementing the method.
[0004] 2. Description of the Related Art
[0005] As inks for producing code marks such as bar codes and OCR characters, infrared absorptive inks capable of producing visually unreadable code marks have been developed to improve security. As such infrared absorptive inks, for example, there were proposed inks in which a cyanine-based or naphthoquinone-based coloring agent is used and inks in which a coloring agent composed of a resin containing powder of tin-doped indium oxide (ITO) is used.
[0006] The above-mentioned infrared absorptive inks in which an organic-based coloring agent is used have a problem that the color tones of the inks may not be controlled, because the inks have absorption in the visible light range. Meanwhile, the infrared absorptive inks in which ITO powder is used have little absorption in the visible light range. ITO powder is an expensive material. In addition, generally, ITO powder is often used in inks containing an organic solvent and other similar inks and cannot be used in water-based inks and in ink-jet recording methods using the water-based inks.
SUMMARY
[0007] It is an object of the invention to provide a water-based infrared absorptive ink for ink-jet recording that absorbs electromagnetic waves in the infrared range without change in the color tone of the ink.
[0008] The present inventor has found that the above object can be achieved by using, as an infrared absorbing agent, antimony-tin composite oxide fine particles (hereinafter, “antimony-tin composite oxide fine particles” may be referred to as “ATO fine particles”) that are less expensive than ITO powder, absorb little visible light, and absorb electromagnetic waves in the near-infrared range.
[0009] An aspect of the present invention provides a water-based infrared absorptive ink for ink-jet recording comprising antimony-tin composite oxide fine particles and a coloring agent (hereinafter, the “water-based infrared absorptive ink for ink-jet recording” may be referred to as an “ink”).
[0010] Another aspect of the present invention also provides an ink-jet recording method for recording an image by ejecting an ink onto a recording medium to cause the ink to adhere to the recording medium. The method is characterized in that a water-based infrared absorptive ink for ink-jet recording that comprises ATO fine particles and a coloring agent is used as the ink to impart infrared absorptivity to the image to be recorded.
[0011] A further aspect of the present invention provides an ink-jet recording apparatus comprising: an ink storage unit that stores a water-based infrared absorptive ink for ink-jet recording that comprises ATO fine particles and a coloring agent; and an ejection mechanism that ejects a droplet of the water-based infrared absorptive ink for ink-jet recording.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] The water-based infrared absorptive ink for ink-jet recording comprises ATO fine particles and a coloring agent.
[0013] The ATO fine particles have little absorption in the visible light range, but exhibit absorbance in the near-infrared range at a wavelength of 800 nm or more, and the absorbance increases as the wavelength increases. In images recorded with the water-based infrared absorptive ink for ink-jet recording, and in particular, in images recorded using the ink-jet recording method and the ink-jet recording apparatus, the color tones of the recorded objects are not influenced by the ATO fine particles. In addition, although it may not be visually confirmed whether the recorded objects have the infrared absorptivity or not, these recorded objects can be distinguished from recorded objects recorded with other infrared absorptive materials by analyzing reflection or transmission spectra in the near-infrared range.
[0014] When the average particle diameter of the ATO fine particles is too small, the specific surface area of the ATO fine particles is excessively large. In such a case, a strong attractive force acts between the particles, and the dispersion stability of the ATO fine particles in the water-based infrared absorptive ink for ink-jet recording tends to decrease. When the average particle diameter thereof is too large, light is strongly scattered. The transparency of images recorded with the water-based infrared absorptive ink for ink-jet recording tends to decrease, and an ink-jet recording head may be easily clogged. The average particle diameter of the ATO fine particles is in the range of from about 5 nm to about 800 nm and in the range of from about 5 nm to about 200 nm. In the above ranges, the dispersion stability of the water-based infrared absorptive ink for ink-jet recording may be ensured. In addition, substantially transparent code marks and the like may be recorded. The transparency of transparent substrates, such as films for an overhead projector, used as recording media may be maintained, and the transparency of undercoat layers may be maintained.
[0015] In particular, when code mark patterns are required to have high transparency, i.e., the scattering of light in the visible light range of from about 400 nm to about 780 nm must be suppressed, the average particle diameter of the ATO fine particles is about 200 nm or less and about 150 nm or less. This is because when the particle diameter is about 200 nm or less, the amount of scattered light decreases and Rayleigh scattering occurs. In the Rayleigh scattering region, the intensity of the scattered light decreases in inverse proportion to the sixth power of the particle diameter, and the transparency increases as the particle diameter decreases. When the particle diameter is about 150 nm or less, the amount of scattered light further decreases, and the absorption efficiency is further improved.
[0016] In view of the dispersion stability, the average particle diameter of the ATO fine particles is about 10 nm or more, about 20 nm or more and about 50 nm or more.
[0017] Particles produced by mixing antimony oxide powder and tin oxide powder, sintering the mixed powder at about 1,000° C. to about 1,300° C., and subjecting the sintered product to size reduction according to routine methods may be used as the above ATO fine particles. Specific examples of the ATO fine particles include, without any limitations, SN-100D (product of Ishihara Sangyo Kaisha, Ltd.), TDL (product of JEMCO Inc.) and the like.
[0018] When the amount of the above-described ATO fine particles in the water-based infrared absorptive ink for ink-jet recording is too small, the infrared absorptivity imparted to recording media is insufficient. Multiple printing, for example, must be performed to obtain sufficient infrared absorptivity, and, disadvantageously, the process for forming code marks becomes complicated. When the amount of the above-described ATO fine particles is too large, disadvantageously, nozzles of an ink-jet recording head is easily clogged. The amount of the ATO fine particles in the water-based infrared absorptive ink for ink-jet recording is in the range of from about 0.3 wt % to about 10 wt %, in the range of from about 0.3 wt % to about 7 wt % and in the range of from about 0.5 wt % to about 7 wt %.
[0019] The coloring agent may be selected from among water soluble dyes, pigments and mixtures thereof. Images recorded with the water-based infrared absorptive ink for ink-jet recording exhibit an absorption spectrum originating from the coloring agent in the visible light range and exhibit a characteristic absorption spectrum originating from the ATO fine particles in the infrared range. Because the ATO fine particles absorb almost no light in the visible light range, the original color of the coloring agent is maintained in the recorded objects. For example, the water-based infrared absorptive ink for ink-jet recording comprising a black dye as the coloring agent allowing infrared light to pass therethrough and a black ink comprising only the black dye are recognized to have the same black color by human eyes but show different transmission profiles under infrared radiation. When an image (recorded object) recorded by use of the above black water-based infrared absorptive ink for ink-jet recording, such as a recorded object having a bar code, is subjected to printing by use of an ordinary black ink comprising no infrared absorptive materials, more complicated and sophisticated security may be realized.
[0020] Any water soluble dye used in conventional ink-jet inks may be used as the water soluble dye, so long as it satisfies the required vividness, water solubility, stability, light fastness, ozone resistance and other required properties. Examples of the dye include, without any limitations, various types of dyes such as direct dyes, acid dyes, basic dyes and reactive dyes. These exemplary dyes are classified according to their structure into azo dyes, metal complex dyes, naphthol dyes, anthraquinone dyes, indigo dyes, carbonium dyes, quinoneimine dyes, xanthene dyes, aniline dyes, quinoline dyes, nitro dyes, nitroso dyes, benzoquinone dyes, naphthoquinone dyes, phthalocyanine dyes, metal phthalocyanine dyes and the like.
[0021] Examples of the water soluble dye include, without any limitations: C.I. Direct Blacks 17, 19, 32, 51, 71, 108, 146, 154, 168 and the like; C.I. Direct Yellows 12, 24, 26, 27, 28, 33, 39, 58, 86, 98, 100, 132, 142 and the like; C.I. Direct Reds 4, 17, 28, 37, 63, 75, 79, 80, 83, 99, 220, 224, 227 and the like; C.I. Direct Violets 47, 48, 51, 90, 94 and the like; C.I. Direct Blues 1, 6, 8, 15, 22, 25, 71, 76, 80, 86, 90, 106, 108, 123, 163, 165, 199, 226 and the like; C.I. Acid Blacks 2, 7, 24, 26, 31, 52, 63, 112, 118 and the like; C.I. Acid Yellows 3, 11, 17, 19, 23, 25, 29, 38, 42, 49, 59, 61, 71, 72 and the like; C.I. Acid Reds 1, 6, 8, 17, 18, 32, 35, 37, 42, 51, 52, 57, 80, 85, 87, 92, 94, 115, 119, 131, 133, 134, 154, 181, 186, 249, 254, 256, 289, 315, 317, 407 and the like; C.I. Acid Violets 10, 34, 49, 75 and the like; C.I. Acid Blues 9, 22, 29, 40, 59, 62, 93, 102, 104, 113, 117, 120, 167, 175, 183, 229, 234 and the like; C.I. Basic Blacks 2 and the like; C.I. Basic Yellows 40 and the like; C.I. Basic Reds 1, 2, 9, 12, 13, 14, 37 and the like; C.I. Basic Violets 7, 14, 27 and the like; C.I. Basic Blues 1, 3, 5, 7, 9, 24, 25, 26, 28, 29 and the like; C.I. Reactive Yellows 2, 3, 13, and the like; C.I. Reactive Reds 4, 23, 24, 31, 56, 180 and the like; and C.I. Reactive Blues 7, 13, 21 and the like.
[0022] When the water soluble dye is used in the water-based infrared absorptive ink for ink-jet recording, the ratio of the amount of the water soluble dye depends on a predetermined printing density and color. When the amount is too small, the color is not satisfactorily developed on a recording medium. When the amount is too large, nozzles of an ink-jet recording head is easily clogged. The amount of the water soluble dye with respect to the total amount of the water-based infrared absorptive ink for ink-jet recording is in the range of from about 0.1 wt % to about 10 wt %, in the range of from about 0.3 wt % to about 10 wt % and in the range of from about 0.5 wt % to about 7 wt %.
[0023] When a pigment is used, an infrared transparent pigment may be used. Examples of such a pigment include, without any limitations: yellow pigments such as C.I. Pigment Yellows 3, 13, 74, 83, 154 and the like; magenta pigments such as C.I. Pigment Reds 5, 48, 112, 122, 177, 202, 207 and the like; and cyan pigments such as C.I. Pigment Blues 15, 15:3, 15:4, 16, 60 and the like.
[0024] In case of using a pigment, when the amount of the pigment used in the water-based infrared absorptive ink for ink-jet recording is too small, the color is not satisfactorily developed on a recording medium. When the amount is too large, nozzles of an ink-jet recording head is easily clogged. The amount of the pigment with respect to the total amount of the water-based infrared absorptive ink for ink-jet recording is in the range of from about 1 wt % to about 10 wt % and in the range of from about 1 wt % to about 7 wt %.
[0025] The particle diameter of the pigment is in the range of from about 5 nm to about 800 nm because of the same reason as that for the ATO fine particles. The upper limit of the particle diameter is about 200 nm or less and about 150 nm or less. The lower limit of the particle diameter is about 10 nm or more, about 20 nm or more and about 50 nm or more.
[0026] The water-based infrared absorptive ink for ink-jet recording comprises water. Deionized water is used. The ratio of the amount of water depends on the type of the water soluble organic solvent used, the composition of the ink and the desired characteristics of the ink and is determined over a wide range. When the amount of water is too small, the viscosity of the ink increases to cause difficulty in ejecting the ink. When the amount of water is too large, the coloring agent or an additive is precipitated and/or aggregated due to the evaporation of water, so that nozzles of an ink-jet recording head is more likely to be clogged. The amount of water with respect to the total amount of the water-based infrared absorptive ink for ink-jet recording is in the range of from about 10 wt % to about 95 wt %, in the range of from about 10 wt % to about 80 wt % and in the range of from about 20 wt % to about 80 wt %.
[0027] The water-based infrared absorptive ink for ink-jet recording further may comprises water soluble organic solvents, such as a humectant and a penetrant, used commonly in ink-jet recording inks.
[0028] The humectant is added to the ink to prevent clogging of nozzles of an ink-jet recording head. Examples of the humectant include, without any limitations: water soluble glycols such as glycerin, ethylene glycol, diethylene glycol, triethylene glycol, polyethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, polypropylene glycol, 1,5-pentanediol, 1,6-hexanediol and the like.
[0029] When the ratio of the amount of the humectant in the water-based infrared absorptive ink for ink-jet recording is too small, clogging of nozzles of an ink-jet recording head is not sufficiently prevented. When the amount is too large, the viscosity of the ink increases to cause difficulty in ejecting the ink. The amount of the humectant with respect to the total amount of the water-based infrared absorptive ink for ink-jet recording is in the range of from about 5 wt % to about 50 wt %, in the range of from about 10 wt % to about 40 wt % and in the range of from about 15 wt % to about 35 wt %.
[0030] The penetrant is used to facilitate the penetration of the ink into a recording material after printing and to adjust the surface tension of the ink. Examples of the penetrant include, without any limitations: glycol ethers typified by ethylene glycol-based alkyl ethers and propylene glycol-based alkyl ethers and the like. Examples of the ethylene glycol-based alkyl ethers include, without any limitations: ethylene glycol methyl ether, ethylene glycol ethyl ether, ethylene glycol-n-propyl ether, ethylene glycol-n-butyl ether, ethylene glycol isobutyl ether, diethylene glycol methyl ether, diethylene glycol ethyl ether, diethylene glycol-n-propyl ether, diethylene glycol-n-butyl ether, diethylene glycol isobutyl ether, triethylene glycol methyl ether, triethylene glycol ethyl ether, triethylene glycol-n-propyl ether, triethylene glycol-n-butyl ether, triethylene glycol isobutyl ether and the like. Examples of the propylene glycol-based alkyl ethers include, but are not limited to: propylene glycol methyl ether, propylene glycol ethyl ether, propylene glycol-n-propyl ether, propylene glycol-n-butyl ether, dipropylene glycol methyl ether, dipropylene glycol ethyl ether, dipropylene glycol-n-propyl ether, dipropylene glycol-n-butyl ether, tripropylene glycol methyl ether, tripropylene glycol ethyl ether, tripropylene glycol-n-propyl ether, tripropylene glycol-n-butyl ether and the like.
[0031] When the ratio of the amount of the penetrant in the water-based infrared absorptive ink for ink-jet recording is too small, sufficient penetrability is not obtained. When the amount is too large, the penetrability becomes excessively high, and blurring such as feathering tends to occur. The amount of the penetrant with respect to the total amount of the water-based infrared absorptive ink for ink-jet recording is in the range of from about 0.5 wt % to about 10 wt % and in the range of from about 0.5 wt % to about 7 wt %.
[0032] In addition to the humectant and the penetrant, another water soluble organic solvent may be added to the water-based infrared absorptive ink for ink-jet recording for the purposes of, for example, preventing the ink from drying at the end portions of nozzles of an ink-jet recording head, increasing the printing density and developing vivid color. Examples of such a water soluble organic solvent include, without any limitations: lower alcohols such as methyl alcohol, ethyl alcohol, n-propyl alcohol, isopropyl alcohol, n-butyl alcohol, sec-butyl alcohol, tert-butyl alcohol and the like; amides such as dimethylformamide, dimethylacetamide and the like; ketones and keto-alcohols such as acetone, diacetone alcohol and the like; ethers such as tetrahydrofuran, dioxane and the like; glycerin; pyrrolidones such as 2-pyrrolidone, N-methyl-2-pyrrolidone and the like; 1,3-dimethyl-2-imidazolidinone; and the like.
[0033] Various surfactants may be added to the water-based infrared absorptive ink for ink-jet recording to adjust the surface tension. Examples of the surfactants include, without any limitations: anionic surfactants such as higher alcohol sulfate ester salts, liquid fatty oil sulfate ester salts, alkyl allyl sulfonates and the like; and non-ionic surfactants such as polyoxyethylene alkyl ethers, polyoxyethylene alkyl esters, sorbitan alkyl esters, polyoxyethylene sorbitan alkyl esters; and the like.
[0034] The water-based infrared absorptive ink for ink-jet recording may be manufactured by mixing the above ATO fine particles, the coloring agent and the solvents such as water, and uniformly dispersing the ATO fine particles and the coloring agent in the solvents according to routine methods.
[0035] The thus manufactured water-based infrared absorptive ink for ink-jet recording may be used in an ink-jet recording method described below. In this ink-jet recording method, an image is recorded by ejecting an ink onto a recording medium to cause the ink to adhere to the recording medium. The method is characterized in that the water-based infrared absorptive ink for ink-jet recording is used as the ink to impart infrared absorptivity to the image to be recorded.
[0036] This ink-jet recording method may be the same as conventional ink-jet recording methods, except that the water-based infrared absorptive ink for ink-jet recording is used as the ink. Any recording medium used for the conventional ink-jet recording methods may be used as the recording medium. For example, recording paper having on one or both sides an ink-receiving layer capable of receiving a water-based ink-jet ink may be used.
[0037] The water-based infrared absorptive ink for ink-jet recording and the ink-jet recording method may be used for an ink-jet recording apparatus including: an ink storage unit that stores the water-based infrared absorptive ink for ink-jet recording; and an ejection mechanism that ejects droplets of the ink. The structure of this ink-jet recording apparatus may be the same as those of conventional ink-jet recording apparatuses, except that the water-based infrared absorptive ink for ink-jet recording is used as the ink.
EXAMPLES
[0038] The present invention will now be specifically described by way of Examples and Comparative Examples. In the Examples and Comparative Examples, infrared absorptive black, yellow, magenta and cyan inks comprising the ATO fine particles were prepared. Subsequently, ink-jet recording was performed using each ink, and a reflection spectrum in the infrared range was measured and evaluated in a recording area formed on an ink-jet recording paper.
(1) Preparation of the Inks
[0039] Each of the inks was prepared using the procedures described below. The compositions of the prepared inks are summarized in Tables 1 to 4. In each of the ink compositions summarized in Tables 1 to 4, the amount of each component actually contained in the ink is expressed in terms of percent by weight. The average particle diameter of the secondary particles of the ATO fine particles used is a value obtained through the measurement of the particle diameter distribution of an ATO fine particle dispersion (SN-100D, product of Ishihara Sangyo Kaisha, Ltd.). Specifically, the particle diameter distribution was measured in a diluted solution obtained by diluting the ATO fine particle dispersion 1,500-fold with ion exchanged water by using a dynamic light scattering nano-analyzer (LB-500, product of HORIBA, Ltd.). Inks 1 to 5, 7 to 11, 13 to 17, 19 to 23, 25 to 29, 31 to 35 and 37 to 41 were water-based infrared absorptive inks for ink-jet recording of the Examples of the present invention. The other inks were water-based inks for ink-jet recording of the Comparative Examples that do not comprise the ATO fine particles.
a) Ink 1 (Infrared Absorptive Black Dye Ink)
[0040] 3.0 parts by weight of C.I. Direct Black 154, 54.3 parts by weigh of water (ion exchanged water), 23.0 parts by weight of glycerin and 3.0 parts by weight of dipropylene glycol-n-propyl ether were mixed, whereby 83.3 parts by weight of a black dye aqueous solution was obtained. 83.3 parts by weight of the obtained black dye aqueous solution was gradually added to 16.7 parts by weight of an ATO fine particle dispersion (SN-100D, product of Ishihara Sangyo Kaisha, Ltd., the average diameter of secondary particles: 128 nm, solids content: 30 wt %) under stirring. After stirred for 30 minutes, the mixture was filtrated through a membrane filter having a pore diameter of 1 μm, whereby ink 1 was obtained. The amount of the ATO fine particles in the ink 1 was 5 wt %.
b) Ink 2 (Infrared Absorptive Black Dye Ink)
[0041] 3.0 parts by weight of C.I. Direct Black 154, 60.0 parts by weigh of water (ion exchanged water), 24.0 parts by weight of glycerin and 3.0 parts by weight of dipropylene glycol-n-propyl ether were mixed, whereby 90.0 parts by weight of a black dye aqueous solution was obtained. 90.0 parts by weight of the obtained black dye aqueous solution was gradually added to 10.0 parts by weight of an ATO fine particle dispersion (SN-100D, product of Ishihara Sangyo Kaisha, Ltd., the average diameter of secondary particles: 128 nm, solids content: 30 wt %) under stirring. After stirred for 30 minutes, the mixture was filtrated through a membrane filter having a pore diameter of 1 μm, whereby ink 2 was obtained. The amount of the ATO fine particles in the ink 2 was 3 wt %.
c) Ink 3 (Infrared Absorptive Black Dye Ink)
[0042] 3.0 parts by weight of C.I. Direct Black 154, 65.7 parts by weight of water (ion exchanged water), 25.0 parts by weight of glycerin and 3.0 parts by weight of dipropylene glycol-n-propyl ether were mixed, whereby 96.7 parts by weight of a black dye aqueous solution was obtained. 96.7 parts by weight of the obtained black dye aqueous solution was gradually added to 3.3 parts by weight of an ATO fine particle dispersion (SN-100D, product of Ishihara Sangyo Kaisha, Ltd., the average diameter of secondary particles: 128 nm, solids content: 30 wt %) under stirring. After stirred for 30 minutes, the mixture was filtrated through a membrane filter having a pore diameter of 1 μm, whereby ink 3 was obtained. The amount of the ATO fine particles in the ink 3 was 1 wt %.
d) Ink 4 (Infrared Absorptive Black Dye Ink)
[0043] 3.0 parts by weight of C.I. Direct Black 154, 66.8 parts by weigh of water (ion exchanged water), 25.5 parts by weight of glycerin and 3.0 parts by weight of dipropylene glycol-n-propyl ether were mixed, whereby 98.3 parts by weight of a black dye aqueous solution was obtained. 98.3 parts by weight of the obtained black dye aqueous solution was gradually added to 1.7 parts by weight of an ATO fine particle dispersion (SN-100D, product of Ishihara Sangyo Kaisha, Ltd., the average diameter of secondary particles: 128 nm, solids content: 30 wt %) under stirring. After stirred for 30 minutes, the mixture was filtrated through a membrane filter having a pore diameter of 1 μm, whereby ink 4 was obtained. The amount of the ATO fine particles in the ink 4 was 0.5 wt %.
e) Ink 5 (Infrared Absorptive Black Dye Ink)
[0044] 3.0 parts by weight of C.I. Direct Black 154, 67.7 parts by weigh of water (ion exchanged water), 26.0 parts by weight of glycerin and 3.0 parts by weight of dipropylene glycol-n-propyl ether were mixed, whereby 99.7 parts by weight of a black dye aqueous solution was obtained. 99.7 parts by weight of the obtained black dye aqueous solution was gradually added to 0.3 parts by weight of an ATO fine particle dispersion (SN-100D, product of Ishihara Sangyo Kaisha, Ltd., the average diameter of secondary particles: 128 nm, solids content: 30 wt %) under stirring. After stirred for 30 minutes, the mixture was filtrated through a membrane filter having a pore diameter of 1 μm, whereby ink 5 was obtained. The amount of the ATO fine particles in the ink 5 was 0.1 wt %.
f) Ink 6 (Black Dye Ink)
[0045] 3.0 parts by weight of C.I. Direct Black 154, 68.0 parts by weigh of water (ion exchanged water), 26.0 parts by weight of glycerin and 3.0 parts by weight of dipropylene glycol-n-propyl ether were mixed. After stirred for 30 minutes, the mixture was filtrated through a membrane filter having a pore diameter of 1 μm, whereby ink 6 was obtained.
g) Inks 7 to 11 (Infrared Absorptive Yellow Dye Inks) and Ink 12 (Yellow Dye Ink)
[0046] The same procedure as in the ink 1 was repeated except that the ink composition was changed as summarized in Table 1, whereby inks 7 to 11 were prepared. The same procedure as in the ink 6 was repeated except that the ink composition was changed as summarized in Table 1, whereby ink 12 was prepared.
h) Inks 13 to 17 (Infrared Absorptive Magenta Dye Inks) and Ink 18 (Magenta Dye Ink)
[0047] The same procedure as in the ink 1 was repeated except that the ink composition was changed as summarized in Table 2, whereby inks 13 to 17 were prepared. The same procedure as in the ink 6 was repeated except that the ink composition was changed as summarized in Table 2, whereby ink 18 was prepared.
i) Inks 19 to 23 (Infrared Absorptive Cyan Dye Inks) and Ink 24 (Cyan Dye Ink)
[0048] The same procedure as in the ink 1 was repeated except that the ink composition was changed as summarized in Table 2, whereby inks 19 to 23 were prepared. The same procedure as in the ink 6 was repeated except that the ink composition was changed as summarized in Table 2, whereby ink 24 was prepared.
j) Ink 25 (Infrared Absorptive Yellow Pigment Ink)
[0049] 15 parts by weight of C.I. Pigment Yellow 74, 5.0 parts by weight of polyoxyethylene lauryl ether ammonium sulfate, 15 parts by weight of glycerin and 65 parts by weight of water (ion exchanged water) were mixed. Subsequently, the mixture was subjected to dispersion in a wet sand mill using zirconia beads having a diameter of 0.3 mm as a medium, whereby a yellow pigment dispersion was obtained.
[0050] Separately, 49.1 parts by weight of water (ion exchanged water), 27.5 parts by weight of glycerin and 2.5 parts by weight of dipropylene glycol-n-propyl ether were mixed, whereby 79.1 parts by weight of an ink solvent was prepared. 79.1 parts by weight of the prepared ink solvent was gradually added to 20.9 parts by weight of an ATO fine particle dispersion (SN-100D, product of Ishihara Sangyo Kaisha, Ltd., the average diameter of secondary particles: 128 nm, solids content: 30 wt %) under stirring. The mixture was further stirred for 30 minutes, whereby a fluid dispersion of the ATO fine particles was prepared.
[0051] Subsequently, 80 parts by weight of the prepared fluid dispersion of the ATO fine particles was gradually added to 20 parts by weight of the yellow pigment dispersion under stirring. The mixture was further stirred for 30 minutes and was filtrated through a membrane filter having a pore diameter of 1 μm, whereby ink 25 was prepared. The amount of the ATO fine particles in the ink 25 was 5 wt %.
k) Ink 26 (Infrared Absorptive Yellow Pigment Ink)
[0052] 15 parts by weight of C.I. Pigment Yellow 74, 5.0 parts by weight of polyoxyethylene lauryl ether ammonium sulfate, 15 parts by weight of glycerin and 65 parts by weight of water (ion exchanged water) were mixed. Subsequently, the mixture was subjected to dispersion in a wet sand mill using zirconia beads having a diameter of 0.3 mm as a medium, whereby a yellow pigment dispersion was obtained.
[0053] Separately, 56.9 parts by weight of water (ion exchanged water), 28.1 parts by weight of glycerin and 2.5 parts by weight of dipropylene glycol-n-propyl ether were mixed, whereby 87.5 parts by weight of an ink solvent was prepared. 87.5 parts by weight of the prepared ink solvent was gradually added to 12.5 parts by weight of an ATO fine particle dispersion (SN-100D, product of Ishihara Sangyo Kaisha, Ltd., the average diameter of secondary particles: 128 nm, solids content: 30 wt %) under stirring. The mixture was further stirred for 30 minutes, whereby a fluid dispersion of the ATO fine particles was prepared.
[0054] Subsequently, 80 parts by weight of the prepared fluid dispersion of the ATO fine particles was gradually added to 20 parts by weight of the yellow pigment dispersion under stirring. The mixture was further stirred for 30 minutes and was filtrated through a membrane filter having a pore diameter of 1 μm, whereby ink 26 was prepared. The amount of the ATO fine particles in the ink 26 was 3 wt %.
l) Ink 27 (Infrared Absorptive Yellow Pigment Ink)
[0055] 15 parts by weight of C.I. Pigment Yellow 74, 5.0 parts by weight of polyoxyethylene lauryl ether ammonium sulfate, 15 parts by weight of glycerin and 65 parts by weight of water (ion exchanged water) were mixed. Subsequently, the mixture was subjected to dispersion in a wet sand mill using zirconia beads having a diameter of 0.3 mm as a medium, whereby a yellow pigment dispersion was obtained.
[0056] Separately, 64.6 parts by weight of water (ion exchanged water), 28.8 parts by weight of glycerin and 2.5 parts by weight of dipropylene glycol-n-propyl ether were mixed, whereby 95.9 parts by weight of an ink solvent was prepared. 95.9 parts by weight of the prepared ink solvent was gradually added to 4.1 parts by weight of an ATO fine particle dispersion (SN-100D, product of Ishihara Sangyo Kaisha, Ltd., the average diameter of secondary particles: 128 nm, solids content: 30 wt %) under stirring. The mixture was further stirred for 30 minutes, whereby a fluid dispersion of the ATO fine particles was prepared.
[0057] Subsequently, 80 parts by weight of the prepared fluid dispersion of the ATO fine particles was gradually added to 20 parts by weight of the yellow pigment dispersion under stirring. The mixture was further stirred for 30 minutes and was filtrated through a membrane filter having a pore diameter of 1 μm, whereby ink 27 was prepared. The amount of the ATO fine particles in the ink 27 was 1 wt %.
m) Ink 28 (Infrared Absorptive Yellow Pigment Ink)
[0058] 15 parts by weight of C. I. Pigment Yellow 74, 5.0 parts by weight of polyoxyethylene lauryl ether ammonium sulfate, 15 parts by weight of glycerin and 65 parts by weight of water (ion exchanged water) were mixed. Subsequently, the mixture was subjected to dispersion in a wet sand mill using zirconia beads having a diameter of 0.3 mm as a medium, whereby a yellow pigment dispersion was obtained.
[0059] Separately, 66.0 parts by weight of water (ion exchanged water), 29.4 parts by weight of glycerin and 2.5 parts by weight of dipropylene glycol-n-propyl ether were mixed, whereby 97.9 parts by weight of an ink solvent was prepared. 97.9 parts by weight of the prepared ink solvent was gradually added to 2.1 parts by weight of an ATO fine particle dispersion (SN-100D, product of Ishihara Sangyo Kaisha, Ltd., the average diameter of secondary particles: 128 nm, solids content: 30 wt %) under stirring. The mixture was further stirred for 30 minutes, whereby a fluid dispersion of the ATO fine particles was prepared.
[0060] Subsequently, 80 parts by weight of the prepared fluid dispersion of the ATO fine particles was gradually added to 20 parts by weight of the yellow pigment dispersion under stirring. The mixture was further stirred for 30 minutes and was filtrated through a membrane filter having a pore diameter of 1 μm, whereby ink 28 was prepared. The amount of the ATO fine particles in the ink 28 was 0.5 wt %.
n) Ink 29 (Infrared Absorptive Yellow Pigment Ink)
[0061] 15 parts by weight of C.I. Pigment Yellow 74, 5.0 parts by weight of polyoxyethylene lauryl ether ammonium sulfate, 15 parts by weight of glycerin and 65 parts by weight of water (ion exchanged water) were mixed. Subsequently, the mixture was subjected to dispersion in a wet sand mill using zirconia beads having a diameter of 0.3 mm as a medium, whereby a yellow pigment dispersion was obtained.
[0062] Separately, 67.4 parts by weight of water (ion exchanged water), 29.7 parts by weight of glycerin and 2.5 parts by weight of dipropylene glycol-n-propyl ether were mixed, whereby 99.6 parts by weight of an ink solvent was prepared. 99.6 parts by weight of the prepared ink solvent was gradually added to 0.4 parts by weight of an ATO fine particle dispersion (SN-100D, product of Ishihara Sangyo Kaisha, Ltd., the average diameter of secondary particles: 128 nm, solids content: 30 wt %) under stirring. The mixture was further stirred for 30 minutes, whereby a fluid dispersion of the ATO fine particles was prepared.
[0063] Subsequently, 80 parts by weight of the prepared fluid dispersion of the ATO fine particles was gradually added to 20 parts by weight of the yellow pigment dispersion under stirring. The mixture was further stirred for 30 minutes and was filtrated through a membrane filter having a pore diameter of 1 μm, whereby ink 29 was prepared. The amount of the ATO fine particles in the ink 29 was 0.1 wt %.
o) Ink 30 (Yellow Pigment Ink)
[0064] 15 parts by weight of C.I. Pigment Yellow 74, 5.0 parts by weight of polyoxyethylene lauryl ether ammonium sulfate, 15 parts by weight of glycerin and 65 parts by weight of water (ion exchanged water) were mixed.
[0065] Subsequently, the mixture was subjected to dispersion in a wet sand mill using zirconia beads having a diameter of 0.3 mm as a medium, whereby a yellow pigment dispersion was obtained. Separately, 54.0 parts by weight of water (ion exchanged water), 24.0 parts by weight of glycerin and 2.5 parts by weight of dipropylene glycol-n-propyl ether were mixed, whereby 80.0 parts by weight of an ink solvent was prepared. 80.0 parts by weight of the prepared ink solvent was gradually added to 20.0 parts by weight of the yellow pigment dispersion under stirring. The mixture was further stirred for 30 minutes and was filtrated through a membrane filter having a pore diameter of 1 μm, whereby ink 30 was prepared.
p) Inks 31 to 35 (Infrared Absorptive Magenta Pigment Inks) and Ink 36 (Magenta Pigment Ink)
[0066] The same procedure as in the ink 25 was repeated except that the ink composition was changed as summarized in Table 4, whereby inks 31 to 35 were prepared. The same procedure as in the ink 30 was repeated except that the ink composition was changed as summarized in Table 4, whereby ink 36 was prepared.
q) Inks 37 to 41 (Infrared Absorptive Cyan Pigment Inks) and Ink 42 (Cyan Pigment Ink)
[0067] The same procedure as in the ink 25 was repeated except that the ink composition was changed as summarized in Table 4, whereby inks 37 to 41 were prepared. The same procedure as in the ink 30 was repeated except that the ink composition was changed as summarized in Table 4, whereby ink 42 was prepared.
[0000]
TABLE 1
Black
Yellow
Infrared absorptive black dye ink
dye ink
Infrared absorptive yellow dye ink
dye ink
Ink. No.
1
2
3
4
5
6
7
8
9
10
11
12
Ink
Water (ion
54.3
60.0
65.7
66.8
67.7
68.0
54.8
60.5
66.2
67.3
68.2
68.5
composition
exchanged water)
(wt %)
Glycerin
23.0
24.0
25.0
25.5
26.0
26.0
23.5
24.5
25.5
26.0
26.5
26.5
Dipropylene glycol-
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
n-propyl ether
SN-100D(*1)
16.7
10.0
3.3
1.7
0.3
—
16.7
10.0
3.3
1.7
0.3
—
C.I. Direct Black 154
3.0
3.0
3.0
3.0
3.0
3.0
—
—
—
—
—
—
C.I. Direct Yellow 86
—
—
—
—
—
—
0.4
0.4
0.4
0.4
0.4
0.4
C.I. Direct Yellow 132
—
—
—
—
—
—
1.6
1.6
1.6
1.6
1.6
1.6
Amount of ATO fine particles (wt %)
5.0
3.0
1.0
0.5
0.1
0
5.0
3.0
1.0
0.5
0.1
0
(*1)Product of Ishihara Sangyo Kaisha, Ltd., aqueous dispersion of ATO fine particles, solids content: 30 wt %
* The ink composition is expressed in the weight percent ratio of each component actually contained in the ink to the total weight of the ink.
[0000]
TABLE 2
Magneta
Cyan
Infrared absorptive magenta dye ink
dye ink
Infrared absorptive cyan dye ink
dye ink
Ink No.
13
14
15
16
17
18
19
20
21
22
23
24
Ink
Water (ion
54.6
60.3
88.6
67.3
68.2
68.3
53.4
59.1
64.8
65.9
67.0
67.1
composition
exchanged water)
(wt %)
Glycerin
23.2
24.2
25.0
25.5
26.0
26.2
24.0
25.0
26.0
26.5
26.8
27.0
Dipropylene glycol-
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
n-propyl ether
SN-100D(*1)
16.7
10.0
3.3
1.7
0.3
—
16.7
10.0
3.3
1.7
0.3
—
C.I. Reactive Red 180
2.5
2.5
2.5
2.5
2.5
2.5
—
—
—
—
—
—
C.I. Direct Blue 199
—
—
—
—
—
—
2.9
2.9
2.9
2.9
2.9
2.9
Amount of ATO fine particles (wt %)
5.0
3.0
1.0
0.5
0.1
0
5.0
3.0
1.0
0.5
0.1
0
(*1)Product of Ishihara Sangyo Kaisha, Ltd., aqueous dispersion of ATO fine particles, solids content: 30 wt %
* The ink composition is expressed in the weight percent ratio of each component actually contained in the ink to the total weight of the ink.
[0000]
TABLE 3
Yellow
pigment
Infrared absorptive yellow pigment ink
ink
Ink No.
25
26
27
28
29
30
Ink
Water (ion exchanged water)
52.3
58.5
64.7
65.8
66.9
67.0
composition
Glycerin
25.0
25.5
26.0
26.5
26.8
27.0
(wt %)
Dipropylene glycol-n-propyl ether
2.0
2.0
2.0
2.0
2.0
2.0
SN-100D(*1)
16.7
10.0
3.3
1.7
0.3
—
C.I. Pigment Yellow 74
3.0
3.0
3.0
3.0
3.0
3.0
Polyoxyethylene lauryl ether ammonium
1.0
1.0
1.0
1.0
1.0
1.0
sulfate(*2)
Amount of ATO fine particles (wt %)
5.0
3.0
1.0
0.5
0.1
0
(*1)Product of Ishihara Sangyo Kaisha, Ltd., aqueous dispersion of ATO fine particles, solids content: 30 wt %
(*2)Average polymerization degree of oxyethylene = 12
* The ink composition is expressed in the weight percent ratio of each component actually contained in the ink to the total weight of the ink.
[0000]
TABLE 4
Magenta
Cyan
pigment
pigment
Infrared absorptive magenta pigment ink
ink
Infrared absorptive cyan pigment ink
ink
Ink No.
31
32
33
34
35
36
37
38
39
40
41
42
Ink
Water (ion
52.1
58.3
64.5
65.7
66.8
66.8
51.8
58.0
64.2
65.5
66.5
66.5
composition
exchanged water)
(wt %)
Glycerin
24.0
24.5
25.0
25.4
25.7
26.0
25.5
26.0
26.5
26.8
27.2
27.5
Dipropylene glycol-
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
n-propyl ether
SN-100D(*1)
16.7
10.0
3.3
1.7
0.3
—
16.7
10.0
3.3
1.7
0.3
—
C.I. Pigment Red 122
4.0
4.0
4.0
4.0
4.0
4.0
—
—
—
—
—
—
C.I. Pigment Blue 15:3
—
—
—
—
—
—
3.0
3.0
3.0
3.0
3.0
3.0
Polyoxyethylene
lauryl ether
1.2
1.2
1.2
1.2
1.2
1.2
1.0
1.0
1.0
1.0
1.0
1.0
ammonium sulfate(*2)
Amount of ATO fine particles (wt %)
5.0
3.0
1.0
0.5
0.1
0
5.0
3.0
1.0
0.5
0.1
0
(*1)Product of Ishihara Sangyo Kaisha, Ltd., aqueous dispersion of ATO fine particles, solids content: 30 wt %
(*2)Average polymerization degree of oxyethylene = 12
* The ink composition is expressed in the weight percent ratio of each component actually contained in the ink to the total weight of the ink.
(2) Measurement of Infrared Reflection Spectrum of Recorded Objects and Evaluation of Infrared Absorptivity
[0068] Each of the prepared inks was filled into a predetermined ink cartridge and was printed on Brother A4 ink-jet paper (BP60MA) using a digital multifunction device equipped with an ink-jet printer (DCP-115, product of Brother Industries, Ltd.). The reflection spectrum of the recorded object with respect to the reflectivity of the recording medium was measured in a wavelength range of from 380 nm to 2,000 nm by using a spectrophotometer (UV-3100PC, product of Shimadzu Corporation). The infrared absorptivity of the recorded object was evaluated by the criteria below according to the reflectivity at wavelengths of 900 nm, 1,400 nm and 2,000 nm. The results obtained are summarized in Table 5.
<Criteria for Evaluating Infrared Absorptivity>
[0069] AA: The reflectivity is less than 60% (sufficiently high infrared absorptivity was found).
[0070] A: The reflectivity is 60% or more and less than 75% (sufficiently high infrared absorptivity was found).
[0071] B: The reflectivity is 75% or more and less than 90% (infrared absorptivity was found).
[0072] C: The reflectivity is 90% or more and less than 95% (absorption was weak, but infrared absorptivity was found).
[0073] D: The reflectivity is 95% or more (no infrared absorptivity was found).
[0000]
TABLE 5
Amount
of ATO
fine
900 nm
1,400 nm
2,000 nm
parti-
Reflec-
Reflec-
Reflec-
Ink
cles
tivity
Eval-
tivity
Eval-
tivity
Eval-
No.
(wt %)
(%)
uation
(%)
uation
(%)
uation
1
5.0
77.93
B
52.82
AA
32.20
AA
7
77.99
B
53.07
AA
32.85
AA
13
77.69
B
52.55
AA
32.06
AA
19
78.13
B
53.30
AA
32.81
AA
25
75.30
B
50.57
AA
30.91
AA
31
79.13
B
56.06
AA
35.78
AA
37
75.24
B
52.77
AA
33.33
AA
2
3.0
86.03
B
64.80
A
42.46
AA
8
84.57
B
62.93
A
41.32
AA
14
87.36
B
67.07
A
44.49
AA
20
86.04
B
65.05
A
42.79
AA
26
83.12
B
62.70
A
41.71
AA
32
86.29
B
68.72
A
48.34
AA
38
83.41
B
65.46
A
44.38
AA
3
1.0
92.79
C
83.15
B
67.35
A
9
95.14
C
84.48
B
68.04
A
15
95.89
C
85.90
B
69.55
A
21
95.39
C
85.18
B
68.93
A
27
92.64
C
81.23
B
64.08
A
33
93.20
C
84.74
B
71.32
A
39
90.50
C
81.76
B
66.36
A
4
0.5
98.21
C
93.14
C
83.65
B
10
97.49
C
92.37
C
82.43
B
16
98.35
C
94.02
C
86.02
B
22
97.57
C
92.87
C
83.02
B
28
97.55
C
91.56
C
80.71
B
34
97.70
C
93.63
C
84.18
B
40
97.14
C
92.75
C
83.14
B
5
0.1
98.96
D
97.09
D
92.98
C
11
98.91
D
96.34
D
91.37
C
17
99.27
D
97.38
D
93.32
C
23
99.08
D
97.55
D
94.49
C
29
99.50
D
97.64
D
93.62
C
35
98.88
D
96.73
D
91.38
C
41
98.20
D
97.34
D
94.03
C
6
0
99.59
D
98.59
D
96.67
D
12
99.76
D
98.67
D
96.35
D
18
99.87
D
98.83
D
96.58
D
24
100.11
D
98.90
D
96.71
D
30
97.64
D
96.86
D
95.89
D
36
96.54
D
96.81
D
95.22
D
42
95.62
D
96.75
D
95.23
D
(3) Evaluation Results
[0074] As can be seen from Table 5, for the recorded objects recorded with the inks not comprising the ATO fine particles, the evaluation results of the infrared absorptivity were “D” at all the wavelengths (900 nm, 1,400 nm and 2,000 nm).
[0075] For the inks comprising 0.1 wt % of the ATO fine particles, the evaluation results of the infrared absorptivity at a wavelength of 2,000 nm were “C.” It may be seen that the infrared absorptivity was improved as compared to that of the inks not comprising the ATO fine particles. For the inks comprising 0.5 wt % of the ATO fine particles, the evaluation results of the infrared absorptivity were “B” at a wavelength of 2,000 nm and “C” at wavelengths of 1,400 nm and 900 nm. It may be seen that the infrared absorptivity was further improved as compared to that of the inks comprising 0.1 wt % of the ATO fine particles. For the inks comprising 1.0 wt % of the ATO fine particles, the evaluation results of the infrared absorptivity were “A” at a wavelength of 2,000 nm and “B” at a wavelength of 1,400 nm. It may be seen that the infrared absorptivity was further improved as compared to that of the inks comprising 0.5 wt % of the ATO fine particles. For the inks comprising 3.0 wt % of the ATO fine particles, the evaluation results of the infrared absorptivity were “AA” at a wavelength of 2,000 nm, “A” at a wavelength of 1,400 nm and “B” at a wavelength of 900 nm. It may be seen that the infrared absorptivity was further improved as compared to that of the inks comprising 1.0 wt % of the ATO fine particles. For the inks comprising 5.0 wt % of the ATO fine particles, the evaluation results of the infrared absorptivity were “AA” at a wavelength of 1,400 nm. It may be seen that the infrared absorptivity was further improved as compared to that of the inks comprising 3.0 wt % of the ATO fine particles.
[0076] The present invention is not limited to the embodiments described in the Examples, which are provided for illustrative purposes only. The material substances, their amounts used, and the conditions of producing them may be varied and modified without departing from the spirit and the scope of the invention as described herein. | A water-based infrared absorptive ink for ink-jet recording is provided that absorbs electromagnetic waves in the infrared range without adversely affecting the color tone of recorded objects. The water-based infrared absorptive ink for ink-jet recording contains antimony-tin composite oxide fine particles and a coloring agent. | 2 |
[0001] Related Applications U.S. Ser. No. 13/274,854, filed Oct. 17, 2011 and U.S. 61/487,137, filed May 17, 2011 are herein incorporated by reference in their entireties.
REFERENCE TO SEQUENCE LISTING SUBMITTED ELECTRONICALLY VIA EFS-WEB
[0002] The content of the electronically submitted, sequence listing (Name: sequencelisting_ascii.txt; Size: 95,663 bytes; and Date of Creation: Oct. 14, 2011) is incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention provides avirulent Salmonella variants and various uses thereof, particularly in the production of Salmonella -specific lytic bacteriophages, pharmaceutical compositions, and feed additives.
[0005] 2. Description of the Related Art
[0006] Currently over 2,000 Salmonella strains are generally classified into host-specific serotypes, and non-host-specific serotypes pathogenic for both animals and humans. Representative among fowl-adapted Pathogens are Salmonella Gallinarum (SG) Salmonella Pullorum (SP) which are known to cause fowl typhoid and pullorum disease, respectively. These Salmonella -caused fowl diseases occur at low frequency in advanced countries, but have inflicted tremendous economic damage on the poultry farming in developing countries.
[0007] Salmonella Gallinarum strains have serologically the same somatic antigen (O-antigen) structures and are classified as being non-motile because they have no flagella. When entering into a host animal via contaminated feed or a contaminated environment, Salmonella pass through the gastrointestinal tract, and invade intestinal epithelial cells by interaction with Peyer's patch M (microfold) cells and penetrate into the intestinal membrane. Salmonella are transported by the M cells to macrophages in adjacent intestinal membranes, and then Salmonella infection develops into a systemic disease.
[0008] The type III secretion system (TTSS) is a protein appendage found in Gram-negative bacteria, which consists of a needle-like protein complex structure through which virulence effector proteins pass from the bacterial cytoplasm directly into the host cytoplasm (Mota L J et al., Ann Med. (2005); 37(4):234-249), The type III secretion system is essential for the delivery of the pathogenicity of Salmonella (Schlumberger M C et al., Curr Opin Microbiol, (2006); 9(1):46-54) Wild-type Salmonella take advantage of TTSS when adhering to and invading host cells, and then survives during the phagocytosis of macrophages and circulates throughout, the body via the bloodstream, causing a systemic infection. Hence, Salmonella infection cannot proceed without the normal (hereinafter referred to as “SPI-1”) is a discrete region of the Salmonella chromosome encoding the type III secretion system and virulent effector proteins which are necessary for invasion into intestinal epithelial cells in the early stage of infection (Kimbrough T G et al., Microbes Infect, (2002); 4(1):75-82). Salmonella pathogenicity island-2 (hereinafter referred to as “SPI-2”) is also a discrete region of the Salmonella chromosome encoding the type III secretion system and effector proteins which involved in survival and proliferation during phagocytosis by macrophages in intestinal immune organs or immune organs such as the spleen and the liver after translocation across epithelial cells (Waterman S R et al., Cell Microbiol, (2003); 5(8):501-511, Abrahams G L, Cell Microbiol, (2006); 8(5):728-737). Genes within SPI-1 and SPI-2 and their functions are summarized in Table 1, below.
[0000]
TABLE 1
Gene
Characteristics
SPI-1
avrA
putative inner membrane protein
sprB
transcriptional regulator
hilC
bacterial regulatory helix-turn-helix
proteins, araC family
orgA
putative flagellar biosynthesis/type
III secretory pathway protein
prgK
cell invasion protein; lipoprotein,
may link inner and outer membranes
prgJIH
cell invasion protein
hilD
regulatory helix-turn-helix proteins,
araC family
hilA
invasion genes transcription activator
iagB
cell invasion protein
sptP
protein tyrosine phosphate
sicP
chaperone, related to virulence
iacP
putative acyl carrier protein
sipADCB
cell invasion protein
sicA
surface presentation of antigens;
secretory proteins
spaSRQPO
surface presentation of antigens;
secretory proteins
invJICB
surface presentation of antigens;
secretory proteins
invAEGFH
invasion protein
SPI-2
ssaUTSRQPON
Secretion system apparatus
VMLKJIHG
sseGF
Secretion system effector
sscB
Secretion system chaperone
sseEDC
Secretion system effector
sscA
Secretion system chaperone
sseBA
Secretion system effector
ssaE
Secretion system effector
ssaDCB
Secretion system apparatus
ssrA
Secretion system regulator: Sensor
component
ssrB
Secretion system regulator:
transcriptional activator, homologous
with degU/uvrY/bvgA
[0009] In addition to these type III secretion systems, fimbriae gene (faeHI) (Edwards R A et al., PNAS (2000); 97(3):1258-1262) and the virulent factor (spvRABCD operon) present in virulent plasmids of Salmonella are implicated in the virulence of Salmonella (Gulig P A et al., Mol Microbiol (1993); 7(6):825-830).
[0010] Salmonella -caused fowl diseases are difficult to control because they are transmitted in various ways including egg transmission, and feed or environmental infection, and show high recurrence rates even after post-infectious treatment with antibiotics. Therefore, it is importance of preventing the onset of disease by using a vaccine as well as sanitizing breeding, farms and feed. In the poultry industry, a lot of effort has been poured into the use of live vaccines (attenuated Salmonella Gallinarum strains—SG9S, SG9R) and dead vaccines (gel vaccines, oil vaccines, etc.) to prevent the onset of fowl typhoid. However, the effects of the vaccine vary with the concentration of the vaccine used, the condition of the fowl vaccinated, and the environment of chicken houses. And, the efficacy of these vaccines is reported to be significantly lower than that of the vaccines for other diseases. Treatment with antibiotics, although reducing the lesion, converts infected fowls into chronic carriers (See: Incidence and Prevention of Hen Salmonellosis, the National Veterinary Research & Quarantine Service, Korea).
[0011] Therefore, new Salmonella -controlling approaches that are better than conventional vaccines or antibiotics are being demanded. Many scientists have recently paid attention to hacteriophages, which infect and lyse bacteria specifically and are safe to humans, as potent alternative to antibiotics. There are many reports concerning, the use of bacteriophages being used in the prevention or therapy of Salmonella diseases (Atterbury R J et al., Appl Environ Microbiol, (2007); 73(14):4543-4549) and as disinfectants or detergents to prevent the putrefaction of foods (PCT 1998-08944, PCT 1995-31562, EP 1990-202169, PCT 1990-03122), and concerning phage display techniques for diagnosis (Ripp S et al., J Appl Microbiol, (2006); 100(3):488-499), Salmonella vaccines prepared by deleting or modifying one or two genes within SPI-2 gene cluster have recently been disclosed (U.S. Pat. No. 6,923,957, U.S. Pat. No. 7,211,264, U.S. Pat. No. 7,887,816).
[0012] For industrial use, bacteriophages are produced by separating the phage progenies from the host cells lysed during the proliferation of bacteriphages which have been inoculated into the host cells cultured on a mass scale. As for bacteriophages specific for pathogenic bacteria, however, their lysates may contain the pathogenic host cells being not removed, and/or virulent materials such, as pathogenic proteins of the host. This likelihood acts as a great risk factor to the safety of bacteriophages produced on the basis of pathogenic host cells.
[0013] Many bacteria have lysogenic phages on their chromosomes; however, most of the phages are cryptic and cannot produce progeny because of the accumulation of many mutations as ancestral remnants. Lysogenic phages, although inactive, may help the survival capacity of Salmonella upon host infection because they contain the genes necessary for lytic and lysogenic growth and some of the genes encode pathogenic factors. However, these genes are, likely to undergo homologous recombination with the viral genome of other similar phages which newly infect animals, thus producing genetically modified phages. As for the typical Salmonella typhimurium , it has fels-1, fell-2, gifsy-1, and gifsy-2 prophages and two cryptic phages. In contrast, Salmonella Gallinarum could be used as a phage-producing host since Salmonella Gallinarum have neither prophages nor cryptic phages, and then are not genetically modified by recombination. (Edwards R A et al, Trends Microbiol, (2002); 10(2):94-99).
[0014] For the purpose of minimizing toxic remnants during progeny production and phage's opportunity for mutation, the present inventors designed the idea that the virulence gene clusters of Salmonella Gallinarum could be inactivated for producing bacteriophages. There have no precedent cases wherein avirulent bacteria, which had been converted from virulent bacteria by inactivating a virulence gene cluster, were used as a bacteriophage host cell.
[0015] In addition to the production of bacteriophages, the Salmonella deprived of virulence by inactivating virulence gene clusters are themselves used for developing attenuated live vaccines for controlling Salmonella or applied to the bioindustry, guaranteeing significant added values.
[0016] In the present invention, avirulent Salmonella Gallinarum variants obtained by inactivating at least one of the main Salmonella virulence gene clusters (SPI-1, SPI-2, spvRABCD and faeHI operons) are used as a bacteriophage-producing host cell and applied to various uses.
SUMMARY OF THE INVENTION
[0017] With the aim of solving the problems with the recombinational modification of progeny phages and the toxic bacterial remnants in the course of bacteriophage production on the basis of the above-described facts, the present inventors developed avirulent Salmonella Gallinarum variants as a host cell for bacteriophage-producing by inactivating at least one of the four main Salmonella Gallinarum gene clusters (SPI-1, SPI-2, spvRABCD and faeHI operons), In addition, the present inventors primarily confirmed reduced virulence by measuring the efficiency of the invasion of Salmonella Gallinarum into avian epithelial cells, and reconfirmed by measuring the mortality of hens infected with avirulent Salmonella Gallinarum variants. On the other hand, the present inventors approve the use of bacteriophage-producing host, the use of the pharmaceutical compositions and feed additives for the prevention or treatment of avian salmonellosis through comparison of the productivity of bacteriophages between wild-type and the avirulent Salmonella Gallinarum variants.
[0018] It is therefore a primary object of the present invention to provide a Salmonella Gallinarum variant in which the SPI-2 gene cluster is inactivated, a Salmonella Gallinarum variant in which both SPI-1 and SPI-2 gene clusters are inactivated, and an avirulent Salmonella Gallinarum variant in which at least one of the four main virulence gene clusters (SPI-1, SPI-2, spvRABCD, and faeHI operon) has been inactivated.
[0019] It is another object of the present invention to provide the use of the avirulent Salmonella Gallinarum variant in the production of Salmonella -specific bacteriophages or a method for producing phages using the avirulent Salmonella Gallinarum variant. The avirulent Salmonella Gallinarum variants according to the present invention can be used for the mass-production of Salmonella -specific lytic bacteriophages free of remnant toxicity and applied to the development of a novel concept of antibiotic substitutes which have high industrial utility value and guarantee significant added value.
[0020] It is a further object of the present invention to provide a pharmaceutical composition comprising avirulent Salmonella Gallinarum variants as an active ingredient, preferably a live vaccine and a feed additive. The SPI-1 gene cluster encodes type III secretion system proteins which remain on cell surfaces, acting as an antigen while the SPI-2 gene cluster encodes proteins which are involved in survival in the phagosomes after passage across epithelial cells. Hence, the inactivation of the SPI-2 gene cluster alone, with SPI-1 gene cluster remaining intact, leaves the antigen necessary for the production of an antibody inducing an immune response, but does not allow the bacteria to survive during phagocytosis, which does not result in a systemic disease. Thus, the SPI-2 gene cluster-inactivated Salmonella Gallinarum variant might be used as a live vaccine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0022] FIG. 1 is a schematic diagram showing virulence genes of avian Salmonella ( Salmonella pathogenicity island-1, Salmonella pathogenicity island-2, spvRABCD, faeHI) and sites corresponding to primers for inactivating the virulence genes; and
[0023] FIG. 2 is a graph showing the efficiency of the in vitro invasion into avian epithelial cells of the virulence gene-inactivated Salmonella Gallinarum variants (SG3-d1, SG3-d2, SG3-d1d2, SG3-d4), together with controls wild-type Salmonella Gallinarum SG2293), Salmonella Gallinarum live vaccine (SG9R), and non-pathogenic E. coli (MG1655). Invasion efficiency is expressed as a percentage of the count of microorganisms within cells divided with the count of microorganisms within a culture medium. The microorganisms were used at concentration of 8.0×10 7 cfu per well.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] In order to accomplish the above objects, an aspect of the present invention provides the avirulent Salmonella Gallinarum variants which are remarkably decreased in pathogenicity.
[0025] The Salmonella Gallinarum variants are rendered avirulent by inactivating at least one of the virulence gene clusters Salmonella pathogenicity island-1, Salmonella Pathogenicity Island-2, spvRABCD, and faeHI.
[0026] As used herein, the term “virulence gene clusters of Salmonella ” refers to the four gene clusters involved in the virulence of Salmonella Gallinarum , including the Salmonella Pathogenicity Island-1 (hereinafter referred to as “SPI-1”) operon coding for the structural proteins and toxic effector proteins of type III secretion system, the Salmonella Pathogenicity Island-2 (hereinafter referred to as “SPI-2”) operon coding for the structural proteins and toxic effector proteins of type III secretion system, the spvRABCD operon coding for pathogenically active proteins on avian Salmonella -specific virulent plasmids, and the faeHI operon coding for fimbriae. So long as it functionally works in Salmonella Gallinarum , any gene cluster may be used.
[0027] The term “gene cluster,” as used herein, refers to a population of adjacent genes on a chromosome or a plasmid that are commonly responsible for the same products. The genes in one cluster are under the regulation of common regulatory genes.
[0028] The inactivation of genes in bacteria can be achieved using various methods. For example, single or multiple nucleotides of an active site within a gene may be modified to decrease the activity of the protein expressed. Alternatively, an antibiotic-resistant gene or other gene(s) may be inserted into the gene of interest to prevent the expression of intact proteins. The most reliable method is to delete the entire sequence of a gene from the genome (Russell C B et al., J. Bacteriol. (1989); 171:2609-2613, Hamilton C M et al., J. Bacteriol. (1989); 171:4617-4622, Link A J et al., J. Bacteriol. (1997); 179:6228-6237). In the present invention, entire sequences of the genes of interest are deleted to effectively promise the inactivation of the genes. For this, the one-step deletion method using lamda Red recombinase, known as a method of deleting gene clusters, developed by Datsenk K A et al., may be employed (Datsenko K A et al., PNAS, (2000); 97(12):6640-6645).
[0029] With regard to the information of virulence genes to be deleted, nucleotide sequences of SPI-1 and SPI-2 were obtained referring to the virulence gene sequences within the Salmonella Gallinarum chromosome ( Salmonella enterica subsp. enterica serovar Gallinarum str. 287/91, NC 011274), disclosed by the NCBI. For the faeHI operon sequence, reference was made to the sequence of the Salmonella Gallinarum virulence plasmid gene ( Salmonella Gallinarum virulence plasmid minor fimbrial subunit genes, AF005899). For the spvRABCD operon, the sequence of the same name gene of Salmonella Typhimurium LT2, which has highly homology with Salmonella Gallinarum , was consulted because its sequence is not disclosed in the NCBI. The sequencing of the spvRABCD operon of Salmonella Gallinarum was also performed with reference to the sequence of the corresponding gene of Salmonella Typhimurium.
[0030] Examples of the Salmonella virulence genes clusters include the SPI-1 gene cluster (SEQ ID NO: 1), the SPI-2 (SEQ ID NO: 2), the spvRABCD operon (SEQ ID NO: 3), and the faeHI operon (SEQ ID NO: 4) of Salmonella Gallinarum 287/91.
[0031] To prepare strains that had definitely been rendered avirulent, all of the plural virulence gene clusters were deleted. To inactivate many gene clusters in one strain, the gene clusters may have been deleted sequentially.
[0032] In the present invention, a Salmonella Gallinarum strain in which only the SPI-2 gene cluster is inactivated (SG3-d2), a Salmonella Gallinarum strain in which both SPI-1 and SPI-2 gene clusters are integrally inactivated (SG3-d1d2) and a Salmonella Gallinarum strain in which all of the four virulence gene clusters (SPI-1, SPI-2, spvRABCD, faeHI) are integrally inactivated (SG3-d4), SG3-d2 is deposited under accession No. KCCM 11009P, SG3-d1d2 under accession No. KCCM 11010P, and SG3-d4 under accession No. KCCM 11011P.
[0033] Studies on the independent deletion of individual genes of the gene clusters have been reported (Hapfelmeier S et al., J Immunol, (2005); 174(3):1675-1685, Brumme S et al., Vet Microbiol, (2007); 124(3-4):274-285, Desin T S et al., Infect Immun, July (2009); 2866-2875), but avirulent Salmonella strains developed by integrally inactivating, two or more entire gene clusters had not been disclosed prior to the study of the present inventors. The Salmonella Gallinarum strain was named Salmonella Gallinarum SG2293-d2 when only the SPI-2 gene cluster is, inactivated, and SG2293-d1d2 when both SPI-1 and SPI-2 were integrally inactivated. Further, it was named SG2293-d4 upon the inactivation of all of SPI-1, SPI-2, spvRABCD, and faeHI.
[0034] To ascertain the avirulence thereof, the strains prepared by inactivating virulence gene clusters according to the present invention were assayed for the efficiency of invasion into avian epithelial cells and for disease outbreak and mortality (%) upon infection into poultry. Preferably, the Salmonella Gallinarum strains in which the virulence gene clusters had been inactivated by transformation were allowed to invade avian epithelial cells so that invasion efficiency could be measured. Also, the strains were injected into brown egg layers to measure mortality.
[0035] In accordance with another aspect thereof, the present invention provides an avirulent Salmonella strain for use in producing Salmonella -specific lytic bacteriophages and method for producing, phages using the same.
[0036] ΦCJ1 (US 20100135962), a Salmonella -specific phage, was used to examine the bacteriophage productivity of the avirulent Salmonella Gallinarum variants. The phage shows a specific bactericidal activity against Salmonella Gallinarum and Salmonella pullorum , belongs to the morphotype group of the family Siphoviridae B1, characterized by isometric capsid and long non-contractile tail, and has a total genome size of 61 kb and major structural proteins with a size of 38 kDa and 49 kDa.
[0037] The method for producing a bacteriophage in accordance with the present invention comprises culturing the avirulent Salmonella Gallinarum variants in a medium, inoculating a bacteriophage into the medium, and recovering the bacteriophage. In this regard, the phage may be produced briefly using a plate or on a mass scale using broth. In the case of production using a plate, a bacteriophage is inoculated at a suitable ratio into bacteria when the bacteria enter a log phase, mixed with top agar, and poured onto a plate. When phage plaques appear, the top agar fractions are collected and centrifuged, followed by filtering the supernatant to afford a phage stock. For mass production as a broth, a mixture of phages and bacteria is prepared in the same manner as in plate production, and incubated for 5 hours in fresh broth, instead of in top agar.
[0038] In accordance with a further aspect thereof, the present invention provides a pharmaceutical composition for the prevention of fowl typhoid, comprising the avirulent Salmonella strain as an active ingredient and optionally a pharmaceutically acceptable vehicle, and preferably a vaccine for the prevention of fowl typhoid, formulated with the avirulent Salmonella strain and optionally a pharmaceutically acceptable vehicle.
[0039] The term “pharmaceutically acceptable vehicle,” as used herein, refers to a carrier or diluent which does not deteriorate the biological activity and property of the active ingredient and, which does not irritate the subject. Preparations intended for oral administration may take the form of tablets, troches, lozenges, aqueous or oily suspensions, powders, granules, emulsions, hard or soft capsules, syrups, elixirs, etc. In regards to the oral forms such as tablets and capsules, the active ingredient may be formulated in combination with a binder such as lactose, saccharose, sorbitol, mannitol, starch, amylpectin, conjugate such as cellulose or gelatin, an excipient such as dicalcium phosphate, a disintegrant such as corn starch or sweet potato starch, or a lubricant such as magnesium stearate, calcium stearate, sodium stearylfumarate or polyethylene glycol wax. As for capsules, they may further comprise a liquid carrier such as fatty oil.
[0040] The composition of the present invention may be formulated into preparations for non-oral administration, such as subcutaneous injections, intravenous injections, or intradermal injections. For this, the composition of the present invention may be mixed with a stabilizer or buffer in water to give a solution or a suspension which is then formulated into unit doses such as, ampules or vials.
[0041] As used herein, the term “vaccine” refers to a biological preparation that improves immunity to a particular disease by inducing the formation of an antibody upon injection into the body, a preparation containing an antigen, e.g., killed or attenuated forms of a disease-causing microorganism. Vaccines may be prepared from killed pathogens. There are also live vaccines, but with the virulence thereof attenuated. The Salmonella Gallinarum variants of the present invention have the same antigenic proteins as those of the wild-type, but are greatly decreased in virulence compared to the wild-type, so that they can be used as live vaccines prophylactic of fowl typhoid.
[0042] In accordance with still another aspect thereof, the present invention provides a feedstuff containing the avirulent Salmonella Gallinarum , and preferably a feed additive containing the avirulent Salmonella Gallinarum . When applied to poultry, the feed additive of the present invention serves as a live vaccine that prevents fowl typhoid.
[0043] The feedstuff of the present invention may be prepared by mixing feedstuff with the Salmonella Gallinarum variant as it is or in the form of a feed additive. In the feedstuff, the Salmonella Gallinarum variant may be in a liquid or dry state. The dry state can be accomplished by various drying methods including, but not limited thereto, pneumatic drying, spontaneous drying, spray drying and freeze drying. In addition to the Salmonella Gallinarum variant of the present invention, the feedstuff of the present invention may further comprise a typical additive useful for improving the preservation of the feedstuff.
[0044] The feedstuff comprising the Salmonella Gallinarum variant of the present invention may be vegetable matter such as a cereal, nut, a by-product of food processing, millet, fiber, pharmaceutical by-product, a vegetable oil, starch, oil seed meals and cereal remnants, or animal matter such as proteins, minerals, fats, mineral oils, unicellular proteins, animal planktons and leftover food etc.
[0045] Examples of the feed additive comprising the Salmonella Gallinarum variant of the present invention include, but are not limited to, various agents for preventing quality deterioration and improving utility, such as binders, emulsifiers, preservatives, amino acids, vitamins, enzymes, probiotics, flavoring agents, non-protein nitrogen compounds, silicates, buffer, colorants, extracts, oligosaccharides, etc. Also, a mixing agent may be within the scope of the feed additive.
[0046] In accordance with still a further aspect thereof, the present invention provides a method for treating the Salmonella Gallinarum infectious disease fowl typhoid using the pharmaceutical composition.
[0047] The composition of the present invention may be administered to animals in the form of a pharmaceutical preparation to animals, or in the form of being mixed with feedstuff or water. Preferably, it is mixed in the form of a feed additive with feedstuff before administration.
[0048] So long as it allows the composition of the present invention to reach tissues or cells of interest, any administration route, such as non-oral, intraartery, intradermal, transdermal, intramuscular, intraperitoneal, intravenous, subcutaneous, oral or intranasal route, may be taken.
[0049] The treating, method of the present invention comprises administering the composition of the present invention in a pharmaceutically effective amount. It will be apparent to those skilled in the art that the suitable total daily dose may be determined by an attending physician within the scope of medical judgment. The specific therapeutically effective dose level for any particular patient may vary depending variety of factors, including the kind and degree of desired reaction, the specific composition, including the use of any other agents according to the intended use, the patient's age, weight, general health, gender, and diet, the time of administration, the route of administration, and rate of the excretion of the composition; the duration of the treatment; other drugs used in combination or coincidentally with the specific composition; and like factors well known in the medical arts. Typically, the composition may be administered at a daily dose of from 10 4 to 10 8 CFU once or in a divided dosage manner.
[0050] Hereinafter, the present invention will be described in more retail with reference to Examples. However, these Examples are for illustrative purposes only, and the invention is not intended to be limited by these Examples.
Example 1
Screening of Target Genes to be Inactivated Through Comparison of Salmonella gallinarum Virulence Genes
[0051] The first step of preparing avirulent avian Salmonella strains was the screening of target virulence genes to be inactivated. Salmonella Pathogenicity Island-1 (SPI-1), and Salmonella Pathogenicity Island-2 (SPI-2), both of which are type three secretion system gene clusters essential for the delivery of the pathogenicity of Salmonella , and spvRABCD and faeHI, both of which are genes on virulence plasmids, were determined as target genes, and the data base of the NCBI was searched for the nucleotide sequences of the target genes ( Salmonella enterica subsp. enterica serovar Gallinarum str. 287/91, NC 011274). Because the nucleotide sequence of spvRABCD of Salmonella Gallinarum had not yet been disclosed, primers were synthesized with reference to the nucleotide sequence of the same name gene of Salmonella typhimurium ( Salmonella typhimurium LT2 plasmid pSLT, NC 003277), which has high nucleotide sequence homology with Salmonella Gallinarum . As for the faeHI operon, the information of its nucleotide sequence was obtained from Salmonella Gallinarum virulence plasmid minor fimbrial subunit genes (AF005899).
Example 2
Preparation of Avirulent Variants by Inactivation of Virulence Genes of Salmonella gallinarum and by Integration of the Inactivated Sites
[0052] 2-1. Inactivation of Virulence Genes oaf Salmonella gallinarum
[0053] To delete TTSS-related virulence genes of the wild-type Salmonella Gallinarum (SGSC No. 2293) as determined in Example 1, the one-step deletion method using lamda Red recombinase, developed by Datsenko K A et al., (Datsenko K A et al, PNAS, (2000); 97(12):6640-6645), was employed.
[0054] A chloramphenicol resistant gene of pKD3 was used as an antibiotic marker for identifying insertion into a target site of chromosome. Using a pair of the primers SPI-1-P1 (SEQ ID NO: 5) and SPI-1-P2 (SEQ ID NO: 6) of Table 1, which correspond to 50 bp of 5′ flanking region of the avrA and 50 bp of 3′ flanking region of the invH gene, wherein SPI-1 comprising from avrA to invH is target for deletion, and a part of the chloramphenicol resistant gene of pKD3, respectively, a polymerase chain reaction (hereinafter referred to as “PCR”) was performed [Sambrook et al, Molecular Cloning, a Laboratory Manual (1989), Cold Spring Harbor Laboratories], with pKD3 as a template. The obtained PCR product was gene fragment about 1100 bp long.
[0055] In this regard, a PCR HL premix kit (BIONEER) was used and 30 cycles of denaturation at 94° C. for 30 sec, annealing at 55° C. for 30 sec and elongation at 72° C. for 1 min was conducted. The PCR product was separated in 0.8% agarose gel by electrophoresis and eluted at a desired band size.
[0056] According to the method of Datsenko K A et al., the 1100 bp-long gene fragment was introduced into pKD46-transformed, competent wild-type Salmonella Gallinarum , which was then spread over LB plates containing chloramphenicol (30 mg/L). As for the resulting transformant, its gene was examined by PCR using a pair of the primers SPI-1-P3 (SEQ ID NO: 7) and SPI-1-P4 (SEQ ID NO: 8), which correspond to regions about 1 kb distant from both ends of the deletion target gene, respectively. The PCR product thus obtained was 3100 bp long, indicating that the SPI-1 gene cluster was inactivated.
[0057] The resulting strain was cultured at 37° C., a condition of removing the pKD46 vector, to select a strain that could not grow on an LB plate containing ampicillin (100 mg/L).
[0058] Subsequently, the antibiotic marker inserted into the inactivated gene cluster was removed by transformation with pCP20. The removal of the antibiotic marker was identified by PCR using the primers SPI-1-P3 & SPI-1-P4. The resulting PCR product was 2000 bp long, also indicating the inactivation.
[0059] Afterwards, the strain which was now free of the antibiotic marker was cultured at 42° C. (a condition of removing pCP20) to select a strain that could not grow on an LB plate containing ampicillin. The SPI-1 gene cluster-inactivated strain thus obtained was named SG3-d1 ( Salmonella Gallinarum SG2293::ΔSPI-1).
[0060] SPI-2, spv, and fae gene clusters were also inactivated in the same manner as in the SPI-1 gene cluster. The resulting gene cluster-inactivated strains were named SG3-d2 ( Salmonella Gallinarum SG2293::ΔSPI-2, Accession No KCCM 11009P), SG3-ds ( Salmonella Gallinarum SG2293::Δspv), and SG3-df ( Salmonella Gallinarum SG2293::Δfae), respectively. Primers used for deleting genes and for identifying gene deletion are summarized in Table 2, below.
[0000]
TABLE 2
Primers for deletion of SPI-1 gene from chromosome
SPI-1-P1
TTATGGCGCTGGAAGGATTTCCTCTGGCAGGCA
(SEQ ID NO: 5)
ACCTTATAATTTCATTAGTGTAGGCTGGAGCTG
CTTC
SPI-1-P2
ATGCAAAATATGGTCTTAATTATATCATGATGA
(SEQ ID NO: 6)
GTTCAGCCAACGGTGATCATATGAATATCCTCC
TTAG
Primers for Deletion of SPI-2 Gene from Chromosome
SPI-2-P1
ACCCTCTTAACCTTCGCAGTGGCCTGAAGAAGC
(SEQ ID NO: 9)
ATACCAAAAGCATTTATGTGTAGGCTGGAGCTG
CTTC
SPI-2-P2
ACTGCGTGGCGTAAGGCTCATCAAAATATGACC
(SEQ ID NO: 10)
AATGCTTAATACCATCGCATATGAATATCCTCC
TTAG
Primers for Deletion of spvRABCD gene from
virulence plasmid
spv-P1
GTGCAAAAACAGGTCACCGCCATCCTGTTTTTG
(SEQ ID NO: 13)
CACATCAAA ACATTTTTGTGTAGGCTGGAGCT
GCTTC
spv-P2
TTACCCCAACAGCTTGCCGTGTTTGCGCTTGAA
(SEQ ID NO: 14)
CATAGGGAT GCGGGCTTCATATGAATATCCTC
CTTAG
Primers for Deletion of faeHI gene from
virulence plasmid
fae-P1
TTACCGATATTCAATGCTCACCGCCAGGGAGGT
(SEQ ID NO: 17)
ATGCCAGCG GGACGGTAGTGTAGGCTGGAGCT
GCTT C
fae-P2
(SEQ ID NO: 18)
ATGAAAATAACGCATCATTATAAATCTATTATT
TCCGCC CTGGCCGCGCTCATATGAATATCCTC
CTTAG
Primers for identification of SPI-1 gene deletion
from chromosome
SPI-1-P3
ATGTTCTTAACAACGTTACTG
(SEQ ID NO: 7)
SPI-1-P4
AGGTAGTACGTTACTGACCAC
(SEQ ID NO: 8)
Primers for identification of SPI-2 gene deletion
from chromosome
SPI-2-P3
TGTTCGTACTGCCGATGTCGC
(SEQ ID NO: 11)
SPI-2-P4
AGTACGACGACTGACGCCAAT
(SEQ ID NO: 12)
Primers for spvRABCD gene deletion from
virulence plasmid
spv-P3
GACCATATCTGCCTGCCTCAG
(SEQ ID NO: 15)
spv-P4
CAGAGCCCGTTCTCTACCGAC
(SEQ ID NO: 16)
Primers for faeHI gene deletion from
virulence plasmid
fae-P3
CAGGCTCCCCTGCCACCGGCT
(SEQ ID NO: 19)
fae-P4
CAGGCCAACTATCTTTCCCTA
(SEQ ID NO: 20)
[0061] 2-2. Integration of Type III Secretion System-Related Virulence Genes Inactivation
[0062] To integrally inactivate the gene clusters in one strain, the SG3-d1 strain was sequentially subjected the inactivation of SPI-2, spvRABCD, and faeHI gene clusters, using a method similar to that of Example 2-1.
[0063] To begin with, PCR was performed using the primers SPI-2-P1 (SEQ ID NO: 9) and SPI-2-P2 (SEQ ID NO: 10) for the purpose of inactivating the SPI-2 cluster gene, with pKD4 serving as a template, resulting a 1600 bp gene fragment. This PCR product was introduced into the SG3-d1 strain in which pKD46 vector remained (Example 1-2), followed by spreading the bacteria over an LB plate containing kanamycin (50 mg/L). As for the resulting transformant, its gene was examined by PCR using a pair of the primers SPI-2-P3 (SEQ ID NO: 11) and SPI-2-P4 (SEQ ID NO: 12), which correspond to both flanking regions of the deletion target gene. The PCR product thus obtained was 3600 bp long, indicating that the SPI-2 gene cluster was inactivated.
[0064] The resulting strain was cultured at 37° C., a condition of removing the pKD46 vector, to select a strain that could not grow on an LB plate containing ampicillin (100 mg/L).
[0065] Subsequently, the antibiotic marker inserted into the inactivated gene cluster was removed by transformation with pCP20. The removal of the antibiotic marker was identified by PCR using the primers SPI-1-P3 & SPI-1-P4 in case of SPI-1 and the primers SPI-2-P3 & SPI-2-P4 in case of SPI-2. The resulting PCR product was 2000 bp long, also indicating that the inactivation had taken place.
[0066] Afterwards, the strain free of the antibiotic marker was cultured at 42° C. (a condition of removing pCP20) to select a strain that could not grow on an LB plate containing ampicillin. The SPI-1 and SPI-2 gene cluster-inactivated strain thus obtained was named SG3-d1d2 ( Salmonella Gallinarum SG2293::ΔSPI-1ΔSPI-2, Accession No. KCCM 11010P).
[0067] In SG-d1d2 strain, spvRABCD and faeHI gene clusters were further inactivated. To this end, the spvRABCD gene cluster (the kanamycin-resistant gene of pKD4 was used as an antibiotic marker) was inactivated in the same manner as in the inactivation of SPI-1 in Example 1-2, while the inactivation of the faeHI gene cluster (the chloramphenicol-resistant gene of pKD3 was used as an antibiotic marker) was conducted in the same manner as in the inactivation of SPI-2 in the SPI-1-inactivated strain. As for the resulting transformants, their genes were examined by PCR using the primer set spv-P3 (SEQ ID NO: 15) and spv-P4 (SEQ NO: 16) for spvRABCD deletion, and the primer set fae-P3 (SEQ ID NO: 19) and fae-P4 (SEQ ID NO: 20) for faeHI deletion, which correspond to regions about 1 kb distant from both ends of the respective deletion target genes. The PCR products thus obtained were 3600 bp, 3100 bp long respectively, indicating that the spvRABCD and faeHI gene clusters were inactivated. The resulting strain was cultured at 37° C., a condition of removing the pKD46 vector, to select a strain that could not grow on an LB plate containing ampicillin (100 mg/L), The Salmonella Gallinarum strain in which all of the four gene clusters SPI-1, SPI-2, spvRABCD and faeHI were integrally inactivated was named SG3-d4 ( Salmonella Gallinarum SG2293::ΔSPI-1ΔSPI-2ΔspvRABCDΔfaeHI) and deposited under accession No. KCCM 11011P.
[0068] 2-3. Sequencing of Salmonella gallinarum spvRABCD Operon
[0069] Nowhere has the genetic information on spvRABCD of Salmonella Gallinarum (SGSC No. 2293) been disclosed yet. Its nucleotide sequence was analyzed in the present invention. For this, primers were synthesized as summarized in Table 3, below.
[0000]
TABLE 3
spv-S1
GGTCAATTAAATCCACTCAGAA
(SEQ ID NO: 21)
spv-S2
ACGGGAGACACCAGATTATC
(SEQ ID NO: 22)
spv-S3
TTCAGTAAAGTGGCGTGAGC
(SEQ ID NO: 23)
spv-S4
CCAGGTGGAGTTATCTCTGC
(SEQ ID NO: 24)
spv-S5
ACTGTCGGGCAAAGGTATTC
(SEQ ID NO: 25)
spv-S6
TTTCTGGTTACTGCATGACAG
(SEQ ID NO: 26)
spv-S7
TCCAGAGGTACAGATCGGC
(SEQ ID NO: 27)
spv-S8
GAAGGAATACACTACTATAGG
(SEQ ID NO: 28)
spv-S9
GTGTCAGCAGTTGCATCATC
(SEQ ID NO: 29)
spv-S10
AGTGACCGATATGGAGAAGG
(SEQ ID NO: 30)
spv-S11
AAGCCTGTCTCTGCATTTCG
(SEQ ID NO: 31)
spv-S12
AACCGTTATGACATTAAGAGG
(SEQ ID NO: 32)
spv-S13
TAAGGCTCTCTATTAACTTAC
(SEQ ID NO: 33)
spv-S14
AACCGCTTCTGGCTGTAGC
(SEQ ID NO: 34)
spv-S15
CCGTAACAATGACATTATCCTC
(SEQ ID NO: 35)
[0070] The analysis result is given in SEQ ID NO:
Example 3
Assay of Virulence Gene-Inactivated Salmonella Gallinarum SG2-d4 for Avirulence by Measurement of Invasion Efficiency into Avian Epithelial Cell
[0071] Salmonella Gallinarum and Salmonella pullorum , which are unique Salmonella species due to the lack of a motile flagella, are specifically infected to avian cells and can invade other animal cells but at very low efficiency. In this example, an in vitro cell invasion assay was conducted (Henderson S C et al, Infect Immun, (1999); 67(7):3580-3586) on the avian epithelial cell line BAT (Budgerigar Abdominal Tumor), provided from M D. Lee, Georgia University. The avirulent Salmonella Gallinarum variants SG3-d1d2 and SG3-d4, developed by the above-described gene deletion method, were expected to invade the host cell with very low efficiency by reduced level of TTSS-related protein. A recent research review on the infection mechanisms of pathogenic microorganisms has it that even when only a specific gene of SPI-1 is deleted, the Salmonella strain shows a decrease in invasion efficiency into epithelial cells (Lostroh C P et al, Microbes Infect, (2001); 3(14-15):1281-1291).
[0072] In the present invention, TTSS-related gene deletion was proven to lead to a decrease in virulence by measuring the efficiency of the invasion of the avian Salmonella variants into the avian epithelial cell line BAT.
[0073] Invasion efficiency into avian epithelial cells was measured on 24-well plates in triplicate, and mean values of three measurements were given. The BAT cell line was cultured at 37° C. in DMEM supplemented with 10% fetal bovine serum, 1 mM glutamine, 100 IU/ml penicillin and 100 μg/ml streptomycin under the condition of 5% CO 2 . The BAT cell line was seeded at a density of 2.5×10 5 cells/well into 24-well plates and incubated at 37° C. for 1-2 days in a 5% CO 2 incubator to form monolayers of cells. After distribution of the cell and incubation for one day, the culture medium was changed out with antibiotic-free DMEM. For comparison of invasion efficiency, wild-type Salmonella Gallinarum SG3 (SGSC#: 2293) the virulence gene-inactivated Salmonella Gallinarum variants SG3-d1, SG3-d2, SG3-d1d2 and SG3-d4, and SG9R, which is a commercially available live vaccine, were employed, with the non-pathogenic E. coli MG1655 serving as a control.
[0074] After being primarily seed cultured, all of test bacteria were vigorously incubated for 4-5 hours in a main LB medium, and the cultures were diluted to OD 600 =1.0. To 200 μL of the animal cells incubated in the antibiotic-free medium, 200 μL of each of the culture dilutions was added so that the bacteria were aliquoted at a concentration of 2.0×10 8 cfu/ml Per well. The plates were incubated at 37° C. for one hour in a 5% CO 2 atmosphere to allow the bacteria to penetrate into the epithelial cells. Thereafter, the medium was aspirated off and the plates were washed with 1×PBS to remove remaining microorganisms. Then, the epithelial cells were incubated at 37° C. for 2 hours in the presence of 50 μg/ml gentamycin in a 5% CO 2 incubator to clear the microorganisms remaining outside the cells. The antibiotic was removed by washing with 1×PBS. To examine the microorganisms which succeeded in penetrating into the epithelial cells, the animal cells were lyzed for 15-30 min in 500 μl of 0.1% Triton X-100. The cell lysates were spread over LB plates and incubated overnight at 37° C. so that the microorganisms that had grown could be counted. To calculate the invasion efficiency, 200 μL of the microorganism culture with OD 600 =1.0 was also incubated.
[0000] Invasion Efficiency(%)=Count of Microorganisms invaded to Cell/Count of Microorganisms within Culture Medium (OD 600 =1.0)×100
[0075] The BAT cell invasion efficiencies of the four transformed Salmonella Gallinarum variants prepared by the inactivation of virulence gene clusters were calculated.
[0076] Of them, the variant in which only the SPI-1 gene cluster, responsible for cell invasion mechanism, was inactivated, was decreased in invasion efficiency by 84% compared to the wild-type. The SG3-d1d2 variant with the deletion of both SPI-1 and SPI-2 and the SG3-d4 variant with the deletion of all the four gene clusters were found to decrease in cell invasion efficiency by approximately 89% and 91%, respectively, compared to the wild-type Salmonella Gallinarum (SG3). The variants of the present invention were also remarkably reduced in invasion ability, in comparison to that of the commercially available live vaccine Nobilis SG9R. These data demonstrated that the inactivation of TTSS-related gene clusters decreases the virulence of Salmonella Gallinarum (see Table 4 and FIG. 2 ).
[0000]
TABLE 4
Index of
Internalization
Strain
Property
Genotype
(%)
Control
MG1655
Avirulent
Wild type
2%
Group
E. coli
SG3
Virulent
Wild type
100%
Salmonella
Gallinarum
(Wild-type,
SGSC No.
2293)
Nobilis
Salmonella
SG:: ΔrecA
67%
SG9R
Gallinarum
Live vaccine
(commercially
available)
Test Group
SG3-d1
Virulence
SG:: ΔSPI-1
16%
(avirulent
gene-deleted
Salmonella
Salmonella
Gallinarum )
Gallinarum
SG3-d2
Virulence
SG:: ΔSPI-2
34%
gene-deleted
Salmonella
Gallinarum
SG3-
Virulence
SG:: ΔSPI-
11%
d1d2
gene-deleted
1/ΔSPI-2
Salmonella
Gallinarum
SG3-d4
Virulence
SG:: ΔSPI-
9%
gene-deleted
1/ΔSPI-
Salmonella
2/Δspv/Δfae
Gallinarum
(SG3 100% = 0.36% invasion efficiency in practice)
[0077] The avirulence of Salmonella Gallinarum variant SG3-d4 was confirmed in vitro test which shows extremely low in invasion efficiency into avian epithelial cells, as was reconfirmed in animal tests and the results are given in Example 4.
Example 4
Assay of Salmonella gallinarum SG3-d4 for Avirulence by Measuring Mortality of Chickens
[0078] The Research Institute of Veterinary Science, Seoul National University, was entrusted with this assay. One-week-old brown egg layers (Hy-Line chicken) were employed in this assay, and they were divided into many groups of 10 which were separated in respective chicken houses before infection with pathogens. No vaccine programs were used on the experimental animals after they hatched.
[0079] Five avian Salmonella strains including the wild-type Salmonella Gallinarum SG3 (SGSC#: 2293), the virulent gene cluster-inactivated Salmonella Gallinarum SG3-d2 and SG3-d4 (identified to decrease in virulence by in vitro invasion assay), the commercially available live vaccine Nobilis SG9R, and the non-pathogenic E. coli MG1655 were employed in the in vivo assay.
[0080] After being primarily seed cultured, the five strains were vigorously incubated for 4-5 hours to OD 600 =1.0 in a main LB medium, and the concentration of each of the cell cultures was adjusted to 1.0×10 8 cfu/ml. The bacteria was subcutaneously injected at an adjusted dose into the chickens which were the monitored for two weeks for mortality. Subsequently, the chickens which were alive were autopsied to examine lesions and to isolate bacteria.
[0081] For the two, weeks after artificial infection of the pathogens (1.0×10 8 cfu/mL), the chickens infected with Salmonella Gallinarum (SG3) were observed and showed typical external syndromes such as low motility, blue diarrhea and low uptake of feedstuff, and looked to be dying. The mortality was not high, but an autopsy disclosed lesions in almost all the chickens.
[0082] In contrast, the chicken group infected with the Salmonella Gallinarum variant (SG3-d4) the avirulence of which was proven by in vitro invasion assay were observed to actively move and not die although some of them had diarrhea during the two weeks. Also, they were found to have almost no lesions in the autopsy. Therefore, the Salmonella Gallinarum variant of the present invention was again proven to have greatly decreased virulence. The chicken groups infected with the SG3-d2 variant in which the gene responsible for primary invasion into host cells remains intact while the SPI-2 gene involved in systemic infection and survival over phagocytosis is inactivated, or with the SG3-ds variant in which the spv gene known to participate in pathogenicity is inactivated, were observed to have low or no mortality (%). Thus, even the inactivation of single gene clusters had a great influence on the reduction of pathogenicity (see Table 5).
[0000]
TABLE 5
Frequency
of lesions
Geno-
Mortality
in live
Strain
Property
type
(%)
birds (%)
Control
MG1655
Avirulent E. coli
Wild-
0%
20% (2/10)
Group
type
SG3
Virulent
Wild-
20%
88% (7/8)
Salmonella
type
Gallinarum
(Wild-type,
SGSC No. 2293)
Nobilis
Salmonella
SG::
0%
40% (4/10)
SG9R
Gallinarum
ΔrecA
Live vaccine
(commercially
available)
Test
SG3-d1
Virulence gene-
SG::
40%
17% (1/6)
Group
deleted
ΔSPI-1
(avirulent
Salmonella
Salmonella
Gallinarum
Gallinarum )
SG3-d2
Virulence gene-
SG::
10%
0% (0/9)
deleted
ΔSPI-2
Salmonella
Gallinarum
SG3-ds
Virulence gene-
SG::
0%
20% (2/10)
deleted
Δspv
Salmonella
Gallinarum
SG3-d4
Virulence gene-
SG::
0%
10% (1/10)
deleted
ΔSPI-1/
Salmonella
ΔSPI-2/
Gallinarum
Δspv/Δfae
[0083] According to autopsy findings, the liver and spleen were swollen and weakened, with the significant frequency of greenish brown or bluish green liver lesions, in the chicken group infected with the wild-type Salmonella Gallinarum (SG3). Like the commercially available live vaccine Nobilis SG9R or the non-pathogenic E. coli MG1655, however, the virulent gene cluster-inactivated variants of the present invention (SG3-d1d2 and SG3-d4) were found to produce almost no lesions, and were demonstrated to be harmless to chickens.
Example 5
Comparison of the Productivity of ΦCJ1 Bacteriophage Specific to Salmonella gallinarum Variants
[0084] Ultimately, the development of avirulent Salmonella stains is to apply to the production of Salmonella -specific lytic bacteriophages. The Salmonella variants prepared in Example 2 were proven to have greatly attenuated virulence in Examples 3 and 4. Finally, ΦCJ1 (Korean Patent Application No 10-2008-121500/US20100135962), which specifically infects avian Salmonella , was used to examine a difference in bacteriophage productivity between the wild-type and the avirulent Salmonella Gallinarum variants.
[0085] The avian-specific bacteriophage ΦCJ1 was cultured on a mass scale, with the wild-type Salmonella Gallinarum strain (SG3) or the variant serving as a host cell. For this, each bacterial strain was cultured to an OD 600 of 0.5 (2.5×10 10 colony forming units (cfu)) in 50 mL of LB broth in a flask with agitation. ΦCJ1 was inoculated at 1.25×10 9 pfu (plaque forming unit) to form an MOI (multiplicity of infection) of 0.05, and allowed to stand for 20 min at 37° C., followed by additional incubation at 37° C. for 4 hours. Chloroform was added in an amount of 2% of the final volume and shakes for 20 min. After passage of the supernatant through a 0.2 μm filter, the titer of ΦCJ1 was counted.
[0086] ΦCJ1 was produced at a titer of 6×10 1 pfu/ml from the wild-type strain (SG3) and at a titer of 8×10 10 pfu/ml from the avirulent Salmonella Gallinarum variant (SG3-d4). These data demonstrated that the avirulent variants prepared by inactivating virulence gene clusters have no problems with infection with bacteriophages and can be used as host cells for producing bacteriophages (see Table 6). In addition, ΦCJ2 (US 20100158870) and ΦCJ3 (US 20100166709), which were both developed by the same applicant, were produced using the variant as a host cell. The host cell was found to allow the production of ΦCJ2 at a titer of approximately 2×10 10 pfu/ml and ΦCJ3 at a titer of approximately 5×10 9 pfu/ml. Like ΦCJ1, ΦCJ2 and ΦCJ3 were produced from the variant of the present invention, without significant difference from the wild-type.
[0000]
TABLE 6
Production
Titer of
ΦCJ1
Strain
Property
Genotype
(pfu/ml)
Control
SG3
Virulent
Wild type
6 × 10 11
Group
Salmonella
Gallinarum
(Wild-type,
SGSC No. 2293)
Test
SG3-d4
Virulence Gene-
SG3::
8 × 10 10
Group
Deleted
ΔSPI-1/
(avirulent
Salmonella
ΔSPI-2/
Salmonella
Gallinarum
Δspv/Δfae
Gallinarum )
[0087] As described hitherto, the avirulent Salmonella Gallinarum variants, prepared by inactivating, virulence genes, according to the present invention are useful as host cells for effectively producing Salmonella -specific lytic bacteriophages on an industrial scale with the advantage of cost saving. The avirulent Salmonella Gallinarum variants simplify the purification process taken to remove toxicity after bacteriophage production, thus greatly reducing the production cost and solving the safety problem of the products. In addition, the variants can be used as live vaccines that guarantee higher immunological effects and safety than do conventional vaccines.
[0088] Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | The present invention relates to avirulent Salmonella Gallinarum variants by inactivating virulence gene clusters of Salmonella Gallinarum (SG), a main pathogen of avian salmonellosis, and various uses thereof notably in the production of Salmonella -specific lytic bacteriophages, pharmaceutical compositions and feed additives. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to novel compounds which are active herbicides having high selectivity to soybean and graminae crops including corn, wheat and rice.
2. Description of the Prior Art
Certain dichloroanilines have shown generally high activity as plant irradicants and herbicides. Foremost of these are discussed in U.S. Pat. Nos. 3,174,842; 3,332,769; and 4,046,758. However, the herbicidal effectiveness and selectivity of a dihaloaniline having substitution by different functional groups cannot be predicted from an examination of its basic chemical structure or homologous relationship. Often structurally related aromatic compounds have markedly different weed control abilities and crop selectivity.
While many of the dihaloanilines exhibit high plant eradicating properties, they show little if any phytotoxic selectivity for certain commercial crops, such as graminae in either pre-emergence or post-emergence applications. Hence, their range of application is limited unless rates are reduced to such a level that they become ineffectual on certain weed species or repeated applications are required throughout the planting and growing seasons.
Accordingly, it is an object of this invention to provide a herbicide having exceptionally high herbicidal activity in a single application while simultaneously showing good crop selectivity towards commercial graminae crops.
Another object of this invention is to provide a herbicide which can be economically produced and applied to crops in small amounts which are non-contaminating to the soil.
These and other objects will become apparent to those skilled in the art.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided novel herbicidal halogenated hydroxy alkyl aniline having the formula ##STR2## where X and Y are independently chlorine or trifluoromethyl.
Examples of the compounds of this invention embraced within the formula include:
2,5-dichloro-3-hydroxymethyl aniline
2-chloro-5-trifluoromethyl-3-hydroxymethyl aniline
2,5-trifluoromethyl-3-hydroxymethyl aniline and
2-trifluoromethyl-5-chloro-3-hydroxymethyl aniline.
DETAILED DESCRIPTION OF THE INVENTION
The halogenated hydroxymethyl anilines of this invention are preferably prepared by reacting the correspondingly halogenated amino benzoic acid with a suitable reducing agent such as borontrifluoride-tetrahydrofuran at a temperature of from about 0° to about 50° C. under atmospheric pressure.
The compounds of this invention are useful both as pre-emergent and post-emergent herbicides. Among the crops on which the compounds may be advantageously employed are, for example, soybean, rice, corn, cotton, wheat, sorghum, peanuts, safflower, beans, peas, carrots, and other cereal crops.
The present halogenating hydroxyalkyl anilines may be applied in any amount which will give the required control of weeds. A preferred rate of application of the benzoates is from 0.05 to 8 lbs. per acre. In practical application, the compounds may be applied in solid, liquid or in vaporized form, or, as an active ingredient in a herbicidal composition or formulation which comprises a carrier and/or a surfactant. A generally accepted carrier is a substance which can be used to dissolve, disperse or diffuse the herbicidal components in the composition. Non-limiting examples of liquid carriers include water, organic solvents such as alcohols, ketones, halogenated hydrocarbons, aromatic hydrocarbons, ethers, amides, esters, nitriles, mineral oils, methyl pyrrolidone, polyvinylpyrrolidone and the like. Non-limiting examples of solid carriers include Kaolin, bentonite, talc, diatomaceous earth, vermiculite, clay, gypsum, grain and seed hulls, ground corn cobs and the like. In addition to a carrier, it is usually desirable to add to the composition additives such as emulsifying agents, wetting agents, binding agents, stabilizer and the like. The compounds may be formulated, for example, as a dust, wettable powders, emulsifiable concentrates, granular formulations or aerosols.
The halogenated hydroxyalkyl anilines herein described may be applied along with plant growth regulators, insecticides, fungicides, nematocides and fertilizers. They may be applied in combination with one or more other herbicides. Non-limiting examples of other herbicides which can be incorporated with the phenoxybenzoates of this invention are anilides, such as N-methoxymethyl (2,6-diethylphenyl) chloroacetamide; dinitroanilines, such as α,α,α-trifluoro-2,6-dinitro-N,N-di-propyl-p-toluidine; carboxylic acids and derivatives; triazines; substituted ureas; carbamates; thiocarbamates; uracils; heterocycles, organo phosphorous compounds and the like.
Having thus generally described the invention, reference is now had to the following examples which represent preferred embodiments but which are not to be construed as limiting to the scope of the invention as more broadly set forth hereinabove and in the appended claims.
EXAMPLE 1
Preparation of 3-Amino-2,5-Dichlorobenzyl Alcohol
Into a 1 liter three-neck flask was introduced 40 g (0.19 mole) of 3-amino-2,4-dichlorobenzoic acid and 150 ml of tetrahydrofuran. The solution was cooled to 8°-10° C. in an ice bath. A borontrifluoride-tetrahydrofuran (1M) solution (280 ml) was added dropwise over a period of 1 hr. After being stirred at 8° C. for an additional 1 hr. the solution was allowed to warm up slowly to room temperature. The reaction flask was then cooled again in an ice bath and 50 ml of water was added through a dropping funnel. The mixture was taken into 1 liter of methylene chloride and washed once with NaHCO 3 and twice with water, then dried over calcium sulfate. The methylene chloride solution afforded 19.2 g of crude solid product, mp 111-121. Five grams of the crude solid was recrystallized from acetonitrile to yield 4.2 g of 3-amino-2,5-dichlorobenzyl alcohol; mp 121-127; nmr (DMSO-d6) δ4.50 (D, 2H), 5.34 (t, 1H), 5.52 (S, 2H), 6.73 (S, 2H); ir (CHCl 3 ) 3490, 3380, 3240, 1630 and 1598 Cm -1 .
The 3-amino-2-chloro-5-trifluoromethyl benzyl alcohol, 3-amino-5-chloro-2-trifluoromethyl benzyl alcohol and 3-amino-2,5-trifluoromethyl benzyl alcohol are prepared according to this example, except that the above benzoic acid is substituted with the benzoic acid having the described substitution, i.e. 3-amino-2-chloro-5-trifluoromethyl-, 3-amino-5-chloro-2-trifluoromethyl-, or 3-amino-2,5-trifluoromethyl- substituted benzoic acid.
EXAMPLE 2
Herbicidal Tests
Tests were made on species of representative monocotyledonous and dicotyledonous plants at a rate of 5 lbs/acre, 3-amino-2,5-dichlorobenzyl alcohol in aqueous solution was applied immediately after seeding with plants shown in the following table. The response was evaluated after 2 weeks on a scale of 0 to 9 where 0 represents no injury and 9 represents complete kill.
TABLE______________________________________Plant Species Toxicity______________________________________Morning Glory 8Mustard 9Pigweed 9Foxtail 9Japanese Millet 9Crabgrass 9Soybean 5Corn 6Wheat 3Rice 5______________________________________
While the invention has been described with particular reference to a certain preferred embodiment thereof, however, it will be understood that certain modifications can be made, such as the substitution in Example 2 of any of the other halogenated hydroxymethyl anilines which compounds provide similar results. | A compound of the formula: ##STR1## where X and Y are independently chlorine or trifluoromethyl. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001]
[0000]
6,439,000
Aug. 27, 2002
Smark
223/99
1,289,183
Dec. 31, 1918
Jerram
112/223
BACKGROUND
[0002] When threading an inherently flexible or bendable, relatively thin and narrow filamentous, fibrous, woven or spun strand-like entity, henceforth referred to herein as a strand 600 , through a hole, tunnel, tube, loop, opening, or orifice, henceforth referred to herein as an orifice or an object that contains an orifice such as, but not limited to, a button, bead or charm henceforth referred to herein as an orifice object 500 , it is one's natural inclination to simply push it through the orifice. This may work at times, but usually is not fast, easily accomplished, or convenient. This approach rarely works when the diameter of the strand 600 being threaded is close to or in some cases exceeds the diameter of the orifice, through which it is being threaded. This is especially true when the strand 600 is very flexible, tends to fold on itself during insertion and or compresses to form a larger diameter or consists of a cut end which frays, further increasing the diameter and stopping the strand 600 from passing through. It further becomes more difficult as the diameter of the orifice becomes smaller and the length of the orifice increases. Since pushing often proves to be of no use, many different tools have been developed for pulling a strand 600 through an orifice. These tools fall into four broad categories:
1. Tools which feature a closed loop such as a needle threader or an orthodontic floss threader or a needle. In order for these tools to work correctly one must have an open-ended strand to thread through the closed loop of the tool. Once the tool is threaded, it can be pulled or pushed in some way through the orifice. While these will work for an open-ended strand, they are not practical if one is seeking to thread a closed or semi-closed strand 600 through the orifice. 2. Tools which are, in general, open hooks and include crochet hooks, heddle threaders, and orifice threaders. These tools work by inserting the hook into an orifice, hooking a strand 600 , and then retracting it through the orifice. These will pull both open and closed strands 600 through a compatible orifice size with reasonable success and with limited frustration, however, they do not work very well at all for applications outside of their intended design. For instance, they are incapable of hooking and pulling yarn through a small diameter orifice as found in many decorative beads. The hooks of these tools are often too shallow to accommodate the entire strand 600 and so the strand 600 , in whole or part, slips off the hook before the threading process is complete. Those hooks that adequately accommodate the strand 600 are usually too thick to pass through the orifice. When a thin hook is required to accommodate the smaller orifice size, shafts often prematurely expand into a handle configuration that is too wide to pass through the orifice and thus do not emerge from the orifice to catch the strand 600 . Hooks that are narrow and wire-like often split the strand 600 and either pierce or fray the strand 600 compromising its integrity in terms of strength and for appearance. The hook end also tends to catch on the orifice edge during retraction even when tools are being used as designed such as the frequent catching when using an orifice hook to pull spun fiber through the orifice of a spinning wheel. 3. Tools which are latched hooks featuring a hinged latch which closes the open hook and thereby captures the open or closed strand 600 . These work well for larger applications, but are far too large for small applications such as threading small seed beads used in jewelry making. Not only does the latch hook hinge fold back on itself during insertion, which then increases the hook size, but it also has rigid construction that does not allow it to squeeze through smaller orifices. In addition, it generally features a relatively large teardrop shape further increasing the minimum orifice size. 4. Tools which are presently used by those skilled in the art such as a cut piece of sewing thread folded around the open or closed strand 600 to be drawn, both ends of thread brought together, threaded through an orifice, and then pulled so as to draw the strand 600 through the orifice. Since thread is thin and slippery, it is hard to grip. One then wraps the thread several times around the fingers in order to pull with adequate force to pull the strand 600 through the orifice. This may hurt the hands and can break the thread. This method is also time consuming, cumbersome, and requires two free hands to complete the process for the average practitioner. The thread is hard to see and is easily lost on the work surface or accidentally adheres to clothes or the project. Thread also tends to fold on itself significantly as it encounters resistance due to friction between it and the orifice surface and thus significantly inhibits threading the strand 600 through the orifice. The problem is exacerbated as the orifice passageway becomes longer. To counteract this problem, thread is often first inserted into a small-eyed needle to then be threaded through the orifice. This is yet another step which results in time loss and may require a needle threader to insert the thread into the eye of the needle.
[0007] In summary, the above methods are not efficient or convenient and work with ever increasing difficulty when the size of the strand 600 and orifice is reduced and the ratio of the strand diameter to the orifice diameter increases. Since people have been artistically working with strands 600 to create closed loops and/or stitches and have sought to embellish the work with beads and the like, no convenient and truly effective methods have been developed to easily add beads, buttons, and embellishments to stitches. Even today the authors of knit beading books will instruct the reader to use the standard inefficient, methods such as a crochet hook or a piece of sewing thread. The solution described herein has proven to provide an optimal solution to pulling almost any strand 600 through an orifice or pushing any orifice over a strand 600 , especially for smaller orifice diameters. This very useful device design, as per a search, has not been suggested, published, developed or otherwise disclosed by those who would find it most useful over the period of at least the last 100 years for this purpose nor comprised in such a way as is described below.
BRIEF SUMMARY OF THE INVENTION
[0008] A key component of this invention has been termed a “Shaft Hook” 100 and a particular embodiment is detailed in FIG. 1 , FIG. 2 , and FIG. 3 . This device will solve the above orifice threading problems and will prove itself useful for a wide range of such threading applications. A Shaft Hook 100 is configured so that a strand 600 may slip into the hook 112 without catching, splitting, or piercing and thus being caught in the hook 112 so it can be securely pulled through an orifice. The key design parameter of the shaft hook 100 is that the terminal end 116 of the shaft hook 100 is angled away from the direct path of the strand 600 as it is compressed under tension over the shaft 110 , slid down the shaft 110 and into the hook 112 . Size, shape, and configuration of the shaft hook 100 may be optimized for different applications. The shaft hook 100 can be used to hook both an open-ended or closed or semi-closed loop strand 600 configuration and may be attached to many other components such as handles, grippers or machinery which would add to its usefulness. A particular embodiment of this invention is shown in FIG. 4 and, when configured in this way, is primarily operated with one hand and can be retained in the hand without holding it directly so it is conveniently retrievable for each use and adds a means of convenient leverage for specific applications described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 illustrates a particular embodiment of the shaft hook 100 component from a side of the shaft hook 100 which places the cross 114 in the front of the shaft 110 , with the hook 112 to the bottom and the terminal end 116 slanting to the top right.
[0010] FIG. 2 illustrates the shaft hook 100 component from a side of the shaft hook 100 which places the cross 114 to the back of the shaft 110 .
[0011] FIG. 3 shows the shaft hook 100 component side view demonstrating the closeness of the shaft 110 with the cross 114 . Note that the shaft 110 is in the front, then the hook 112 turns away, and then the terminal end 116 comes back toward the front.
[0012] FIG. 4 shows a particular embodiment of this invention as an assembled device described herein and comprised of the shaft hook 100 , handle 300 , and ring 400 components.
[0013] FIG. 5 illustrates how this particular embodiment of the assembled Loop Hook Orifice Threader and Beader device shown in FIG. 4 is to be held in the hand and shows an orifice object 500 , in this case a seed bead, on the shaft hook 100 .
[0014] FIG. 6 demonstrates the shaft hook 100 device in use with a strand 600 latched into the hook 112 with an orifice object 500 past the terminal end 116 and sitting on the cross 114 . The orifice object 500 will next slide over the hook 112 and latched-in strand 600 resulting in FIG. 7 .
[0015] FIG. 7 shows the orifice object 500 after it slides over the hook 112 and latched strand 600 and onto the closed-loop strand 600 . In this illustration the looped strand 600 is a small, stretchy, silicone band often used in crafting jewelry or holding hair.
[0016] FIG. 8 shows the orifice object 500 after it slides over the hook 112 and latched strand 600 and onto the looped strand 600 . In this illustration the looped strand 600 is a knit stitch which was originally created by a knitting needle 700 .
DETAILED DESCRIPTION OF INVENTION
[0017] The solution to effectively and efficiently pulling a strand 600 through an orifice, is the relatively long and thin shaft hook 100 FIG. 1 , FIG. 2 , FIG. 3 described herein. The shaft hook 100 is configured into a unique shape with a width that is consistent with the minimum orifice diameter for which it is designed. In this regard, it's size is limited only by available and suitable construction materials and methods, thus allowing it to slide into any orifice object 500 diameter such as, but not limited to, the hole of small seed beads 500 or the orifice of a spinning wheel. The length and thickness of the shaft hook 100 component will and can vary for the specific range of strand 600 and orifice combination use. All or part of the shaft 110 may not necessarily be straight. In fact, it may be gently curved, extremely curved, twisted, or bent as necessary for the particular application.
[0018] The shaft 110 results in a continuous or attached upturned hook 112 which will then cross 114 the shaft 110 again in another plane with the terminal end 116 angled away from the strand 600 as it slides down the shaft 110 and into the hook 112 . Most often this angle will be slanted away from the shaft 110 as shown in FIG. 1 , but could take on another angle such as a curve toward the shaft 110 . The key is that the terminal end 116 is not in the path of the strand 600 as it slides down the shaft 110 and into the hook 112 providing a snag free space through which the strand 600 can pass without being split or pierced by the terminal end 116 . The cross 114 serves to secure, snare, catch, hold or lock the strand 600 into the base of the hook 112 . The distance from the cross 114 to the terminal end 116 will vary and depend on the use and specifications of the shaft hook 100 including the strand 600 it is intended to hold and the orifice it must pass through. The shaft hook 100 will essentially be touching at the point of the cross 114 . Very little space if any is desirable at this point so that it keeps the strand 600 latched into the hook 112 . Some space is possible however and may be necessary depending on shaft hook 100 material characteristics FIG. 3 . The cross 114 could even by carved out so as to allow the cross 114 to fit over or interlock over the shaft 110 . In this case the diameter of the total shaft hook 100 would be further reduced increasing shaft hook 100 versatility. The amount of positive or negative space between the cross 114 and the shaft 110 will be determined by material characteristics and intended application or use. A shaft hook 100 comprised of a material with optimal give or flex while still returning to its predetermined shape will reduce the needed space at the cross 114 to zero. The material will give slightly to the force of the strand 600 and allow the strand 600 to enter the hook 112 . A material that “gives” slightly is also very desirable so that it will more easily pull through the orifice both reducing the potential for snagging the orifice opening and to increase its ability to move through even smaller orifices before resiliently returning to its predetermined shape.
[0019] The shaft hook 100 diameter and length, as well as the hook 112 , cross 114 , and terminal end 116 design will vary for different purposes and applications. This particular embodiment of the shaft hook 100 will accommodate a fine sewing thread to a size 5 or 6 (bulky) yarn and can be inserted into an orifice as small as approximately 0.055″ (1.5 mm) in diameter (such as a size 6 seed bead) and as long as approximately 0.75″ (2 cm) in length. The shaft hook 100 can be manufactured to accommodate many other size ranges.
[0020] As with any hook device that is retracted through an orifice some edge catching may occur at times, as is the case with existing orifice threader hooks, but this shaft hook 100 design will effectively minimize this occurrence. Use by those skilled in the art has shown that a little practice will effectively eliminate any catching. In addition, it should be recognized to anybody skilled in the art that this unique shaft hook 100 component can be mounted on a multiplicity of different handles, arms or machine fixtures to produce devices that effect easy and efficient manual or automatic use.
[0021] A particular embodiment of this invention is the device shown in FIG. 4 . which has most immediate use as a tool that allows fiber artists, banders, and others the ability to quickly, efficiently, and conveniently embellish their work with only one hand and thereby allowing the artist a free hand with which to hold the work. The shaft 110 is of adequate rigidity such that it will not bend due to the frictional resistance of an orifice. Further speeding the process, it may allow one to string multiple orifice objects 500 , either all the same or different and in any desired sequence, at once on the shaft 110 . The Loop Hook Orifice Threader and Beader FIG. 4 sits in the hand FIG. 5 while both in and out of use and so eliminates time and frustration looking for and picking up the tool as is often the case when practicing this art form with other methods.
[0022] This Loop Hook Orifice Threader and Beader device FIG. 4 can thread an open-ended strand, but in addition, it is ideal for threading an orifice object 500 , onto a loop or two sides of one strand 600 at once FIG. 7 and FIG. 8 . Situations where this Loop Hook Orifice Threader and Beader FIG. 4 would be most useful include 1. Placing orifice objects 500 on a stretchy closed loop band 600 often used to make jewelry crafts or hold hair. 2. Placing orifice objects 500 on a knit stitch 600 3. Placing orifice objects 500 on a crochet stitch 4. Placing orifice objects 500 on a hand sewing or embroidery stitch such as a chain stitch, 5. Placing orifice objects 500 on any other fully or partially closed strand 600 and 6. Pulling any open-ended strand, chain, etc. or closed or partially closed strand 600 or loop through any orifice.
[0023] The preferred embodiment in FIG. 4 is comprised of the shaft hook 100 attached to a handle 300 at approximately a right angle which is designed to telescope to an appropriate span for a specific application or user. The handle 300 also includes a free rotation mechanism that allows the shaft hook 100 unit to be turned upwards or downwards easily and aide in ease of use both in convenient position and gravitationally keeping the orifice object(s) 500 on the shaft hook 100 . The handle 300 is designed to fit across the inside of the hand giving leverage to the user FIG. 5 . The handle 300 is attached to a ring 400 which is adjustable in size to fit the user and detachable/interchangeable with different sizes or styles. Other preferred embodiments may or may not utilize these features for best use in a specific application.
[0024] The intended use of this Loop Hook Orifice Threader and Beader FIG. 4 is for embellishing handwork. The user will slip the clip or ring 400 onto the hand, most likely a comfortable finger, with the handle 300 held under the second joint knuckles of the hand FIG. 5 . The handle 300 will then be adjusted so that the entire handle 300 fits comfortably under the width of the fingers. The handle 300 will also be adjustable in angle so that the shaft hook 100 is in line with the thumb and forefinger to comfortably allow a user to slide an orifice object 500 down the shaft 110 over the hook 112 and onto the strand 600 FIG. 6 .
[0025] The process to use the preferred embodiment FIG. 4 to embellish handwork with an orifice object 500 such as a bead is as follows: 1. Place the clip or ring 400 on a comfortable finger and adjust the handle 300 span and angle of the shaft hook 100 to comfortably fit the user's hand FIG. 5 . 2. Load an orifice object 500 onto the shaft 110 and hold it in place with your finger. 3. Loop the strand 600 over the shaft 110 and pull the strand 600 taught while slipping it down the shaft 110 and into the hook 112 . 4. If applicable, remove the looped strand 600 from any other tool or implement that was initially used to hold or create the loop 600 , such as but not limited, to a knitting needle 700 . 5. Using the thumb and forefinger slide an orifice object 500 down the shaft 110 , over the terminal end 116 , cross 114 , and hook 112 (with a slight rock or wiggle of the orifice object 500 if necessary) FIG. 6 , and onto the looped strand 600 , FIG. 7 , FIG. 8 . 6. Replace the looped strand 600 onto the original tool or implement if desired in order to continue the project. 7. Remove the hook 112 from the looped strand 600 by applying a bit of pressure which will both tension the strand 600 and release the strand 600 with relative ease. Longer shafts 110 will allow more orifice objects 500 to be pre-threaded or loaded onto the Hook Loop Orifice Threader and Beader FIG. 4 so they may be released at any rate as the user desires. Longer shafts 110 will also allow for longer orifices to be threaded including the orifice of a spinning wheel or other tubes or other decorative embellishments.
[0026] In concept, all parts of the Loop Hook Orifice Threader and Beader FIG. 4 are interchangeable allowing additional shaft hook 100 components to be used for different orifice and strand 600 specifications. Different handles 300 may be used for adding or reducing potential span or for changing the sensitivity of the shaft hook 100 angle adjustment. Different handles 300 may be interchanged to accommodate style and design decoration preferences. Clips or rings 400 may be interchanged as well to meet size, style, and finger placement requirements. The Hook Loop Orifice Threader and Beader FIG. 4 may also be manufactured as a single unit without interchangeable parts or any combination of such. | A uniquely shaped hook which allows a relatively large strand to be hooked securely without snagging or piercing and drawn through a relatively small orifice. The hook can be combined with an adjustable handle which will provide a point of leverage and a clip or ring that will allow the user to keep the device on the hand without holding it directly. A method of embellishing handwork using the device by which the user pre-loads one or more embellishments containing an orifice on the shaft, hooks a strand, slides the embellishment over the hook and onto the strand, and then unhooks the strand with primarily only one hand. | 3 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to a motor vehicle propeller shaft assembly and a constant velocity joint (CVJ) cap of such an assembly.
BACKGROUND OF THE INVENTION
[0002] For safety reasons, propeller shaft assemblies for motor vehicles which are oriented longitudinally with constant velocity joints are typically designed with a shock absorption capability during telescopically collapse of the shaft assembly in the event of a frontal impact. These assemblies also need proper sealing against lubricant leakage on the one hand and a venting system on the other hand. All these requirements make the construction of a propeller shaft assembly complex.
SUMMARY OF THE INVENTION
[0003] The present invention simplifies the propeller shaft assembly by providing a cap inserted into or abutting the outer race of a constant velocity joint (CVJ) that enables both proper sealing and venting without interfering with the energy absorption capability of the assembly.
[0004] The grease retention and vent cap of this invention may enable a collapse of the propeller shaft assembly in various ways. In a first example, the grease retention and vent cap has a rim pressed into or adjacent the outer race of the CVJ which stays rigid during a vehicle crash. If the propeller shaft is fabricated with a beaded weld which projects into the inside diameter of the shaft, this rim may be retained or broken by the weld bead during a crash. Internal CVJ components abut a central portion of the cap and cause this central portion to break away from the cap rim and pass through the tubular propeller shaft ahead of the internal joint components, allowing the propeller shaft assembly to collapse telescopically.
[0005] Alternatively, the entire rim of the cap can disintegrate into pieces small enough to enter the tubular propeller shaft.
[0006] For applications for a propeller shaft which does not have an inwardly protruding weld bead, the entire cap may be pushed into the tubular propeller shaft without breaking. The cap has an arrangement of vent ducts leading from the internal components of the CVJ to a radial annular groove surrounding the entire circumference of the cap. From there, a connection to the atmosphere is established by radial bores in the outer race of the CVJ in the axial area of the annular groove at any angular position on the tubular shaft. The invention thus encompasses both a venting system incorporated into the cap and a crash feature for a propeller shaft assembly, eliminating the need for two separate systems for such features.
[0007] Grease is retained inside the outer race of the CVJ in the propeller shaft assembly by providing a vent hole for communication with the interior components of the CVJ in the axial center of the cap, thereby ensuring that the vent hole is never at the bottom of the tubular shaft, regardless of the orientation of the cap. The rim thus forms a seal along the entire circumference of the cap.
[0008] In this configuration, the cap will act as a venting system, provides grease retention for the CVJ, and allows for crash optimization.
[0009] Additional benefits and advantages of the present invention will become apparent to those skilled in the art to which the present invention relates from the subsequent description of the preferred embodiment and the appended claims, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 depicts a side view of a first illustrative example of a cap in accordance with this invention;
[0011] FIG. 2 depicts the cap of FIG. 1 in a first perspective view showing one of two major surfaces of the cap;
[0012] FIG. 3 depicts the cap of FIG. 1 in a second perspective view showing the other one of the two major surfaces of the cap;
[0013] FIG. 4 is a longitudinal cross-sectional view of a propeller shaft assembly according to this invention showing the components thereof during normal vehicle operation; and
[0014] FIG. 5 is a longitudinal cross-sectional view of a propeller shaft assembly according to this invention showing the components thereof following a vehicle crash.
[0015] FIG. 6 depicts a first perspective view of a grease retention and vent cap according to a second exemplary embodiment of the invention.
[0016] FIG. 7 depicts a second perspective view of the grease retention and vent cap of FIG. 6 .
[0017] FIG. 8 depicts a cross-sectional view of the venting system in the grease retention and vent cap of FIG. 6 .
[0018] FIG. 9 depicts a side view on the grease retention and vent cap of FIG. 6
[0019] FIG. 10 depicts the grease retention and vent cap of FIG. 6 within a propeller shaft system during normal vehicle operation.
[0020] FIG. 11 depicts the grease retention and vent cap of FIG. 6 within a propeller shaft system during a vehicle crash.
[0021] FIG. 12 depicts the grease retention and vent cap of FIG. 6 within a propeller shaft system after a vehicle crash.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The figures of the drawings are provided for purely illustrative purposes and are not intended to limit the scope of the invention.
[0023] Referring to FIGS. 1 through 3 , a first exemplary embodiment of a grease retention and vent cap 1 has a rim 2 dimensioned to be placed and retained in an outer race 9 of a CVJ. As shown, CVJ has a counter-bored region for receiving cap 1 . Other embodiments (not shown) can provide an inside diameter surface for retaining cap 1 adjacent to the CVJ. Retaining the rim 2 in the outer race 9 may be accomplished by a slight radial annular indent placed on a corresponding annular protrusion in the outer race 9 .
[0024] Axially adjacent to the rim 2 is an axial area forming a hollow chamber 3 that extends radially across the entire width of the cap 1 . The hollow chamber 3 is open at both radial ends and terminates in an annular groove 4 that extends around the entire circumference of the cap 1 . An axial vent hole 5 is located centrally in cap wall 18 that bounds the hollow chamber 3 at an axial end opposite the rim 2 . The vent hole 5 establishes fluid communication of the hollow space 3 to the outside of the cap 1 .
[0025] Referring now to FIG. 4 , the cap 1 is pressed into a recessed inside diameter portion of the outer race 9 of a propeller shaft CVJ and retained at its outer diameter by rim 2 . The cap 1 separates internal components of a CVJ, such as a stub shaft 12 , an inner race, a cage and balls (known as the internal joint components and referred to by reference number 8 ) from a tubular shaft portion 11 of the propeller shaft. A dust boot 13 seals the gap between the stub shaft 12 and the outer race 9 to prevent contamination. Air is allowed to pass from the internal components 8 of the CVJ to the cap hollow chamber 3 through the vent hole 5 , which is centrally located in the cap 1 and extends axially through a face of the cap 1 into the hollow chamber 3 . This allows atmospheric pressure venting which prevents the development of pressure differentials between the area of the joint internals 8 and atmosphere, which can lead to the introduction of contaminants which can degrade the service life of the CVJ.
[0026] The vent hole 5 is located on a major face of the cap wall 18 and oriented to face the internal CVJ components 8 . Air is then allowed to pass from the hollow air chamber 3 of the cap 1 through the radially open ends of the hollow chamber 3 into the radial annular groove 4 that runs 360 degrees around the outer periphery of the cap 1 . The air then passes through bores 17 drilled into the outer race 9 of the CVJ to the atmosphere.
[0027] The hollow air chamber 3 in the cap 1 has a cavity volume which ensures that the propeller shaft CVJ does not allow water ingress during an event in which the CVJ is hot and then cooled quickly, for example by water submersion during operation of the associated motor vehicle. In such a situation, the rapid quenching can cause water to be sucked into the cap 1 . By providing sufficient volume in the internal hollow chamber 3 of the cap 1 , the sucked-in water will be retained in the hollow chamber 3 and will not reach the internal joint components 8 through vent hole 5 . The exact volume of the hollow chamber 3 depends on anticipated temperature differences and on physical properties of the propeller shaft assembly, such as enclosed air volume. The central location of vent hole 5 ensures that the vent hole 5 is never at the bottom of the hollow chamber, regardless of the angular orientation of the cap 1 inside the propeller shaft assembly. Therefore, any water accumulated at the bottom of the hollow chamber 3 cannot flow into the area of the internal joint components 8 .
[0028] The tubular shaft 11 of the propeller shaft assembly is connected to the outer race 9 via a weld 10 . The weld 10 as shown, has a bead which extends both radially outwardly, and also inwardly from the inside diameter of shaft 11 , which is typical in a friction welding process. To not interfere with axial movement of a cap, machining of the bead of weld 10 would be required. In order to still allow for a telescopic collapse during a frontal impact without interior machining of the weld 10 , the cap 1 is configured to withstand axial displacement of the internal joint components 8 in direction 14 only to a limited extent. Upon a vehicle crash exceeding such displacement, the rim 2 of the cap 1 are retained inside the CVJ outer race 9 . A central portion 6 of the cap 1 shears away, separating from the rim 2 , and allows the internal joint components 8 to escape from the outer race 9 into the tubular shaft 11 .
[0029] The cap 1 is made of a material, for instance a suitable plastic material, that is tunable to collapse at a certain energy produced by the vehicle during a crash. The exact energy and resulting force to trigger a separation of the central portion 6 from the rim 2 can be empirically determined and depends on several factors that may include vehicle weight and spatial dimensions inside the vehicle.
[0030] FIG. 4 depicts the cap 1 used within a propeller shaft system during normal vehicle operation. The cap 1 is pressed inside the outer race 9 . The internal joint components 8 are retained and sealed by the cap 1 . Grease is retained within the outer race 9 by the cap 1 . The air vent bores 17 in the outer race 9 allow venting from the internal joint components 8 through the axial vent hole 5 , via the hollow chamber 3 and the bores 17 to the atmosphere.
[0031] FIG. 5 depicts the cap 1 used within a propeller shaft system during a vehicle crash. During the impact, forces acting on the vehicle transmission shift the stub shaft 12 , producing displacement in the direction shown by the arrow 14 . The internal joint components 8 impact the cap 1 , forcing the cap toward the tubular shaft 11 until the rim 2 , acting as a low force retention feature, contacts the interior bead of the weld 10 . The rim 2 remains in contact with the weld 10 , while the impact causes the central portion 6 of the cap 1 to shear and break away. The central portion 6 exits the outer race 9 ahead of the internal joint components 8 and enters the tubular shaft 11 , giving way for the internal joint components 8 to follow.
[0032] The internal joint components 8 are small enough to pass from the outer race 9 through the tubular propeller shaft 11 following a backward shift of an engine or transmission during a vehicle collision, to absorb the energy created by the vehicle collision, thereby enabling the telescopic effect described earlier.
[0033] The cap 1 may be used in a propeller shaft which uses either a friction weld, gas metal arc weld or magnetic arc weld to join the CVJ outer race 9 to the tubular propeller shaft 11 . With the use of a friction weld 10 , during a collision, the cap 1 contacts the internal bead of the weld 10 and the central portion 6 of the cap 1 is sheared away from the rim portion 2 as described above.
[0034] With the use of either a gas metal arc weld or magnetic arc weld forming a smooth surface at the inner tube diameter, the cap 1 may be made with a diameter small enough such that it is able to pass through the weld portion and into the tubular propeller shaft 11 . Accordingly, absent an interior weld bead, the grease retention and vent cap 1 remains intact during the collision. In the drawings, the cap 1 of FIG. 4 would simply move to the right as a whole, ahead of the internal CVJ components, without shearing of the cap.
[0035] Referring now to FIGS. 6 through 9 showing an alternative embodiment of cap 101 , axes x, y, and z of a virtual coordinate system are indicated in the drawings to illustrate the respective perspectives of the individual drawing figures. In a second exemplary embodiment of the present invention, a grease retention and vent cap 101 has a rim 102 dimensioned to be placed and retained in an outer race 109 of a CVJ. Retaining the rim 102 in the outer race 109 may be accomplished by a slight radial annular indent or expansion matched with a corresponding annular shape in the outer race 109 .
[0036] Axially adjacent to the rim 102 is an axial area forming a plurality of hollow channels 103 that extend parallel across the entire radial width of the cap 101 . The hollow channels 103 are separated by parallel walls 107 arranged in such a way that the radial center of the cap 101 is not obstructed by a wall 107 . The hollow channels 103 are open at both radial ends. A radial annular groove 104 in end portions of the walls 107 extends around the entire circumference of the cap 101 . An axial vent hole 5 is located centrally in a radially extending wall 118 that bounds the hollow channels 103 at an axial end opposite the rim 102 . The vent hole 105 establishes an axial communication of that one of the hollow channels 103 that extends across the central location to the axial outside of the cap 101 .
[0037] FIG. 6 shows optional reinforcing webs 115 supporting the rim 102 , the thickness as well as radial and axial dimensions of these webs 115 can be dimensioned to meet specifications regarding a threshold force along the arrow 114 (shown in subsequent figures) required to separate the rim 102 from the central portion 106 of the cap 101 or to disintegrate the rim as explained in more detail in connection with FIGS. 10 through 12 .
[0038] Referring now to FIG. 10 , the cap 101 is pressed into the outer race 109 of a propeller shaft CVJ and retained at its outer diameter at rim 102 . The cap 101 separates a stub shaft 112 , an inner race, a cage and balls (known as the internal joint components and collectively identified by reference number 108 ) from a tubular portion 111 of the propeller shaft. The stub shaft 112 and the outer race 109 are sealed via a dust boot 113 to prevent contamination. Air is allowed to pass from the internal components 108 of the CVJ to the central one of the hollow channels 103 through the vent hole 105 which is centrally located in the cap 101 and extends axially through a face of the cap 101 into the hollow channel 103 .
[0039] The vent hole 105 is located on a major face of the cap 101 oriented to face the internal CVJ components 108 . Air is then allowed to pass from the central hollow channel 103 of the cap 101 through the radially open ends of the hollow channel 3 into the radial annular groove 4 that runs 360 degrees around the outer periphery of the cap 101 . The air then passes through bores 117 drilled into the outer race 109 of the CVJ to the atmosphere.
[0040] The hollow air channels 103 in the cap 101 have a cavity volume which ensures that the propeller shaft CVJ does not allow water ingress during an event in which the CVJ is hot and then cooled quickly, for example by water submersion. In such a situation, the rapid quenching can cause water to be sucked into the cap 101 . By providing sufficient volume in the internal hollow channels 103 of the cap 101 , the sucked-in water will be retained in the hollow channels 103 and will not reach the internal joint components 108 through vent hole 105 . The exact volume of the hollow channels 103 depends on anticipated temperature differences and on physical properties of the propeller shaft assembly, such as enclosed air volume.
[0041] The central location of vent hole 105 ensures that the vent hole 105 is never at the bottom of the hollow channels 103 , regardless of the angular orientation of the cap 101 inside the propeller shaft assembly. Therefore, water accumulated at the bottom of the hollow channels 103 , even in the central hollow channel 103 , cannot flow into the area of the internal joint components 8 .
[0042] The tubular shaft 111 of the propeller shaft assembly is connected to the outer race 109 via a weld 110 . The weld 110 of the type shown has an interior bead that would require machining to remove. In order to still allow for a telescopic collapse during a frontal impact without interior machining of the weld 110 , the cap 101 is configured to withstand axial forces from the internal joint components 108 in direction 114 only to a limited extent. Upon a vehicle crash exceeding such limited force, the rim 102 of the cap 101 is retained inside the CVJ outer race 109 . The central portion 106 of the cap 101 gives way, separates from the rim 102 , and allows the internal joint components 108 to escape from the outer race 109 into the tubular propeller shaft 111 . The rim 102 is configured to break into pieces at the time of separation from the central portion 106 . The pieces of the rim 102 are small enough to disperse into the tubular propeller shaft 111 without impeding the telescopic movement of the internal joint components 108 into the tubular propeller shaft 111 .
[0043] The cap 101 is made of a material, for instance a suitable plastic material, that is tunable to collapse at a certain energy produced by the vehicle during a crash. The exact energy and resulting force to trigger a separation of the central portion 106 from the rim 102 or to break the rim 102 can be empirically determined and depends on several factors that may include vehicle weight and spatial dimensions inside the vehicle. The dimensions of the webs 115 can be utilized for fine-tuning the cap properties to given demands, for instance by model simulations or by experimentation.
[0044] The cap 101 may be used in a CVJ outer race 109 that is joined to a tubular propeller shaft 111 by welding. When the joining method is friction welding, during a collision the grease retention and vent cap 101 contacts the weld 110 and collapses as illustrated in FIGS. 11 and 12 . Upon a frontal impact, the walls 107 may collapse when the cap 101 first abuts the interior bead of the weld 110 as illustrated in FIG. 11 . This collapse leaves the webbed axial surface of the cap 101 intact. Once the rim 102 reaches the weld, it may either be retained as shown in the embodiment of FIGS. 1 through 5 , or it may break into pieces that may disperse inside the tubular propeller shaft 111 as illustrated in FIG. 12 . In FIG. 12 , the stub shaft 112 has been pushed so far into the tubular shaft 111 that the dust boot 113 is torn. The rim 102 of the cap 101 is destroyed and broken into many small pieces dispersed in the tubular shaft. 111 . The pieces are small enough not to impede the movement of the internal joint components 108 .
[0045] If the CVJ and tubular propeller shaft 111 are fabricated by a process other than friction welding, such as a magnetic arc welding or gas metal arc welding, no interior bead is created. In this approach, the cap 101 may be small enough to pass through the connection between the CVJ and the tubular propeller 111 shaft into the tubular propeller shaft 111 during a collision, without breaking the cap.
[0046] The caps 1 and 101 are dimensioned to be sufficiently robust to withstand general handling and operation during normal use over the entire lifetime of a propeller shaft.
[0047] The foregoing description of various 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 embodiments disclosed. Numerous modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby 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 to which they are fairly, legally, and equitably entitled. | Disclosed is a cap that will act as a grease retention feature and venting system, while allowing crash optimization of a propeller shaft with a plunging constant velocity joint. The cap is located between a constant velocity joint and a tube of the propeller shaft system. The cap includes: a rim sealed against the inner diameter of the constant velocity joint, an interior vent chamber, a vent hole facing the interior components of the constant velocity joint and leading to the vent chamber, and an annular radial groove along the entire circumference connected to the vent chamber. The outer race has a hole perpendicular to the joint axis to complete venting to the atmosphere. In the event of a vehicle crash, the constant velocity internal joint components contact the device, causing the device to dislodge from its fixed position, contact the friction weld curls and fracture at a determined load. | 8 |
BACKGROUND OF THE INVENTION
1) Field of the Invention
The present invention relates to a device for lubricating railroad rails which is mountable to a track vehicle.
2) Description of the Prior Art
It has long been the practice to apply grease, friction modifying materials or similar gel-like lubricants to the sides of rails at curves, switches and other parts of the railroad track. Such materials are applied to the sides of the rail to reduce the friction which occurs as the flanges of the train's wheels contact the sides of the rail. Lubricants and/or friction controlling gels are also applied to the top of the rail. The friction reduction results in reduction of wear of both the rail and the wheels and reduces fuel consumption of the locomotion of the train and reduces squealing noises.
Devices for lubricating rails are already known, such as U.S. Pat. No. 5,687,814. Typically, these devices for lubricating rails are mounted on a track vehicle, such as a pickup truck equipped with additional flanged wheels. The lubricating nozzle of the device is secured to a rail gear mounted to a truck body.
As shown in FIG. 1A, preferably, devices for lubricating rails should direct lubricants 1 and 2 along a straight line at a constant fixed distance as measured from a head of a rail 3 and along a straight line at the top of the head. However, due to the suspension of the track vehicle and the varying weight of the vehicle due to varying loads, the positions of the lubricants 1 ′ and 2 ′ vary on the rail 3 ′ as shown in FIG. 1 B. These varying positions of the lubricants can cause excessive waste, inefficient lubricant use and locomotion traction problems if the lubricant is mistakenly placed on the top of the rails.
Therefore, it is an object of the present invention to provide a device for lubricating a rail that can accurately apply lubricant and/or friction modifying material to a rail.
SUMMARY OF THE INVENTION
The present invention is a device for lubricating a rail that includes a mounting frame, a first support frame, a roller and a lubricating nozzle. The first support frame includes a first end and a second end. The second end is pivotally secured to the mounting frame. The roller is rotatably secured to the first end of the first support frame and is adapted to ride on a rail. The roller is adapted to rotate about a first axis relative to the first support frame. The lubricating nozzle is mounted to the first support frame for directing lubricant toward a rail.
The device for lubricating a rail can further include a biasing member having two ends, one end mounted to the mounting frame and the other end mounted to the support frame. The biasing member assists in maintaining the support frame in a first position and a second position. The first position maintains the roller in an engaged position with a rail and the second position maintains the roller in a disengaged position. The biasing member can include a gas charged chamber and a piston slidably received by the chamber, where the piston is biased relative to the chamber.
The roller can include a tapered surface defining a recess adapted to receive a portion of the rail. The tapered surface can include a first tapered surface spaced apart from a second tapered surface. The first tapered surface may be dissimilar from the second surface.
Preferably, the first tapered surface and the second tapered surface are frusto-conical shaped and have differing base diameters. More preferably, the roller is made of an electrically insulating material.
Preferably, the first support frame is pivotally secured to the mounting frame and pivots about a second axis parallel to the first axis. Alternatively, the first support frame may be secured to the mounting frame to pivot about a second axis which is not parallel to the first axis. The mounting frame can include a pivot bracket pivotably secured to a mounting bracket frame. The second end of the first support frame is pivotably secured to the pivot bracket. The pivot bracket in the first support frame pivots about a second axis relative to the mounting bracket frame and the first support frame pivots about a third axis relative to the pivot bracket, wherein the first axis and third axis are parallel to each other and the second axis is not parallel to the first axis and the third
A stop may be secured to one of the mounting bracket frames and the pivot bracket. The stop is adapted to contact the other of the pivot bracket and the mounting bracket frame to limit pivotal movement of the pivot bracket relative to the mounting bracket frame. The stop is adjustable to limit pivotal movement of the pivot bracket relative to the mounting bracket frame. The stop may be a threaded member threadably received by the pivot bracket.
The present invention may also include a second lubricating nozzle mounted to the first support frame for directing a lubricant toward a rail. One of the nozzles is arranged to direct lubricant toward the top portion of the rail and the other of the lubricating nozzles arranged to direct a lubricant toward a side portion or gage face of the rail. Preferably, the first support frame includes two spaced apart arms wherein the roller is positioned between the arms. The present invention may further include a centering spring having two ends, one end secured to the mounting bracket frame and the other end mounted to the pivot bracket. The centering spring may be a torsional spring.
The present invention may further include a bumper to which the mounting frame is secured. A second mounting frame may be secured to the bumper. A second support frame is secured to the second mounting frame. A roller is rotatably secured to the second support frame and a lubricating nozzle is mounted to the second support frame for directing lubricant toward a rail, wherein the mounting frames are spaced apart from each other.
The present invention is also a combination that includes the above-described device for lubricating the rail and a wheeled vehicle having a bumper, wherein the device for lubricating the rail is mounted to the bumper.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a perspective view of a rail with a lubricant applied to a rail in a uniform manner;
FIG. 1B is a perspective view of a rail with a lubricant applied to the rail in a non-uniform manner;
FIG. 2 is an elevation of a device for lubricating a rail made in accordance with the present invention, which is attached to a pickup truck;
FIG. 3 is a plan view of the device for lubricating a rail made in accordance with the present invention, which is attached to a bumper of the pickup truck shown in FIG. 2;
FIG. 4 is an elevation of the bumper shown in FIG. 3;
FIG. 5 is a top plan view of the device for lubricating a rail shown in FIG. 2;
FIG. 6 is an elevation of the device shown in FIG. 5;
FIG. 7 is a top plan view of a nozzle shown in FIG. 5;
FIG. 8 is a top plan view of another nozzle shown in FIG. 5;
FIG. 9 is an elevation of the nozzles shown in FIGS. 7 and 8;
FIG. 10 is an elevation of a roller of the device for lubricating a rail shown in FIG. 2;
FIG. 11 is a plan view of a mounting bracket frame made in accordance with the present invention;
FIG. 12 is a side elevation of the mounting bracket frame shown in FIG. 11;
FIG. 13 is an end elevation of the mounting bracket frame shown in FIGS. 11 and 12;
FIG. 14 is a plan view of a pivot bracket frame of the device for lubricating a rail shown in FIG. 2;
FIG. 15 is a side elevation of the pivot bracket shown in FIG. 14;
FIG. 16 is an end elevation view of the pivot bracket shown in FIGS. 14 and 15;
FIG. 17 is an elevation of the device for lubricating a rail in a first or engaged position;
FIG. 18 is an elevation view of the device for lubricating a rail in a second or intermediate position;
FIG. 19 is an elevation of the device for lubricating a rail in a third or disengaged position;
FIGS. 19A-19D show another embodiment of the present invention that includes a flanged wheel and tension spring;
FIG. 20 is a top plan view of another embodiment of a rail lubricator made in accordance with the present invention;
FIG. 21 is an elevation of the rail lubricator shown in FIG. 20;
FIG. 22 is an elevation of the rail lubricator shown in FIG. 20 engaged with a rail;
FIG. 23 is a top plan view of a portion of the rail lubricator shown in FIG. 20;
FIG. 24 is an elevation of the portion of the rail lubricator shown in FIG. 23;
FIG. 25 is an elevation of a mounting channel of the rail lubricator shown in FIG. 20;
FIG. 26 is a top plan view of another embodiment; and
FIG. 27 is an elevation view of the embodiment shown in FIG. 26 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 shows a pickup truck 4 engaged with rails 3 (of which only one rail 3 is shown) via rail gears 5 . Rail gears 5 are known in the art and include, respectively, arms 6 and guide wheels 7 pivotally secured thereto. The arms 6 are secured to the pickup truck 4 . The pickup truck 4 also includes a friction modifier supply 8 , which supplies a friction modifying material to two spaced apart rail lubricators 10 or devices for lubricating rails, made in accordance with the present invention. Each rail lubricator 10 is secured to a bumper 12 of the pickup truck 4 .
Referring to FIG. 3, the rail lubricators 10 are spaced apart a distance X and engage respective spaced apart rails 3 . The rail lubricators 10 are secured by fasteners to the bumper 12 . The fasteners, such as threaded bolts and nuts, as shown in FIGS. 2 and 3, pass through respective slots 14 as shown in FIG. 4 .
Referring now to FIGS. 5-9, each rail lubricator 10 includes a frame or support frame 16 that is made up of two spaced apart parallel arms 18 and 20 secured to each other through a cross member 22 . A roller 24 , as shown in FIGS. 5, 6 and 10 , is rotatably secured to the arms 18 and 20 through a shaft 26 and bearings 28 positioned at a first end 30 of the rail lubricator frame 16 . The roller 24 is adapted to rotate about an axis 31 relative to the frame 16 and is positioned between the arms 18 and 20 .
A nozzle assembly 32 is also secured to the first end 30 of the frame 16 . The nozzle assembly 32 is adapted to direct friction modifying materials toward a respective rail 3 . The nozzle assembly 32 includes a bracket 33 secured to the frame 16 at arms 18 and 20 . Nozzles 34 and 36 are secured to the bracket 33 and are adapted to direct friction modifying material to the top portion of the rail and side portion of the rail, respectively. Each nozzle 34 and 36 includes adjustment brackets 37 A and 37 B that are secured to the bracket 33 via threaded bolts. Slots are defined in brackets 37 A and 37 B for adjustment of the nozzles 34 and 36 relative to each other. A pin 38 is removably received by the shaft 26 to enable removal of the roller 24 from the frame 16 . Specifically, the pin 38 can be removed from the frame to permit removal of the shaft 26 from the frame 16 , thereby permitting the roller 24 to be removed from the frame 16 . Hoses 40 are secured to nozzles 34 and 36 for supplying the nozzles with friction modifying material. By friction modifying material, it is meant to include both friction increasing material or friction reducing material. Further, it is to be understood that different types of friction modifying materials can be supplied to each nozzle 34 and 36 .
A second end 41 of the frame 16 is pivotably secured to a pivot frame or mounting frame 42 . As shown in FIGS. 11-16, the pivot frame 42 includes a mounting bracket frame 44 and a pivot bracket 46 pivotally mounted to the mounting bracket frame 44 . The pivot bracket 46 , as shown in FIGS. 14-16, includes plates 48 and 50 secured to side plates 52 and 54 . Plates 48 and 50 and side plates 52 and 54 are secured to a backplate 56 . Two oppositely positioned stops 58 and 60 , which are threaded fasteners, are threadably secured to the backplate 56 .
The mounting bracket frame 44 , as shown in FIGS. 11-13, includes an upper plate 62 spaced apart from a lower plate 64 , which are secured to a rear plate 66 . As shown in FIGS. 5 and 6, a shaft 68 extending along a Y-axis, passes through the plates 48 , 50 , 54 and 64 . Bearings 70 and 72 pivotally receive the shaft 68 and are secured to plates 48 and 50 and include lips 73 A and 73 B. A hair pin 71 removably secures the shaft 68 in place. The bearings 70 and 72 are made of an electrically insulating material. In this arrangement, the pivot bracket 46 and mounting bracket frame 44 can pivot relative to each other about the Y-axis. Tabs T are provided at the second end 41 of the frame 16 on respective arms 18 and 20 . A pivot pin 74 passes through the tabs T and the plates 52 and 54 . Specifically, bearings 76 and 78 are received by plates 52 and 54 and the pivot pin 74 passes through the bearings 76 and 78 . This arrangement permits the frame 16 to pivot about a Z-axis passing through the pivot pin 74 relative to the pivot frame 42 , which is parallel to the axis 31 . The Z-axis and the axis 31 are perpendicular and not parallel to the Y-axis. Hairpins 80 and 92 are received by the pivot pin 74 to permit removal of the pivot pin 74 from the pivot frame 42 . Preferably, the bearings 76 and 78 are made of an electrically insulating material to electrically insulate the pivot frame 16 from the mounting bracket frame 46 .
Lock pins 81 and 82 are provided and removably securable to tabs provided on plates 52 and 54 . The tabs are positioned at the end of the lanyard 90 . Bolts pass through tabs and holes defined in plates 52 and 54 . The bolts are secured with flat washers, lock washers and nuts. The lock pins 81 and 82 are adapted to be removed from the tabs defined on plates 52 and 54 , so that holes 83 A and 83 B provided in the arms 18 and 20 , can be aligned with respective holes defined in the tabs of plates 52 and 54 and the lock pins 81 and 82 can be passed through the holes 83 A and 83 B and those provided in the tabs of plates 52 and 54 to maintain the frame 16 in a disengaged position as shown in FIG. 19 .
Gas springs or biasing members 84 and 86 are secured between the opposite ends of respective arms 18 and 20 . Opposite ends of the gas springs 84 and 86 are pivotally secured to the plates 52 and 54 and arms 18 and 20 . Each of the gas springs 84 and 86 includes a piston slidably received by a gas charged chamber, which are well known in the art. The piston is biased relative to the chamber. Each gas spring 84 and 86 also includes ball members 88 defined on the chamber and piston which are received by respective receiving members 89 to permit the pivotal movement. Each of the lock pins 81 and 82 are also secured to the respective plates 52 and 54 through a lanyard 90 . Preferably, handles 110 are secured to arms 18 and 20 .
Referring back to FIG. 10, preferably the roller 24 is made of an electrically insulating material such as uhmw polyethylene. The roller 24 includes a roller surface 94 that includes a first tapered surface 96 spaced apart from a second tapered surface 98 . A cylindrical surface 100 is positioned between the first tapered surface 96 and the second tapered surface 98 . A recess 102 is defined between the first tapered surface 96 , the second tapered surface 98 and the cylindrical surface 100 . The roller 24 is adapted to contact the top portion 3 A of the rail 3 on the first tapered surface 96 and second tapered surface 98 within the recess 102 . The tapered surfaces 96 and 98 permit alignment of the roller 24 with the rail 3 .
As can be seen in FIG. 10, the tapered surfaces 96 and 98 are dissimilar. Specifically, the tapered surfaces 96 and 98 are frusto-conical in shape having the same interior smaller diameters d and d′ but differing larger exterior base diameters D and D′. Preferably, the larger base diameter tapered surface D′ is positioned along the inner surfaces I of the rail 3 . The roller 24 also includes cylindrical portions C and C′ which are positioned adjacent tapered portions 96 and 98 .
The operation of the rail lubricator device 10 will now be discussed. First, the bumper 12 is secured to the pickup truck 4 . Two rail lubricators 10 are spaced apart and secured to the bumper (preferably at the rear of the pickup truck 4 ) through bolts passing through the rear plate 66 of the mounting bracket frame 44 and the slots 14 and as shown in FIGS. 2 and 3. The rail lubricators 10 can be slightly adjusted on the bumper 12 through tolerances of the respective slots 14 so that the rollers 24 are positioned directly above respective rails 3 . Once the rail lubricators 10 are secured to the bumper 12 via the bolts, then a rail lubricator arrangement 200 is formed.
The gas springs 84 and 86 are configured so as to apply pushing force P against the arms 18 and 20 , as shown in FIG. 6 . This will cause the frames 16 to be pushed downwardly toward the rail 3 , as shown in FIG. 17, in a first or engaged position 104 . In the first or engaged position 104 , the rollers 24 engage with the rail 3 and the gas springs 84 and 86 apply a downward force P against the frame 16 so as to maintain the rollers 24 in engagement with the rails. The rail lubricators 10 can then be activated by applying pressure, via a pump to the friction modifier supply 8 so as to supply friction modifying material to nozzles 34 and 36 , whereby friction modifying material can be applied to the top or side of the rail 3 or both. The gas springs 84 and 86 also assist in maintaining the rollers 24 in engagement should rollers 24 engage a bump or inconsistency on the rail 3 . Further, the pivot frame 42 permits the frame 16 to rotate about the shaft 68 (and the Y-axis) so as to permit the roller 24 to turn as the track weaves and bends.
After lubrication is complete, an operator may grab the handles 110 and pivot the frames 16 about the pivot pin 74 (and about the Z-axis) to first a second or intermediate position 106 and then to a third or disengaged position 108 , which is a position disengaged from the rail, as shown in FIGS. 18 and 19, respectively. Due to the arrangement of the gas springs 84 and 86 known as an over the center arrangement, the frame 16 is maintained in the disengaged position 108 because the gas springs 84 and 86 again apply a pushing force P toward the frame 16 . The pickup truck 4 can now continue either on the rails 3 or on the road without the lubricators 10 engaged with the rails 3 . This arrangement will prolong the life of the rollers 24 . Further, preferably, the frame 16 maintains the disengaged position 108 by placing the lock pins 81 and 82 through the holes 83 A and 83 B and the holes defined in the tabs of plates 52 and 54 . When the lubricators 10 are to be engaged with the rails 3 , then the lock pins 81 and 82 are removed and the operator moves the frame 16 from the disengaged third position 108 to the first position 104 via the handles 110 .
The present invention results in lubricant applied accurately to the rails 3 . The use of the gas springs permits proper engagement of the rollers 24 with the rails 3 and applies a pushing force P against the frames 16 so as to maintain the rollers 24 engagement with the rails 3 . Further, the arrangement of the gas springs 84 and 86 permit the frame to be maintained in a disengaged position 108 as well as the engaged position 104 . Finally, the pivot frame 42 permits the frames 16 to pivot when the pickup truck 4 makes turns on the rails 3 resulting in improved performance of the lubricators 10 and results in minimum wear of the rollers 24 . Alternatively, extension springs can be provided in lieu of the gas springs 84 and 86 .
An optional centering spring such as a torsional spring S, shown in phantom, may be provided and have one end secured between the face plate 48 and another end secured to the upper plate 62 so that the pivot bracket 46 can be maintained in a central or straight position as shown in FIG. 5 . In this manner, a rotational force or torsional force will be applied to the pivot bracket 46 , and in turn the frame 16 , should the pivot bracket 46 pivot or move from the central or straight position. This will minimize the tendency of the roller 24 to leave the rails 3 due to sharp turns of the rails 3 . Alternatively, a standard flanged rail wheel can be provided in lieu of the roller 24 and an extension spring Q, shown in phantom in FIG. 5, can be provided secured to plates 56 and 66 so as to abut the flange against the rail 3 . FIGS. 19A-19C show such a flanged wheel F and FIG. 19D shows the extension spring Q. Finally, the stops 58 and 60 are threaded members, which are threadably adjustable to limit the pivotable movement of the pivot bracket 46 relative to the mounting bracket frame 44 . Should the pivot bracket 46 rotate above a fixed value, the stops 58 and 60 will contact rear plate 64 preventing additional rotation about the shaft 68 . Alternatively, the stops 58 and 60 could be provided on the rear plate 64 to contact the pivot bracket 46 to limit rotation.
FIGS. 20-25 show a second embodiment of rail lubricator 200 made in accordance with the present invention. The rail lubricator 200 is similar to the rail lubricator 10 , except for the below noted differences. Like reference numerals will be used for like parts. Handles 210 are positioned closer to the first end 30 of the frame 16 of the rail lubricator 200 than the rail lubricator 10 .
The rail lubricator 200 includes a nozzle assembly 220 that differs from the nozzle assembly 32 of the rail lubricator 10 . Specifically, the nozzle assembly 220 includes two extension channels 222 extending forwardly from the arms 18 and 20 . A bar stock 224 is secured to the channels 222 . A clamp mounting channel 226 is secured to the bar stock 224 . A nozzle clamp 228 is slidably received by the clamp mounting channel 226 . Such an arrangement is manufactured by Stauff Corporation of 7WM Demerest Pl., Waldick, N.J. 07463, U.S.A. A nozzle 230 is secured to the nozzle clamp 228 . The position of the nozzle 230 relative to the rail 3 is adjusted by sliding the nozzle clamp 228 in the mounting channel 226 .
A further difference between the rail lubricator 200 and rail lubricator 10 is the inclusion of a stiffening brace 232 secured to the arms 18 and 20 . Furthermore, tabs T are eliminated in the rail lubricator 200 .
FIGS. 26 and 27 show another arrangement of a rail lubricator 300 that incorporates the features of the rail lubricator 200 except that it can swivel about the Y-axis with the lubricator in a horizontal position, such as shown in FIG. 27, and moved in a stowed position, substantially parallel to a tail gate or bumper of a vehicle. In this arrangement, the bumper 12 extends along an axis A and the frame 16 is adapted to be pivoted about the second end so that the frame 16 extends along an axis B parallel to the axis A. The bumper 12 extends along so that the frame 16 is in a stowed position. A removable pin P is provided for coacting with the mounting frame 46 and the frame 16 to maintain the frame 16 in the stowed position.
Having described the presently preferred embodiments of the present invention, it is to be understood that it may otherwise be embodied within the scope of the appended claims. | A device for lubricating a track or a rail that is adapted to be mounted tog wheeled vehicle. The device includes a frame member adapted to be mounted to the vehicle and an arm pivotally attached to the frame member. A roller, which is adapted to ride on the rail, mounts to the arm. A lubricating nozzle is secured to the arm. | 1 |
BACKGROUND OF INVENTION
(i) Field of the Invention
This invention relates to scaffolding systems, and more particularly to a pole jack for travelling up and down a pole for supporting a scaffold.
(ii) Description of the Related Art
In numerous industries, it is necessary to erect scaffolding both for internal use as well as for external use in order to permit workers to stand at an elevation above ground surface. Typically, by way of example, a scaffolding system is utilized in the installation of aluminum siding on the exterior of housing. Such scaffolding is conventionally erected by utilizing pump jack poles which are spaced apart and secured in spaced relationship to a house by means of braces. Pump jacks are used to ride up and down the poles. The pump jacks typically include support arms on which are extended scaffold staging. The workers can stand on the scaffold staging and operate the pump jacks to move the staging up and down along the pump jack poles.
U.S. Pat. No. 4,597,471 discloses a heavy duty pump jack which includes a frame with upper and lower shackle members supported by the frame. A pump arm is pivotally provided on the frame and operates the shackles in alternating relationship. The pump arm serves to position the upper shackle in a twist gripping securing relationship on the pole while it then serves to raise the frame stepwise upwardly along the pole. The weight of the jack then shifts so that the lower shackle twist grips the pole and the upper shackle steps up to a next position on the pole. In this manner, the non-gripping shackle steps up the pole while the opposing shackle grips the pole. To ride the pump jack down the pole, the lower shackle is released from its gripping relationship and the upper shackle is rolled down the pole by means of a handle.
U.S. Pat. No. 4,382,488 describes a pump jack pole formed of elongated hollow metal with a rubberized surface on one side of the pole. Such poles were found to be strong, long lasting and easier to manipulate than the standard wooden poles. U.S. Pat. No. 4,463,828 and aforementioned U.S. Pat. No. 4,597,471 describe improved pump jacks which include features to improve the safety of the pump jack as well as its strength. Such features include the ability to release one of the shackles by means of a foot release pedal, thereby avoiding the necessity of bending over and releasing the lower shackle by hand. It is also known to employ an over-the-center spring loaded handle to control the rolling down of the pump jack.
The aforementioned features provided in pump jacks have served to improve the operation and safety of such pump jacks in the industry. Nevertheless, additional safety measures are always warranted with respect to this type of scaffold system. For example, the known spiral rod utilized to control rolling down of the pump jack along the pump jack pole has a tendency to wear, thereby causing accidental sliding of the pump jack down the pole. Additionally, as the spiral rod wears, it may have a tendency to snap outwardly, thereby further causing additional accidents.
While heretofore pump jacks and pump jack poles were typically utilized to support scaffolding in the installation of aluminum siding, such equipment can actually by utilized in other scaffolding sectors. For example, in industrial or marine use, scaffolding is often required both for internal use and external use. In warehouses, where access to various tiers of stored objects is required, the use of the pump jack and pump jack poles would be convenient. Platform and pallet staging could be raised and lowered in order to reach the desired objects. Similarly, in marine applications, the loading and unloading of ships could use the present pump jack and pump jack pole arrangement to advantage.
While utilizing the pump jack and pump jack pole for industrial use, however, additional strength would be needed for the pump jack in order to support the extra weight of the platforms. Such extra strength is required not only in the construction of the pump jack itself, but in the operative portions thereof, including the shackles, the platform, etc.
Accordingly, while the aforementioned prior art patents have provided improvements in the utilization of pump jacks and pump jack poles, all such systems are dependent on frictional engagement for climbing and for support.
Accordingly, it is a principal object of the present invention to provide an alternative to the use of pump jacks and pump jack poles dependant on friction for supporting scaffolding equipment.
Another object of the present invention is the provision of an improved primary pole jack having a positive interlock system to prevent accidental disengagement or slipping of the jack on the pole.
Still another object of the present invention is the provision of an improved jack which includes a simple directional selector arrangement for lowering the pole jack down the jack pole.
And a further object of the present invention is to provide a pole jack having an independent secondary locking system to engage the pole in the event of failure of the primary mechanism.
SUMMARY OF THE INVENTION
Briefly, in accordance with the present invention, there is provided a pole jack arranged for travelling up and down a pole. The pole jack includes a frame member, with upper and lower engagement mechanisms supported on the frame member. A pump lever is pivotally coupled to the frame member for causing a pair of upper and lower engagement mechanisms to alternately engage the pole. The non-engaging mechanism is stepped upwardly along the pole while the other mechanism engages the pole. A support arm projects from the pole for holding a weight such as a scaffold platform. A spring loaded selector is provided for alternately disengaging the one mechanism from the pole while ensuring that the other engages the pole. A button on the top of the jack is depressed to release a secondary engagement during descent.
In an embodiment of the invention, the upper and lower mechanisms are each comprised of a horizontal pin mounted within two lugs and arranged with a spring to move the pin into engagement with an extended lip or flange on the pole which contains a series of equipspaced climbing holes. A linkage bracket is also provided so that the lower mechanism is coupled to the pump arm.
The two engagement pins are able to move horizontally but are prevented from rotating by means of horizontal spring pins that engage a horizontal slot adjacent to each pin. The engagement end of the pin is inclined to provide a ramp effect so that the pin automatically disengages the climbing holes when moved in the up direction. The rear of each pin is angled to provide a vertical ramp profile that engages a vertical interlock member when the pin moves into the disengaged position. The rear ramp profiles on the upper and lower pin are opposite to one another so that engagement with the interlock element by one pin causes the interlock element to move into a blocking position with the other pin. This feature prevents both pins from disengaging the pole at the same time.
A separate spring-biased dog brake device is fitted within the operating mechanism. This dog device automatically engages the climbing holes and must be held in the released position by depressing a release button during descent.
In its broad aspect, the pole jack of the invention for climbing and descending a pole having a plurality of vertically equispaced holes formed therein comprises a frame member, upper and lower engagement mechanisms mounted for horizontal reciprocal travel in said frame member for selectively engaging the holes in the pole, a pump lever pivotally mounted on the frame member and operatively connected to the lower engagement mechanism for causing the upper and lower engagement mechanisms to alternately engage the holes in the pole for climbing the pole or descending the pole, and a vertically aligned interlock member pivotally mounted within the frame member for engaging at least one or other of the engagement mechanisms whereby the engagement mechanism engaging a post hole is blocked from releasing the pole while the other engagement mechanism is stepped up or down the pole by pivoting of the pump lever. Each said engagement mechanism comprises an engagement pin mounted for horizontal reciprocal travel within the frame member, spring means for biasing the engagement pin in a forward extended frame hole engaging position, the upper and the lower engagement pins having oppositely bevelled rear ends, and means for biasing the pivotally mounted, vertically aligned interlock member into a neutral position, said interlock member having a mating bevelled ramp surface opposite each engagement pin bevelled rear end, whereby retracting an engagement pin causes the engagement pin bevelled rear end to engage the interlock mating bevelled ramp surface to pivot the interlock member to block the other interlock pin while in its forward extended post hole engaging position.
The interlock member comprises a vertical bar attached to a cylindrical rod mounted for rotation within the frame member, a pin extending radially from the rod, and a spring secured to the frame member receiving the pin coaxially therein whereby the spring biases the rod and the bar attached thereto to a neutral position.
More particularly, the upper engagement mechanism comprises an engagement pin having a downwardly bevelled front end mounted for horizontal reciprocal travel on the frame member, said engagement pin having a guide pin extending diametrically therethrough with exposed radial ends for anchoring a compression spring concentric with the engagement pin for biasing the engagement pin in a forward extended frame hole engaging position and for guided reciprocal travel of an end of the guide pin in a horizontal slot for preventing rotation of the engagement pin, a slide plate mounted for vertical reciprocal travel within the frame member, means for interconnecting the pump lever to the slide plate, the lower engagement mechanism comprises an engagement pin having a downwardly bevelled front end mounted for horizontal reciprocal travel on the slide plate, said engagement pin having a guide pin extending diametrically therethrough with exposed radial ends for anchoring a compression spring concentric with the engagement pin for biasing the engagement pin in a forward extended frame hole engaging position and for guided reciprocal travel of an end of the guide pin in a horizontal slot formed in the guide plate for preventing rotation of the engagement pin, said upper and lower engagement pins having oppositely outwardly bevelled rear ends, and means for biasing the pivotally mounted, vertically aligned interlock member into a neutral position, said interlock member having a mating bevelled ramp surface opposite each engagement pin bevelled rear end, whereby retracting an engagement pin causes the engagement pin bevelled rear end to engage the interlock mating bevelled ramp surface to pivot the interlock member and to block the other interlock pin in its forward extended post hole engaging position.
The means for connecting the pump lever to the slide plate comprises as downwardly extending lever pivotally connected to the pump lever, an actuating pin extending from the downwardly extending lever to the slide plate, and means for resiliently connecting the actuating pin to the side plate and lifting the slide plate upon upward pivotal movement of the pump lever. The means for resiliently connecting the actuating pin to the slide plate comprises a vertical slot formed in the slide plate, said actuating pin having an extension projecting through the vertical slot for vertical reciprocal travel therein, and a tension spring interconnecting the actuating pin to the slide plate whereby upward movement of the actuating pin lifts the slide plate while compensating for excess lifting resistance.
The pole jack further comprises a ramp guide mounted for vertical reciprocal travel within the frame member, and means for raising and lowering the said ramp guide and locking the ramp guide in a selected position, said ramp guide having a pair of spaced apart ramps selectively actuable upon raising or lowering the ramp guide to engage the upper and lower guide pins upon lowering of the pole jack to alternately disengage the upper and lower engagement pins. A tension spring for connecting the ramp guide to the frame member continuously biases the ramp guide downwardly.
The pole has an elongated flange extending the pole has an elongated flange extending the length of the pole, said flange having a plurality of equispaced holes formed along it length for receiving the upper and lower engagement pins, the frame member has a slot for receiving the pole flange for slidable travel therein, and the frame member has upper and lower brackets attached thereto, each bracket having a roller at a distal end thereof for engaging the pole for lateral support of the frame member on the pole. A pair of pole jacks, each in combination with a pole on which the pole jack is mounted and each spaced apart in proximity to a wall surface, have brace means attached to an upper end of each pole for securing the pole to the wall surface and a scaffold extending between the pole jacks mounted on pole jack support arms extending laterally from the frame member at the base thereof for raising and lowering of the scaffold on the poles.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects of the invention and the manner in which they can be attained will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view of pole jacks of the invention supporting a platform;
FIG. 2 is a side elevational view of the pole jack shown in FIG. 1;
FIG. 3 is an enlarged perspective view of the pole jack shown in FIG. 2;
FIG. 4 is a side elevation of the pole jack in two positions on the pole;
FIG. 5 is a perspective fragmentary view of a portion of the pole;
FIG. 6 is a horizontal section of the pole jack through line 6--6 of FIG. 3;
FIG. 7 is a perspective view, partly cut away, of the pole jack mechanism;
FIG. 8 is a side elevation of the pole jack mechanism illustrated in FIG. 7 in a first operative "up" position;
FIG. 9 is a side elevation of the pole jack mechanism shown in FIG. 7 in a second operative "up" position;
FIG. 10 is a side elevation of the pole jack mechanism shown in FIG. 7 in a first operative "down" position;
FIG. 11 is a side elevation of the pole jack mechanism shown in FIG. 7 in a second operative "down" position;
FIG. 12 is a horizontal section taken along line 12--12 of FIG. 8;
FIG. 13 is a horizontal section taken along line 13--13 of FIG. 9;
FIG. 14 is a horizontal section taken along line 14--14 of FIG. 9 when both engagement pins are extended;
FIG. 15 is a vertical section along line 15--15 of FIG. 16, additionally showing a post flange by ghost lines;
FIG. 16 is a perspective view of the top of jack 10; and
FIG. 17 is a side elevation, partly in section, of the top of jack 10.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1-5, there is shown a pair of pump jacks, shown generally at 10, each housed in a vertical U-shaped frame 12. Each pump jack 10 is slidably mounted on a jack pole 14 which is seated on a supporting surface, not shown, and attached at its upper distal end to a lateral support such as a roof surface 16 or a wall surface 17 of a building by a brace 18 to ensure lateral stability and safe attachment of each pole. A supporting bracket arm 20, shown projecting laterally from the base of each vertical frame 12, can support a plank 22, shown in ghost lines, to form a scaffold platform. Upper and lower brackets 24, 26 extending outwardly from the opposite of each pump jack frame 12 at each end thereof, can support a work bench bracket 28, shown in ghost lines, secured to brackets 24, 26 by connectors in holes 30. The upper horizontal portion 32 of bracket 28 can support a work bench or a guardrail, not shown.
Vertical pivotal movement or jacking of pump lever arm 36 and linkages 37 pivotally connected thereto selectively raises or lowers the pump jack up or down post 14, jack frame 12 straddling and sliding vertically along post flange 38 by engagement with flange holes 39, while supported laterally by rollers 40 rotatably mounted in brackets 26, 30 and 42, as shown most clearly in FIG. 3.
Turning now also to FIGS. 6-9, the jack mechanism housed in frame 12 comprises pump lever arm 36 with fork extensions 36a straddling and pivotally mounted onto the opposite sides of vertical frame 12 by bolts 50. Downwardly depending linkages 37 are pivotally mounted at one end on lever arm extensions 36a by bolts 52. The opposite lower ends of linkages 37 converge and are secured such as by welding to horizontal actuating pin 54 which is mounted for vertical reciprocal travel in central slot 56 of frame 12. Actuating pin 54 extends through vertical slot 58 in slide plate 60 which is mounted for vertically reciprocal guided travel in frame 12 by guide rods 62 welded to opposite sides of frame 12. The extension of pin 54 is operatively connected to slide plate 60 by a tension spring 64, whereby lowering or downward pivoting of lever arm 36 with lower sliding engagement pin 66 biased to the left as viewed in FIG. 8 by compression spring 68 for engagement with pole flange 38 through a flange hole 39, raises frame 12 until upper sliding engagement pin 70 is urged into the next upper hole 39 in flange 38 by compression spring 72, as viewed in FIG. 9. Lower engagement pin 66 is mounted for horizontal slidable travel in aligned apertures in a pair of spaced-apart plates 73, 75 secured such as by welding to plate 60 (FIG. 13). Upper engagement pin 70 is mounted for horizontal slidable travel in aligned apertures in a pair of spaced-apart plates 77, 79 secured such as by welding to plate 81 of frame 12 (FIG. 12).
The operator then raises, i.e. pivots upwardly, lever arm 36 causing lower sliding pin 66 to disengage from the pole flange 38 and move upwardly with upward vertical travel of sliding plate 60 to its next hole-engaging position. Repeating the pivotal lever action results in continued upward vertical travel of the pole jack.
With reference to FIGS. 7-9, particularly FIG. 7, vertical interlock bar 74 attached to cylindrical rod 76 is shown rotatably mounted in aligned apertures in upper and lower plates 78, 80 welded to frame 12. Bar 74 is biased into the neutral position typified in FIG. 7 by radial pin 82 extending from rod 76 inserted into spring 84; the interaction of pin 82 with spring 84 tending to bias the bar into the neutral position while allowing the bar to pivot by rotation of rod 76 as depicted by arrow 86.
Turning to FIGS. 12 and 13, FIG. 12 illustrates upper pin 70 retracted and pin 66 extended into a flange engaging position. The rear end of pin 70 is bevelled as depicted by numeral 90 to engage mating ramp 92 of interlock bar 74 to pivot bar 74 counter-clockwise as viewed in FIG. 12, thereby locking lower pin 66 in its forward flange-engaging position. The retraction of lower pin 66 as viewed in FIG. 13 pivots bar 74 clockwise, thereby blocking upper pin 70 in its forward, flange-engaging position.
The blocking of pins 66 and 70 in their respective forward-extended flange-engaging positions ensures that at least one pin will be engaged with flange 38 at all times. The interaction of pin 28 with spring 84 urges bar 74 to pivot to its neutral position as shown in FIGS. 7 and 14 when both engagement pins 66, 70 are in their extended engagement position with flange 38.
There will be occasions during initial engagement between the pole jack 10 and the pole 44 when the upper engagement pin 70 is not aligned with a hole 39 in the pole flange 38 and, as a result, engagement pin 70 is held back and in contact with interlock bar 60 so that continued upward operation of lever 36 could force lower pin 66 out into contact with the interlock bar 74, potentially causing damage to the mechanism. To protect against this, linkage 37 is connected to sliding pin plate 60 by means of a slot 58 and spring 64 which are arranged to provide positive upward transmission of lever force when the lever is lifted up but allow the force to dissipate through spring 64 in the event that excess resistance is encountered.
As the jack moves up the pole, the pivotally-mounted deadman emergency locking dog 91 functions as a ratchet, engaging and disengaging holes 39 in pole flange 38 in succession (FIG. 15). Compression spring 93 mounted coaxially on release pin 94 maintains positive contact between dog 91 and pole flange 38 during upward travel so that in the event of a failure of the climbing mechanism dog 91 will engage a hole 39 in the flange and arrest the load.
In order to return down the pole, vertical ramp guide 100 is moved downwardly from the upper position shown in FIGS. 8 and 9, and by ghost lines in FIG. 17, to the lower position shown in FIGS. 10, 11, 16 and 17. Ramp guide 100 is selectively held in its upper, up-travel position by spring-loaded selector knob 102 which is urged to the right as viewed in FIG. 17 to engage detent 106 by compression spring 104 concentric with rod 105. Extension of knob 102 to the left, again as viewed in FIG. 17, clears detent 106 to allow knob 102 to be moved downwardly and to slide ramp guide 100 connected to knob 102 by rod 105 downwardly. Tension spring 110 secured to ramp guide 100 and to frame 12 biases ramp guide 100 downwardly to maintain ramp guide 100 locked in its downward position.
Follower guide pins 110, 112 mounted diametrically through lower and upper locking pins 66, 70 respectively have exposed radial ends which slide in horizontal recesses 114, 116 during reciprocal travel of pins 66, 70 to maintain the bevels 113, 115 of pins 66, 70 facing upwardly while engaging and anchoring compression springs 68, 72. During upward travel of the jack 10, follower pins 110, 112 are not deflected by ramp guide 100 as shown in FIGS. 8 and 9. During downward travel of jack 10, however, ramp guide 100 engages follower pins 110, 112, as shown in FIGS. 10 and 11, to alternately disengage engagement pins 66, 70 from pole flange 38. The vertical spacing of ramps 116, 118 allows the vertical load on the jack to be supported by extended lower engagement pin 66 while upper ramp 118 causes upper engagement pin 70 to retract from the pole flange (FIG. 10). As the operator releases the downward pressure on jack lever 36, the jack moves down the pole. When upper engagement pin 70 moves closer to lower engagement pin 66, the lower ramp 116 contacts horizontal engagement pin 66 through follower pin 111 to urge engagement pin to the right, as viewed in FIG. 10. However, since the pin 66 supports the load on the jack, frictional engagement between pin 66 and post flange 38 prevents retraction of engagement pin 66, forcing ramp guide upwardly against the bias of tension spring 110 so that contact between upper ramp 118 and follower pin 112 is removed, as shown in FIG. 11, allowing upper engagement pin 70 to re-engage a hole 39 in pole flange 38 as the pin 70 moves into alignment with the next lower hole position. The operator at this time reverses the pivotal travel of lever 36 so that the jack load shifts to upper engagement pin 70. The lower ramp 116 causes the lower engagement pin 66 to disengage the pole flange, permitting pin 66 to move down the pole to the next lower hole 39. The continued lowering of lever 36 lowers plate 60 whereby lower engagement pin 66 moves below lower ramp 116 and is biased to the left as viewed in FIG. 11 to re-engage the pole flange 38. Repeat of this procedure continues downward travel of the jack.
During downward travel the operator must depress release pin 94, to cause locking dog 91 to be held clear of the pole flange 38. In the event of a mechanical failure resulting in sudden downward movement of the jack, it is expected that the operator will lose contact with release pin 94, thus allowing locking dog 91 to engage the pole flange 38 and arrest the load.
It will be understood that modifications can be made in the embodiment of the invention illustrated and described herein without departing from the scope and purview of the invention as defined by the appended claims. | A pole jack apparatus for travelling up and down a pole including a frame member with a jacking mechanism. A pump lever is utilized for causing the jacking mechanism to engage the pole for upward and downward travel. The jacking mechanism includes an interlock device to ensure that one of two engagement pins is engaged with the pole at all times. A separate spring biased, "dead man" brake is also provided for added safety. | 4 |
This application is directed to disposable blood collection devices and more particularly to a system designed for self use at home.
BACKGROUND OF THE INVENTION
A number of diagnostic procedures can now be performed by the patients at home utilizing relatively small quantities of blood which can be conveniently obtained from capillary blood sources such as a fingertip. While various blood sampling devices have been proposed and are in use, most of them, as exemplified by the following listed patents, are of the type which draw venous blood from patients in a procedure which should be performed by a trained medical technologist:
______________________________________3,200,813 Christakis 4,256,120 Finley3,536,061 Ogle 4,298,011 Mangurten et al3,545,427 Ryan 4,409,990 Mileikowsky4,024,857 Blecher et al 4,418,703 Hoch et al4,155,350 Percarpio 4,449,529 Burns et al4,215,700 Crouther et al______________________________________
While not all of the foregoing patents are directed to devices which accumulate venous blood, none have been sufficiently versatile to accomplish all of the objects of the present invention.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a micro-blood collection device which accumulates the blood flow from a skin or epidermal puncture in a sterile sampler container in a manner which insures that the skin puncture will occur before the double-ended cannula penetrates a cap sealing an evacuated collection chamber.
Still another object of the invention is to provide a blood sampling device of the character described in which the depth of penetration of the double-ended cannula into the tip of the finger, or other selected part of the body, is reliably controlled.
A further object of the invention is to provide a blood sampling device having a box-like housing which hides the double-ended needle from view, and thus reduces the trauma involved in this self-testing procedure.
Still another object of the invention is to provide a blood collection device which is economically manufactured so that it can be used at home with a diagnostic kit, and then thrown away.
Still a further object of the invention is to provide a device which reliably collects the desired volume of blood in a sterile chamber in a very simple manner.
These and other objects of the invention are accomplished in a housing comprising inner and outer spaced apart pads or walls separated by a compressible, axially extending, pad-bridging enclosure. A double-ended cannula is axially slideably carried by the inner pad and is axially aligned with an evacuated collecting tube closed by a penetrable cap. The system is designed to prevent the double-ended cannula from penetrating the cap of the evacuated collecting tube upon compression of the inner and outer pads of the housing, until after penetration of the epidermis by the cannula.
Other objects and advantages of the invention will be pointed out specifically or will become apparent from the following description when it is considered in conjunction with the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings FIG. 1 is a sectional side elevational view showing the device in initial position placed in contact with a tip of a finger or the like which is illustrated in chain lines.
FIG. 2 is a similar view illustrating the position of the component parts when a compression of the housing has occurred and the lower end of the needle or cannula has penetrated the skin of the finger.
FIG. 3 is a further view illustrating the final position of the various components when a full compression of the device has occurred and blood is being drawn into the sample-collecting tube.
FIG. 4 is a fragmentary view showing the components in the FIG. 3 position and illustrating an alternative construction.
FIG. 5 is a view similar to FIG. 1 wherein another embodiment of the invention is disclosed, wth the components in initial position prior to compression.
FIG. 6 is a view similar to FIG. 2 in which a partial relative compression of the upper and lower portions of the housing has occurred; and
FIG. 7 is a view similar to FIG. 3 in which a full compression of the housing parts has occurred and blood is being drawn up into the sampling chamber.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now more particularly to the accompanying drawings, and in the first instance to FIGS. 1-3, rectangular or circular upper and lower pads 10 and 11 are shown connected by an enclosing bellows 12 to form a housing generally designated H. The pads or end wall members 10 and 11 are mentioned as upper and lower members only for the sake of convenience since it should be clear that the device will also be operative when turned on its side. The lower pad 11 is provided with a central bore or opening 13 which can be placed adjacent the tip of a finger generally designated F, for instance, when it is desired to draw a blood sample.
Fixed to the lower member 11 is a rigid tubular guide 14 having an inner passage 15 which accommodates and slidably guides a double-ended cannula or needle 16 having sharpened puncturing ends 16a and 16b. Mounted above the needle is a collection container 17, which is fixed in a well 10a provided in the top member 10. The outer end of chamber 17 is removably closed by a cap assembly, generally designated C, which includes a puncture sealing rubber stopper member 18 inboard of an outer foil cap backer 19. Cap C snugly closes the open end of the tube 17, which is evacuated at the time cap C is tightly applied.
Provided in surrounding relation with the tubular post 14, is a coil spring 20 which exerts a predetermined upward pressure on a stop disk 21 which is fixed to the cannula 16 at a predetermined spaced distance from the lower end of the cannula. The spring 20 normally maintains the cannula 16 in the FIG. 1 position with the lower end 16b of the cannula in axial alignment with the opening 13. The resistance to compression of cannula return spring 20 is such that the lower end of cannula 16 will penetrate the epidermis or skin of the finger F prior to the time the upper end 16a of the cannula 16 penetrates the stopper portion 18. The durometer of stopper 18 is therefore such that its resistance to penetration is greater than the force required to compress spring 20. Thus, both the spring 20 and stopper 18 are carefully engineered so that, when the parts are in the FIG. 2 position, penetration of the skin has occurred prior to the time stopper 18 has been penetrated. With this construction, there is assurance that the vacuum in tube 17 will not be dissipated and will be effective to draw the blood up into the container. The foil 19 is so thin as to offer no appreciable resistance to penetration.
THE OPERATION
In operation, with the device placed in contact with the tip of the finger F as shown in FIG. 1, the pad 10 is depressed toward the lower pad 11 to compress the housing H. As FIG. 2 indicates, the relative resistance to puncture of the rubber 18 and the skin of finger F, taken with the resistance to compression of spring 20, are such that the cannula 16 first penetrates the skin as indicated in FIG. 2. A further compression of the pad 10 toward the pad 11 is illustrated in FIG. 3 and shows the final position of the parts when a blood sample is being delivered to the interior of container 17.
AN ALTERNATIVE PENETRATION CONTROL DEVICE
In FIG. 4, a dual-spring device is utilized in which a second stiffer compressible spring 22 surrounds the upper end of the cannula and bears against the upper side of stop 21. Except for this, all of the parts are identical to the components previously described and for purposes of convenience have been identified by the same numerals and will not be redescribed. In this embodiment of the invention, spring 22 acts to increase the resistance to puncture of the cap C, the springs 22 and 16 acting in opposition to one another on opposite sides of the stop 21 to ensure that it is the epidermis of the skin which is punctured prior to puncture of the cap assembly C.
ANOTHER EMBODIMENT OF THE INVENTION
FIGS. 5-7 illustrate another embodiment of the invention, and in these Figures those components which remain the same have been identified by the same numbers as previously, and the description of these components will not be repeated In this embodiment of the invention, a pair of compressible rigid plastic foams 23 and 24 forming an enclosure for the tube 17 and needle 16 are provided between the pads 10 and 11, and the spring 20 can be eliminated. The upper foam member 23 is recessed as at 23a, 23b, and 23c centrally to receive the container 17 and to provide a passage for cannula 16. The foam layer 24 is recessed as at 24a and 24b to receive the tubular post 14 and the needle stop 21. Foam layer 23 is a more riqid foam than foam 24 and is considerably more resistant to crush than lower foam layer 24.
In operation, when the upper pad 10 is moved toward the lower pad 11 to compress the device the greater resistance to crush of layer 23 ensures penetration of the cannula 16 into the skin to the extent shown in FIG. 6 prior to complete penetration of the cap assembly C. With further compression of the layers 23 and 24 to the FIG. 7 position, blood is being drawn by the vacuum in container 17 up into the container 17 in the same manner as previously. The relative crushability of foam layers 23 and 24, taken with the resistance to puncture of the cap assembly C insures the sequential penetration of the two ends of cannula 16.
It is to be understood that the embodiments described are exemplary of various forms of the invention only and that the invention is defined in the appended claims which contemplate various modifications within the spirit and scope of the invention. | A disposable blood sampling device wherein inner and outer spaced apart pad members, separated by a compressible pad-bridging enclosure respectively carry an axially extending evacuated collecting container closed by a penetrable end cap and an axially aligned, double-ended cannula. In normal position the cannula is maintained in withdrawn position within the enclosure. The cannula is prevented from penetrating the cap of the collecting tube when the outer member is depressed toward the inner member until after penetration of the epidermis has occurred. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a double beam scan type optical apparatus. Such apparatus are used in laser printers and the like.
2. Description of the Related Art
In a laser printer in which the laser beam is deflected in a scan mode, in order to increase the scanning speed or scanning accuracy it is necessary to increase the number of times that the scanning beam strikes the scanning surface. In order to meet this requirement, a method exists in which a plurality of light sources are provided, and the output light beams of these light sources are simultaneously deflected in a scan mode. That is a beam position control method by servo control using a light position detector for maintaining the accurate mutual positions of a plurality of light sources.
FIGS. 9 through 12 (prior art) show one example of a conventional laser beam control method using two light sources (cf. the publication "Ohyou Hikari Erekutoronikusu (Opto-electronics Applications) Handbook", April 1989). As shown in FIG. 9 (prior art), the output light beams 11a and 11b of two light sources 1a and 1b are collimated by coupling lenses 2a and 2b so that they are applied to a light splitter 4 by way of movable reflectors 3a and 3b, respectively. As a result, the two light beams are split in such a manner that they advance towards a light deflector 5 and a light position detector 10.
The light beams advancing towards the light deflector 5 are focused on a drum surface 7 by an Fθ lens 6 or the like, so that two scanning lines 18a and 18b are formed as the light deflector 5 rotates. The light beams 11a and 11b forming the two scanning lines 18a and 18b are moved across a light scan detector 8 with a distance P therebetween in a main scanning direction, and the light scan detector 8 outputs light beam (11a and 11b) passage signals 19. A control device 16 receives the light beam passage signals 19 as reference signals, and applies printing signals, as modulating signals 12a and 12b, to the light sources 1a and 1b to modulate the light sources 1a and 1b. As a result, printing information is applied to the drum surface 7.
On the other hand, the light beams advancing towards the light position detector 10 are focused on the surface of the light position detector 10 by a focusing lens 9. The light position detector 10 is a position detecting sensor for maintaining the relative positions of the two light beams 11a and 11b constant. The drum surface 7 and the light position detector 10 are in the focusing planes of the lens systems. Therefore, the beam diameters and the beam distances on the drum surface 7 and those on the light position detector 10 are in proportion to each other. Hence, the distance (d) between the auxiliary scanning directions of the scanning lines 18a and 18b on the drum surface 7 can be maintained constant by maintaining the beam distance on the light position detector 10 constant For this purpose, the light position detector 10 applies beam position signals 14a and 14b representing the beam positions to a servo control circuit 17. The latter 17 processes the beam position signals 14a and 14b to provide beam correcting signals 15a and 15b to move the movable reflectors 3a and 3b, thereby controlling the beam positions on the light position detector 10.
FIG. 10 (prior art) shows the arrangement of the light position detector 10 shown in FIG. 9 (prior art), and FIG. 11 (prior art) shows the arrangement of the servo control circuit 17 shown in FIG. 9 (prior art).
In the light position detector 10, as shown in FIG. 10 (prior art) the light beam 11a is applied to photo-detectors 20 and 21, which output beam position signals Va 1 and Va 2 , respectively. Similarly, in response to the application of the light beam 11b to photo-detectors 22 and 23, beam positions signals Vb 1 and Vb 2 are output. As shown in FIG. 11 (prior art), the beam position signals Va 1 and Va 2 are applied to a difference output unit 24 which provides a difference signal 30. The difference signal 30 is Va 1 -Va 2 . The difference signal 30 is amplified by an amplifier 26, the output of which is applied to a driver 28. In response to the output of the amplifier 26, the driver 28 applies the beam correcting signal 15a to the movable reflector 3a, so that the reflector 3a is so moved as to decrease the difference signal 30. As a result, the difference signal 30 is zeroed; i.e., Va 1 -Va 2 =0 is established with the light beam 11a positioned between the photo-detectors 20 and 21 Similarly, Vb 1 -Vb 2 =0 is established with the light beam 11b positioned between the photo-detectors 22 and 23. Thus, with the light beams 11a and 11b being servo-controlled, the beam distance (d') is maintained constant.
FIG. 12 (prior art) shows the arrangements of the light sources 1a and 1b which are semiconductor lasers, the light scan detector 8, and the control device 16. As shown in FIG. 12 (prior art), the light scan detector 8 comprises a front detector 31 and a rear detector 32, to which the beams 11a and 11b are applied successively, as a result of which the front detector 31 outputs a front passage signal 19a and the rear detector 32 outputs a rear passage signal 19b. Those passage signals 19a and 19b are applied to a difference output unit 33 which provides a difference analog output 34. The output 34 is supplied to a slicer 35 where it is sliced near OV. That is, the difference analog output 34 is sliced near the zero cross. The instants of time that the centers of the light beams 11a and 11b reach the boundary of the front detector 31 and the rear detector 32 are detected, and the difference in diameter of the light beams 11a and 11 b is compensated. Thus, the sliced signal is a pulse signal 37. The pulse signal 37 is applied to a timer 36 which is started by the trail edge 38 of the pulse signal 37 so that the timer 36 provides a timer output 39. The pulse signal 37 is further applied to AND gates 41. The timer output 39 is supplied to one of the AND gates 41 and an invertor 40, the output of said invertor 40 is applied to the other AND gate 41. Thus, the AND gates 41 output signals 43 and 44, respectively. These output signals 43 and 44 are converted by print timers 45a and 45b into print start signals indicating the arrival of the beams 11a and 11b to the print start positions respectively, to make access to line buffers 46a and 46b in which printing data has been stored, respectively. The line buffers 46a and 46b apply the printing signals to voltage-current exchangers 47a and 47b, which provide the modulating signals for the light source 1a and 1b, respectively. The outputs of the voltage-current exchangers 47a and 47b are applied to current adders 48a and 48b respectively.
The light sources 1a and 1b comprise: semiconductor lasers 49a and 49b; and laser power monitor sensors 50a and 50b, respectively. When energized, the semiconductor lasers 49a and 49b output the beams 11a and 11b and also output light beams to the laser power monitor sensors 50a and 50b in proportion to the beams 11a and 11b, respectively. In response to the light beams, the laser power monitor sensors 50a and 50b output beam power signals 13a and 13b which are supplied to power difference output units 51a and 51b, respectively. The power difference output unit 51a outputs the difference between the beam power signal 13a and a reference power voltage 52a and applies this output to a voltage-current exchanger 53a. The voltage-current exchanger 53a outputs current so that the difference between the beam power signals 13a and the reference voltage 52a is zeroed and applies a current signal to the current adder 48a. Similarly, the power difference output unit 51b outputs the difference between the beam power signal 13b and a reference power voltage 52b and applies this output to a monitor voltage-current exchanger 53b. The monitor voltage-current exchanger 53b outputs current so that the difference between the beam power signal 13b and the reference voltage 52b is zeroed and applies a current signal to the current adder 48b. The output current signals of the current adders 48a and 48b are applied to the semiconductor lasers 49a and 49b, so that the latter 49a and 49b provide the beams 11a and 11b with powers corresponding to the reference power voltages 52a and 52b, respectively. The two beams 11a and 11b can be maintained equal in power by adjusting the reference voltages 52a and 52b.
The above-described high-performance double beam scanning technique in which the positions of two beams are maintained constant, the difference between the beam diameters is compensated, and the beam powers are maintained unchanged suffers from the following possible reliability problems:
(1) The beams may become abnormal, therefore it is necessary to check the conditions of the two beams at all times.
(2) The cause of an abnormality is not always obvious, therefore when an abnormal condition occurs, it is necessary to detect what part of the apparatus is out of order.
Conventional techniques for solving the above-described problems (1) and (2) will be described.
A conventional technique which may solve the problem (1) has been disclosed by Japanese Patent Application (OPI) No. 67374/1982 (the term "OPI" as used herein means an "unexamined published application"). In the conventional technique, the front part of a photo-detector is designed so that the output signal of the photo-detector is sliced with a reference voltage, and the sliced signal is processed by count means and gate means so that a plurality of beams are distributed to line signals and the time interval between the first and last line signal is monitored with a timer. If this technique is applied to a double beam scanning technique, then the zero cross detection used for compensation of the difference between the beam diameters raises another problem. That is, since the slice point is near OV as shown in FIG. 12 (prior art), if the beam power is decreased due to an abnormal condition, the difference analog output 34 is still output even though it is low, and the pulse signal is output normally. Furthermore, as for the signal check, since the access signal of the count means is provided after the slicing of the output signal of the photo-detector, the spur due to the time delay of the count means is output through the gate means, thus lowering the control reliability. Also, the method of monitoring the first and last beam signals cannot handle a high speed beam scanning operation, thus the reliability is decreased. Therefore, it is necessary to provide a technique other than that disclosed by the Japanese Patent Application (OPI) No. 67374/1982.
With respect to the above-described problem (2), the different components employed in a double beam scan technique are each subject to different abnormalities. For instance, in FIG. 9 (prior art), the lens systems suffer from a problem of possible contamination, the beams 11a and 11b for some reason may not be applied to the movable reflectors 3a and 3b, and the light sources 1a and 1b are semiconductor lasers which have a specific service life and deteriorate over time. No technique for detecting these problems individually has been provided in the prior art.
SUMMARY OF THE INVENTION
Accordingly, an object of this invention is to eliminate the above-described difficulties accompanying a double beam scanning technique.
More specifically, an object of the invention is to provide a double beam scan type optical apparatus with an improved double beam scanning technique.
The foregoing object and other objects of the invention have been achieved by the provision of a double beam scan type optical apparatus comprising: two light sources, scanning means for scanning a scanning surface with parallel output light beams of the two light sources, and beam distance controlling means for controlling the distance between the light beams. According to the invention, the beam distance controlling means further comprises: means for detecting the intensity of the light sources, means for detecting the intensity of the output light beams, and means for detecting the intensity of reference beams indicative of a positioning of said output light beams.
In the double beam scan type optical apparatus of the invention, the conventional detectors are utilized, but the output signals of the detector are processed in a specific manner so that the abnormal conditions of various parts in the apparatus can be detected with ease. That is, a front passage signal and a rear passage signal provided by a light scan detector are added to form a signal, and the signal thus formed is utilized to check the powers of the two beams. Similarly, beam position signals output by the light position detector are added to form a signal, and the signal thus formed is utilized to check the two beams. The service lives of semiconductor lasers for outputting the light beams are checked on the basis of the characteristic of current temperature deterioration such that a current limiter is provided to check the beam power signal through current limitation. By these three detections, conditions such as abnormalities with the light sources, contamination of the lens system including contamination of the coupling lens, light splitter and focusing lens, the shift of the beams at the movable reflectors, and contamination of the light deflector and the Fθ lens are separately identified.
In a conventional timer-operated distribution circuit, when one of the two beams becomes abnormal, the beam signal occurring later becomes abnormal. Based on this fact, the beam signal is monitored by a timer whose set time is longer than the scanning period of the light deflector which operates with relatively slow timing, thus the lowering of the reliability is prevented. That is, in the double beam scan type optical apparatus of the invention, the control unit and servo control circuit are improved to increase the reliability.
The nature, principle and utility of the invention is further explained in the following detailed description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram describing an operation of processing the output signals of a light scan detector;
FIG. 2 is a table showing four states of outputs VA and VB with respect to "1" and "0" in FIG. 1;
FIG. 3 is a time chart showing the transition of states "11", "10" and "00".
FIG. 4 is a circuit diagram describing an operation of processing the output signals of a light position detector;
FIG. 5 is a circuit diagram describing an operation of processing the output of a laser power sensor;
FIG. 6 is a graphical representation indicating characteristics of a semiconductor laser 49a;
FIG. 7 is a circuit diagram showing a voltage-current converter 47a, a monitor voltage current converter 53a, a current limiter 48a, and a current limiter 96 of FIG. 5;
FIG. 8 is a table indicating errors with outputs VA through VF;
FIG. 9 (prior art) is an explanatory diagram for a description of a conventional laser beam control method using two light sources;
FIG. 10 (prior art) is an explanatory diagram showing the arrangement of a light position detector 10 in FIG. 9;
FIG. 11 (prior art) is an explanatory diagram showing the arrangement of a servo control circuit 17 in FIG. 9 (prior art); and
FIG. 12 (prior art) is a circuit diagram showing the arrangements of light emitting sources 1a and 1b which are semiconductor lasers, a light scan detector, and a control unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
One preferred embodiment of this invention, a double beam scan type optical apparatus, will be described with reference to FIGS. 1 through 8.
In FIG. 1, when light beams 11a and 11b are applied to a light scan detector 8 comprising a front detector 31 and a rear detector 32, the front detector 31 and the rear detector 32 provide analog outputs, namely, front passage signal 19a and rear passage signal 19b, respectively. These passage signals 19a and 19b are applied to an adder 54, where they are added and output as a power passage signal 55. The power passage signal 55 is applied to a slicer 56, where it is sliced with a power slice voltage 57 into a pulse signal 58. The pulse signal 58 is applied to one input terminal of an AND gate 59 and to a timer 60 which is started by the trail edge of the pulse signal 58. The set time of the timer 60 is determined to be slightly longer than the difference between the time of arrival of the two beams 11a and 11b to the light scan detector and is sufficiently shorter than the scanning period of the light deflector 5 in FIG. 9 (prior art).
Referring back to FIG. 1, the timer output 61 of the timer 60 is applied to the other input terminal of the AND gate 59. That is, the pulse signal 58 and the timer output 61 are ANDed by the AND gate 59, and the output is applied as a power check signal 62 to an error timer 63 which is started by the lead edge of the power check signal 62 and to the S input of an RS latch 64 which provides an output "1" or "0" according to the power check signal 62. The set time of the error timer 63 is so determined that it is slightly longer than the scanning period of the light deflector 5 in FIG. 9 (prior art), and much shorter than twice the scanning period. The error timer 63 is started by the lead edge of the power check signal 62 and outputs a pulse 70 with the lapse of the set time. The output 70 of the error timer 63 is applied to the R input terminal of the RS latch 64. The RS latch 64 provides an output VA 65 which is at "1" when a pulse is received through the S input terminal, and at "0" when a pulse is received through the R input terminal.
A pulse check signal 66 indicative of the zero cross pulse signal 37 which is derived from the difference of the passage signals 19a and 19b is also obtained. The pulse check signal 66 is processed by an error timer 67 and an RS latch 68 into an output VB 69 which indicates the condition of the zero cross signal. The characteristic of the error timer 67 is equal to that of the above--described error timer 63, and the characteristic of the RS latch 68 is equal to that of the above-described RS latch 64.
FIG. 2 shows four states, state "11" through state "00", of the outputs VA and VB. In FIG. 2, "1" means a normal state, and "0" means an abnormal state. The output VA is indicative of the sum of the front passage signal 19a and the rear passage signal 19b, and the output VB is indicative of the zero cross signal of the front passage signal 19a and the rear passage signal 19b. More specifically, state "11" represents a normal condition; state "10" means that the beam power is insufficient, but the zero cross signal is normal; state "01" means that the beam power is sufficient, but the zero cross signal is abnormal; and state "00" means that both the beam power and the zero cross signal are abnormal.
FIG. 3 is a time chart describing the transition of states "11", "10" and "00". More specifically, FIG. 3 shows the front passage signal 19a, the rear passage signal 19b, the power passage signal 55, the pulse signal 58, the timer output 61, the power check signal 62, the error timer output 70, the VA 65, the difference analog output 34, the pulse signal 37, the timer output 39, the pulse check signal 66, the error timer output 72, the VB 69, and the states 73. Further in FIG. 3, reference character T designates the scanning period of the light deflector in FIG. 9. Normally, the signal 75 of the beam 11a and the signal 76 of the beam 11b appear in the front passage signal 19a and 19b repeatedly with the period T. The two signals are added into the power passage signal 55, which is sliced with the pulse slice voltage 57 into the pulse signal 58. The timer output 61, to which access is made with the trail edge of the pulse signal 58, allows the passage of the following pulse 78 of the pulse signal 58 to form the power check signal 62. The error timer output 70 is effected in response to the lead edge 79 of the power check signal 62, and provides a pulse 80 when the next lead edge does not come in the set time. The pulse 80 thus provided sets the VA 65 to "0". The VB 69 is set to "0" in a similar manner with error timer output 72. In this embodiment, the detection is made when the signal 75 of the beam 11a is decreased. However, in the case where the signal 76 of the beam 11b is decreased, VA 65=0 can be obtained by the function of the timer output 61.
FIG. 4 is a circuit diagram describing the processing of signals provided by the light position detector 10. As shown in FIG. 4, the light position detector 10 comprises: photo-detectors 20 and 21 provided for the beam 11a; and photo-detectors 22 and 23 provided for the beam 11b. A control method for the beam 11a is equal to that for the beam 11b. Therefore, the operation will be described with reference to the beam 11a only.
The output beam position signals 80 and 81 of the photo-detectors 20 and 21 are applied to a difference output unit 24, the output of which is applied through an amplifier 26 and a driver 28 to a movable reflector 3a to drive the latter 3a, thereby to control the position of the beam 11a. In this operation, control is so made that the difference between the beam position signals 80 and 81 is zeroed. Therefore, when the beam 11a is shifted from the photo-detectors 20 and 21, it cannot be detected. In order to overcome this problem, the beam position signals 80 and 81 are applied to an adder 82 to form a sum signal 83. The sum signal 83 is applied to a slicer 85, where it is sliced with a reference voltage 84 into an output VC 86. When the beam 11a is applied to the photo-detectors 20 and 21 the sum signal 83 of the beam position signals 80 and 81 is larger than the reference voltage 84, and the output VC 86 is at "1". Similarly as in the above-described case, when the beam, 11b is applied to the photo-detectors 22 and 23, the sum signal 89 of the beam position signals 87 and 88 is larger than the reference voltage 120, and the output VD 90 is at "1". As the power of the beam 11a decreases, the sum signal 83 is also decreased, and becomes smaller than the reference voltage 84, and the output VC 86 is set to "0". Also, when the beam 11a is shifted from the photo-detectors 20 and 21, the output VC 86 is set to "0". Thus, it can be determined by reading the outputs VC 86 and VD 90 whether or not the beams 11a and 11b are normal.
FIG. 5 is a block diagram describing the operation of processing the output of a laser power sensor. The beams 11a and 11b are checked in the same manner, and therefore only the operation of checking the beam 11a will be described with reference to FIG. 5. The semiconductor laser 49a in a light source 1a outputs the beam 11a with the aid of the drive current 91 provided by a current adder 48a, and simultaneously applies a light beam to a laser power monitor sensor 50a in proportion to the beam 11a. In response to the light beam, the laser power monitor sensor 50a outputs a beam power signal 13a, which is applied to a power difference output unit 51a. The beam power signal 13a is further applied to another slicer 92, where it is sliced with a reference voltage 93. When the beam power signal 13a is greater than the reference voltage 93, the power of the output beam 11a of the semiconductor laser 49a is normal, and the output VE 94 is at "1". On the other hand, the power difference output unit 51a applies the difference between the beam power signal 13a and a reference power voltage 52a to a monitor voltage-current converter 53a. The voltage-current converter 53a outputs a control current 95 to zero the difference between the beam power signal 13a and the reference power voltage 52a. The control current 95 is supplied through a current limiter 96 to the aforementioned current adder 48a, where the output of current limiter 96 is added to a modulating current 98 which a voltage-current converter 47a provides by subjecting the output printing signal 97 of a line buffer 46a to voltage-to-current conversion. As a result, the current adder 48a outputs the aforementioned drive current 91 which is applied to the semiconductor laser 49a.
The characteristics of the semiconductor laser 49a are as shown in FIG. 6, in which the horizontal axis I represents the drive current 91, and the vertical axis P represents the output P 99 of the semiconductor laser 49a. The characteristic of the semiconductor 49a is dependent on temperature. At high temperatures, the characteristic of the semiconductor laser 49a as indicated at T H 100; and at low temperatures it is as indicated at T L 101. When a drive current I o 102 is supplied, with the characteristic T L 101, an output P H is provided whereby the beam power signal 13a is fed back to the control current 95 in FIG. 5 so that the drive current 91 is I L 104 and the output is P o 105.
With the characteristic T H 100 in FIG. 6, an output P L 106 is provided, whereby the drive current 91 is I H 107, and the output is P o 105.
Thus, in the circuit of FIG. 5, even if the temperature changes, the output is maintained at P o 105 at all times. The semiconductor laser 49a has a characteristic L o 108 and deteriorates gradually with time. In this configuration, a limit current I 1 111 is set by the current limiter 96. If this limit current is not set, then the following problem will occur. Through the above-described control, the drive current I 91 is increased in order to maintain the output P o 105. As a result, the internal temperature of the semiconductor laser is increased, and therefore the semiconductor laser will have the high-temperature characteristic T H 100. In order to maintain the output P o 105 under this condition, the drive current I 91 is further increased. Thus, the deterioration of the semiconductor laser is accelerated and the laser develops a characteristic L d 109, thus being damaged. On the other hand, by the setting of the limit current I 1 111, the semiconductor laser has a characteristic L 1 110, and provides an output P 1 113. In FIG. 5, the beam power signal 13a proportional to the output P 1 113 is checked with the reference voltage 93 in the slicer 92, and the output VE 94 is set to "0", whereby the deterioration of the semiconductor laser 49a can be detected before the laser 49a is damaged. Similarly, for the other semiconductor laser 49b, with the output VF being set to "0", the deterioration of the semiconductor laser 49b can be detected before the laser 49b is damaged.
FIG. 7 is a circuit diagram showing the voltage-current converter 47a, the monitor voltage-current converter 53a, the current adder 48a, and the current limiter 96 in FIG. 5.
In FIG. 7, the voltage-current converter 47a and the monitor voltage-current converter 53a are made up of a transistor 47a and a transistor 53a, respectively. The current adder 48a is realized by connecting the collectors of transistors 47a and 53a, and the current limiter 96 is made up of a resistor R 2 .
In the circuit of FIG. 7, the drive current I 91 is the sum of the modulating current I 1 98 determined by a resistor R 1 115 and a control current I 2 95. Transistor 47a is in on-off switching operation, and transistor 53a is in non-saturated operation. However, when the output of the power difference output unit 51a increases the control current I 2 to the limit value, the transistor 53a is saturated, and the control current I 2 is saturated, therefore, the drive current I 91 becomes the limit current I 1 111.
FIG. 8 shows examples of errors corresponding to the outputs VA through VF. In FIG. 8, in State Sa, all the outputs VA through VF are each at "1" (VA through VF="1"), and no error exists.
In State Sb, outputs VA=VC="0", and the others are at "1". This represents the following: Because outputs VE=VF="1", in semiconductor lasers 49a and 49b, both the beams 11a and 11b are normal. Because output VC="0" and output VD="1", the input of the beam 11a the light position detector 10 is insufficient. Because output VA="0" and output VB="1", the input of the beam 11a to the light scan detector 8 is insufficient. Hence, there is a high probability that the lens system is contaminated between the coupling lens 2a and the light splitter 4 in FIG. 9 (prior art).
In State Sc, outputs VD=VF="1", and the others are at "0". This represents the following: There is a high probability that the beam 11a of the semiconductor laser 49a is deteriorated. For more accurate detection of the state of the semiconductor laser 49a, the deviations from the normal state Sa should be taken into account.
As was described above, in the double beam scan type optical apparatus of the invention, the conventional detectors are utilized, but the output signals of the detector are specifically processed according to the invention so that the abnormal conditions of various parts in the apparatus can he detected with ease. Thus, the reliability of a double beam scan type laser printer can be remarkably improved by the invention.
Although the preferred embodiment of this invention has been described, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the invention. Therefore, the claims are intended to include all such changes and modifications that fall within the true spirit and scope of the invention. | A double beam scan type optical apparatus for use in a laser printer or the like. Such apparatus comprises two light sources and a lens system which provide scanning means for scanning a surface with parallel output light beams of the two light sources and beam distance controlling means for controlling the distance between the light beams. The reliability of the invention is improved by monitoring the intensity of the beams. Beam intensity checking means provide signals to verify that the intensity of each beam is maintained equal thus assuring that no abnormal conditions exist with the light sources or the lens system of the apparatus. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of laser processing, and, in particular to a system in which a laser machining apparatus automatically performs focus position detection as a required preparatory operation to perform laser machining, stores detected data in a memory, and automatically performs focus position determination.
2. Description of the Background Art
A two-dimensional laser machining apparatus has been employed to cut a plate workpiece in contactless relation at a high speed and with a high accuracy. The two-dimensional laser machining apparatus controls a machining head along X, Y and Z axes, and cuts a workpiece using a laser beam which is introduced from a laser oscillator and outputted from the tip of the machining head. Usually, from a machining quality point of view, it is desirable that the laser beam be focused on the surface of the workpiece, so that when the workpiece is cut using the laser beam, it is necessary to perform a focus setting operation distinct from the actual machining operation. During actual machining, based on the height of the machining head determined by the focus setting operation, a height detecting sensor is mounted to the tip of the machining head, and machining is performed by following the outline of the workpiece so as to keep constant the distance from the tip to the workpiece by using the detecting sensor.
With reference to FIGS. 8 and 9, the general configuration of a two-dimensional laser machining apparatus will be explained hereinafter. Numeral 1 indicates a machining head which is mounted for movement along a Z axis 10. Numeral 2 indicates a distance sensor which functions as a focus detection means and is mounted on the tip of the machining head 1. Numeral 11 indicates a Z axis guide which guides the movement of the machining head 1 driven by the motor M3 in the direction of arrow Z; numeral 12 a Y axis guide which guides the movement of the machining head 1 driven by the motor M2 in the direction of arrow Y; and numeral 13 an X axis guide which guides the movement of the machining head 1 driven by the motor M1 in the direction of arrow X. The motors M1 through M3 are driven by a drive signal M from an NC (numerical control) control section 15, and controlled in such a manner that the spot of a laser beam L follows a machining line K according to a machine processor, while the distance from the machining head 1 to a workpiece W is kept constant. In order to keep constant the distance from the machining head 1 to the workpiece W, the distance sensor 2 mounted on the tip of the machining head 1 measures the distance between the workpiece W and the machining head 1, and feeds back a measuring signal to the NC control section 15, thereby finally controlling the spot of the laser beam L. Connected to a control section 16 is a local operation box 17 which is used at the time of focus position detecting and the like. Numeral 18 indicates a laser oscillator for outputting the laser beam; and numeral 19 a machining apparatus body comprising the three guides for the X, Y and Z axis directions.
Generally, the method used for focus detection is such that a weak laser beam irradiates the workpiece, and a blue flame, derived from a plasma state occurring when the focus of the laser beam is placed on the surface of the workpiece, is visually monitored. In that method, the machining head 1 is allowed to move back by manual operation to widen the distance between the tip of the machining head and the workpiece installed on a machining table so that the tip of the machining head 1 does not interfere with the workpiece during a focus position detecting operation. Thereafter with a focusing program, the machining head is moved relatively and parallel to the workpiece while the laser beam irradiates the workpiece, and an operator finely moves only a lens in the machining head in the plus and minus directions of the Z axis by using the local operation box 17, whereby the blue flame, produced by the plasma occurring near the focus position, is visually monitored.
By using the local operation box of the two-dimensional laser machining apparatus, the operator can input the lens height for which the blue flame is found, as the height of the lens when focused, thereby setting the focus position.
After the focus position has been set, the two-dimensional laser machining apparatus is operated, while keeping the just-focused lens position found by said monitoring and setting operations, and the height of the machining head is adjusted by manual operation so as to provide the proper distance between the machining head and the workpiece.
FIG. 10 is a flowchart showing the steps of a conventional blue flame monitoring operation. In order to perform the operation to monitor the blue flame, after moving back the machining head, the workpiece (or test piece) W is installed on the machining table 14 to determine a focus (S101); the distance between the tip of the machining head and the workpiece W is adjusted so that the tip of the machining head 1 does not interfere with the workpiece or test piece W during the focus position detecting operation (S102); and a program for determining focus is read in the control section 15 (S103). Thereafter, according to the program operation performed by the program for determining focus, the machining head is moved relatively to the workpiece while keeping a constant distance between them (S104); and the laser beam L is irradiated (S105); whereby, while moving the machining head in the Z axis using the local operation box 17 (S106), occurrence of the blue flame is monitored by the operator (S107).
FIG. 11 is a flowchart showing the steps of a conventional focus position setting operation. The blue flame is monitored (S201); whether the blue flame occurs properly is checked (S202); and the operator inputs the height of the current position, when the blue flame properly occurs, as the proper focus height of the machining head, into the control section 16 of the laser machining apparatus (S203). When a proper blue flame does not occur in S202, using the local operation box, the machining head is moved along the Z axis up and down (S204), and the operation beginning with S201 is repeated.
FIG. 12 is a flowchart showing a conventional focusing operation. After the distance between the machining head and the workpiece is widened in S101 shown in FIG. 10, the blue flame occurring is monitored by the operator (S301); whether the blue flame occurs properly is checked (S302); the operator inputs the height of the current position, as the height of the proper focus machining head, into the control section of the laser machining apparatus (S303); and the widened distance between the machining head and the workpiece is adjusted to a proper state (S304). Where a test piece has been used in the above focusing operation, the test piece on the machining table is replaced with the workpiece to start an actual machining operation. Where the above focusing operation has been performed using the workpiece, after completion of the above operation, an actual machining operation is started in that condition.
Conventionally, the distance between the machining head and the workpiece being cut is controlled by a contactless sensor mounted on the tip of the machining head as disclosed in Japanese Laid-Open Patents SHO64-78691 and SHO64-78692.
The former reference discloses a laser machining apparatus which includes a contactless gap sensor, sampling command/drive means and a sampling data storage circuit, wherein, while a machining head is moved away from a reference position from a workpiece in an increment of a specified amount by performing a sampling command with the command means, an output value of the gap sensor is stored in the data storage circuit, whereby the gap sensor output value is controlled in a manner to become the stored data value corresponding to the command gap from a control section.
The latter reference discloses a laser machining apparatus which includes machining head check means, reference output setting means and machining head good/bad judgment means, wherein a machining head is automatically positioned at a check reference position by being given a check command, and a sensor output is measured, whereby the position of the machining head is judged by whether the value is within a predetermined reference output or not. Another device, in which the tip of a machining head is provided with a contactless sensor, and which relates to the control that controls the distance between a workpiece and a machining head during teaching based on a height set in a control panel, is disclosed in Japanese Laid-Open Patent SHO61-165288.
None of the above-mentioned three conventional devices provide continuous monitoring and recording of blue flame, and processing of the data to calculate a focus position.
Although in the blue flame monitoring operation in conventional art a laser beam irradiates a workpiece, and an operator finely moves a machining head in the Z direction using a local operation box such that the workpiece and the machining head are allowed to move relatively to each other at a certain speed, whereby the operator visually monitors the occurrence of the blue flame produced by plasma occurring near the just-focused position, there has been a problem that the monitoring is too complex. Another problem is that the occurrence of the blue flame as detected by the monitoring operation cannot be continuously stored, so that the operator must frequently perform the focus position detection for each monitoring operation to input a current Z axis value through a control section.
Still another problem is that the conventional art focusing is performed by an operator, whereby the detected focus position depends on the degree of skillfulness of the operator, and also whereby the determination of focus position requires non-productive time not accompanied by actual machining. Another problem is that a proper focus position is difficult to determine, whereby a proper focusing cannot be performed, thereby providing a poor machining.
SUMMARY OF THE INVENTION
One aspect of the invention may be summarized as follows:
The method of setting the focus of a laser machining apparatus, comprising the steps of:
(1) reading a program for setting the focus of the laser beam on a workpiece (FIG. 3-S12);
(2) irradiating the workpiece with the laser beam according to said program for setting the focus (FIG. 3-S14);
(3) moving a machining lens relative to the workpiece while keeping constant the distance between the machining head and the surface of the workpiece (FIG. 3-S15);
(4) detecting information regarding the relative distance between said machining lens and said workpiece (FIG. 3-S17);
(5) judging that the laser beam has focused on the workpiece when the detected relative distance information has exceeded a predetermined range (FIG. 3-S18); and
(6) storing the position information of the machining lens at the time when it is judged that the laser beam has focused on said workpiece (FIG. 3-S20).
A laser machining apparatus in connection with a second aspect has an oscillator, a machining lens which is movably mounted in a machining head and directs a laser beam outputted from the oscillator onto a workpiece, and focus detection means for detecting a focus of the machining lens, wherein the machine has focus information storage means for storing the information outputted by the focus detection means.
A laser machining apparatus in connection with a third aspect has an oscillator, a machining lens which is movably mounted in a machining head and directs a laser beam outputted from said oscillator onto a workpiece, and focus detection means for detecting a focus of the machining lens, wherein said machine has focus information storage means for storing the information outputted by the focus detection means, and position information storage means for storing the position information of the machining lens.
A laser machining apparatus in connection with a fourth aspect has an oscillator, a machining lens which is movably mounted in a machining head and gathers a laser beam outputted from said oscillator on a workpiece, and focus detection means for detecting a focus of the machining lens, wherein said machine has machining lens position information processing means for determining a machining lens position at which focusing is suitable, from the information outputted by the focus detection means.
A laser machining apparatus in connection with a fifth aspect has a composition such that the laser machining apparatus of the first or second aspect has focus interval detection means for detecting an interval of focusing is suitable, from the information outputted by the focus detection means, and machining lens position information processing means for determining the machining lens position at each of starting and ending points of said interval.
A laser machining apparatus in connection with a sixth aspect has a composition such that the laser machining apparatus of the fifth aspect has focus position calculation means for calculating the focus position of said machining lens based on the two positions determined by the machining lens position detection means.
A laser machining apparatus in connection with a seventh aspect has a composition such that the focus detection means of the laser machining apparatus of the second through sixth aspects detects a blue flame occurring when the focus of the laser beam is placed on the surface of the workpiece.
The laser machining method in connection with the first aspect improves machining accuracy and therefore product quality.
The laser machining method in connection with the second aspect enables the focus information to be stored.
The laser machining method in connection with the third aspect enables the focus information and the machining lens position information to be stored simultaneously.
The laser machining method in connection with the fourth aspect enables the machining lens focus position to be determined.
The laser machining method in connection with the fifth aspect enables the machining lens position suitable for machining to be determined.
The laser machining method in connection with the sixth aspect enables the machining lens focus position to be determined with a higher accuracy.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a laser machining apparatus system as an embodiment of the first through third aspects.
FIG. 2 is a schematic diagram of a focus setting equipment of a laser machining apparatus as an embodiment of the first through third aspects.
FIG. 3 is a flowchart of a focus setting operation of a laser machining apparatus as an embodiment of the first through third aspects.
FIG. 4 is a graph showing the relationship between sensor output and machining lens position data recorded by a laser machining machine as an embodiment of the first through third aspects.
FIG. 5 is a perspective view of a laser machining apparatus system as an embodiment of the fourth through sixth aspects.
FIG. 6 is a schematic diagram of focus setting equipment of a laser machining apparatus as an embodiment of the fourth through sixth aspects.
FIG. 7 is a flowchart of a focus setting operation of a laser machining apparatus as an embodiment of the fourth through sixth aspects.
FIG. 8 is a block diagram of a two-dimensional laser machining apparatus.
FIG. 9 is a perspective view of a two-dimensional laser machining apparatus.
FIG. 10 is a flowchart showing the steps of a conventional blue flame monitoring operation.
FIG. 11 is a flowchart showing the steps of a conventional focus position setting operation.
FIG. 12 is a flowchart showing the steps of a conventional focusing operation.
DESCRIPTION OF PREFERRED EMBODIMENTS
Embodiment 1
FIG. 1, which shows an embodiment of the first through third aspects, is a perspective view of a two-dimensional laser machining apparatus monitoring a plasma state. Numeral 1 indicates a machining head; numeral 2 a capacitance type distance sensor; numeral 10 a Z axis unit capable of moving the machining head in the Z axis direction; numeral 14 a machining table; numeral 19 a machining apparatus body; numeral 15 a control section of the machining apparatus body 19; numeral 17 a local operation box connected to the machining apparatus body 19; and numeral 5 a data monitoring section which monitors continuously with time both the output processed in a sensor processing section for processing a sensor output obtained by the distance sensor 2, and the current value of a machining lens sequentially varying and obtained by a machining lens drive mechanism 4.
FIG. 2 is a view showing the details of focus setting equipment of the laser machining apparatus of FIG. 1. In FIG. 2, numeral 3 indicates a sensor processing section for processing a sensor output "h" obtained by the distance sensor 2; and numeral 4 indicates the machining lens drive mechanism for driving a machining lens 9. Numeral 5 indicates the data monitoring section which monitors continuously with time both the output processed in the sensor processing section 3 and the current value of the machining lens sequentially varying and obtained by the machining lens drive mechanism 4, and includes a position information storage subsection 5b for storing a position information "δ" from the machining lens drive mechanism 4 and a position information storage subsection 5a for storing an output from the sensor processing section therein. Numeral 15 indicates an NC control section; and numeral 6 indicates a machining lens drive control section.
FIG. 3 is a flowchart of an automatic focus data recording of the laser machining apparatus shown in FIG. 2. Based on FIGS. 2 and 3, the operational steps of the automatic focus data recording will be explained hereinafter. A workpiece is installed on the machining table 14 in the workpiece W installing step S11; a program for determining focus is called in the program calling step S12; and, while according to the program called in step S12 the machining head is moved relatively to and kept at a certain distance from the installed workpiece W in the program-run operational step S13, a laser beam L having an output specified by the program called in step S12 irradiates the workpiece W (S14). At this point, while the laser beam L is irradiating the workpiece, the machining lens is allowed to move up and down by the machining lens drive mechanism 4 (S15) to monitor sensor information and machining lens position information (S16, S17). While the above operations are being performed, the occurrence of a blue flame is monitored (S18), and if the blue flame occurs, the sensor output and the machining lens position information are respectively recorded with time in the information storage subsections 5a and 5b shown in FIG. 2 (S19, S20). If the blue flame does not occur, the operation is returned to step S15, where the machining lens is again allowed to move up and down, thereby monitoring for occurrence of the blue flame. The NC control section 15 controls the lens drive control panel 6 using the data of the information storage subsections 5a and 5b.
FIG. 4 shows a relationship between the sensor output data and the position data of the machining lens 9 recorded by the laser machining apparatus of an embodiment of the first through third aspects of the invention. The machining head 1 moves from the position 1A, through 1B, to 1C in parallel with the workpiece W at a certain speed while keeping a certain height above the workpiece. The machining lens 9 is moved in the Z axis direction interlocking with the movement of the machining head 1. When the focus of the laser beam L approaches a just-focused position on the surface of the workpiece W, a blue flame occurs by the plasma occurring by the micro laser beam L irradiated to the workpiece W (for interval between t1 and t2). This state is read in the sensor processing section 3 as the sensor output obtained by the distance sensor 2 mounted to the tip of the machining head 1, and both the read data and the current position of the machining lens 9, driven by the machining lens drive mechanism 4, are read continuously with time to record. Where the machining state becomes bad because of an external cause during actual machining, the position data of the machining lens 9 within the blue flame occurring interval (t1 to t2) is fetched from the focus information storage subsection 5a and the lens position information storage subsection 5b of the focus setting equipment, and the position of the machining lens 9 when just focused is determined, whereby the machining lens 9 is again moved to the just-focused position to restart the machining.
Embodiment 2
FIG. 5, which shows an embodiment of the fourth through sixth inventions, is a perspective view of a two-dimensional laser machining apparatus for determining a plasma state. Numeral 1 indicates a machining head; numeral 2 a capacitance-type distance sensor; numeral 10 a Z axis unit capable of moving the machining head in the Z axis direction; numeral 14 a machining table; numeral 19 a machining apparatus body; numeral 15 a control section of the machining apparatus body 19; numeral 17 a local operation box connected to the machining apparatus body 19; and numeral 7 a data processing section which records continuously with time both the output processed in a sensor processing section 3 for processing a sensor output obtained by the distance sensor 2, and the current value of a machining lens sequentially varying and obtained by a machining lens drive mechanism 4 and processes the data.
FIG. 6 is a view showing the details of focus setting equipment of the laser machining apparatus of FIG. 5. In FIG. 6, numeral 3 indicates a sensor processing section for processing a sensor output "h" obtained by the distance sensor 2; and numeral 4 indicates a machining lens drive mechanism for driving a machining lens 9. Numeral 7 indicates a data processing section, which determines the position of the machining lens 9, when just focused, from both the position information of the machining lens and the sensor output, and includes: a blue flame occurrence start/end time-detecting subsection 7a for detecting the start time t1 and the end time t2 of a blue flame occurrence interval; a machining lens position information processing subsection 7b for determining machining lens position data δ1, δ2 at the two times (t1, t2) by a signal outputted from the time-detecting subsection 7a when the blue flame occurs or ends, and a focus-position calculating subsection 7c for calculating an optimum focus position based on the two position data δ1, δ2. Numeral 15 indicates an NC control section; and numeral 6 indicates a machining lens drive control section.
FIG. 7 is a flowchart showing the operational steps of the laser machining apparatus of an embodiment of the fourth through sixth aspects of the invention. Based on this flowchart and FIG. 6, the operation of the machine of an embodiment of the fourth through sixth aspects of the invention inventions will be explained hereinafter. The sensor output data and the position data of the machining lens 9 in FIG. 6 are read in step S21; and the blue flame occurrence start time t1 and the blue flame occurrence end time t2 are determined by the blue flame occurrence start/end time detecting subsection 7a in the data processing section 7 in step S22. Then, the signal from the blue flame occurrence start/end time detecting subsection 7a is received, whereby the position data δ1 and δ2 of the machining lens 9, which correspond to the times t1 and t2, are determined from the occurrence interval by the machining lens position information processing subsection 7b in the data processing section 7 (S23, S24); and the position 6 of the machining lens 9 when just focused is calculated from the two positions of the machining lens 9 by the focus position calculating subsection 7c in the data processing section 7 (S25). The calculated position of the machining lens 9 when just focused is instructed through the NC control section to the machining lens drive control panel, whereby the machining lens 9 is moved, in a manner to reach the just-focusing state, by the machining lens drive mechanism 4 (S26).
In the blue flame occurrence start/end time detecting subsection 7a, if a variation of the sensor output data exceeds a threshold limit value, a blue flame is judged to occur. That is, a time when the sensor output state turns from a steady one to an unsteady one is recognized to be the time of the start of blue flame occurrence; and a condition that the threshold limit value is reversely exceeded, that is, a time when the sensor output state turns from an unsteady one to a steady one is recognized to be the time of the end of blue flame occurrence. The output data is recorded continuously with time, so that the blue flame occurring time can also be determined by the blue flame occurrence start time t1 and the blue flame occurrence end time t2.
In the focus position calculating subsection 7c, the position δ of the machining lens 9 when just focused is determined by the following arithmetic equation (S26).
Generally, δ is represented by the following equation:
δ(δ1, δ2)=(m δ1+n δ2)/(m+n)
provided that m and n are coefficients varying with the machining method. For example, where m=1, and n=1, δ is determined by the following equation:
δ=(δ1+δ2)/2
Although the above embodiments have shown the focusing operation using a workpiece, a test piece may be used in place of the workpiece, in which case, after completion of the focusing operation, the test piece on the machining table needs only to be replaced with the workpiece. In the above description, the distance sensor 2 has been shown as a capacitance type but is not limited to that type, and sensors of other types capable of checking the occurrence of blue flame may be used. For example, an optical sensor, a magnetic sensor and the like may be used. Although in the above description, the present invention has been described in case where it is loaded into an equipment other than a control one and utilized for a two-dimensional laser machining apparatus, it will be appreciated that the present invention can be incorporated into, for example, the NC control equipment of a two-dimensional laser machining apparatus.
According to the present invention as previously described, the focus position detection can be performed in a short time regardless of the skill of an operator, and the focus position can be determined uniquely, so that the present invention has the effect of reducing poor machining caused by an error in fine focus position setting by an operator. | The focus of a laser machining apparatus is set by reading a program for setting the focus of the laser beam on a workpiece; irradiating the workpiece with the laser beam according to the program for setting the focus; moving a machining lens relative to the workpiece while keeping constant the distance between the machining head and the surface of the workpiece; detecting information regarding the relative distance between the machining lens and the workpiece; judging that the laser beam has focused on the workpiece when the detected relative distance information has exceeded a predetermined range and when a blue flame occurs; and storing the position information of the machining lens at the time when it is judged that the laser beam has focused on the workpiece. | 1 |
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/964,854 filed Jan. 16, 2014.
FIELD OF THE INVENTION
[0002] This application relates generally to the field of automobile sun visors and, more particularly, to an attachment arranged to be removably coupled to the visor of an automobile and repositioned to suit the user without having to adjust the positioning of the existing visor to which it is attached.
BACKGROUND OF THE INVENTION
[0003] Since the earliest automobiles took to the roads, they have been equipped with sun visors to help shield the driver's and passengers' eyes from glare from sunlight. A typical sun visor comprises an opaque material that can be rotated to position the visor at the choice of the user, and rotated out of the way when not in use. The most familiar type of automobile sun visor moves with two degrees of freedom, with a vertically oriented post to allow movement of the visor left and right and a horizontal axis the permit rotation of the sun visor up and down.
[0004] Many improvements have been made to this typical sun visor, commonly in the form of attachment to the visor. Vandagriff, U.S. Pat. No. 5,445,427; is exemplary of the art. The '427 patent teaches a sun visor attachment that secures to a pre-existing sun visor. A main body of the attachment having laterally and vertically extendable panels is secured to the pre-existing sun visor. A wing body is connected by a multi-axis pivot to the main body portion and is swung away from a closed position adjacent the main body to an open position, including discrete rotations from the vertical. The wing body also has vertically and laterally extendable panels and, in addition, has a support assembly for maintaining the wing body in its open position.
[0005] However, to use the visor attachment of the '427 patent, the driver must move the existing sun visor to position the visor and attachment to a desired position. Thus, there remains a need for a sun visor attachment that permits the driver to leave the existing visor in a default position while independently moving an attachment on the visor to a desired orientation. The attachment disclosed herein solves these and other needs in the art.
SUMMARY OF THE INVENTION
[0006] The automobile sun visor attachment disclosed herein solves many of these types of problems a driver faces when driving in a variety of light glare conditions. For example, a driver might encounter different driving conditions while driving into the sun when it is in a low position, or when driving at night, especially on a rainy day, facing blinding lights from oncoming traffic. Alternatively, a driver might be blinded by a backwards facing outside minor with a following driver using headlamps set on high beams. Conditions also change as a driver moves along a curving road as the source of the glare moves along the driver's field of view.
[0007] By using the attachment of this disclosure, a driver can leave the existing visor of the automobile in its place to cover a bright sky or blinding white clouds in front of the windshield, while using the herein disclosed attachment visor for coverage on the side. It solves the problem of having to move the visor from front to side, as the automobile keeps changing direction and the sun moves back and forth between front and side.
[0008] As the attached visor is moved to the side, it can also be rotated up or down, depending on the height of the sun from the side. It can be moved down enough to cover the outside minor, which cannot be dimmed like the inside rear view mirror, since a drive can be blinded by a careless driver approaching from the rear without dimming their lights from high to low beam.
[0009] The attachment visor can also be put into a vertical position on the left side of the windshield to eliminate glare at night from oncoming traffic, which would be especially useful on a rainy night, when every raindrop on the windshield outside of the reach of the wiper blade acts like a tiny bright lantern.
[0010] Drivers who are short enough to just barely look over the steering wheel would appreciate the possibility to use the attachment visor as a downward extension to the existing visor.
[0011] These and other features and advantages will be apparent to those of skill in the art from a study of the following disclosure along with the accompanying drawings. For example, the attachment may be produced and sold as retrofit equipment, or as original equipment on an automobile.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a rear view of the visor attachment as seen by a driver, mounted on an existing automobile visor.
[0013] FIG. 1A is another presently preferred embodiment of a visor attachment that may be installed by an automobile manufacturer as original equipment, rather than as a retrofit.
[0014] FIG. 2 is a side view of the visor attachment of FIG. 1 .
[0015] FIG. 3 is a bottom view of the visor attachment of FIG. 1 .
[0016] FIG. 4 is a cross section view as seen along section lines 4 - 4 in FIG. 1 .
[0017] FIG. 5 is a cross section view as seen along section lines 5 - 5 in FIG. 1 .
[0018] FIG. 6 is a cross section view as seen along section lines 6 - 6 in FIG. 1 .
[0019] FIG. 7 is a detail view of a preferred embodiment of a main knee of FIG. 1 .
[0020] FIG. 8 is a side detail view of the main knee shown in FIG. 7 .
[0021] FIG. 9 is a view, as seen by a driver looking forward through a windshield, showing the attachment visor mounted onto the main visor in a storage position.
[0022] FIG. 10 is a view, as seen by a driver looking forward through a windshield, showing the existing visor together with the attachment visor tilted down.
[0023] FIG. 11 is a view, as seen by a driver looking forward through a windshield, of a visor tilted down with attachment visor rotated out to the side.
[0024] FIG. 12 is a view, as seen by a driver looking forward through a windshield, of a visor tilted down with attachment visor rotated out to the side and partially rotated down along a horizontal axis.
[0025] FIG. 13 is a view, as seen by a driver looking forward through a windshield, of a visor down and partially forward with the attachment visor partially down, serving as downward extension of the existing.
[0026] FIG. 14 is a view, as seen by a driver looking forward through a windshield, of a visor in its storage position with the attachment visor in a vertically downward position to shield against blinding lights from oncoming traffic at night off to the left of the driver.
[0027] FIG. 15 is a view, as seen by a driver looking forward through a windshield, of a visor in its storage position with the attachment visor down to provide shielding from the outside driver's-side rear view mirror.
[0028] FIG. 16 is a view, as seen by a driver looking forward through a windshield, of a visor in a down position, rotated to the side, with the attachment visor down to serve as downward extension of the existing visor.
[0029] FIG. 17 is a view, as seen by a driver looking forward through a windshield, of a visor in a down position, rotated partially backwards, with the attachment visor down and rotated to the side.
[0030] FIG. 18 is a view, as seen by a driver looking forward through a windshield, of a visor in a down position, rotated partially forward, with the attachment visor down from the existing visor and rotated to the side’
[0031] FIG. 19 is a view, as seen by a driver looking forward through a windshield, of a visor in a down position, with the attachment visor rotated to the side and down to cover outside minor.
[0032] FIG. 20 is a view, as seen by a driver looking forward through a windshield, of a presently preferred embodiment of the visor attachment with a sliding extension.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0033] FIGS. 1 , 2 , and 3 illustrate a presently preferred embodiment of a visor attachment assembly 21 in its intended environment, i.e. attached to an existing sun visor 58 . The visor attachment assembly 21 includes a foam board blade 22 which is joined to two clamp halves 24 . The foam board blade is preferably opaque, but may be made of a dark, polarizing material that stops glare but allows some view through the blade 22 . Whatever the material that is chosen, it must be lightweight to minimize the frictional forces necessary to maintain the positions of the blade that are chosen by the user, and yet it must be strong enough to provide robust support. The clamp halves 24 are cantilevered on and rotatably positioned around a vertical shaft 26 . The friction between the clamp halves 24 and the shaft 26 can be increased by tightening one or both of a pair of screws 28 . A horizontal rod 30 connects to the shaft via a hinge knee 32 . The hinge knee 32 comprises two halves 34 jointed together about an axis, which are connected by a co-axial screw 36 and a lock nut 38 ( FIG. 3 ). Wavy (compressible) washers 40 are placed under the head of the screw 36 . The friction between the knee halves 34 can be increased by tightening the screw 36 , thereby compressing the wavy washers 40 .
[0034] FIGS. 1 , 2 , and 3 also illustrate one preferred way to attach the visor attachment to an existing visor, although many such attachment methods may be used within the spirit and scope of this invention. In the figures, two saddle pieces 42 and 44 ride on the horizontal rod 30 . Further details of the saddle pieces are shown in FIGS. 4 , 5 , and 6 and described below. The rotational friction between the rod 30 and the saddle piece 42 can also be increased by tightening a screw 46 . The saddle pieces 42 and 44 are equipped with slots 48 and 50 , respectively, through which Velcro® belts 52 are fed. Each belt 52 is equipped with a belt buckle 54 to receive a belt end 56 . Each belt 52 can be placed around the existing visor 58 and tightened by pulling on its respective belt end 56 and pressing them against belt 52 . Preferably, the belts 52 are spaced apart so as not to obscure a vanity mirror 59 on the existing visor 58 . In another preferred alternative embodiment, the saddle piece 44 is replaced by a second saddle piece 42 to increase the rotational friction even more between the saddle pieces and the rod 30 .
[0035] FIG. 1A shows another presently preferred embodiment of a sun visor attachment 60 as made by the automobile manufacturer, and not as a retrofit item of equipment. In FIG. 1A , a rod 62 is placed inside the automobile's existing visor 64 , eliminating the saddle pieces 42 and 44 , which are only required for the after-market (retrofit) variation.
[0036] FIGS. 4 , 5 , and 6 illustrate cross sections of FIG. 1 to illustrate in more detail how the saddle pieces 42 and 44 are held in place on the rod 30 under the bottom edge of the existing visor 58 . As shown in FIG. 4 , a section view along section lines 4 - 4 of FIG. 1 , the foam board blade 22 is joined to two clamp halves 24 and held in place around the vertical rod 26 , preferably by an adjustable screw 28 . FIG. 5 , a section view along section lines 5 - 5 of FIG. 1 , shows the mounting of the saddle piece 42 around the rod 30 and held in place by an adjustable screw 46 . In contrast, FIG. 6 , a section view along section lines 6 - 6 , shows a saddle piece 44 which entirely encircles the rod 30 . FIG. 6 also illustrates the slot 50 , through which the belt 52 is threaded and them tightened to attach the attachment to the existing visor 58 .
[0037] FIGS. 7 and 8 show a presently preferred embodiment of a joint that may be used in place of the hinge knee 32 . The embodiment of FIGS. 7 and 8 includes a universal ball joint 70 . A rod 72 is connected to a ball receiving end 74 , inside which a ball-shaped end 76 of a rod 78 is held by a retainer ring 80 . Those of skill in the art will recognize that the rod 78 corresponds in the embodiment of FIG. 8 to the rod 30 of FIG. 1 . A pair of screws 82 attach the retainer ring 80 to the ball receiving end 74 . The friction between ball receiving end 74 and the ball-shaped end 76 can be increased by tightening the screws 82 , preferably uniformly.
[0038] FIGS. 9 to 20 illustrate the most useful positions of the foam board blade 22 relative to the existing visor and the automobile. For example, FIG. 9 shows the visor attachment mounted onto the main visor in a storage position. This is the position of the existing visor and its attachment where it will be positioned most of the time, i.e. without glare annoying the driver. FIG. 10 , with the visor and the attachment lowered down, the assembly operates in a manner similar to the existing visor without the attachment.
[0039] In FIG. 11 , the visor attachment is rotated to the left as seen in the drawing, to block glare from the left of the driver. FIG. 12 illustrates the foam board blade lowered down, rotated slightly about the rod 30 , to block glare lower down through the driver's side window.
[0040] In FIG. 13 , the existing visor 58 is rotated down from its storage position and the blade 22 is also rotated down to a position immediately below the existing visor. FIG. 14 shows the existing visor 58 in its up or storage position and the blade positioned in a rotated and downwardly extended position. This position of the blade is useful to block glare from approaching headlamps, whether because they are on high beam or because the light from the headlamps is reflected off the roadway, such as during a rain.
[0041] FIG. 15 shows the blade 22 positioned to block glare from the driver's side rear view minor by rotating the blade about the hinge knee 32 . In FIG. 16 , the existing visor 58 is rotated to the left and the blade 22 is simply lowered by rotating about the rod 30 . This orientation of the assembly effectively blocks glare from all of the driver's side window.
[0042] FIG. 17 illustrates the combination of the existing visor and the visor attachment with the existing visor angled back toward the driver at roughly a 45° angle, with the visor attachment positioned to the left of the driver, approximately parallel to the driver's side window. Similarly, in FIG. 18 , the existing visor is angled away from the driver and approximately 45° with the visor attachment as before in FIG. 17 . Recall that the joint 70 , shown in FIGS. 7 and 8 , could be used in place of the hinge knee joint 32 for even greater flexibility. FIG. 19 shows the existing visor in the same position as in FIG. 18 , but the visor attachment is rotated down using the hinge knee 32 to block glare from the driver's side minor.
[0043] Finally, FIG. 20 illustrates an additional feature 90 wherein the blade comprises a hollow sleeve-like blade portion 92 and a second extension blade 94 . The extension blade 94 is inserted into the hollow space of the blade portion 92 and can slide in and out to change the combined length of blade 90 . As before, the blade portion 92 and the extension blade 94 may be made of a opaque material, or a dark polarizing material, or any appropriate material.
[0044] The principles, preferred embodiment, and mode of operation of the present invention have been described in the foregoing specification. This invention is not to be construed as limited to the particular forms disclosed, since these are regarded as illustrative rather than restrictive. Moreover, variations and changes may be made by those skilled in the art without departing from the spirit of the invention. | An automobile sun visor attachment is configured to attach to a sun visor. The attachment includes means to easily apply and remove the attachment to an existing sun visor. An opaque or dark translucent blade is flexibly joined to the existing visor offering degrees of freedom of movement, allowing the user to orient the blade at any desired position and orientation. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention.
The field of the invention is broadheads or points (also called arrowheads) for arrow shafts used with a bow for hunting. More particularly, the field involved concerns broadheads which assume one configuration during flight and a second configuration after it strikes the target, such as to more efficiently accomplish its function of humanely disabling and killing the game animal.
2. Description of the Related Art.
In recent years there has been significant advances in the art of broadheads for hunting arrows designed to cause the animal to cease its travel by more effectively disabling and killing the animal being hunted and while doing so, reduce suffering by the animal.
Other inventions include the arrowhead assembly by Vance in U.S. Pat. No. 2,820,634 where two blades pivotably mounted to the head of the arrow shaft, when striking the side of the animal, immediately begin to rotate past each other to a expanded "V" configuration. The blades are initially joined in a somewhat pointed orientation. It is noted that the sharpened edge which is presented in the initial orientation remains the sharpened edge in the final opened "V" configuration.
The patent of Vance is modified somewhat in Rickey, U.S. Pat. No. 3,578,328, where in a similar construction, the arrow shaft body continues beyond the front point of the two pivotable blades to form a front piercing point. The two blades, like those in Vance, rotate past each other when rotational movement is forced upon the blades by the blades engaging the hide of the animal. A same sharpened edge which engages the animal initially is the forward sharpened edge as the arrowhead proceeds through the body of the game animal.
Lastly, Steinbacher in U.S. Pat. No. 2,568,417 adopts the forward point of an arrow shaft as the leading point and secures rotatable blades within the arrow shaft forward point. The blades are rotated outwardly not crossing each other as outstanding flanges on the blades engage the animal after initial penetration by the forward point portion. Other U.S. patents which show features similar to the features described above but constructed in a different manner include Bergmann, U.S. Pat. Nos. 4,166,619; Vocal, 4,615,529; Cox, 3,738,657; and Hendricks, 3,600,835.
All of the above prior art patents are characterized by arrowpoint bodies which have protruding spurs or cutting blades extending outwardly from its sides, some extending prior to the arrowpoint entering the body of the animal and some extending after the arrowpoint has entered the body of the animal. The extending blades or spurs appear to accomplish their function very efficiently, i.e., that of cutting as wide a swath as possible in order to bring the game down.
All of the arrowheads or points illustrated above employ a cylindrical pointed arrowhead body (with the exception of Vocal and Vance) with the spurs or blades emerging from the body, either being pivotable near the head of the body or at the rear of the body, some pivoting upon entering the body of the animal and some pivoting after entry into the body of the animal. This, of course, is not without reason since for the arrow to travel through to its target with minimum air resistance, it is generally necessary that the smallest point cross-section as possible be utilized. However, the cylindrical body portion of the arrow point itself is relatively inefficient as it contributes very little to the end results of the arrowhead.
Thus, the relative efficiency of the arrowhead or point may well be improved if the whole point itself comprises the blades which ultimately rotate outwardly. Vance does present an arrowhead assembly wherein the cutting blades also comprise the forward point, however, the blades are so arranged that they commence rotation and open to the widest possible configuration immediately upon hitting the hide of the animal and thus suffer the possibility of not only dulling on the animal hide, especially if the animal has dried mud or dirt on its side, which is highly likely, but also being forced to engage a heavy hide in the open position on initial penetration and thereby wasting considerable energy. In addition, since the sharpened edges are always exposed, a safety hazard is always presented to the hunter in handling the arrowhead prior to use.
It is also apparent that an obvious improvement to the state of the art exists if the rather small point on the arrow shaft necessary for guiding the arrow to it's mark should, upon striking the animal, metamorphosis entirely into outstanding cutting blades which bring down the game more efficiently.
It is also apparent that an obvious improvement exists if the sharpened edges can be protected against dulling or operator injury prior to the arrowhead entering the body of the game animal. Further it would also be a considerable improvement if both blades could be locked together during initial penetration until the heavy hide and ribs have been penetrated.
SUMMARY OF THE INVENTION
The embodiment of the invention described consists of two blades pivotably mounted to a rearward located cylindrical body, the cylindrical body adapted to be attached to one end of an arrow shaft. More specifically, the two blades, which are identical in construction, are so constructed as to form a pointed first forward penetrating portion of the hunting broadhead (well before the cylindrical body touches the game hide). As the hunting broadhead enters the body of the animal, outstanding spurs attached to the blades and situated rearward of the forward section of the blades are engaged by the animal hide or bones (ribs) on contact to cause the blades to pivotally separate to form an inverted "V" configuration, all within the body cavity of the animal. At that time, the hunting broadhead has gone through a complete metamorphosis from a relatively sharp and narrow pointed hunting broadhead for initial penetration to a very wide broadhead that relies entirely upon the extending blades for cutting while penetrating. Further, the cylindrical body never is the predecessor of the blades.
My first hunting point, (U.S. Pat. No. 5,046,744 issued Sep. 10, 1991) depended upon friction between two blades to keep the blades positioned together to form the narrow sharpened hunting point which was maintained during storage of the hunting point, handling by the operator, and initial flight from the bow to the animal. Further, my first hunting point also depended upon one angled side of each of the blades of the sharpened front edge of the point engaging the animal to keep the blades together after initial penetration until the rearwardly located outstanding spurs engage the animal's hide and bones.
In my present invention, I utilize a rubber band situated at some point in front of the outstanding spur on each blade (later discussed) as well as side pressure created by contact to exposed edges anterior to the spurs to keep the blades together.
Each blade is an elongated thin piece of metal having a combination of partially sharpened edges, blunted partially chamferred edges, and square cut edges (edges unmodified after the blade is stamped or cut out of flat stock). At a first or forward end is a point (formed from two angled partially chamferred edges), with a first side joining one of the partially chamferred edges of the pointed first end, said first side having a long, slightly curved, sharpened cutting edge which extends to the opposite second or rear end where it terminates in a substantially right angle foot, the edges making up the right angle foot also being sharpened.
Along the second side joining the other partially chamferred edge making up the pointed first forward end is a substantially straight partially chamferred angled edge extending approximately 60 percent of the length of the blade, this partially chamferred edge terminating into an outwardly protruding spur, which spur also has a partially chamferred edge on its forward portion. The rubber band previously discussed is preferably retained at the intersection of the substantially straight partially chamferred edge and the outwardly protruding spur edge.
Proceeding rearward from the outwardly protruding spur, the falling edge of the blade is square cut (having neither a sharpened edge nor a partially chamferred edge), and retreats toward the first side at an angle to form a second stop until it reaches the vicinity of the opening formed in each blade to accommodate a pivot pin. Surrounding that opening is a semi-circular outwardly directed protrusion. Lastly, the semi-circular protrusion accommodating the pivot pin opening then joins with a short straight square cut edge to form a first stop which terminates at the right angle foot. This first stop is urged against the side of the cylindrical body by the rubber band to define the position of each blade forming the pointed configuration.
Receiving two blades in a back-to-back configuration is an elongated cylindrical body having at a first end a chamferred rounded edge (not necessarily forming a point although it could) and at the opposite end, male threads to be received in female threads at the end of an arrow shaft, or any other arrangement to attach to the end of an arrow shaft. At the first end of the cylindrical body is a lengthwise elongated slot, the slot adapted to receive the two identical blades of the invention. Transversely to the elongated slot and on opposite sides are openings to secure the previously mentioned pivot pin. This pivot pin resides in the opening of each of the two blades making up one complete hunting broadhead.
When the hunting broadhead is assembled, the blades are positioned so that their back surfaces, which are completely flat not having the formed sharpened edges or partially chamferred edges, are placed juxtaposed each other. By this means, the surfaces making up the sharpened edges and partially chamferred edges of each blade will be on the outside and never hidden by the opposite blade. The hunting broadhead is assembled by aligning each of the blade's opening over the opening in the cylindrical body and then inserting the pivot pin into the opening on one side of the cylindrical body, through each of the openings in each of the blades, and into the opening on the other side of the cylindrical body so that the pivot pin completely crosses the elongated slot. The diameters of the openings in the cylindrical body and the pivot pin are very close to each other so that there is a tight frictional holding relationship between the two such as to keep the pivot pin in place once inserted, i.e., the pin is best driven into the openings in the cylindrical body. Other means, such as threading, may be used to retain the pivot pin in the body. However, the opening in each of the blades is slightly larger than the diameter of the pivot pin so that the blades freely rotate. In addition, unlike my first hunting point, the width of the elongated slot in the cylindrical body need no longer be sized as to frictionally compress the two blades against each other but, may be larger.
It is noted that when the hunting broadhead is assembled and the first forward ends of each blade brought together to form the point of the broadhead, the first stop of each blade is urged against the sides of the cylindrical body. In this configuration, the sharpened first side or edge of each blade is recessed in position behind the partially chamferred edge of the opposite blade such that if a person were to grab the forward point or first end (at its sides) of each broadhead, their fingers come in contact with the two opposite partially chamferred edges and not the sharpened edges. The point of the resulting broadhead is also formed from two partially chamferred edges on each blade. The rubber band may be installed upon the hunting broadhead by slipping it down over the forward 60 percent or so length of the broadhead to stop at the base of each spur. In slipping the rubber band down over the broadhead, the band only engages the partially chamferred edges and is thus not severed.
The feature of utilizing the partially chamferred edge on one side of each blade and recessing the sharpened edge back behind the partially chamferred edge of the opposite blade (when assembled) provides an obvious safety measure in that the operator's fingers never come in contact with the sharpened edge so long as the hunting broadhead is handled in its forward 60 percent of its length or so. Additionally, if the animal which is shot has caked dirt or mud on its side, and this is very common, or if the animal's hide is very tough, the sharpened edges of the blades never directly engage the mud, hair, hide, or ribs or initial impact of the animal. Thus they are protected against dulling during entry into the animal and prior to each blade beginning its pivotal action to form the widened "V" configuration whereby the sharpened edge is placed forward. This pivotal operation commences after approximately 60 percent of the broadhead has entered the body of the animal's body and is completed entirely within the body cavity.
After entry, when the two blades rotate to open, the blades reach a point where the second stop of each blade engages the side of the cylindrical body at which time the blades form a common sharpened point of a widened "V" configuration. This point is formed by the right angle boots previously spoken of. As the hunting point continues along through the animal body, the rubber band may roll off each blade along its spur and end up residing on the arrow shaft or may be cut depending upon the hardness of the animal part interacting with the broadhead.
To withdraw the hunting broadhead from a game animal, the hunter grasps the arrow shaft and pulls backwardly. This causes the sharpened blades to rotate back to their initial flight position and present minimum resistance to the withdrawal of the arrow shaft and attached broadhead.
The advantage of providing one edge highly sharpened for cutting and the other edge partially chamferred for exposure at all other times provides great benefits in the subject hunting broadheads.
Accordingly, it is an object of the subject invention to provide a hunting broadhead which presents a relatively small sharp end or projection with minimum cross-section designed to penetrate the hide of the game animal but which, upon travel through the game, expands to provide a very sharp cutting edge to kill the animal in the most humane way possible. By such means, energy is not wasted in making a large surface entry opening.
It is another object of the subject invention to provide a hunting point which is most efficient and provides that the blades making up the hunting point metamorphoses from a relatively sharpened narrow point to a broad cutting inverted "V" sharpened formation.
It is still a further object of the subject invention to provide a hunting broadhead without a forward cylindrical body leading the arrow shaft into the game animal.
It is still further an object of the subject invention to provide a hunting broadhead which provides non-sharp partially chamferred edges for handling by the hunter so as to prevent cutting injuries to the hunter when using the hunting broadhead.
It is still a further object of the subject invention to provide a hunting broadhead having sharpened cutting edges which are protected against dulling prior to their designed time for cutting internally into the game animal.
Other objects of the invention will in part be obvious and will in part appear hereinafter. The invention accordingly comprises the apparatus possessing the construction, combination of elements, and arrangement of parts which are exemplified in the following detailed disclosure and the scope of the application which will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For further understanding of the features and objects of the subject invention, reference should be had to the following detailed description taken in connection with the accompanying drawings wherein:
FIG. 1. is a top view of the subject hunting broadhead in a stored and in-flight configuration;
FIG. 2. is a top view of the subject hunting broadhead in a configuration after entering the game animal where the spurs have struck the animal hide or ribs and the blades have just started to rotationally separate;
FIG. 3. is a top view of the subject hunting broadhead in its final inverted "V" configuration for travel internally to the game animal;
FIG. 4. is a side view of the cylindrical body of the invention;
FIG. 5. is a side view of the pivot pin of the invention;
FIGS. 6.A. and 6.B. are top views of each of the blades which make up the invention; and
FIG. 7. is a sectional view of the hunting broadhead taken along lines 7--7 of FIG. 1.
In various views like index numbers refer to like elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a top view of the subject inventive hunting broadhead is shown apart from an arrow shaft. Firstly, hunting broadhead 10 is made up of two elongated flat metal blades, namely first blade 12 and second blade 14, the blades so oriented that they lay or are juxtaposed one upon another with the back sides of the blades touching each other.
Blades 12 and 14 are situated within an elongated slot (not shown) formed in solid cylindrical body 16 so that they will, at the proper time, rotate about pivot pin 18 attached to cylindrical body 16 and pass transversely across its slot. However, the two blades are secured together in a closed position by an elastic or rubber band 20 (or they may be tied together with string), band 20 urging each of the blades' first stop (36 and 44) located at the rear or bottom of each of the blades against cylindrical body 16 whereby rotation in the direction normally urged by the rubber band upon each blade is terminated. As shown in FIG. 1, the blades overlap, but not completely, in that, by judicious recession of a substantial portion of the length of each blade's sharpened edge behind the opposite blade's partially chamferred or beveled edge, great safety benefits are provided. Other benefits provided are discussed later.
Also as seen in FIG.1, cylindrical body 16 is terminated in threaded shaft 17 adapted to be engaged by the threaded female opening of an arrow shaft (not shown).
Elongated first blade 12, which front or top face is shown, comprises a thin flat piece of high quality steel, preferably having a thickness of about 0.050 inch, an overall length of approximately 21/2 inches, and a width of approximately 1 inch (including the protruding spur). Blade 12 has the top flat face of its right hand side (first side) peripheral edge 22 ground off to form a razor sharp edge which traverses substantially the length of the blade. All sharpened edges are preferably formed this way. In the preferred embodiment, peripheral edge 22 is slightly arcuate or concave along its length. Peripheral edge 22 could, however, be straight.
The top end of the blade 12 is terminated in a point 26 and the bottom end with foot 28. At the top, joining sharpened peripheral edge 22 point 26 is angled edge 19 which is blunted by partially chamfering or beveling. When an edge is partially chamferred, only a portion of the right angle corner of the edge is knocked off (by preferably grinding) so that the right angle edge is present for approximately 15% of the blade thickness. Blunting of an edge may also be accomplished by rounding the edge.
At the bottom, foot 28 is formed by a blade 12 making substantially a right angle at its joiner with sharpened edge 22. Foot terminates on its other side in first stop 36. Along the bottom peripheral edge of foot 28, the edge is highly sharpened as it was along sharpened edge 22.
Opposite peripheral edge 22 and an the left hand side (second side) of blade 12, starting at the top, angled edge 21 intersects with previously discussed angled edge 19 to form point 26. Angled edge 21 is also a blunted partially chamferred peripheral edge. Next, blunted partially chamferred or beveled peripheral edge 23 recedes rearward from a second location along a substantially straight angled line from angled edge 21 diverging from first side 22 approximately 60 percent of the length of the blade 12 to a first location where it joins outstanding spur 30. Outwardly protruding spur 30 also has a forward portion, partially chamferred edge 24. Residing at the first location, i.e., intersection of the second side partially chamferred edge 23 and forward peripheral edge 24 of spur 30, is rubber band 20.
Proceeding rearward, outwardly protruding spur 30 falls off along its rearward portion towards the first side along square cut peripheral edge 25, which constitutes second stop 25 later discussed. Continuing, second stop 25 next joins a semi-circular outwardly producing extension (covered by cylindrical body 16) which accommodates an opening receiving pivot pin 18. After the semi-circular protrusion, the left hand edge joins first stop 36 shown resting against the cylindrical side of body 16. First stop 36 holds first blade 12 in the forward position in FIG. 1 as rubber band 20 urges first blade 12 and second blade 14 together. The first stop of each blade engage opposite sides of cylindrical body 16.
Shown beneath first blade 12 is second blade 14, the unmodified flat back or underside of blade 14 visible. Second blade 14 is a duplicate of first blade, being only reversed in position in cylindrical body 16 so that neither its sharpened peripheral edges nor partially chamferred edges may be seem in FIG. 1. The back side of partially chamferred second side peripheral edge 50 and a portion of sharpened peripheral edge 48 are shown.
Further, second blade 14 second side outwardly protruding spur 40 is detailed, the bottom or back side of its forward partially chamferred peripheral edge 52 shown. The bottom of second blade 14 first side's arcuate sharpened edge 48 is revealed emerging from below the straight partially chamferred edge 23 and spur 30 of first blade 12. Also seen in the back side of sharpened foot 42 and first stop 44. Again, in the position shown, first stop 44 of second blade 14 is urged against the side of cylindrical body 16.
The most forward point 46 (not shown) of second blade lies immediately beneath and is aligned with point 26 of first blade 12 and, like point 26 of first blade 12, is formed by the intersection of two partially chamferred edges. By reducing the sharpness of points 26 and 46 with partially chamferred edges, the safety features of the subject invention have been additionally enhanced as the point of broadhead 10 will be less likely to stick the person handling it. Nevertheless, points 26 and 46 are still sufficiently sharp that they will easily puncture the hide of the struck animal when delivered by the hunter's bow.
With rubber band 20 at the base of partially chamferred peripheral edge 23 of the second side of the first blade 12 at the same place on the second side of second blade 14, the two blades are held together with their first stops engaging cylindrical body 16 to place the blades in the forward pointed position with their respective front points overlapping.
In the forward approximately three-quarters of the length of broadhead 10, the sharpened edge of each blade is protected by being recessed back from a partially chamferred edge of the opposite blade. For example, right sharpened peripheral edge 22 of first blade 12 is recessed behind the partially chamferred edge 50 of second blade 14 from its joinder with angled edge 19 near point 26 to its emergence from behind second stop 45 below outstanding spur 40. It is also important to keep this sharpened blade protected until after it has entered the body of the animal since the hide of the animal or rib bones (or for that matter, dirt on the animal's hide) will dull the sharpened edge.
Similarly, sharpened edge 48 second blade 14 is similarly recessed away from the partially chamferred edge 23 of first blade 12. By such means, the hunter can handle the subject broadhead in the forward three-quarters of the broadhead without danger of cutting himself. Typically, sharpened blades utilized in broadheads are razor sharp.
Rubber band 20 then may be slipped over the blunted partially chamferred edges of the second sides of each of the overlapping blades to position itself at the base of the two partially chamferred forward edges 24 and 52 of spurs 30 and 40 without danger of being severed.
While a rubber od elastic band has been suggested to secure the two blades together, other means have also been used. For example, I have applied an adhesive between the two blades at or near the first end. Also, it is possible to place a dimple or detent in the blades at or near the first end whereupon a concave dimple of one blade would reside in a convex dimple of the other. Of course, the blades with detents would not be interchangeable and separate blades with detents in opposite directions would need be fashioned. In addition, not shown, but it is apparent that a spring clip may be fashioned which would secure the lower rear end portions of both blades in the closed position.
The configuration of broadhead 10 shown in FIG. 1 is the configuration of the blades during storage, during time of flight between the hunter's bow and the game animal, and during the initial penetration of the game animal. When penetrating the game animal, the two blades continue to stay together until the broadhead has penetrated to a depth such that the hide of the animal engages the forward partially chamferred peripheral edges 24 and 54 of the spurs 30 and 40 respectively. On most occasions, the animal will be struck in the rib cage area and the ribs immediately beneath the animal's hide will be engaged by the spurs. At that time, each blade begins to rotate about pivot pin 18 to begin opening of the two blades as shown in FIGS. 2 and 3.
As previously indicated, in my prior application, I depended upon friction between the backsides of the blades caused by carefully sizing the width of the elongated slot in the cylindrical body to tightly compress the blades to keep the blades in the closed position during storage, flight of the hunting point, and initial penetration of the animal. Also, during first few inches of penetration of the animal, the forward point of each blade was so shaped that pressing of the flesh and internal organs against the left hand angled edge which substantially made up the point, together with a slightly less angled left hand portion of each blade extending from near the point to the rear spur, continually urged the first stop of each blade against the cylindrical body and thereby kept the blades together.
This is not to say that a frictional relationship between the two blades to keep them together can not be utilized in my present invention, because it could. Such an embodiment would be obtained by carefully sizing the width of the slot in the cylindrical body.
In the embodiment of the subject invention, I no longer depend upon a frictional relationship between the blades or a left front angled side retreating from the point together to keep the blades together. Now I utilize a rubber band and a long extending angled straight left side to accomplish that feat. The angled sides situated immediately on each side of the point of the blade are almost symmetrical, although the left hand side is still slightly favored. Further, by my new design, the forward 60% or so of the blades have a thinner width for easier penetration.
In the process of modifying my original design, I have greatly enhanced the safety features to remove the sharpened edges away from the hunter's fingers well over three-quarters of the length of the broadhead as well as protecting the sharpened edges from dulling at all times prior to actual presence in the body cavity of the animal.
Referring now to FIG. 2, a top view of broadhead 10 is shown in a partially open configuration such as the broadhead might encounter just as its spurs have engaged the hide or ribs of a game animal and started rotation of each of the blades. Note that the rubber band is now being stretched as the blades open, the hitting force of the spurs against the hide or ribs of the game animal being sufficient to overcome the resistance of the rubber band holding the blades together. At this point, the forward portion of each of the blades is interiorly the body of the game animal and the hide or ribs of the animal are still restraining spurs 30 and 40 respectively. One additional advantage of having the forward edges of each of the spurs not razor sharp is that any tendency on the part of the blades to slice through the hide or the ribs and not open the blades is considerably lessened. At this point in time, the sharpened peripheral edges 22 and 48 of blades 12 and 14 respectively have begun to engage and cut the interior body of the animal between the two blades, which also helps to spread the blades. Additionally, animal flesh pressing against rubber band 20 may at this time cause it to be severed across partially chamferred edges 24 and/or 52.
A more revealing picture of the back or underside of second blade 14 is seen in FIG. 2, this side showing the flatness of the blade and the lack of sharpened or partially chamferred edges. It is of course realized that the peripheral sharpened edges 22 and 48 could be formed by taking equal amounts of metal off both sides of the blade to achieve a razor sharp edge, however, for economy of manufacture, to construct the sharpened edge, only one side has metal removed. Also, if the blades are sharpened to a central "V", then opportunity is afforded for hair and hide to wedge between the flat surfaces of the blade. Similarly, the partially chamferred or beveled edges 23 and 50 (and others) might also be constructed by partially chamferring both the top and the bottom face to leave a flat ridge between the two chamfers (rather than a sharp cutting edge), however again, for economy of manufacture and to prevent material from being wedged between flat sides of the blades during penetration, metal was removed from only one side of the blade to achieve the partial chamfer or bevel.
As previously mentioned, alternate embodiments of the invention may include other means to keep the blades together, such as adhesive 60 shown at the first end of second blade 14. The adhesive used by the inventor was a silicone sealant. This adhesive was sufficiently strong enough to keep the blades together in flight, in penetration and initial movement into the animal, yet did not prevent the blades from separating when the spurs struck the animal's hide. The adhesive was applied by placing a small amount upon one blade end and then moving the blades together to allow it to adhere to both blades. Then the adhesive was allowed to harden. Excess adhesive which might ooze out between the blades was wiped off.
Also seen in FIG. 2 is a second embodiment, namely the dimple or detent 62 placed into each blade. On the second blade 14, the dimple is concave. First blade 12 has a convex shaped dimple or detent (not shown) which is so aligned as to mate with dimple 62 when the blades are in the fully closed position. The interlocking dimple or detent arrangement similarly provides sufficient holding to keep the blades together until time for the blades to pivot apart.
Also seen in FIG. 2, first stop 36 of first blade 12 and first stop 44 of second blade 14 have now left their position abutting the circular sides of cylindrical body 16.
FIG. 3 shows broadhead 10 in its fully open position, that position assumed by blades 12 and 14 where both foots 28 and 42 (formerly at the bottom of each blade) now overlap with overlapping points formed from the intersection of elongated sharpened edges 22 and 48 with sharpened foots 28 and 42 respectively. Elongated cutting edges 22 and 48 of blades 12 and 14 now are in full array to humanely kill the animal. Each of the blades have rotated from their position shown in FIG. 2 until each of their respective second stops engaged the circular sides of cylindrical body 16. More particularly, second stop 25 of blade 12 and second stop 45 of blade 14 each fully engage cylindrical body 16 which keep the blades in position shown in FIG. 3 throughout the broadhead's travel interiorly of the animal.
It is noted at this point that rubber band 20 has now slipped from its position (if not severed) at the base of partially chamferred sides 23 and 50 of respective blades 12 and 14 along partially chamferred leading edges 24 and 45 of respective spurs 30 and 40. Even with rubber band 20 coming off, if it has not been severed and if desired, it may be retrieved and reused. It will remain upon the shaft of the arrow (not shown) when it comes off. The alternate means of holding the blades together prior to their opening are also shown, namely first alternate, a small amount of adhesive 60 and second alternate, a dimple or detent 62.
FIG. 4 is a side view of solid cylindrical body 16 in which the two blades 12 and 14 reside. Firstly, cylindrical body 16 has a chamferred or beveled top conical surface 15 formed at its front so as to prevent undue opposition to its passage in the animal's interior. Cut parallel to the cylindrical axis of body 16 is elongated slot 33 in which resides the semi-circular protrusion of each of the two blades 12 and 14. These semi-circular protrusions are shown in FIGS. 6.A. and 6.B. infra. Shown also passing through cylindrical body 16 and at right angles to slot 33 is opening 35, opening 35 adapted to accommodate pivot pin 18 shown in FIG. 5 to secure the pivot pin across the slot. Since it is intended that pivot pin 18 shall frictionally reside in opening 35, the diameter of opening 35 should by only slightly less than the diameter of pivot pin 18 so that the pin may be driven in. Lastly, shaft of arrow 60 is shown attaching to the lower portion of cylindrical body 16, arrow shaft 60 having female threads formed in a blind cavity therein which mate with the male threads shown on the lower portion of cylindrical body 16 in FIGS. 1-3. Of course, other provision may be made for attaching the body 16 to an arrow shaft.
It is noted that in the subject invention, the width of slot 33 need not be tightly controlled as it was in my prior invention, subject of the above referenced patent application, since I no longer depend upon friction between the blades to keep the two blades together. Previously, the width of slot 33 was carefully cut to ensure that the two blades rubber each other sufficient friction therebetween that they would stay together during storage, flight, and initial penetration of the animal. Since I now depend upon a rubber band to keep the blades together, the width of slot 33 is no longer critical and the blades can fit more loosely therein.
FIG. 5 is a side view of elongated, cylindrical pivot pin 18 which passes through the opening in each of the blades and is secured within opening 35 of cylindrical body 16.
Referring now to FIG. 6.A. and 6.B., a top or front view of each of the blades 12 and 14 is shown. As can be seen, each were constructed identical to the other to simplify manufacture. When mounted in the cylindrical body, they are placed with their flat uninterrupted back sides together.
Commencing with FIG. 6a, at the very top is point 26 which is almost equally divided between angled sides 21 and 19 although in the preferred embodiment, left angled side 21 is slightly longer than right angled side 19. Both sides 21 and 19 have blunted partially chamferred edges so as not to present a sharp cutting edge. Point 26, however, is an angled point which has not been blunted as a point as it is formed by the two sides 21 and 19. Along the elongated right-hand or first side of blade 12, elongated peripheral edge 22 is sharpened from a second location at its joinder with angled side 19 wherein metal has been removed along the surface at the edge to meet the backside of blade 12 and achieve a razor sharp edge. Sharpened edge 22 is in the preferred embodiment slightly arcuate along its length, but may be straight providing it does not extend beyond the partially chamferred edge of the opposite blade when the unit is assembled and the blades fully overlapping. At the bottom end of blade 12 is sharpened foot edge 28, the angle made between the two sharpened edges 22 and 28 which became the front point in the configuration of FIG. 3, being just slightly less than a right angle.
On the opposite left hand or second side of blade 12 in FIG. 6.A. is blunted partially chamferred edge 23 which commences at the top second location connecting with left angled edge 21 and falls back in an angled substantially straight line diverging from the first side 22 to meet with spur at a first location. Along the forward peripheral edge of spur 30 is blunted partially chamferred edge 24, edge 24 at an acute angle to a longitudinal line drawn between point 26 and the center of opening 32. The angle of spur 30 to the longitudinal line referred to is shown at about 70 degrees. It may however be varied between 45 degrees and 90 degrees. Outwardly protruding spur 30 then falls off downwardly with second stop 25 angled towards sharpened edge 22, second stop 25 terminating at semi-circular protrusion 34, protrusion 34 having circular opening 32 formed in it. Opening 32, as earlier eluded to, receives pivot pin 18 shown in FIGS. 1-3 and 5 rotatably secure blade 12 to cylindrical body 16. Opening 32 is just slightly greater in diameter than pivot pin 18 so that while the blade will rotate easily, there is not excessive side-to-side movement.
Lastly, semi-circular protrusion 34 joins with first stop 36, stop 36 defining one side of sharpened foot 28. Both first stop 36 and second stop 25 provides limits to the rotation of blade 12 within cylindrical body 16, first stop 36 serving to define broadhead 10 in a position with penetrating point 26 forward of cylindrical body 16 for partial penetration of the animal and second stop 25 serving to define the position of broadhead 10 in its fully widened inverted "V" configuration cutting position.
FIG. 6.B. is a top view of second blade 14 (turned over from the view seen in FIGS. 1-3) to reveal its top or front side. It has forward most point 46 formed in part by right hand or first side angled edge 47 joining with the first side elongated sharpened peripheral edge 48 which continues in a sweep to sharpened peripheral foot 42 at the bottom of blade 14. Like blade 12, left angled side 43 and right angled side 47 define point 46 and are blunted partially chamferred edges. Sharpened edge 48 is also slightly arcuate (or it could be straight under circumstances outlined above) and the angle it make with foot sharpened edge 42 is approximately 90 degrees. On the opposite or second side of blade 14 in its upper part is angled left hand edge 50, edge 50 falling substantially straight from left angled edge 43 to the forward peripheral edge 52 of protruding spur 40. Rearward of spur 40 is second stop 45 which falls off towards the first side edge 48 to join with semi-circular outwardly extending protrusion 66 encompassing circular opening 68, opening 68 adapted to accommodate pivot pin 18 when blade 14 is situated in slot 33 of cylindrical body 16. Lastly, semi-circular protrusion 66 then joins with first stop 44 immediately below, first stop 44 then forming one side of sharpened foot 42. Again, as was the case with identical blade 12, if a longitudinal line were to be drawn from point 46 through the center of opening 68, forward peripheral edge 52 of spur 40 would make an angle of approximately 70 degrees.
Lastly, referring now to FIG. 7, a sectional view taken through the upper portions of blades 12 and 14 of FIG. 1 is shown. Here, the overlapping of the blades is more clearly seen to show the safety factor which has been built into the invention, namely that the sharpened edges are protected from coming in contact with the hunter's fingers when the broadhead is in the closed position, and that the blade is protected from dulling by recessing the sharpened edge behind the partially chamferred edge of the opposite blade. In FIG. 7, blade 12 is shown with its sharpened edge 22 recessed behind the partially chamferred edge 50 of blade 14. Similarly, sharpened edge 48 of blade 14 is recessed behind partially chamferred edge 23 of blade 12. In the preferred embodiment, the following are representative of the angles the surfaces make, for example, sharpened edges (22 and 48) are 30 degree angles and partially chamferred edges (23 and 50) are 45 degree angles, both angled relative to the flat top of bottom of the blades. As indicated earlier, the partially chamferred edge constitutes about 85% of the thickness of the blade and the right angle cut portion occupies about 15% of the thickness of the blade. This, of course, may be varied. In this configuration, so long as the blades are in the closed position shown in FIG. 1, the hunter may grab the tip of the broadhead without concern of being cut. Also, rubber band 20 may be pushed down over the two blades shown in FIG. 1 without being cut as it slides over the partially chamferred edges.
While a preferred embodiment of the invention has been shown and described, it is appreciated that other embodiments of the invention are possible and that there is no intent to limit the invention by such disclosure, but rather, it is intended to cover all modifications and alternate embodiments falling within the spirit and scope of the invention as defined in the appended claims. | A hunting broadhead for attachment to an arrow used in bow hunting of a game animal having two thin flat metal elongated blades juxtaposed each other pivotally secured in a slot situated in a rearwardly located tubular body. Each blade has a pointed first end adapted to precede the arrow in flight for penetration of the animal's hide and initial movement into the animal. Each blade has one sharpened lengthwise side and one blunted side with the outstanding spur, the blunted sides extending outwardly of the sharpened sides when the pointed front ends overlap permitting an elastic band to encompass both said blades to maintain such configuration for flight and initial penetration of the animal. After penetration into the game animal, rearwardly located outwardly protruding spurs engage the animal's hide causing a metamorphosis whereupon the blades rotate with the rear moving to the front to become the forward leading point. After rotation, the sharpened blades become the leading members of the wide "V" configuration for continued movement through the animal to effect a clean kill. | 5 |
FIELD OF THE INVENTION
The invention relates to a gate for a sliding window or door.
BACKGROUND OF THE INVENTION
Sliding windows are common in typical residential and commercial buildings. Generally, the windows comprise a window frame and a plurality of sliding windows situated therein. Typically the sliding windows are frictionally held within the frame in tracks. Each window can be slid along the track to various positions relative to the frame. As such, the window elements collectively can be arranged to fully close an area of the window frame or to open an area within the frame, thereby allowing air to move between the outside and inside of the building.
When the window is open, many things can pass through the open area, including burglars, children, adults, pets and other objects. In high-rise apartment buildings there is always the potential danger of a child (or adult) falling through an open window.
Previously, barriers have been installed around window frames to inhibit things passing through window openings. Gates can be installed around the window frame; however such frames span the entire window frame and thus block the view outside through closed parts of the window. Examples of such gates are described in Canadian Patents 2,003,533 and 1,144,428.
There remains a need for a window gate which addresses the shortcomings of the prior art.
SUMMARY OF THE INVENTION
The present invention provides a gate for a window frame having windows. The invention comprises first and second gate elements. The first gate element is attachable at its far end to the frame and the second gate element is attachable at its far end to one of the windows. The gate elements are coupled together to allow the gate elements to slide along each other and to provide a barrier in a space created between the window and the window frame when the sliding window is in an open position.
It is a further aspect of the invention to provide a gate comprising first and second gate elements, with each gate element having a substantially U-shape configuration comprising arms attached to a base. The first gate element can be attached at its open end to the frame and the second gate element can be attached at its open end to the sliding window. The first and second gate elements are coupled together allowing the gate elements to slide along each other and providing a barrier in the space created between said window and said window frame.
It is a further aspect of the invention to provide a gate comprising a plurality of substantially rectangular-shaped gate elements. The gate elements are oriented adjacent to one another in a side-by-side arrangement. Each gate element is pivotally attached along its adjacent edge to the adjacent edge of the adjacent gate element. The exterior ends of the gate can be pivotally attached to the frame and the sliding window.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are shown in the drawings, wherein:
FIG. 1 . is a diagram of a typical sliding window;
FIG. 2 is a diagram of a gate embodying the invention;
FIG. 2 a is a diagram of another gate bodying the invention;
FIG. 2 b is a diagram of another gate embodying the invention;
FIG. 3 is a diagram of the invention installed in an open sliding window;
FIG. 4 is a diagram of the invention installed in a closed sliding window;
FIG. 5 is a diagram of the invention installed in a horizontal sliding window;
FIG. 6 is a diagram of another embodiment of the invention; and
FIG. 7 is a diagram of another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides an inexpensive, easily manufactured, assembled and installed window gate to provide a barrier for window openings.
The various figures show aspects of the invention alone and installed in a window frame. For clarity, same reference numbers are used to identify same items throughout the figures where appropriate.
As seen in FIG. 1, vertical window unit 1 comprises window frame 2 and windows 3 and 3 a . Each window 3 , 3 a slidably moves vertically along the inside of the frame. Opening 4 is created when windows 3 and 3 a are positioned in the frame as shown. Window units are available which allow vertical or horizontal movement its windows.
FIG. 2 shows a gate incorporating the invention uninstalled in a window frame. Gate 5 comprises a generally U-shaped first gate element 6 and a generally U-shaped second gate element 7 . The first gate element generally comprises a plurality of parallel arms 11 a transversely attached to an end 12 . The second gate element generally comprises a plurality of parallel arms 11 b transversely attached to an end 12 . The gate elements can be made from various metals, plastics or wood. It can be appreciated that the gate elements may be formed from a single piece of material suitably shaped or, alternatively, by assembling several separate pieces including arms, bases and joints. Coupling elements 10 couple arms 11 a and 11 b together. In a preferred embodiment of the invention, the coupling elements are circular rings attached to one of the arms through which the other arm slides. It can be appreciated that other coupling elements, such as tubes or the like, may be used. With this coupling arrangement, gate elements 6 and 7 can be slidably moved towards and away from each other. At distal ends 9 of the arms, loops provide means to facilitate fastening the gate elements to appropriate locations on windows using screws, nails or other fasteners. It can be appreciated that other loop-like designs accomplish the same functionality. Hooks 18 may also be used which may be fastened appropriately to a window or window frame.
FIG. 2 a shows another gate incorporating the invention uninstalled in a window. Gate 5 a comprises a generally rectangular first gate element 6 a and a generally rectangular second gate element 7 a . The first gate element generally comprises a plurality of arms 11 a attached to an end 12 a . End 12 b transversely joins members 11 a at a spaced distance from end 12 a . The second gate element generally comprises a plurality of arms lib attached to an end 12 a . Similarly, end 12 b transversely joins members 11 b at a spaced distance from end 12 a . It can be appreciated that the gate elements may be formed from a single piece of material suitably shaped or, alternatively, by assembling several separate pieces including arms, bases and joints. Coupling elements 10 couple arms 11 a and 11 b together. Fastening hook 18 is shown in place in loop 9 .
FIG. 2 b shows another gate incorporating the invention uninstalled in a window. Gate 5 b comprises a generally rectangular first gate element 6 b for attachment to a slidable window and a generally rectangular second gate element 7 b for attachment to the window frame. The first gate element 6 b generally comprises an open rectangle comprised of arms 11 c attached to an end 12 c . End 12 d transversely joins members 11 a at a spaced distance from end 12 c . The second gate element generally comprises a plurality of arms 11 d attached to an end 12 c . Similarly, end 12 d transversely joins members 11 d at a spaced distance from end 12 c . It can be appreciated that the gate elements may be formed from a single piece of material suitably shaped or, alternatively, by assembling several separate pieces including arms, bases and joints. Coupling elements 10 couple arms 11 c and 11 d together. Fastening tabs 18 are shown slidably engaged with ends 12 b for attachment of the gate to a window.
FIG. 3 shows the invention installed and operating on a partially open window. There, gate 5 is attached to frame 2 and window 3 a . At distal ends 9 of arms 11 a , the first gate element is attached to the side of the window frame adjacent to opening 4 . At distal ends 8 of arms 11 b , the second gate element is attached to the distal end of window 3 a . Screws 15 , bolts or other suitable fasteners may be used to attach the distal ends of the gate elements to the window frame and window. Coupling elements 10 couple arms 11 a and 11 b of each gate element together, while allowing the gate elements to slide along each other.
It can be appreciated that with the window gate installed, open area 4 is effectively blocked by gate 5 . A child, adult or sufficiently large object cannot easily pass through opening 4 . At the same time, upper portion 19 of window 3 remains unblocked by gate 5 , thereby allowing an unobstructed view therethrough.
FIG. 4 shows the invention installed and positioned in a closed window. Gate 5 covers the area around window 3 a , but not window 3 . This provides an unobstructed view through window 3 .
FIG. 5 shows the invention installed and positioned a closed horizontal window. The invention operates in the same relative manner as described for a vertical window. Gate 5 is attached to frame 2 and window 3 a . First gate element 6 is attached to frame 2 at distal ends 9 of arms 1 a . Second gate element 7 is attached to window 3 a at distal ends 10 of arms 11 b . Coupling elements 10 couple arms 11 a and 11 b of each gate element together. Again, there is an unobstructed view through window 3 .
FIG. 6 shows another preferred embodiment of the invention. For clarity, only window 3 a is shown. Here, first and second gate elements are generally rectangular in shape. At distal end 9 of first gate element 6 a it is pivotally attached to the side of the window frame adjacent to opening 4 . At distal end 8 of second gate element 7 a , it is pivotally attached to the proximal end of window 3 a to the opening. Hinges 14 , latches or other pivoting attachment arrangements can be used to pivotally attach the gate elements to their respective parts of the window. At the proximal ends 16 of each gate element, the gate elements are pivotally coupled with coupling elements 10 . Coupling elements can be coils. As such, gate 5 pivots between a closed position where the gate elements pivot outwardly away from the window frame to an open position where the gate elements pivot towards the window frame as window 3 a is opened. In this embodiment, it can be appreciated that when the window is fully closed, gate 5 is fully pivoted away from the frame and is not in view of the frame, thereby not obstructing the view through window 3 a . Spring 13 attaching the first and second gate elements biases together the two gate elements.
As shown in FIG. 7, the embodiment of the invention shown in FIG. 6 can be modified to utilize a plurality of gate elements 17 . These gate elements may be connected together at their edges to form an accordion-styled gate arrangement, with the exterior gate elements being connected to the window and the window frame respectively. When a plurality of gate elements are used, the size of each gate element may be reduced, thereby decreasing the distance which the folded portion of the window gate extends outwardly from the window frame when the window is not fully open. Generally, the number of gate elements must be an even number to ensure that the fastened ends of the exterior gate elements can be coincidentally near the window and the window frame.
It can be appreciated that other shapes and configurations for the first and second gate elements can be used which provide the essential functionality and novelty of the invention.
Referring to FIG. 3, it can be appreciated that the size of opening 4 may be restricted by varying the lengths of arms 11 a and 11 b . As window 3 a is opened, the first and second gate members extend from each other. When the travel of the first and second gates is fully extended, window 3 a cannot be opened further. As such, it is possible to install a gate having a total extension distance less than the full travel distance of window 3 a in frame 2 . This allows the installer to control the distance to which window 3 a can be opened.
It can be appreciated that the gate is a simple, elegant design, which is easily manufactured and installed and is inexpensive.
Although various preferred embodiments of the present invention have been described herein in detail, it can be appreciated that the present invention is not restricted to what is described above and shown in the drawings, but can be changed or modified in many different ways within the scope of the invention defined in the attached claims. | A gate for sliding windows or doors in a frame is provided. The gate provides two gate elements. The first element is attached to the window frame. The second element is attached to the sliding window. The two elements are coupled together to allow each element to slide across the other. The elements are positioned in the frame to create a barrier in a space created when a window is slid to an open position. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a workpiece guide for sewing machines.
This guide is of the type comprising: one or more superposed plates which are spaced apart and disposed substantially parallel to the work surface of the sewing machine and at right angles to the sewing axis, a vertical wall disposed between one plate and the work support surface and one or more vertical walls disposed between the plates.
In the case of the known guide, the plates may be stationary with respect to the sewing axis or they may be totally or partially displaceable with respect thereto by means of a translational or rotational movement, thereby facilitating insertion of the workpiece beneath the presser foot of the sewing machine and permitting the passage of thicker portions of the layers forming the workpiece resulting, for example, from the presence of pockets, belts, etc.
The object of the present invention is to obviate a common disadvantage of the guides comprising movable plates which are most widely used for matching two pieces of fabric which are to be joined together.
For displacement of the plates, the conventional guides are provided with openings within which the plates can be displaced. These openings form clearance slits or gaps between the movable plates and the stationary walls of the guide. It has been found that during the sewing operation some of the threads which protrude from the edges of the layers of fabric to be joined will enter into these slits or gaps so as to prevent said layers of fabric from sliding freely between the plates in the direction of the sewing elements. Such a condition will create undesirable bunching or crumpling of the fabric whereby one layer will be out of alignment with the other during the stitching operation.
To obviate the above-mentioned disadvantage, the technical problem which the present invention is intended to solve consists in providing a guide devoid of the so-called slits or gaps between the plates and the vertical walls in the zone in which edges of the layers are pressed against the vertical walls while still enabling the plates to be moved away from the sewing elements.
The object of the present invention is to ensure that the guide is automatically displaced when the sewing machine starts or stops.
The above-mentioned technical problem is solved and the above object attained by means of the guide according to the present invention which comprises a base plate integral with the guide disposed beneath the vertical wall and interposed between lower plates and the work surface; a stationary bedplate comprising a recess adapted to receive the base plate while enabling it to be displaced therein; means for displacing the entire guide with respect to the base plate on the right of the sewing axis so as to move it away from the sewing elements.
Other objects, features and advantages of the present invention will be made apparent in the course of the following detailed description of the guide according to the invention which is provided by way of non-limitative example only with reference to the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the guide in an inoperative position and spaced apart from the sewing elements of the sewing machine;
FIG. 2 is a plan view of the guide rotated into the work position;
FIG. 3 is a front view of the guide rotated into the work position;
FIG. 4 shows the pneumatic control circuit controlling the rotation of the guide.
DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 which shows a presser foot 1, a needle 2 and the advancement means 3 for a normal sewing machine (not shown).
A stationary guide 5 consisting of a vertical wall integral with the work surface 6 of the sewing machine and a movable guide 7 are disposed on the right of a sewing axis 4. The movable guide 7 is formed by an upper plate 8, a lower plate 9, and a base plate 10 which are arranged one above the other in the given order, spaced apart from one another and disposed parallel to the work surface.
The above-mentioned plates are integral with an end wall 11 such that vertical walls 12, 13 are defined between the plates.
The upper plate 8, the lower plate 9 and the vertical wall 12 together define a guide channel 14 for an upper layer of fabric and the lower plate 9, the base plate 10 and the vertical wall 13 define a guide channel 15 for a lower layer of fabric. The base plate 10 is received in a recess 16 in a bedplate 17 integral with the work surface 6 of the sewing machine. The recess 16 is defined by at least one curved wall that is shaped to mate with the outermost wall of base plate 10, as viewed in FIG. 1.
The bedplate 17 also comprises a bevel 18 designed to keep the lower layer of fabric slightly raised from the work surface so that it can be more easily slid and inserted into the guide channel 15.
The movable guide 7 comprises means 19 for rotating the entire guide with respect to the bedplate 17 about a vertical axis 20 passing through a point situated on the right of the sewing axis 4. The means 19 comprise a double-acting pneumatic cylinder 21, the body of which is hinged at 22 to the bedplate 17 and the stem 23 of which is hinged at 24 to the upper plate 8 in correspondence with the end wall 11 of the movable guide. The upper plate 8 comprises an arm 25, the free end of which is hinged at 26 on the bedplate 17.
Referring now to FIG. 4, the means for rotating the guide also includes a five-way direction control electrovalve 27 which is supplied by means of a compressed air line 28 and which, in turn, supplies one or other of the chambers of the cylinder 21 by means of two conduits 29 and 30, each of which is equipped with a volume regulator 31 and 32, respectively. The latter constitute means for regulating the rotational speed of the guide. Two other lines 33 and 34 branch off from the line 28. The two lines 33 and 34 are designed to supply power for starting and stopping the electric motor for driving the sewing machine and for raising the presser foot 1. More specifically, a three-way direction control electrovalve 35 which is adapted to supply a pneumatic control means (not shown) for controlling the clutch of the electric motor, is inserted in line 33 and an electrovalve 36 designed to supply a pneumatic cylinder (not shown) which is connected to the presser bar of the sewing machine for lowering or raising the presser foot 1, is inserted in line 34.
The exciting windings 37 and 38 of the electrovalves 27 and 35 are connected in parallel to an electric line 39 and are simultaneously excited by means of a control contact 40 disposed in series with both electrovalves. The contact 40 may be activated by a relay (not shown) which can be controlled manually or by means of a photocell. The two electrovalves 27 and 35 which are connected in such a way that they may be simultaneously closed or open, constitute means for synchronizing the rotation of the guide with the starting or stopping of the sewing machine. The exciting winding 41 of the electrovalve 36 is also connected in parallel to line 39 and is excited by means of a control contact 42 activatable by means of a relay (not shown) which may be controlled manually or by means of a manual control (knee operative).
The guide operates in the following manner: when the sewing machine is not in operation the presser foot is in the raised position and the guide is in the rotated position shown in FIG. 1 such that the operator can easily insert the workpiece beneath the presser foot of the sewing machine and can insert one of the layers forming the workpiece in guide channel 14 and the other layer in guide channel 15. In this position the electrovalve 27 sends compressed air into conduit 29 and thus keeps the piston stem 23 of the cylinder 21 in a fully retracted position. When the control contact 42 is actuated, the electrovalve 36 is excited and air is admitted to a pneumatic cylinder which controls the lowering of the presser foot 1. At this point the operator can actuate the control contact 40 in order to simultaneously excite the two electrovalves 27 and 35 and thus start the sewing machine and reverse the intake of compressed air from conduit 29 to conduit 30. This reversal causes the stem 23 to be extended from cylinder 21 and results in the guide being rotated about the axis 20 which is brought into the work position.
By virtue of the fact that the sewing machine is already in operation and has already begun to advance and sew the workpiece when the guide is rotated, it is necessary for the rate of rotation of the guide to be equal to or slightly less than the advancement rate so as to prevent crumpling of the workpiece. The volume regulators 31 and 32 are responsible for regulating the rate of rotation of the guide. Should it be necessary to displace the guide in the course of sewing to permit the passage of thicker portions of fabric, the operator must keep open a contact 43 which is normally closed and which is connected in series in the supply line to the winding 37, so as to produce excitation thereof and thus reverse the passage of compressed air from conduit 30 to conduit 29. When the sewing operation has been completed, the following operations are triggered by a control means comprising a photocell which determines when the sewn workpiece emerges from the presser foot: the control contacts 40 and 42 are opened and consequently there results the raising of the presser foot, the motor of the sewing machine is arrested and the guide is rotated into a position which is spaced apart from the sewing elements, thereby facilitating insertion of a fresh workpiece.
The position into which the guide is rotated may be such that the plates intersect the sewing axis, as shown in the embodiment according to FIG. 1, or it may be such that the plates are completely removed from the sewing axis. The first solution is employed when it is wished to ensure that the layers of the workpiece always remain in their respective guide channels -- even when the guide is being rotated. This is a particular advantage when sewing especially light fabrics, for example, linings.
As the guide channels do not possess any slits or gaps, it is not possible for any possible frayed portions on the edges of the fabric to become stuck in the proximity of the vertical walls 12 and 13, thus obstructing the sewing operation.
The only slit which is present is the one between the baseplate 10 and the bedplate 17 in correspondence with the recess 16. However, this slit is sufficiently far away from the zone where the frayed edges of fabric will be located during the sewing operation. | A workpiece guide for a sewing machine which comprises a guide made up of a pivotably mounted body having a plurality of integrally formed and outwardly extending plates that define vertical walls on the end adjacent the main body and means to rotate the entire guide about an axis located to the right of the sewing axis. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
This is a division of application Ser. No. 89,180 filed Oct. 29, 1979, now U.S. Pat. No. 4,392,633.
SUMMARY OF THE INVENTION
Various types of blowout preventers, including wireline blowout preventers has been known and are in use. For example, U.S. Pat. No. 2,839,263 is illustrative of a form of blowout preventer useable with wirelines or other elongate members to seal off therewith as various well operations are conducted. However, so far as known to applicant, seal arrangements used on the front of the rams in prior art preventers have been secured thereon in a manner so that when it becomes worn, substantial difficulty has been encountered in replacing the worn seal. Also, so far as known to applicant, no equalizing means has been provided within the preventer body to enable the pressure below the closed rams to be equalized with the pressure above the closed rams in the longitudinal bore of the preventer body which pressure equalization is desirable before opening the rams from their closed, sealably engaged position with an elongate member in the longitudinal bore.
The present invention provides a novel seal arrangement which may be easily positioned on the front of the blowout preventer rams during use, but which may be readily removed and replaced when it is necessary due to wear. The seal means are constructed and arranged so that they are self energizing to form a seal.
The present invention also contemplates the provision of equalizing valve means within the blowout preventer body to enable the pressure in the longitudinal bore beneath the rams to be equalized with the pressure in the longitudinal bore above the rams when desired, the equalizing valve including a needle valve and movable seat which is responsive to pressure to urge it into a tighter sealing engagement with the valve element on the seat thereof when it is desired to keep the valve closed. The seat is also rotatable so that it may rotate with the stem during opening and closing of the valve to thus reduce wear and galling of the valve seat and stem.
A further object is to provide a novel needle valve means wherein the valve seat is movable in relation to the valve body and in relation to the needle stem of the needle valve to reduce wear and galling between the valve seat and needle stem which seats on the valve seat.
A further object is to secure seal means to a blowout preventer ram end without the use of bolts. The securing means substantially completely eliminates the probability of its becoming loose during use and yet may be readily removed if desired when the ram is disconnected from the preventer.
Other objects and advantages of the present invention will become more apparent from a consideration of the following drawings and description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view, partly in section illustrating a form of a blowout preventer with features of the present invention;
FIG. 2 is a side sectional view partly in elevation illustrating the position of the rams when moved in the transverse bores to close off communication in the longitudinal bore and seal with an elongate member therein;
FIG. 3 is a sectional view illustrating further details of the equalizing valve means;
FIG. 4 is an exploded view illustrating one of the preventer rams and details of the removable seal arrangement;
FIG. 5 is a sectional view through the front end of a ram and the removable seal means in position therein; and
FIG. 6 is a sectional view on the line 6--6 of that portion of the seal means shown in exploded view in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Attention is first directed to FIG. 1 of the drawings wherein a blowout preventer body is illustrated generally by the numeral 10. The preventer body includes a longitudinal bore 12 with transverse bores 14 and 16 intersecting the longitudinal bore. The transverse bores 14 and 16 are closed at their outer ends by any suitable means such as that illustrated at 17 and 18 as shown in FIG. 2. Operating means referred to generally by the numeral 20 extend through each of the closure means 17 and 18 for operating or moving the preventer rams 21 and 22 within the transverse bores 14 and 16 to effect sealing with any suitable elongate member M extending in the longitudinal bore. When the rams 21, 22 are sealably engaged with a member M as shown in FIG. 2, communication is prevented between that portion of the longitudinal bore illustrated at 12a beneath the rams 21 and 22 and that portion of the longitudinal bore designated at 12b above the closed rams 21 and 22, as shown in FIG. 2 of the drawings.
The closure means 17 and 18 of the transverse bores 14 and 16 may assume any suitable form well known in the art, and in addition the operating means 20 may be either mechanical or hydraulic of any suitable form well known to those skilled in the art.
The invention is shown and described in detail with reference to its use in a wireline blowout preventer; however, such is intended only by way of example as the novel features of the invention may be incorporated in any type blowout preventer.
Attention is directed to FIG. 4 of the drawings wherein the details of the ram bodies is illustrated, one such ram body 22 being there shown. It can be appreciated that the construction of ram 21 is the same as that of ram 22 described herein in detail. The ram body 22 is a cylindrical member 24 which may be provided with any suitable arrangement such as that illustrated at 25 at its outer end for engagement with the operating means 20. The inner end 26 of each ram is provided with a longitudinal semicircular groove 27 to better enable the rams 21 and 22 to conform with the elongate member M, such as a wireline cable or the like and seal therewith when the rams 21, 22 are closed as shown in FIG. 2.
Groove means referred to generally by the numeral 30 is provided on each ram, such groove means 30 includes a portion extending diametrically across the front end 26 of each ram as illustrated at 31, another portion along each side of each ram 21 and 22 as illustrated at 32 and yet another portion which extends transversely and circumferentially over about half of each ram 21 and 22 between the side grooves 32 as illustrated at 33. Each ram 21 and 22 is provided with ram guides as illustrated generally at 35 of well known configuration which project beyond the front end 26 of each of the rams 21 and 22.
Openings or passages 36 and 37 extend through each ram 21, 22 adjacent the front end 26 and intersects the lower surface 31a of groove portion 31 extending across the front end of each of the rams 21 and 22 as shown in FIG. 4. Also, a bore 38 in each ram 21, 22 extends transversely of the openings or passages 36, 37 and intersects each of them a predetermined spaced distance from the lower surface 31a of the groove portion 31 as better seen in FIG. 5.
Seal means referred to at 40 in FIG. 2 are provided for each ram 21 and 22 for sealably engaging each ram 21, 22 with its respective transverse bore 14 and 16 which seal means also extends across the front end 26 of each of the rams 21 and 22 for sealably engaging with each other and with the elongate member or wireline M when the rams 21, 22 are closed as shown in FIG. 2 of the drawings.
More specifically, the seal means for the groove portion 31 of the groove 30 which extends diametrically across the front end 26 of each of the rams 21 and 22 is referred to generally by the numeral 45 in FIGS. 4 and 5 and includes an elastomer body 46 having the members 47, 48 embedded in the upper and lower surfaces thereof as shown in FIGS. 4 and 5. Preferably, the members 47 and 48 are substantially flat and they are of less extent than the extent of the elastomer body 46, as shown in the drawings. The seal 45 including the plates 47, 48 and the elastomer body 46 are of a size and conform to fit snugly within the groove 31 at the front end 26 at each of the rams 21, 22. It can be appreciated that the edge or side surfaces of the elastomer body 46 are suitably contoured to conform with the contour of the cylindrical ram and transverse bore within which the ram is received. Also, a semicircular groove 46a extends vertically the front of the body 46 for sealing with wireline or Member M. The plate members 47, 48 in the embodiment illustrated in the drawings, extend substantially all the way across the upper and lower surfaces of the elastomer body 46 and are provided with recesses 47a, 48a to match groove 46a as shown in FIGS. 4 and 5. The flat, plate like members 47 and 48 are each provided with recesses 50 and 51 which are spaced longitudinally along each plate 47 and 48 as illustrated, such recesses 50 and 51 being aligned with the openings or passages 36 and 37 through each ram 21 and 22 when the seal 45 is positioned in the groove portion 31 in the groove 30 as shown in FIG. 5 of the drawings.
Suitable means such as spherical means, or ball means 55 may then be slidably inserted through each of the openings 36 and 37 to seat in the recesses 50 and 51 as shown in FIG. 5 of the drawings and the pin 38a then slidably inserted in the transverse bore 38 beneath the balls 55 as shown in FIGS. 4 and 5. As previously noted, the transverse bore 31 is spaced from the surface 31a of the groove 31 and the balls 55 are of a diameter so that when the seal 45 is positioned in the groove 31, the balls 55 will project outwardly from the recesses 50 and 51 into the openings 36 and 37 and abut against the retaining pin 38a.
From the foregoing, it can be appreciated that the passages 36, 37 transverse bore 38, pin 38a, and balls 55 function as positioning means which when positioned in each ram body 21 and 22 and in the recesses 50 and 51 of the seal 45 retain the seal means 45 including the elastomer body 46 in position in the groove portion 31 of the groove 30 during use.
A molded seal member 60 illustrated in FIG. 4 includes side portions 61 for fitting within the groove portions 32 extending along each side of the rams 21, 22 and an arcuate portion 62 which connects the portions 61 as shown, the arcuate portion 62 fitting within the groove portion 33 extending between the side grooves 32. The arcuate portion 62 is provided with a lip 63 as more clearly illustrated in FIG. 6 of the drawings to effect a more positive seal during functioning of the device.
From the foregoing, it can be appreciated that should the front seal means 45 on either ram become worn over a period of time, it can be readily and easily removed by withdrawing either or both rams from the transverse bore in which they are received by removing caps or closures 17 and 18. The pin 38a is then removed from bore 38 whereupon the balls 55 are free to dislocate so that the seal 45 can be removed. If possible, it may be reused by turning it over since recesses 50 and 51 are also provided in the upper plate, but at any event it can be readily replaced if necessary. Similarly, the molded member 60 may be readily replaced should such replacement become necessary. In addition, it can be appreciated that the needle valve disclosed herein may have applications in other fields of use and provides a floating valve seat which is responsive to pressure in a passage to form a tighter seal with a needle valve member seated thereon and reduces wear by cutting action as the valve is opened.
The preventer of the present invention also includes an equalizing arrangement illustrated generally by the numeral 70 in FIGS. 1 and 3. The equalizing means 70 includes passage means 71 which includes lateral portions for communicating the portion 12a of bore 12 beneath the rams 21 and 22 with the portion 12b of bore 12 above the rams. A bonnet 72 is threadedly connected in the body 10 of the preventer as shown in FIGS. 1 and 3 of the drawings and is provided with a threaded longitudinal passage 73 therein. A needle valve 74 is provided with threads 75 adjacent one end for threadedly engaging the threaded portion 73 and includes the tapered, annular surface 76 at the other end thereof. A valve seat 77 is received in one of the lateral portions of the passage means 71 and the valve seat is provided with seal means 78 for sealing between the valve seat 77 and the lateral portion of the passage means in which it is received. The valve seat 77 includes an annular, tapered portion 79 shaped to receive the tapered, annular closure surface 76 on valve 74 and in addition includes the passage 80 extending longitudinally therethrough with the lateral passages 81 intersecting the longitudinal passage 80 as shown in FIG. 3. The needle valve 74 is sealed within the bonnet 72 by means of the seal 83, and the bonnet 72 is sealed with the preventer body by the seals 72a.
When it is desired to close off the needle valve 74, any suitable means such as an Allen screw or the like may be engaged with a recess (not shown) in the threaded end 75 of the needle valve 74 to move the stem inwardly and seat on the surface 79 as shown in FIG. 3. It can be appreciated that any pressure within the portion 12a of the bore 12 will act on seal means 78 tending to urge the valve seat 77 in tighter engagement with the annular, tapered closure surface 76 to effect a tighter seal.
When it is desired to equalize pressure between the portions 12a and 12b of the longitudinal passage 12, before opening rams 21, 22 the stem 74 may be unthreaded to move it off the surface 79. In this connection, the valve seat 77 is provided with an annular shoulder 77a which abuts, or will engage the end 72b of the bonnet 72 to prevent engagement of the seat 77 with the packing 83 and to enable the stem 74 to be backed away from the annular surface 79 to open passage 71 between portions 12a and 12b of bore 12.
The preventer body 10 in effect provides a valve body for the needle valve 74, While the needle valve arrangement has been described in its use in relation to a blowout preventer, it can be appreciated that such needle valve arrangement may be employed in any situation where a needle valve is used. It provides advantages over other needle valves heretofore used in that the floating seat arrangement tends to eliminate wear, galling and scoring which is encountered in prior art needle valve construction. The valve seat 77 in the valve body 10 is separate from the stem and is separate from the valve body, although sealably engaged with the latter. Thus, the seat 77 may move longitudinally and rotatably relative to the body 10 while still sealably engaging therewith. Also the seat 77 is free to rotate with the stem as the needle valve 74 is rotated during opening and closing of the valve to thus reduce wear and galling.
In the form of the needle valve 74 shown, the stem terminates within bonnet 72; however it may extend through the bonnet so that a conventional valve wheel or handle can be secured thereto for rotating the valve 74.
By incorporating the equalizing means within the preventer body, external plumbing and fittings which are presently employed to accomplish such function are eliminated.
It can be appreciated from the foregoing description that the positioning means which secures the seal means 45 in each ram is operative without requiring any torque. Where screws or bolts are used, care must be employed to use sufficient torque to retain the seal in position without interferring with its sealing function. Also, if the screw or bolt becomes loose during use, it may interfere with proper sealing of the rams or cause damage during use.
More specifically bolts inside of a blowout preventer have several disadvantages, the two prime being, first, there is no means to check for correct tightness, except by disassembly; second, vibrations or incorrect tightening at assembly can cause the bolts to loosen and fall out, which may either impair operation of the blowout preventer, or even drop parts into the well, impairing operation of other mechanisms. Once the positioning means of the present invention is assembled, it can't be disturbed until the rams are removed from the preventer body.
In the present invention all parts (rubber, balls and pin) are either fully in place or not at all, and do not depend upon the judgment of the installer as to correct tightness. Once the parts are in place, they cannot come out while assembled in the blowout preventer.
With the positioning means of the present invention, these problems are eliminated. The transverse bore 38 and the pin 38a is always within the confines of the transverse bores 14 and 16 and is thus never exposed so that the pin might fall in the longitudinal bore 121a, as is the case with a bolt as used in the prior art. The balls 55 and pin 38 are slidably received in position within the ram body, and when the preventer is removed from the transverse bore, the balls and pin may be readily removed.
Also, the lip 63 provides an arrangement so that the arcuate seal portion 62 is self energizing. For example, in prior art arrangements, force applied to the seal 45 is relied upon to expand the arcuate seal portion 62 into sealing engagement with the respective trannsverse bore. However, the lip 63 eliminates the necessity of relying upon such force to provide a seal as the lip 63 responds to pressure and self energizes to seal between the ram and transverse bore.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape, and materials as well as in the details of the illustrated construction may be made without departing from the spirit of the invention. | Ram bodies mounted in transverse bores of a blowout preventer body with a longitudinal bore therethrough are operable by operating means extending through closures on one end of the transverse bores to move the rams to close off fluid communication through the longitudinal bore in the body and to retract the rams from the longitudinal bore. Removable seal means are provided on each ram body to seal with the transverse bore in which each ram body is mounted. Removable seal means extend diametrically across the front of each ram for sealingly engaging an elongate member in the longitudinal bore when the rams are closed. The removable seal means is retained in position by non-torquing means during use but may be readily replaced when necessary. Self energizing seal means on the ram body sealingly engage the transverse bores.
Valve means is incorporated in the blowout preventer body to equalize pressure in the longitudinal bore above and below the closed rams when desired, which valve means is constructed and arranged to respond to pressure below the rams to remain closed until it is desired to open the valve means. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to flushing toilets; and, more particularly, to a lid actuated toilet flushing system.
2. Description of the Prior Art
Automatic flushing toilets are of course well known in the art. In the past, it has been suggested to modify such toilets to flush the same using movement of the toilet lid. This avoids the problem of someone sitting down on the toilet when the seat is up. However, most such prior art devices, as in U.S. Pat. Nos. 657,278; 1,083,815; 1,605,939; 1,919,700; 2,428,685; 3,590,397; and 4,573,223 all require that the toilet be modified to accomplish the effect desired. That is, Such systems are not readily adaptable to a preexisting toilet. There is a need for a toilet system wherein the toilet seat lid acts as the automatic flushing handle ensuring that the toilet seat will be put back down after use. Such a system should simply connect the lid of a preexisting toilet to the standard flushing system of the toilet to hold the flapper valve open and close the same regardless of the position of the lid.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a lid actuated toilet flushing system adaptable to a preexisting toilet.
It is a further object of this invention to provide such a system which completes the flushing cycle regardless of the position of the lid.
These and other objects are preferably accomplished by providing a pull chain coupled to both the conventional flapper valve of a preexisting toilet tank and the lid of the toilet. The lid must be moved from the up to the down position to flush the toilet and a ratchet mechanism is provided for completing flushing of the toilet even if the lid is left in the down position. The instant system can be utilized with side and front mounted flushing handled toilets.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front perspective view of a conventional toilet having the automatic flushing assembly of the invention assembled thereto;
FIG. 2 is a top plan view of the combination of FIG. 1, the lid of the tank being removed for convenience of illustration;
FIG. 3 is a top plan view of the lid attachment member alone of FIG.2;
FIG. 4 is a view taken along lines IV--IV of FIG. 3;
FIG. 5 is a vertical front view of the interior of housing 17, the front cover being omitted for convenience of illustration;
FIG. 6 is a view taken along lines VI--VI of FIG. 5 and including a portion of the wall of the tank and parts of assembly 15 interior of the tank;
FIG. 7 is a view of the opposite side of the pawl 32 alone of FIG. 5;
FIG. 8 is an exploded view of the tooth assembly alone of FIGS. 1 to 8;
FIG. 9 is a view taken along lines IX--IX of FIG. 8; and
FIG. 10A, B, C, D, E and F illustrate the movement of the various parts during the operation of the flushing assembly of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 of the drawing, a conventional toilet 10 is shown having a toilet bowl 11, a pivotally mounted toilet seat 12, closure lid 13 and toilet tank 14. As seen in FIG. 2, toilet tank 14 has a conventional flushing assembly 15 in the interior thereof with a conventional flushing flapper 16, and an overflow tube 15'. The normally present remaining parts have been omitted for convenience of illustration. Assembly 15 is of conventional type wherein a lever outside of tank 14 is actuated to open flapper 16 to flush the toilet 10, the flapper 16 returning to a non-flushing position upon release of the lever.
As is known in a conventionally activated toilet upon "flushing" the flapper is raised by hand action to relieve the suction, allowing the water level in the tank to recede (flush out). The next step upon release of the conventional handle is for the flapper to float with water downwardly to a reseat position. It will reseat and stay there as the water level rises in the tank after the hand action has ceased. In this invention the flapper acts in like manner, only being activated (raised) differently.
The foregoing has described a conventional flushing toilet and, other than as set forth hereinbelow in the environment of the invention, and said toilet forms no particular part of the invention and further discussion is deemed unnecessary.
However, it is to be understood that the automatic flushing assembly to be discussed herein can be quickly and easily adapted to any flushing toilet having a flushing tank ball valve or flapper as shown.
Thus, as seen in FIG. 1, a main housing 17 is mounted on the front exterior wall 18 of tank 14. However if the toilet has a side mounted flush handle location, housing 17 would mount at that side location. A chain 19 extends downwardly out of housing 17 through the bottom thereof and is coupled to a lid attachment member 20 (see also FIG. 3). This member 20 has a generally rectangular main body portion 21 with a tab or flange 22 on one side thereof. As seen in FIG. 4, flange 22 is stepped or angled as shown to provide a reduced size area 23 on one side of main body portion 21 for gluing or otherwise securing the member 20 to one edge of the underside of closure lid 13, as seen in FIG. 1 (the reduced area 23 being glued or otherwise secured to lid 13 so that flange 22 is on the outside of lid 13). A key hole slot 24 is provided through flange 22 for receiving one end of chain 19 therein, as seen in FIGS. 1 and 3. Chain 19 is a conventional ball chain having a plurality of spaced balls which are of a diameter to enter hole 25 in slot 24, the links between such balls entering elongated slot portion 26 to releasably retain chain 19 to lid 13.
As seen in FIG. 6, housing 17 includes a cover 27 and a base plate 29. Cover 27 has a plurality of conventional bosses, not seen, which snappingly engage the recesses 75 located around the perimeter of the forward extending lip 74 of base plate 29 that is disposed normal to wall 29', per FIG. 5. In FIG. 5 the cover 27 of housing 17 has been removed. Alternatively and less preferred, since the housing 17 includes a front cover 27 and a separate spaced base plate 29, fastening of cover 27 may be achieved by using apertured spacers between walls 28 and 29' at each corner to receive a nut and bolt assembly for securing the walls 28, 29' together.
Returning to FIG. 5 a generally triangularly shaped pawl 32 which acts as a flushing lever is pivotally mounted interiorly of housing 17 between walls 28 and 29'. Pawl 32 has a plurality of spaced interconnected cavities 33 (FIG. 7) at its pointed end 34 for receiving the ball links of one end of pull chain 19 therein as seen in FIG. 5. Pawl 32 may be held between walls 28, 29 by a threaded bolt threaded into an internally threaded shaft, or preferably by a built in shaft 36 as per FIG. 6, extending from wall 29'. Shaft 36 is smooth on its exterior so pawl 32 pivots thereon. As seen in FIG. 8, spring 40 curls about the hub 41 of pawl 32 and terminates in an end 39'. As seen in FIG. 5, an annular raised area 38 on base plate wall 29' elevates the pawl 32 above the base plate. At the area proximal to extension portion 38' there is a gap 43 between 38 and 38' in which is received end 39 of spring 40.
Spring 40 thus normally biases pawl tip 34 to the "up" position shown in FIG. 5.
As seen in FIG. 8, tooth 44 includes shaft portion 81 and an integral tooth 45. A cylindrical portion 46 extending above the level of tooth 45 and concentric with shaft 81 may be provided at the free end of tooth 44 and to be receivable in a round opening 47 (FIG. 6) provided in front wall 28. Tooth 45, as seen in FIG. 6, is thus pivotally mounted between front and back walls 28, 29'.
Shaft 81 extends through a mounting bolt 48 which has a molded-in washer head 49 adjacent a tapered square-shaped enlarged seating head 49'; furthermore which bolt 48 has a threaded shaft 50 which engages nut 57. As seen in FIG. 8, seating head 49' is disposed in an opening of and the front wall 18 of the conventional toilet tank 14. The preexisting hole 56 for the toilet's conventional flushing lever--now removed--can be used).
As heretofore mentioned and shown in FIG. 6, shaft 81 extends through the threaded shaft 50 of bolt 48. An internally threaded lock nut 57 is now threaded onto shaft 50, which compresses washer head 49 against recess 29", thereby providing a firm leak-proof assembly while permitting pivoting of tooth 45. In most instances, however, shaft 50 is above the water line.
As seen in FIG. 8, an elongated flushing rod 61 is provided having an elbow end 59 (FIG. 6) with integral key shaft 62 which is receivable in slotted area 64 of shaft 81. Key shaft 62 and reduced portion 63 and 58 thereon extends through a hole in the nut 52 to a mating slot 64 of shaft 81 of the tooth assembly 44 to thereby engage tooth 45. The key 52 engages the key slot 51 of shaft 81 to provide a locking attachment to the tooth assembly 44.
As seen in FIG. 9, the terminal end 58 of shaft 81 is recessed with slotted area 64 to receive therein key shaft 62 in its entirety including the reduced portion 63 and end 58 abuts shoulder 58' of flushing rod 61 when assembled (see FIG. 6).
A return spring 82 seen in FIG. 5, but omitted in FIG. 6 is provided having a midportion 83 coiled about a shaft 60 extending from a boss 65 (see FIG. 6). Shaft 60 is lesser in outer diameter, per FIG. 6 than the outer diameter of boss 65 and boss 65 may be secured or otherwise integral with wall 29'. Shaft 64 may also be secured to wall 28 if desired. One end of return spring 82 has a leg portion 66 (FIG. 5) receivable in a hole 67 in wall 29. The other end 68 is generally U-shaped and abuts or bears against tooth 45 as seen. Spring 82 normally biases tooth 45 almost horizontally as seen in FIG. 5.
Obviously, various modifications may occur to an artisan. For example if tooth 45 which acts as a trip lever were removable from shaft 81, then shaft 81 and flushing rod 61 could be made as one piece. As seen in FIGS. 5 and 8, a plurality of spaced apertures 69 may be provided along rod 61 with a hook 70 receivable in one of the apertures 69 and having a chain 71 coupled to flapper 16 connected thereto.
A retrofit of the flushing mechanism of this invention to a conventional toilet may be accomplished by removing the plastic or chrome flushing lever on the exterior of the tank and by coupling the flushing rod 61 to the main housing as shown in FIG. 6.
OPERATION
In order to best understand the operation of the flush assembly of this invention, reference should now be made to both FIG. 5 and to the series of FIGS. 10A through 10F. However prior to discussing the technical aspects of toilet flushing according to this invention, a brief discussion on the use of a toilet bearing this invention is in order.
As has been mentioned previously, the flushing of the toilet according to this invention takes place, when the lid is moved from the up or vertical position to a down or horizontal position. The locus of the toilet seat has no bearing on the operation of this invention. Therefore if one assumes that for best etiquette, the seat is down and the lid is down, then the toilet is not useable and as such the cycle is ready to commence. Thus when little Johnny desires to urinate, he raises the lid and the seat and does his business. The raising of the lid to the open position, relaxes the pull chain 19, allowing the pawl spring 40 to push the pawl 32 i.e the flushing lever to the start position. See FIG. 10A. After Johnny is done, he lowers the toilet seat; and then lowers the lid. This closing of the lid 13, i.e. moving it from the FIG. 1 locus to the FIG. 2 locus, puts a pulling force on the pull chain 19 thereby forcing the pawl 32 to rotate the tooth 45, which fact lifts connecting rod 61 to open the flapper 16, to thus flush the toilet. Now let us go through the procedure in "slow motion" with reference to the figures previously noted.
During the period prior to any flush, the flapper 16 is in the down or at rest position. Little Jane raises the toilet lid 13 to do her thing. The pawl 32 in housing 17 is now in the start position as shown in both FIG. 5 and in FIG. 10A. When she is done, she commences lowering of the toilet lid 13 to the FIG. 2 locus. The chain 19, which is coupled to lid 13 via member 20, pulls the spring biased pawl 32 downwardly as per FIG. 10B. The end 34 of pawl 32 strikes the pointed end 72 of tooth 45, to then move said tooth downwardly about 30 degrees.
While this is happening, the connecting rod 61 leaves its first position and rises about 30 degrees to a second position, and in doing so lifts the flapper 16 which flushes the toilet in conventional style. The flapper 16 then drops back into place and the connecting rod 61 also starts to drop back down 30 degrees to its original first position.
Prior to FIG. 10C, the pawl 32 continues to move down past position on FIG. 10B,--witness the lower directional arrow of FIG. 10B--, and when the pawl is positioned below the tooth 45, the tooth returns to the start position as shown in FIG. 10C, where the pawl is shown to be below the tooth 45. However, due to the bias of the spring 40 the pawl 32 will rise if the tension on the chain is eased. The presence of tooth spring 82 stops the counter rotation of the tooth, and rod 61 reaches its first position, also shown in FIG. 10C. The lid 13 is now fully down.
In FIG. 10D, one sees that the pawl 32 in its upward travel, impacts upon the tooth 45 to push the tooth upwardly. Note the location of rod 61. The action continues in FIG. 10E, where the tooth moves upwardly about 10 degrees after impact with the pawl. The tooth spring 82 then compresses; and the pawl still travelling passes by the tooth 45. Once the pawl is past the tooth, the tooth spring 82 relaxes and returns the tooth to its normal position per FIG. 10F. Rod 61 moved slightly downward in reaction to the impact on the tooth 45 by the pawl, per FIG. 10E, but returned to its at rest position as seen in FIG. 10F. The cycle is now over, ready to begin again when and as the lid is raised for the next male or female user of the facility.
The foregoing has described a quick and inexpensive system for flushing a toilet in a manner ensuring that the toilet seat will be put back down after use. The lid operates to flush the toilet in a manner preventing continual flushing even though the lid is in the down position. Any suitable materials, such as plastics, metals, etc. may be used. Although there is disclosed a preferred embodiment of the invention, variations thereof may occur to an artisan and the scope of the invention is only to be limited to the scope of the appended claims. The device herein while shown in the figures as being for a front located flusher toilet, is readily adapted for a side located flusher toilet. | A lid actuated toilet flushing system wherein a conventional flushing flapper valve is actuated by a pull chain controlled by the positioning of the lid fo the toilet. The lid must be moved from the up to the down position to flush the toilet and a ratchet mechanism is provided for completing flushing of the toilet even if the lid is left in the down position.
Moving the lid actuates a pawl (flush lever) which rotates a tooth (trip lever) which trip lever is connected to a conventional flusing rod and other elements interposed between the flusing rod and a flapper valve. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present Application is based on International Application No. PCT/EP2006/069255, filed on Dec. 4, 2006, which in turn corresponds to French Application No. 0512609 filed on Dec. 13, 2005, and priority is hereby claimed under 35 USC §119 based on these applications. Each of these applications are hereby incorporated by reference in their entirety into the present application.
FIELD OF THE INVENTION
The invention relates to photolithography, and notably to photolithography at very short wavelengths. It relates more precisely to a lithography mask structure intended for use in reflection and to a process for fabricating this mask structure.
BACKGROUND OF THE INVENTION
Photolithography is used to produce electronic optical or mechanical microstructures, or microstructures combining electronic and/or optical and/or mechanical functions. It consists in irradiating, with photon radiation, through a mask that defines the desired pattern, a photosensitive resin or photoresist layer deposited on a planar substrate (for example a silicon wafer). The chemical development that follows the irradiation reveals the desired patterns in the resist. The resist pattern thus etched may serve for several usages, the most common being the etching of an underlying layer (whether insulating or conducting or semiconducting) so as to define therein a pattern identical to that of the resist.
It is sought to obtain extremely small and precise patterns and to align etched patterns very precisely in multiple superposed layers. Typically, the critical dimension of the desired patterns is nowadays a fraction of a micron, or even a tenth of a micron and below.
Attempts have been made to use photolithographic processes not using light but electron or ion bombardment. These processes are more complex than photolithography processes using photons at various wavelengths (visible, ultraviolet, X-ray). Sticking to optical photolithography, it is the reduction in wavelength that allows the critical dimension of the features to be reduced. Ultraviolet photolithography (at wavelengths down to 193 nanometers) has become commonplace.
It is endeavored at the present time to go well below these wavelengths and to work in extreme ultraviolet (EUV) at wavelengths between 10 and 14 nanometers which are in practice soft X-ray wavelengths. The objective is to obtain a very high resolution, while still maintaining a low numerical aperture and a sufficient depth of field (greater than 1 micrometer).
At such wavelengths, one particular aspect of the photolithography process is that the resist exposure mask operates in reflection and not in transmission: the extreme ultraviolet light is projected onto the mask by a source; the mask comprises absorbent zones and reflecting zones; in the reflecting zones, the mask reflects the light onto the resist to be exposed, impressing its image thereon. The path of the light between the mask and the resist to be exposed passes via other reflectors, the geometries of which are designed so as to project a reduced image of the mask and not a full-size image. The image reduction makes it possible to etch smaller patterns on the exposed resist than those etched on the mask.
The mask itself is fabricated by photoetching a resist, this time in transmission, as will be explained later, and with a longer wavelength, permitted by the fact that the features are larger.
Typically, a reflection mask is made up of a planar substrate covered with a continuous reflecting structure, in practice a Bragg mirror structure, covered with an absorbent layer etched in the desired masking pattern.
The mirror must also be as reflective as possible at the working wavelength designed for the use of the mask. The absorbent layer must also be as absorbent as possible at this wavelength and must be deposited without causing deterioration of the reflecting structure, which notably implies deposition at not too high a temperature (below 150° C.). It must also be able to be etched without damaging the reflecting structure and in general a buffer layer is provided between the absorbent layer and the mirror. The height of the stack comprising the buffer layer and the absorbent layer must be as small as possible so as to minimize the shadowing effects when the incidence of the radiation is not perfectly normal to the surface of the mask.
SUMMARY OF THE INVENTION
To reconcile these various requirements, the invention proposes to use as absorbent layer an indium-based material, either pure indium or in the form of an alloy with other materials and preferably with phosphorus and/or gallium arsenide and/or antimony. The preferred alloys are InP, InGaAsP and InSb.
Consequently, the invention provides an extreme ultraviolet photolithography mask (for wavelengths between 10 and 14 nanometers), operating in reflection, comprising a substrate, a reflecting structure deposited uniformly on the substrate, and an absorbent layer which is absorbent at the operating wavelength of the mask and is deposited on top of the reflecting structure and etched in a desired masking pattern, this mask being characterized in that the absorbent layer contains indium as principal absorbent constituent.
Preferably, a buffer layer (or etch stop layer) facilitating the selective etching of the absorbent layer relative to the reflecting structure (and therefore preventing deterioration of the latter) is interposed between the reflecting structure and the absorbent layer.
Preferably, the buffer layer is based on aluminum oxide, most particularly when the absorbent layer is made of indium phosphide.
The invention is mainly applicable to what are called “binary” masks in which the pattern is defined simply by the strong absorption of the extreme ultraviolet rays in the zones comprising the absorbent layer and the strong reflection in the zones that do not comprise the absorbent layer. However, the invention is also applicable to what are called “attenuated phase shift” masks in which the pattern is defined not only by this difference in absorption but also by the increase in contrast due to the phase difference between the rays reflected in the absorbent zones and the rays reflected in the neighboring nonabsorbent zones.
The invention also relates, in addition to the mask itself, to a process for fabricating an extreme ultraviolet reflection photolithography mask (operating at wavelengths between 10 and 14 nanometers), in which they are deposited, on a substrate coated with a reflecting structure which is reflective at the operating wavelength of the mask, an absorbent layer which is absorbent at this wavelength followed by a photolithography resist, the resist is irradiated in a desired exposure pattern, the resist is developed and the absorbent layer is etched through the resist pattern remaining, so as to define a pattern of zones that are absorbent at the operating wavelength of the mask, characterized in that the absorbent layer is a layer based on indium as principal absorbent constituent of the layer.
Among the advantages of indium, and most particularly of indium phosphide, there is also the fact that its reflectivity is low in deep ultraviolet at 257 nanometers. Now, this low reflectivity is useful for optical inspection of the mask at this wavelength for the purpose of discovering any defects in the absorbent layer.
Still other objects and advantages of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein the preferred embodiments of the invention are shown and described, simply by way of illustration of the best mode contemplated of carrying out the invention. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious aspects, all without departing from the invention. Accordingly, the drawings and description thereof are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF DRAWINGS
The present invention is illustrated by way of example, and not by limitation, in the figures of the accompanying drawings, wherein elements having the same reference numeral designations represent like elements throughout and wherein:
FIG. 1 shows a mask of the prior art of the binary type, operating in reflection; and
FIGS. 2 a to 2 d and 3 a to 3 e show the main steps in the fabrication of an EUV mask according to the invention operating in reflection.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a “binary” photolithography mask of the prior art operating in extreme ultraviolet reflection. It is made up of a planar substrate 10 covered with a continuous reflecting structure. The reflecting structure is a superposition of layers c 1 , c 2 , . . . cn which are transparent at the extreme ultraviolet wavelength at which the mask will be used in reflection. The layers are alternating layers of different optical index and their thicknesses are chosen according to the indices and the operating wavelength so as to constitute a Bragg mirror having a high reflection coefficient at this wavelength.
The Bragg mirror thus formed is coated with an absorbent layer 20 , which is absorbent at this wavelength and is etched in the desired masking pattern. This pattern is geometrically in a ratio greater than 1 (typically a ratio of 4) with the pattern that the mask will project during use onto a layer to be etched.
A buffer layer 22 is in principle provided between the absorbent layer and the reflecting structure. Said buffer layer possibly contributes to the absorption but it serves above all as an etch stop layer during photoetching of the absorbent layer.
In the prior art, the materials used as absorbent layer are typically metals such as titanium, tantalum, tungsten, chromium or aluminum, and also compounds of these metals such as tantalum silicide, titanium nitride and titanium-tungsten.
The thickness of the stack comprising the buffer layer and the absorbent layer is relatively large whenever it is desired to obtain a sufficient absorption (reflection less than 0.5%). For example, 70 nm of chromium on 90 nm of silica buffer layer is typically required.
This overall height is large and results in non-negligible shadowing effects as illustrated in FIG. 1 : rays arriving obliquely at an angle of incidence θ (even when θ is low) are masked over a distance d 1 , to the detriment of resolution during use of the mask. For a given angle of incidence, the distance d 1 is greater the higher the height h 1 of the stack.
According to the invention, it has been found that indium can be used as principal constituent of the absorbent layer, by itself or alloyed with other compounds, while still conforming to considerable constraints such as low-temperature deposition so as not to damage the subjacent reflecting structure. A much smaller absorbent stack height, for example about 40 nanometers, can then be used, thereby reducing the shadowing effects.
The preferred absorbent layer is an indium phosphide (InP) alloy. Other alloys can be used, notably InGaAsP and InSb.
Most particularly when the absorbent layer is made of indium phosphide, the buffer layer or etch stop layer is preferably alumina (Al 2 O 3 ). This may also be silica (SiO 2 ) or else an alternating stack of alumina and chromium.
It is also conceivable for the absorbent layer to be made up of a stack of at least one indium-based layer and another layer based on a material used in the prior art, such as titanium or tantalum or chromium, etc.).
The process for producing the mask will now be described in its major steps with reference to FIGS. 2 a to 2 d and 3 a to 3 e.
The main steps are the following:
deposition of a reflecting structure on a planar substrate 40 , said structure being reflective at the operating wavelength of the extreme ultraviolet mask. The structure is a stack 42 of an alternation of transparent layers c 1 , c 2 , . . . cn of different indices and thicknesses chosen according to the indices so as to constitute a reflecting structure of the Bragg mirror type ( FIG. 2 a ); deposition of a buffer layer 44 acting as etch stop layer, which will be explained later ( FIG. 2 b ); deposition of an indium-based layer 46 on the buffer layer ( FIG. 2 c ) for the purpose of producing the absorbent element of the mask for extreme ultraviolet wavelengths; spreading of a photosensitive resin or photoresist 48 on the indium-based layer ( FIG. 2 d ); production, by ultraviolet photolithography in the resist, of a pattern corresponding to the mask pattern to be produced ( FIGS. 3 a and 3 b ). The ultra-violet irradiation wavelength is not in the extreme ultraviolet, rather it is a much longer wavelength at which the resist is sensitive, for example about 248 nanometers. Irradiation using an electron beam on a resist sensitive to this type of beam is also possible; etching of the indium-based layer ( FIG. 3 c ) causing a pattern of absorbent zones 50 to appear. The etching is stopped when the buffer layer 4 starts to be etched, which means that the entire thickness of the indium-based layer has been removed at a point where it has to be removed; removal of the photoresist 48 ( FIG. 3 d ); and etching of the buffer layer 44 causing the reflecting structure to appear between the absorbent zones 50 of the mask, which is now complete ( FIG. 3 e ).
The role of the buffer layer is to protect the surface of the reflecting structure during etching of the indium-based layer. This is because the etchants used for etching the indium-based layer run the risk of damaging the surface layers of the reflecting structure at the end of etching this layer, which is unacceptable, the quality of the reflecting structure being essential. The buffer layer is etched more slowly than the absorbent layer by the etchants for the latter. Moreover, the buffer layer must be able to be etched selectively relative to the upper layer of the Bragg mirror so that this upper layer is not etched while the buffer layer is being etched.
The use of an indium-based material for producing the absorbent layer reduces the shadowing effects on the surface of the reflective coating of the mask. This is because the absorptivity of indium at the envisioned wavelengths (10 to 14 nanometers, and most particularly between 13 and 14 nanometers) is such that an absorbent layer having a thickness of around twenty nanometers and not around sixty nanometers or higher can be used. Furthermore, owing to the etchants used to etch the absorbent layer, a buffer layer can also be provided with a thickness of around 20 nanometers. This is in particular the case if the absorbent layer is made of indium phosphide and if the buffer layer is made of alumina. By reducing the thickness of the absorbent layer and of the buffer layer, and therefore the total thickness h 2 of the absorbent stack, the shadowing effects are reduced to a lateral distance d 2 ( FIG. 3 e ), which is smaller than d 1 ( FIG. 1 ) for the same angle of incidence θ.
It should be noted that the buffer layer, most particularly if it comprises alumina, may serve as reflecting layer for “visual” inspection of defects in the absorbent layer, which inspection is carried out in deep UV at 257 nanometers.
The buffer layer may also be made of silica or be formed by a stack of several layers, for example chromium and aluminum oxide layers.
In an alternative form of the process for fabricating the mask operating in reflection according to the invention, the absorbent layer comprises one or more metallic layers. For example, the absorbent layer may be formed by a stack of indium-based layers and at least one metallic layer. The metallic layer may be made of titanium, tantalum, tungsten, chromium or ruthenium.
A detailed example of the implementation of the procedure for fabricating the mask according to the invention will now be described:
production of a reflective coating on the substrate by ion beam sputtering. Sputtered onto the substrate are several tens of pairs of transparent layers, for example 40 pairs, each pair comprising a molybdenum layer and a silicone layer. The total thickness of each pair is about 6.9 nanometers for optimum reflection at a wavelength of about 13.8 nanometers. The reflection coefficient then exceeds 60% and may even reach 75%. The pairs of layers may also be molybdenum/beryllium or ruthenium/beryllium pairs. The substrate may be a silicon wafer or a glass or quartz plate 200 mm in diameter. The flatness of the substrate must be high and it is preferable for the flatness imperfections not to exceed 0.4 microns for a wafer of this diameter. The sputtered deposition is preferably carried out at a temperature of about 50° C.; deposition of an aluminum oxide (Al 2 O 3 ) buffer layer with a thickness of about 20 nanometers on the reflective coating. The deposition of this stop layer is carried out by atomic layer chemical vapor deposition at a temperature of 120° C., which is acceptable for the subjacent reflecting structure; low-temperature deposition (at below 100° C.) of an extreme ultraviolet absorbent layer, based on InP and with a thickness of about 20 nanometers, on the buffer layer, using a molecular beam epitaxy machine; spreading of a lithographic resist, such as a resist of the PMMA (polymethyl methacrylate) type sold by the company Rhom & Haas Electronics Materials or RHEM; production of a desired pattern in the resist by UV lithography (for example at 248 nanometers) or by electron-beam lithography; etching, for example plasma etching, of the indium-based material at a temperature of around 100° C., for example using a Cl 2 /Ar chemistry, in order to remove the absorbent layer just where it is not protected by the resist. The plasma etching gases depend on the material to be etched. The buffer layer protects the Bragg mirror at the end of this etching operation; removal of the resist, for example in two steps, namely dry stripping followed by wet extraction, for example by EKC 265 treatment, the product EKC 265 being sold by the company EKC and corresponding to the resist indicated above. The temperature reached is between 65° C. and 70° C., which is acceptable. The dry stripping is carried out using argon, oxygen and CF 4 . The temperature reached during the dry stripping is between 54° C. and 60° C., which is acceptable; and removal of the buffer layer just where it is not protected by the InP absorbent layer, so as to locally bare the reflective coating. This step may, for example in the case of an Al 2 O 3 stop layer, be HF chemical etching by using a 1% solution, which does not etch the absorbent layer and does not damage the subjacent reflecting structure.
The mask thus produced according to the invention, having been the subject of tests and simulations, has the following characteristics: the absorption index in the EUV (at 13.5 nanometers) of the InP is 0.0568. This index obtained is better than those of the materials used in the prior art, such as TaN having an absorption index of 0.044 and chromium having an index of 0.0383. Indium has an absorption index of 0.07.
By simulation, the reflectivity of the stack comprising the 20 nanometer InP base layer and the 20 nanometer Al 2 O 3 layer was found to be less than 0.5% for illumination in EUV (13.5 nanometers). The software used for simulation was XOP software.
The EUV mask operating in reflection is satisfactory for an absorbent stack thickness (h 2 ) significantly smaller than that of the masks of the prior art since an overall thickness of 40 nanometers is sufficient, this being much smaller than the 160-nanometer thickness of the prior art (70 nm of Cr+90 nm of silica).
The invention has been described in detail with regard to a binary mask, but it may also be used to produce an attenuated phase shift mask in which the absorbent layer not only plays an absorbent role but also a role of phase shifting the light fraction that it reflects.
It will be readily seen by one of ordinary skill in the art that the present invention fulfils all of the objects set forth above. After reading the foregoing specification, one of ordinary skill in the art will be able to affect various changes, substitutions of equivalents and various aspects of the invention as broadly disclosed herein. It is therefore intended that the protection granted hereon be limited only by definition contained in the appended claims and equivalents thereof. | The invention relates to an extreme ultraviolet photolithography mask, operating in reflection, the mask comprising a substrate, a mirror structure deposited uniformly on the substrate, and an absorbent layer which is absorbent at the operating wavelength of the mask and is deposited on top of the mirror structure and etched in a desired masking pattern. The absorbent layer contains indium among its principal constituents. | 6 |
BACKGROUND OF THE INVENTION
Our invention relates to fishing gear holding apparatus, and more particularly, to a portable implement or caddy which may be worn or carried by a user to support and carry a fishing rod and various other articles of fishing equipment frequently used by fisherman. The invention is especially intended for use by fisherman who stand and/or walk while fishing in a stream or at the edge of a lake or other body of water. In most of the ensuing description the invention may be simply termed a fishing rod holder, but it should be kept in mind that many varied items of fishing equipment also may be carried by the device of the invention.
Many types of fishing desirably involve pluralities or sets of operations which a normal person having only two hands finds difficult to perform. For example, if a fly fisherman standing in a stream catches and reels in a fish, he ordinarily wishes to remove the fish, either to return it to the stream, or to put in a creel or bucket. The act of removing a hook from a live fish's mouth requires two hands, and hence the fisherman finds it difficult to remove a hook while continuing to support his fishing rod. One alternative is to wade out of the stream to dry land where he can lay all of his equipment on the ground. That strategm is anathema to most experienced fisherman because wading out of the stream is likely to stir up mud and encourage all fish to leave that fishing area. Thus it becomes desirable to provide a device which so supports various items of fishing equipment that the two-handed user can perform numerous acts which he otherwise could not conveniently perform.
Fisherman use a wide variety of types and sizes of fishing rods, and one object of the invention is to provide a fishing gear holder which will readily accommodate or be useful with a wide number of types and sizes of fishing rods. One important object of the invention is to provide a fishing rod holder which may be worn and carried in a secure fashion with any of a variety of different articles of clothing which fisherman commonly use. Some prior art fishing rod holders require mounting on a belt worn by the user. Some fisherman wear waders with which a belt is not usually worn. As will be seen below, the holder of the present invention can be worn not only with a typical belt of the type frequently encircling a user's hips, but with chest waders, or bib overalls, or with many plain shirts and pants, and providing a fishing rod holder with such added utility is one important feature of the invention. Provision of a device which need not be made differently for right-handed and left-handed users, and which will operate similarly for either type of user is another object of the invention. Another object of the invention is to provide a fishing gear holder which is simple and sturdy, economical to manufacture, preferably from a single piece of material, and, importantly, impervious to rust and rough handling.
BRIEF DESCRIPTION OF THE PRIOR ART
The broad idea of providing a one-piece plastic device for supporting a fishing rod is not per se new, such a device being shown in Fruscella et al U.S. Pat. No. 3,874,573, but the holder of the present invention is believed to provide many advantages which will be mentioned below as the description proceeds.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a front elevation view of a preferred embodiment of the invention.
FIG. 2 is a side elevation view taken at lines 2--2 in FIG. 1.
FIG. 3 is rear elevation view of the embodiment of FIGS. 1-4, and
FIG. 4 is a top view taken at lines 4--4 in FIG. 3.
FIG. 5 is a downward section view taken at lines 5--5 in FIG. 3.
FIG. 6 is an unrolled view useful in describing the dimension of a preferred embodiment of the invention.
FIG. 7 is a partial front view illustrating a fisherman employing the invention to carry a plurality of articles while his hands are free for other tasks.
FIG. 8 is a partial view showing the holder of the invention installed on a belt, which is only partly shown; and
FIG. 9 is a partial view showing the holder installed over an upper edge of a wearer's trousers, which are only partly shown.
In FIG. 1 a vertically-extending y-axis shown in dashed lines is provided solely to facilitate accurate description of the preferred embodiment shown in the drawing. The device of FIGS. 1-9 is preferably made symmetrical about the y--y axis shown in FIG. 1, though it is by no means necessary that the device be symmetrical.
DETAILED DESCRIPTION
Referring now to FIGS. 1-7, the holder 10 preferably comprises a single piece of plastic, such as polypropylene, high-density polyethylene, polyvinylchloride, or other suitable plastic material, molded or formed to provide the entire holder as a one-piece unit. The device theoretically may be formed as separate pieces and then assembled into a single unit, but with no apparent advantage. The device is preferably injection-molded to provide economical mass production, but the device can be entirely formed, if desired, by heating and bending a piece cut (with a jig-saw or band-saw) from a sheet of polypropylene sheet approximately 1/8 inch thick. {Give mfr and catalog or type no. of sheet you used to make prototypes} High impact polystyrene can instead be used.
As viewed in FIG. 1 it will be seen that the preferred form of the device is precisely symmetrical about the y-axis. The single plastic piece includes attachment means 11 at its upper edge, those attachment means being shown as comprising a front pad 12 having a generally rectangular shape, with a stiff, folded-over rear tab or rigid flap 13. The front pad 12 carries a pair of spaced-apart vertically-extending slot apertures 14,14 which may accommodate a belt (not shown in FIGS. 1-4) worn by the user, thereby to support holder 10 on the user's person. Alternatively, rear folded-over rigid flap or tab 13 may be inserted over the waistband of pants worn by the user, or into a hip-pocket of trousers worn by the user, a shirt pocket of the user, or, importantly, over the upper edge of chest waders or bib overalls worn by the user, none of the mentioned articles of user clothing being shown in FIGS. 1-4. Provision of attachment means which allows rapid and easy installation of the device on the fisherman's body under the widely varying conditions given by different types of dress by different individuals is believed to be extremely desirable and an important feature of the invention. It also should be noted that the mentioned articles of clothing are all quite common fisherman costume items, and none of the different manners in which the holder may attached to fisherman garb requires any close fitting to size. Hence a given holder of ideal size for a grown man can as well be readily used by his wife or his young sons and daughters.
In between the upper attachment means and the lower end of the device, the holder comprises a central strip portion 16 having a generally semi-circular or trough-like cross-section, as best seen in FIG. 5. The provision of such a cross section stiffens the device against bending in the fore and aft directions, i.e. toward and away from the observer as viewed in FIG. 1, and it facilitates the holding in the device of numerous objects having a generally circular cross-section, such as many fishing rod handles. It is by no means necessary that the mentioned cross-section be precisely semi-circular. As clearly seen in FIGS. 1-4, a plurality of arm members 17a to 17f are provided to extend generally forwardly in pairs from the semi-circular central rear area 16, and as best seen in FIG. 4, the arms of each pair curve away from each other, thereby providing an arm pair spacing at a nearest point which is less than the spacing of the arms where they join rear strip portion 16. It will be apparent that an object forced between the arms of a pair will be gripped by those arms with a force dependent upon both the size and position of the object being gripped. Because the arms of a pair extend partially laterally as well as outwardly (as viewed in FIG. 5), it can be seen that a pair of arms which grip an object between them tend also to urge the object rearwardly, i.e. toward plate 12 and tab 13.
Preferred dimensions of the presently preferred embodiment of the invention may be given and understood most readily by reference to a flat, or unrolled piece of plastic sheet of the nature shown in FIG. 7, even though it is preferred that the holder be formed for quantity production by injection molding. Such dimensions are those which may be cut from a flat piece of plastic sheet, prior to the central tube portion being formed to a semi-cylindrical shape, and prior to the arms and hook portions being formed. In one successful prototype model of the invention various dimensions identified by letters in FIGS. 7 had the following exemplary dimensions:
______________________________________Dimension Inch Cm. Dimension Inch Cm.______________________________________a 3.0 7.62 g 2.31 5.87b 2.25 5.72 h 1.88 4.76c 2.87 7.29 i 0.94 2.38d 4.5 11.43 j 0.94 2.38e 2.0 5.08 k 2.0 5.08f 1.38 3.49 1 3.75 9.53______________________________________
The holder is shown provided with three pairs of forwardly-extending arms 17a-17f, the arms of each pair being shown extending from the rear half-tube or trough portion 16 of the device mutually symmetrically on opposite sides of the y-axis. The rear trough or half-tube portion of the caddy is quite stiff, having no appreciable resilience insofar as operation is concerned, but not so stiff as to be brittle, of course. The arms 17a-17f which extend forwardly from the trough portion have substantial resilience, however, so that they act as spring arms. Each arm extends forwardly from the rear trough portion, first curving laterally inwardly toward the y-axis as well as forwardly, and then changing direction to present a rounded bend away from the y-axis and away from the companion bend of the other arm of the pair. It will be apparent that a cylindrical object such as a broomstick, billy club, or fishing rod handle forced between a pair of such arms will be gripped by the arms with a spring force. It may be noted that because the rounded bend on each plastic arm has a substantial radius, no sharp corners (and, of course, no hard metal surfaces) are urged against a fishing rod to possibly damage the rod.
The lower end of the caddy comprises a forwardly extending shelf or platform 19 which supports the lower end of a fishing rod carried in the caddy and limits downward movement of the same. Shelf 19 preferably presents a seat having a slightly lowered or slightly recessed central area 19a, so that the end of a fishing rod handle seated in such a recess tends to be captured, making the rod tend to be not removable from the caddy unless the rod is lifted very slightly. The dimensions between the extending arms is fashioned, given the resiliency of the plastic material used, so that a generally cylindrical fishing rod handle having a diameter of approximately 0.75 inch (1.9 cm.) seated between such arms may be inserted therebetween or removed therefrom with an outward pull of the order of roughly ten pounds. With that order of resilience a rod will be held securely without attention from a fisherman while the fisherman moves to perform any one of a number of tasks, but readily removable from the holder when the fisherman desires that. As well as a plurality of pairs of spring arms, the holder also includes a plurality (only two are shown) of hook arms 21a, 21b from which any of a large variety of articles of fishing equipment may be temporarily suspended, yet readily removed when desired. Exemplifying typical use of the invention, a fisherman shown in FIG. 7 has the holder of the invention supported by rear pad 13 being slipped over the upper edge of the wearer's bib overalls. The trio of pairs of arms grip the handle of a fishing rod 31 and keep the rod erect while the fisherman uses his hands to work with an artificial bait. Simultaneously, a conventional fishing net 32 and a bait can 33 are suspended from hooks 21a, 21b of the holder. FIG. 8 shows the invention attached to the belt 34 of a wearer, and FIG. 9 shows the invention supported by the upper edge of trousers of a wearer.
It is deemed important that the holder be attachable to a user near the upper end of the holder, and that any hook means such as those shown at 21a, 21b be located below the attachment means. It is deemed desirable that the holder have a modest width, of the order shown, so that it not interfere with the user's walking even though it is located on the user's front side.
While a preferred embodiment has been shown and described, it should be recognized that various changes which could be made will become readily apparent to those skilled in the art upon a perusal of this disclosure. | A portable fishing gear holder comprises a single piece of plastic having attachment means at its upper end to readily attach the device to any of many types of clothing, a plurality of forwardly-extending spring arms adapted to grasp and hold the handle of a standard fishing rod, a lower tongue acting as a shelf to limit downward movement of such a rod, and one or more hooks from which various articles of fishing gear may be suspended. | 8 |
FIELD OF THE INVENTION
[0001] Then invention relates to a motor vehicle door lock housing with at least one outwardly facing recess for receiving electric strip conductors, and with passages in the recess for connecting the strip conductors to the housing interior.
BACKGROUND OF THE INVENTION
[0002] Such motor vehicle door lock housings generally consist of several parts and typically comprise a metal lock case and an actual plastic lock housing or a plastic cover or a plastic housing body. Said recess is located in the actual plastic lock housing. The recess faces outwards and can thus receive one or several strip conductors from the outside. As a result, the basic motor vehicle door lock and the motor vehicle door lock housing can be produced after which the strip conductors are arranged in the recess only at the end. The recess is sealed with a sealing compound in order to protect the strip conductors against corrosion or environmental influences.
[0003] The generic state of the art of WO 2010/136004 A1 discloses that the strip conductors are placed as printed or stamped conductor screens in the recess and are connected to electric/electronic components located in the housing interior. This arrangement has generally proven to be successful but could be improved as regards the required assembly and production, as nowadays, manufacturers often use standardised components, which require, for instance, for different strip conductors or strip conductor structures to be accommodated in the motor vehicle door lock housing. Prior art arrangements have so far not produced any convincing solutions in this respect.
SUMMARY OF THE INVENTION
[0004] The invention is based on the technical problem of further developing such a motor vehicle door lock housing in such a way that it can be universally used and that assembly/manufacture is simplified.
[0005] To solve this technical problem, a generic motor vehicle door lock housing as part of the invention is characterized in that the strip conductors with at least one strip conductor board, on which they re arranged, can be positioned in the recess.
[0006] As part of the invention, the strip conductors are thus expressly not positioned in the recess as printed or stamped conductor screens according to WO 2010/136004 A1. Instead, the invention uses a strip conductor board carrying the strip conductors. This strip conductor board generally contains feet on the housing side. It has proven to be advantageous for the feet to be designed as strip conductor extensions. The feet or the strip conductor extensions of the strip conductor board engage in each case in individual passages in the recess. As a result, the strip conductor board is centred inside the recess and the feet designed as strip conductor extensions also ensure that the strip conductors carried by the strip conductor board can assume the desired electrical connection with the electric/electronic components provided in the housing interior.
[0007] The chosen design may consequently such that the feet on the housing side of the strip conductor board engage in respective plug receptacles in the housing interior. Said plug receptacles can be mechanical plug receptacles, if the feet on the housing side are non-conductive. Generally, the feet on the housing side are, however, strip conductor extensions extending mainly at right angles from the underside of the strip conductor board. In this case, the plug receptacles are electrical plug receptacles, i.e. those that provide a direct electric contact as soon as the feet designed as strip conductor extensions engage in said electric plug receptacles. Individual electric/electronic components in the housing interior of the motor vehicle door lock housing can be connected to the electric plug receptacles.
[0008] Typically the inside of a motor vehicle door lock housing contains one or several electric motors, individual sensors, micro switches, etc., required for the operation of the motor vehicle door lock or that monitor individual functional positions of the motor vehicle door lock.
[0009] The strip conductor board can generally be any type of strip conductor board, i.e. a printed board with single or multiple layer, typically produced from an insulation material. The strip conductors are defined on such a strip conductor board by chemical and or physical processes. Also, the top of the strip conductor board, i.e. the upper side facing the housing feet on the bottom, can contain electric/electronic components. In particular electronic SMD components (surface-mounted device) have proven to be advantageous. This is naturally only an example and not mandatory.
[0010] The strip conductor board with its feet on the housing side protruding from its base, is normally applied to one or several supports of the recess. The recess consequently contains one or several supports for the strip conductor board. The one or several supports are typically a continuous frame. Alternatively or in addition, the support or the frame can also be designed as a seal.
[0011] Such an embodiment has shown to be particularly advantageous where the strip conductor board closes off the recess in the manner of a cover. In this case, the plane internal cross section of the recess and the plane extension of the strip conductor board are typically adapted to each other in such a way that the strip conductor board can be positively accommodated in the recess, on which one or several supports rest, as a result of which the recess is closed off in the manner of a cover. The casting compound subsequently applied to the strip conductor board or filled into the recess can consequently easily seal the recess. In most cases, the casting compound will be mainly arranged between a surface or top side of the strip conductor board and the edge at the head of the recess. As regards application of the casting compound, only a thin layer of casting compound is, on the other hand, applied to the area from the bottom surface or base of the strip conductor board up to the base of the recess. In this way the quantity of casting compound for each recess to be sealed can be considerably reduced compared to previous embodiments. The described design is therefore particularly cost effective.
[0012] Also, the strip conductor board including the strip conductors and any additionally installed electric/electronic components defines or can define a pre-assembled subassembly. Ideally, the motor vehicle door lock including all levers, assemblies, etc. to be arranged in the housing interior is fully assembled and enclosed by the motor vehicle door lock housing of the invention. The electric/electronic components arranged inside the motor vehicle door lock housing are then controlled and electrically connected by the strip conductor board or the already preassembled subassembly being inserted in the recess. During the process the thus provided strip conductor board or strip conductor board with the strip conductors arranged thereon or possible electric/electronic components, uses the one or several supports inside the recess for positioning.
[0013] This ensures that the feet or strip conductor extensions can extend directly through the associated passages in the recess and engage on the other side of the passages and in the housing interior in the provided plug receptacles. This means that the positioning of the preassembled subassembly or of the printed circuit board or strip conductor board in the recess also ensures that the strip conductors on the strip conductor board are electrically connected with the associated and desired assemblies in the housing interior. No other work is required. As soon as the preassembled subassembly or the strip conductor board is positioned in the recess, the recess and the strip conductor board can be sealed by said casting compound.
[0014] In other words, no complicated installation work is required and instead, the pre-installed subassembly or strip conductor board only has to be placed in the recess with this process also providing the required electric contact. To complete the process, the strip conductor board is sealed in the recess, so that the motor vehicle door lock housing of the invention is directly ready for use and prepared for installation. These are the main advantages.
[0015] In another advantageous embodiment, the support for the strip conductor board or the pre-installed subassembly is provided at an edge of the recess. It has also shown too be particularly advantageous if the height of the support in question in connection with, where applicable, the height of the equipped and supported strip conductor board is equal to or thinner than the depth of the recess. This ensures that the strip conductor board resting on the support or any components on said board do not exceed the edge on the head of the recess or do not “protrude”. The casting compound applied after assembly of the strip conductor board then ensures that the strip conductor board is completely or nearly completely covered by the casting compound or that no components protruding over the edge on the head of the recess are visible.
[0016] Of further significance is the fact that the passages in the recess describe a hole pattern adapted to the strip conductor board inserted in the recess. In other words, each strip conductor board inserted in the recess corresponds to a special hole pattern of the passages in the recess. In order to achieve a particular standardized manufacture and to allow, where possible, the use of the same door lock housing for different door lock designs, it has further proven to be advantageous for the recess to be designed for receiving different printed circuit boards. It is for instance feasible that the same door lock housing is used to accommodate a motor vehicle door lock with central locking and a motor vehicle door lock without central locking.
[0017] Both types, i.e. with and without central locking or with opening and closing assistance naturally require different strip conductor boards, as for instance in the central locking model a central locking motor has to be controlled, the position of a central locking lever has to be sensed, etc. Naturally, none of these described functions are required for a motor vehicle door lock without central locking functions. Consequently, the respective strip conductor board for the central locking model tends to have considerably more feet on the housing side to provide the contact for subassemblies contained in the housing interior compared to models without central locking.
[0018] In order to, however, be able to accommodate both models of the example in the recess or in the same motor vehicle door lock housing, all strip conductor board hole patterns correspond to a universal hole pattern of the passages in the recess. This means that the strip conductor board placed in the recess defines its own strip conductor board hole pattern or a pattern of the feet on the housing side on the strip conductor board. All strip conductor boards placeable in the recess and the respective strip conductor board hole patterns thus define a universal hole pattern, typically implemented in the recess.
[0019] This universal hole pattern is characterized in that in general feet on the housing side of the strip conductor board inserted in the recess do not extend through all openings or passages. Instead more or fewer passages remain uncovered during this process. Only when inside of the motor vehicle door lock housing contains a lock, fulfilling all conceivable functions, also all passages of the universal hole pattern are “occupied” by the associated feet on the housing side.
[0020] In this way, manufacture and assembly is simplified even more as different types of the motor vehicle door lock can be accommodated in the same motor vehicle door lock housing. This also applies to the strip conductor board belonging to the respective motor vehicle door lock, as the outwardly facing recess, accommodating the strip conductor board, is universally designed for receiving the respective strip conductor board. This simplifies positioning and also assembly is significantly easier than before. At the same time resources are saved as the required quantity of casting compound is significantly reduced compared to prior art embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Below, the invention is described in more detail with reference to exemplary drawings showing only one embodiment, as follows:
[0022] FIG. 1 shows a schematic overview of the motor vehicle door lock housing according to the invention; and
[0023] FIG. 2 shows a cross section of the object of FIG. 1 .
[0024] Other features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] FIG. 1 shows a motor vehicle door lock housing containing first of all a housing body 1 made of plastic. Apart from this plastic housing body 1 a metal lock case is typically provided. This is, however, not shown. Together, the metal lock case and the plastic housing body 1 make up the motor vehicle door lock housing. Of special significance for the below observations is an outwardly facing recess 2 on this motor vehicle door lock housing. The recess 2 serves to receive electric strip conductors 3 . Also, passages 4 are provided in the in the recess 2 . The strip conductors 3 are connected to the housing interior by means of the passages 4 in the recess 2 . This is schematically shown in the sectional view of FIG. 2 . The housing interior contains motors, sensors, plug-in contacts, etc. connected via the strip conductors 3 . For this purpose, the strip conductors 3 produce an electric connection to a socket 5 in the example. A plug, not shown, can be connected to the socket 5 , which in turn ensures the electric connection of the shown motor vehicle door lock to, for instance, a control unit inside a motor vehicle.
[0026] In this embodiment and according to a preferred embodiment of the invention, the strip conductors 3 together with the strip conductor board 6 accommodating the strip conductors 3 , is placed in the recess. This means that in the embodiment, strip conductors 3 are arranged on the strip conductor board 6 , as electrically conductive conductors that are, for instance, printed or applied by any other process onto the strip conductor board 6 . The strip conductor board 6 is also provided with feet 7 on the housing side, providing an electric connection to the individual strip conductors 3 . The feet 7 on the housing side extend more or less vertically from a base U of the strip conductor board 6 , as clearly shown in the cross sectional view of FIG. 2 . The top O of the strip conductor board 6 can contain electric/electronic parts 8 . The so-called SMD technology has proven to be particularly advantageous in this respect.
[0027] In this way, the strip conductor board 6 including the electric/electronic components 8 and the feet 7 on the housing side can be produced together as a preassembled subassembly 6 , 7 , 8 . This preassembled subassembly 6 , 7 , 8 can be positioned in the recess 2 . For this purpose, the recess 2 contains one or several supports 9 also best apparent from the sectional view of FIG. 2 . The support 9 in the example is indeed a frame 9 , provided at an edge of the recess 2 .
[0028] For this purpose, the support 9 has, as shown in FIG. 2 , a height H 1 , which together with a height H 2 of the strip conductor board 6 and its components resting on the support 9 or the height H 2 of the subassembly 6 , 7 , 8 corresponds to a depth T of the recess 2 or is smaller than said depth. According to the invention, the following relation does thus apply:
[0000] H 1 +H 2 S≦T.
[0029] As, furthermore, the area of the strip conductor board 6 matches the area of the recess 2 or the strip conductor board 6 sits predominantly flush in the recess 2 , this explains that the strip conductor board 6 seals the recess 2 like a cover, as soon as it rests on the supports 9 . Indeed it is ensured in this way that the casting compound 10 is mainly located between the surface or top O of the strip conductor board 6 and an edge 11 on the head of the recess 2 . In contrast, an area between the base U of the strip conductor board 6 and a base 12 of the recess 2 only contains a thin layer of casting compound 10 .
[0030] The recess 2 is arranged on the plastic housing body 1 and typically forms a single plastic piece with the housing body 1 and is moulded in the body. The same applies to the supports 9 or the edge 9 .
[0031] The recess 2 or the housing body 1 made of plastic are consistently retained even if different embodiments of the respective implemented door lock are positioned in the interior of the housing. It is for instance feasible that the same motor vehicle door lock housing is used to accommodate a motor vehicle door lock with central locking or a motor vehicle door lock without central locking in its interior.
[0032] As, in addition, the openings or passages 4 in the recess 2 describe a hole pattern 13 adapted in each case to a strip conductor board 6 inserted in the recess 2 , it is clear that depending on the level of equipment of the door lock (with or without central locking) also different preassembled subassemblies ( 6 , 7 , 8 ) are used. These different preassembled subassemblies 6 , 7 , 8 correspond to adapted and varied hole patterns 13 . This means that the recess 2 is designed for receiving different strip conductor boards 6 or different preassembled subassemblies 6 , 7 , 8 .
[0033] The individual corresponding hole patterns 13 are now part of the associated preassembled subassembly 6 , 7 , 8 or the associated strip conductor board 6 . This results in a strip conductor board hole pattern 13 , ultimately defined by the arrangement of the feet 7 on the housing side, extending (having to extend) through the associated passages 4 .
[0034] All different strip conductor board hole patterns 13 now define a universal hole pattern 14 of the passages 4 in the recess 2 . This universal hole pattern 14 is arranged and designed in such a way, that any conceivable type of the motor vehicle door lock accommodated inside of the motor vehicle door lock housing can be accommodated, with each respective type being associated with a preassembled subassembly 6 , 7 , 8 . This arrangement is made possible as the recess 2 is sealed by the strip conductor board 6 or the preassembled subassembly 6 , 7 , 8 in the manner of a cover and by the casting compound 10 basically being predominantly arranged between the surface or top O of the strip conductor board 6 and the edge 11 at the head of the recess 2 . It is virtually impossible for casting compound 10 to enter unassigned passages 4 and thus the inside of the housing.
[0035] As soon as the preassembled subassembly 6 , 7 , 8 or the strip conductor board 6 is positioned in the recess 2 on the frame 9 , the feet 7 on the housing side engage in the plug receptacles 15 in the housing interior. During this process, the feet 7 on the housing side extend through individual or all passages 4 in the recess 2 . In the embodiment, the plug receptacles 15 are designed as electrical plug receptacles 15 and are connected to the assemblies inside the housing by means of conductors. In this way, the subassembly 6 , 7 , 8 positioned inside the recess 2 directly provides the required electrical connection from the bushing 5 through the strip conductors 3 up to the assemblies in the housing interior to be controlled or scanned.
[0036] It is to be understood that the above-described embodiment is illustrative of only one of the many possible specific embodiments which can represent applications of the principles of the invention. Numerous and varied other arrangements can be readily devised by those skilled in the art without departing from the spirit and scope of the invention. | A motor vehicle door lock housing comprising at least one outwardly facing recess ( 2 ) for receiving electric strip conductors ( 3 ) and with passages ( 4 ) in the recess ( 2 ) for connecting the strip conductors ( 3 ) to the housing interior, wherein the strip conductors ( 3 ) together with at least one strip conductor board ( 6 ) carrying the latter can be placed in the recess ( 2 ). | 4 |
REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No. 61/817,077 of the same title filed Apr. 29, 2013, which is incorporated by reference in its entirety.
SEQUENCE LISTING
The instant application contains a Sequence Listing which has been submitted electronically in ASCII format and is hereby incorporated by reference in its entirety. Said ASCII copy, created on Apr. 28, 2014, is named 3060.002.US_SL.txt and is 29,528 bytes in size.
BACKGROUND
1. Field of the Invention
The invention is directed to systems, compositions and methods for the expression and purification of lipoxygenases, to amino acid and nucleic acid sequences of all or portions of lipoxygenases, to molecular constructs for the expression of lipoxygenases, and, in particular, to methods for the large scale production and use of lipoxygenases in food products.
2. Description of the Background
Lipoxygenases (LOXs; EC1.13.11_), also known as lipoxydases, are non-heme iron-containing dioxygenases distributed in plants and animals. LOXs catalyze hydroperoxidation of polyunsaturated fatty acids in the first step of fatty acid metabolite synthesis, to produce an unsaturated fatty acid hydroperoxide. A LOX definition according to enzyme classification is linoleate: oxygen oxidoreductase (for plant LOX) and arachidonate: oxygen oxidoreductase (for mammalian LOX). In plants, the most common LOX substrates linoleic acid and linolenic acids are converted into a variety of bioactive mediators involved in plant defense, senescence, seed germination, as well as plant growth and development (Grechkin A. Recent developments in biochemistry of the plant lipoxygenase pathway; Prog Lipid Res. 1998 November 37(5):317-52). Lipoxygenases with different specificities, subcellular location, and tissue-specific expression patterns have been identified as ubiquitously found across kingdoms from bacteria to mammals.
LOXs are of commercial value in various industries including but not limited to food-related applications in food processing including bread making (bleaching and improved texture), aroma and flavor enhancement as well as for production of perfumes, paint driers (lipoxygenases: potential starting biocatalysts for the synthesis of signaling compounds. Joo YC, Oh DK. 2012) and pitch control in softwood pulp (Microbial and enzymatic control of pitch in the pulp and paper industry, Ana Gutiérrez & José C. del Río & Angel T. Martínez, Appl Microbiol Biotechnol (2009) 82:1005-4018). Lipoxygenase is present in seeds (e.g. soybeans), grains and many other plant tissues. In the presence of oxygen, lipoxygenase oxidizes unsaturated fatty acids and produces lipid hydroperoxides, which improve dough structure through the oxidation of unsaturated fatty acids and subsequently react with specific chemical components of flour. As a consequence, dough stability and rising is increased, which either or together can increase the volume of the final product.
Regarding the processing of bread, lipoxygenase enzymes offer an advantage over current chemical additives. The flour ingredient industry had long been using chemical bleach, mostly benzoyl peroxide (BPO). Because of potential health concerns over BPO, some Euro countries and China banned the usage of BPO in flour. In the U.S., BPO is still widely used, but the demand keeps shirking although there is currently no safe alternative. Azodiformamide is another chemical alternative, but the dosage is limited to 40 ppm. At this trace dosage, the bleaching effect is quite restrained. In contrast, enzyme additives especially LOXs can replace chemicals to allow for the processing of flour, resulting in the bleaching of bread and its improved texture. In addition, lipid hydroperoxidases decolorize dough and oxidizes carotinoids, converting them into colorless compounds. This blanching of the dough results in lighter colored product, which is highly desired.
With regard to enzymes employed in the food industry, regulations frequently require enzymes to be recognized or proven as safe for use. In the case of lipoxygenases, considering that they are ubiquitously found in plants and consumed by humans and animals alike, plant lipoxygenases are considered safe for use, and therefore, of major value to the industry. Although soy extracts containing high levels of lipoxygenases have been used as an additive for bread manufacturing, soy produces an undesirable taste and smell and, accordingly, not often a useful option.
Because of plant LOX value, many attempts at high-level expression of recombinant plant derived LOX from soy, rice, potato and other sources by heterologous expression in microbial hosts including, but not limited to bacteria such as E. coli (BL21 strain), Bacilli , and in yeast has been attempted, though production was limited [3-8]. The best of these, although still a poor expression from E. coli , was observed at very cold temperatures [8]. Only one lipoxygenase was produced in Bacilli at high-levels (˜160 mg/L), but the lipoxygenase was from a bacterial enzyme, not a plant and consequently not approved for use in the human food industry [9, 10]. In addition, yields still could not achieve desired levels. Accordingly, a need exists for high level expression of plant lipoxygenases that is generally recognized as safe for use in foods, and easily produced in large quantities.
SUMMARY OF THE INVENTION
The present invention overcomes the problems and disadvantages associated with current strategies and designs, and provides new methods and compositions involving the heterologous expression, purification and use of lipoxygenases.
One embodiment of the invention is directed to the heterologous expression of lipoxygenases in microbes.
Another embodiment of the invention is directed to methods for the purification of lipoxygenases, preferably from heterologous expression systems according to the invention.
Another embodiment of the invention is directed to lipoxygenase polypeptide and nucleic acids sequences and molecular constructs of lipoxygenase coding sequences, preferably for the high level expression of lipoxygenase as compared to expression in wild-type host cells. Preferably wild-type host cells are cells that do not contain a protease deficiency and/or cells that do not contain one or more chaperones.
Another embodiment of the invention is directed to methods for the manufacture of bread products comprising adding lipoxygenases of the invention to a dough containing unsaturated fatty acids and/or carotinoids. Preferably the lipoxygenase reacts with components of the flour forming lipid hydroperoxides increasing the stability of the dough and enhancing the volume of the baked goods.
Another embodiment of the invention is directed to purified lipoxygenase enzyme made by the methods of the invention. When the purified enzyme is added to dough, another embodiment of the invention comprises products made with the purified enzyme added to dough such as, preferably, bread products. The manufacture of bread products of the invention preferably comprises adding lipoxygenases to a dough containing unsaturated fatty acids and/or carotinoids. Preferably the lipoxygenase reacts with components of the flour forming lipid hydroperoxides increasing the stability of the dough and enhancing the volume of the baked goods.
Other embodiments and advantages of the invention are set forth in part in the description, which follows, and in part, may be obvious from this description, or may be learned from the practice of the invention.
DESCRIPTION OF THE FIGURES
FIG. 1 Western analysis of SLP1 indicates varying profiles of degradation. M=marker. Different K12 cells with different genotypes are presented in sets of “U” (uninduced) and “I” (induced).
FIG. 2 Co-expression of the GroEL-GroES chaperone enhances SLP1 production. Four chaperones A-D were co-expressed in E. coli with SLP1. Left Panel: SLP1 is directed detected as a weak band in SDS-PAGE as a result of Co-expression with Chaperone B. Right Lane: Enhanced expression of SLP1 with co-expressed GroEL-GroES is confirmed by standard Western analysis.
FIG. 3 Single step purification of SLP1 from the 424 vector (native protein sequence, no polyhistidine tag). All lanes: SLP1 lacking a his tag was eluted from Zinc-NTA (IMAC) columns and run in SDS PAGE followed by protein staining: Lanes 1—crude lysate; Lane 2—column flow-through; Lane 3—column wash; Lanes 4-7—Zinc-NTA (IMAC) elution with SLP1 loaded in the presence of 0, 2, 5 and 10 mM imidazole, each eluted with 80 mM imidazole.
FIG. 4 E. coli cell lines used to verify experiments.
FIG. 5 SLP1 expression in E. coli ; SDS PAGE protein gel of whole cell K12 E. coli lysate expressing SLP1.
DESCRIPTION OF THE INVENTION
Lipoxygenase enzymes (also referred to herein as LOX) are widely used in commercial processing of food products, the manufacture of perfumes and painting products, and in the processing of wood pulp. Although all lipoxygenase catalyze the same basic function, only plant lipoxygenases have been approved by the United States Food and Drug Administration for use in foods and food products. Despite their broad uses, lipoxygenase enzymes are only expressed at low levels and, consequently, commercial quantities are both expensive and difficult to produce.
Despite previous failures in achieving high level LOX expression, it has been surprisingly discovered that considerable enhancement of plant lipoxygenase expression can be achieved. At least part of this high-level of expression is attributed to the selection of sequences being expressed, expression of the sequences in a protease deficient host, and/or the co-expression with one or more chaperone plasmid sequences. Preferable, the increased expression achieved is at a higher level than expression in host cells that do not contain a protease deficiency and/or cells that do not contain one or more chaperone plasmids. Preferably the expression of the one or more proteases is eliminated, reduced to an undetectable level using conventional detection or reduced by at least 90%, all as compared to wild-type expression levels.
One embodiment of the invention comprises a system containing a bacterial cell host, preferably with a deficiency or one or more proteases, containing a coding sequence for lipoxygenase enzyme and preferably a chaperone system comprising one or more chaperone molecules. The system is preferably inducible and also preferably maintained from about 10° C. to about 37° C. for a period of time for maximal expression of enzyme product. The period of time is preferably from minutes to hours to days, and more preferably from about 1 to about 24 hours, more preferably from 2 to 12 hours and more preferably from about 2 to about 4 hours. The cells are preferably maintained at temperatures from about 15° C. to about 25° C. during this period.
The lipoxygenase enzyme may be derived from animal or bacterial cells, and is preferably derived from plant cells. Expression constructs may contain all or a portion of the lipoxygenase gene or coding region. Preferably constructs contain a portion of the coding region sufficient to create functional lipoxygenase activity. Preferably the constructs of the invention encode the sequences of SEQ ID NOs 1-3, or contain the nucleic acid sequences of SEQ ID NOs 4-6. Also preferably the sequence is a functional sequences that generates functional lipoxygenase activity.
Preferably the host cell is a microorganism that rapidly and economically proliferates in vitro such as, for example, one or more of the bacterial cell strains of K12 cells, E. coli cells, Bacillus cells, Lactococci or yeast cells. Also preferably, the host cells contain one or more protease deficiencies as compared to wild-type cells. For E. coli host cells, the deficiency is preferably of one or more of the proteases Lon, OMPT, and/or Lon/ClpP.
Preferably the host cells further contain one or more chaperone plasmid expression vectors. Chaperones function in assisting protein folding, benefiting the co-expressed molecules.
Expression of lipoxygenase in the systems of the invention typically involves inducing expression of the lipoxygenase sequence and also preferably the chaperone sequences before, during or after expression of the lipoxygenase, and preferably simultaneously or nearly simultaneously to allow for maximal expression of the enzyme.
Lipoxygenase produced according to methods of the invention can be further isolated and purified. Preferably, purification of lipoxygenase produced according to the methods of the invention involves contact the with immobilized-metal affinity chromatography media. The enzyme remains bound and can be washed with wash buffer and subsequently eluted with elution buffer.
Preferably the increased lipoxygenase expression of the invention is 5 fold greater as compared to expression in wild-type cells (e.g., cells that are not protease deficient and/or cells without one or more expression chaperones), more preferably 10 fold greater, more preferably 50 fold greater, more preferably 100 fold greater, more preferably 200 fold greater, more preferably 300 fold greater, more preferably 400 fold greater, and more preferably 500 fold greater or more.
Lipoxygenase made according to the invention is preferably useful in the manufacture of food products such as bread products (for either, or both bleaching and improving texture), the manufacture of paints thinners, perfumes, aroma and flavor enhancers, as signaling compounds, and for pitch control in softwood pulp in paper industry.
The following examples illustrate embodiments of the invention, but should not be viewed as limiting the scope of the invention.
EXAMPLES
Example 1
LOXs Employed for Protein Production
SLP1 (seed linoleate 13S-lipoxygenase-1 [ Glycine max ] NCBI Reference Sequence: NP_001236153.1, length 839 amino acids) and SLP3 seed linoleate 9S-lipoxygenase-3 [ Glycine max ] NCBI Reference Sequence: NP_001235383.1) were employed as LOXs for production in microbes. In addition, a shortened version of SLP1 (herein minilox) from amino acid Serine 278 containing an additional methionine before the Serine 278 were cloned and expressed in microbes.
Example 2
Synthesis of DNA Encoding Protein Sequences for SLP1, SLP3 and Minilox Optimized for Expression
Optimal gene codon usage in plants and bacteria differ. New DNA encoding sequences for SLP1, SLP3 and minilox were determined and synthetically generated according to instructions (Genscript USA Inc.). The sequence for minilox was identical as that of SLP1 with the exception of having an ATG encoding for an initiator methionine prior to nucleotide bases encoding for SLP1 Serine 278. Optimized sequences with desired cloning sites were created.
Example 3
Cloning of Soybean Lipoxygenase 1 (SLP1) and 3 (SLP3) and MiniLox
Initially, SLP1 and SLP3 were cloned into the pET 47b vector (Novogen) using SmaI-XhoI restriction sites, so that each contained the pET47b initiating methionine and a 6× histidine tag (SEQ ID NO 7). The SLP1 and minilox encoding DNA were then transferred to the DNA2.0 expression vector 424 purple, a low copy number plasmid without the histidine tags using NdeI-XhoI sites, so that expressed proteins would not contain the histidine tags. Similarly, the SLP1 encoding sequence was cloned into the 424-purple vector (herein 424 vector) with the exception of using NdeI-EcoRI cloning sites. The SLP1 encoding sequences were then transferred to the DNA2.0 purple-444 vector (herein 444 vector), a high copy number plasmid using restriction sites NdeI-XhoI. The vectors contained promoters for expression of the insert DNA with the pET47 containing a T7-promotor, and the DNA2.0 vectors contained a T5-promotor.
Example 4
Expression of SLP1, Minilox and SLP3
Vectors were transfected into cell lines. Initially, expression of SLP1 was performed with the 6 histidine (SEQ ID NO 7) tagged SLP1 vector in E. coli BL21 cells, an E. coli B cell line suitable for the expression of the pET47b vectors. Thereafter, all expression was performed in E. coli K12 strains. Expression was tested in LB media, with 50-100 μg/ml ampicillin, and induction of expression for all vectors was with 0.5-1 mM IPTG.
Example 5
Activity Assay
The activity assay utilized linoleic acid as a substrate and colorimetric detection of product. Detected values for the assay varied depending on the substrate preparation, age of substrate, and substrate batch, which may be subject to variation due to oxidation from the environment. As such, approximate expression levels of SLP1 in BL21 are presented as 1 unit/cell OD550 SLP1-LB culture and relative and approximate values for expression in other strains is relative to the BL21 expression. Cell OD550 is defined as a cell density at OD550.
Example 6
Improvement of SLP1 Production
SLP1 expressed with or without a histidine tag using the pET47b vector and BL21 cells was very poor when induced at room temperature. The standard level of activity, 1 unit/OD cells was established for induction at 15° C. with and overnight expression. Dramatically improved activity was observed using the purple-424 vector (herein 424 vector), in the K12 HMS174 cell line (4 units/Cell OD550). Unlike BL21 cells, activity was also observed when induced at 20° C.-25° C. with overnight expression. Slp1 activity could be further enhanced by growing cells at 15° C. for up to several days. In all E. coli strains tested, growth at 37 C of was found to generate little or no SLP1 activity, and protein degradation products were observed upon western analysis ( FIG. 2 ).
An additional increase in activity was discovered using protease deficient E. coli K12 strains with the 424 vector. Lon, OMPT, or Lon/ClpP mutants all showed a further minimum two-fold increase in activity with (˜10 units/cell OD550). The specific E. coli cell lines with specific protease deficiencies also showed some similar characteristics of protein degradation ( FIG. 3 ) yet some cell lines had less degradation than others, signifying that proteases play a role in the limited production of lipoxygenases.
An additional enhancement of activity was observed when using the 444 high plasmid copy vector in the K12 Pam155 (lon protease deficient) E. coli cell line and with chaperones. Chaperone plasmid sets consisting of five different plasmids from Takara Bio Inc. each designed to express a single or multiple molecular chaperone sets can enable optimal protein expression and folding and reduce protein misfolding. Each Takara plasmid carries an origin of replication (ORF) derived from pACYC and a chloramphenicol-resistance gene (Cm r ) gene, which allows the use of E. coli expression systems containing ColE1-type plasmids that confer ampicillin resistance. The chaperone genes are situated downstream of the araB or Pzt-1 (tet) promoters and, as a result, expression of target proteins and chaperones can be individually induced if the target gene is placed under the control of different promoters (e.g., lac). These plasmids also contain the necessary regulator (araC or tet r ) for each promoter. Takara Bio Inc. plasmids containing chaperones or sets thereof either tetracycline or arabinose inducible were coexpressed with SLP1. These include: groES-groEL, dnaK-dnaJ-grpE, groES-groEL-tig, or tig in plasmids (TakaraBo Inc.). Expression of SLP1 in the presence of groES-groEL alone or with tig (groES-groEL-tig) enhanced the amount of active enzyme produced roughly to 40-60 units/cell OD. Activity was optimal at 15° C. but also observed at or below 25° C. At 37° C., expression was more limited.
Expression of SLP1 in the Pam153 cell with concomitant GroESL chaperone expression, in LB, produces 68 micrograms of SLP1 per milliliter at a bacterial OD550 of 3, when grown in test tubes at 37° C. and induced at 20° C. overnight. However, SLP1 expression in an E. coli strain that is not a protease deficient strain and without chaperone expression can either not be detected at all with standard SDS PAGE analysis, or western analysis, or expresses less than 1 μg per milliliter LB under similar conditions at an OD550 of 3 (see FIG. 4 ). In general, expression of SLP1 in E. coli strains grown and induced under optimal conditions was undetectable or less than 1 microgram per milliliter when appropriate chaperones were absent and strains were not protease deficient. However when expressing SLP1 in E. coli K12 protease deficient strains with co-expression of an appropriate chaperone, 68 micrograms of SLP1 per milliliter at a bacterial OD550 of 3 was attained.
Example 7
Purification of SPL1
Purification of SLP1 with the 6×his tag (SEQ ID NO 7) was highly effective using standard Ni-NTA IMAC purification. In the 424 or 444 vectors lacking the 6×his tag (SEQ ID NO 7), where SLP1 was encoded by the native SLP1 sequence alone, IMAC was equally efficient though under modified conditions. Nickel and zinc were each tested with similar results and calcium or other divalent metals should do as well. Buffers for IMAC were either 50 mM phosphate or Tris-HCl at pH 7-9, with 400 mM NaCl and 10% glycerol. Cells were disrupted using B-PER (Peirce) or by a homogenizer, in the presence of PMSF as a protease inhibitor. Employing Zinc-NTA, it was discovered that loading the sample in buffer with 10 mM imidazole and elution in buffer with 80 mM imidazole was effective in purification of SLP1. Other column media that effectively binds SLP1 include MonoQ and DEAE, but not negatively charged resins.
Example 8
Novel Information Provides Improved SLP1 Expression
Preliminary studies indicate that relatively poor production of SLP1 is the result of rapid proteolysis accompanied by improper folding of the enzyme. The limited soluble SLP1 and lack of insoluble protein suggests that most of the protein produced was rapidly degraded. Degradation products of SLP1 are visible in different E. coli strains with different protease deficient genetic backgrounds (see FIG. 1 ). An increase in both active enzyme and total protein was observed when inducing at suboptimal growth temperatures, where proteases are less functional. A relative increase in production and activity of SLP1 when protein folding is enhanced by an over-expressed chaperone.
Example 9
High Level Expression of Lipoxygenase in the E. Coli , K12
Unless otherwise stated, all bacterial media employed in this example was Luria Broth (herein LB, consisting of 10 grams Tryptone, 5 grams Yeast Extract, and 10 grams NaCl, dissolved in 1 liter water, and sterilized for a minimum of 20 minutes in an autoclave). Soybean Lipoxygenase 1 (herein SLP1) was expressed from a plasmid transfected into E. Coli K12 cells. FIG. 5 represents an SDS-PAGE protein gel of whole cell soluble proteins extracted from the K12 cells employing the commercial B-PER Protein Extraction Reagent (Pierce, Cat#78243), following company protocols. The highest level of soluble SLP1 protein relative to total soluble protein in the cell extract was 30% or greater and approximated at 34% as estimated by the ImageJ (National Institute of Health public software) analysis software. These levels are consistent with high level production of the enzyme. M=marker, 1 Uninduced, 2 SLP1 induced with 0.5 mM IPTG 3&4 Induced with 0.5 mM IPTG and expressing a molecular chaperone.
CITED REFERENCES
1. Permiakova, M. D. and V. A. Trufanov, Effect of soybean lipoxygenae on baking properties of wheat flour, Prikl Biokhim Mikrobiol, 2011. 47(3): p. 348-54.
2. Permiakova, M. D., et al., [Role of lipoxygenase in the determination of wheat grain quality]. Prikl Biokhim Mikrobiol, 2010. 46(1): p. 96-102.
3. Kanamoto, H., M. Takemura, and K. Ohyama, Cloning and expression of three lipoxygenase genes from liverwort, Marchantia polymorpha L., in Escherichia coli . Phytochemistry, 2012. 77: p. 70-8.
4. Osipova, E. V., et al., Recombinant maize 9-lipoxygenase: expression, purification, and properties. Biochemistry Biokhimiia, 2010. 75(7): p. 861-5.
5. Hwang, I. S, and B. K. Hwang, The pepper 9-lipoxygenase gene CaLOX1 functions in defense and cell death responses to microbial pathogens. Plant Physiol, 2010. 152(2): p. 948-67.
6. Padilla, M. N., et al., Functional characterization of two 13-lipoxygenase genes from olive fruit in relation to the biosynthesis of volatile compounds of virgin olive oil. J Agric Food Chem, 2009. 57(19): p. 9097-107.
7. Knust, B. and D. von Wettstein, Expression and secretion of pea-seed lipoxygenase isoenzymes in Saccharomyces cerevisiae . Appl Microbiol Biotechnol, 1992. 37(3): p. 342-51.
8. Steczko, J., et al., Effect of ethanol and low-temperature culture on expression of soybean lipoxygenase L-1 in Escherichia coli . Protein Expr Purif, 1991. 2(2-3): p. 221-7.
Sequence Information
SLP1 polypeptide sequence
(SEQ ID NO 1)
MFSAGHKIKGTVVLMPKNELEVNPDGSAVDNLNAFLGRSVSLQLISATK
ADAHGKGKVGKDTFLEGINTSLPTLGAGESAFNIHFEWDGSMGIPGAFY
IKNYMQVEFFLKSLTLEAISNQGTIRFVCNSWVYNTKLYKSVRIFFANH
TYVPSETPAPLVSYREEELKSLRGNGTGERKEYDRIYDYDVYNDLGNPD
KSEKLARPVLGGSSTFPYPRRGRTGRGPTVTDPNTEKQGEVFYVPRDEN
LGHLKSKDALEIGTKSLSQIVQPAFESAFDLKSTPIEFHSFQDVHDLYE
GGIKLPRDVISTIIPLPVIKELYRTDGQHILKFPQPHVVQVSQSAWMTD
EEFAREMIAGVNPCVIRGLEEFPPKSNLDPAIYGDQSSKITADSLDLDG
YTMDEALGSRRLFMLDYHDIFMPYVRQINQLNSAKTYATRTILFLREDG
TLKPVAIELSLPHSAGDLSAAVSQVVLPAKEGVESTIWLLAKAYVIVND
SCYHQLMSHWLNTHAAMEPFVIATHRHLSVLHPIYKLLTPHYRNNMNIN
ALARQSLINANGIIETTFLPSKYSVEMSSAVYKNWVFTDQALPADLIKR
GVAIKDPSTPHGVRLLIEDYPYAADGLEIWAAIKTWVQEYVPLYYARDD
DVKNDSELQHWWKEAVEKGHGDLKDKPWWPKLQTLEDLVEVCLIIIWIA
SALHAAVNFGQYPYGGLIMNRPTASRRLLPEKGTPEYEEMINNHEKAYL
RTITSKLPTLISLSVIEILSTHASDEVYLGQRDNPHWTSDSKALQAFQK
FGNKLKEIEEKLVRRNNDPSLQGNRLGPVQLPYTLLYPSSEEGLTFRGI
PNSISI
SLP3 polypeptide sequence
(SEQ ID NO 2)
MLGGLLHRGHKIKGTVVLMRKNVLDVNSVTSVGGIIGQGLDLVGSTLDT
LTAFLGRSVSLQLISATKADANGKGKLGKATFLEGIITSLPTLGAGQSA
FKINFEWDDGSGIPGAFYIKNFMQTEFFLVSLTLEDIPNHGSIHFVCNS
WIYNAKLFKSDRIFFANQTYLPSETPAPLVKYREEELHNLRGDGTGERK
EWERIYDYDVYNDLGDPDKGENHARPVLGGNDTFPYPRRGRTGRKPTRK
DPNSESRSNDVYLPRDEAFGHLKSSDFLTYGLKSVSQNVLPLLQSAFDL
NFTPREFDSFDEVHGLYSGGIKLPTDIISKISPLPVLKEIFRTDGEQAL
KFPPPKVIQVSKSAWMTDEEFAREMLAGVNPNLIRCLKDFPPRSKLDSQ
VYGDHTSQITKEHLEPNLEGLTVDEAIQNKRLFLLDHHDPIMPYLRRIN
ATSTKAYATRTILFLKNDGTLRPLAIELSLPHPQGDQSGAFSQVFLPAD
EGVESSIWLLAKAYVVVNDSCYHQLVSHWLNTHAVVEPFIIATNRHLSV
VHPIYKLLHPHYRDTMNINGLARLSLVNDGGVIEQTFLWGRYSVEMSAV
VYKDWVFTDQALPADLIKRGMAIEDPSCPHGIRLVIEDYPYTVDGLEIW
DAIKTWVHEYVFLYYKSDDTLREDPELQACWKELVEVGHGDKKNEPWWP
KMQTREELVEACAIIIWTASALHAAVNFGQYPYGGLILNRPTLSRRFMP
EKGSAEYEELRKNPQKAYLKTITPKFQTLIDLSVIEILSRHASDEVYLG
ERDNPNWTSDTRALEAFKRFGNKLAQIENKLSERNNDEKLRNRCGPVQM
PYTLLLPSSKEGLTFRGIPNSISI
Minilox 1 polypeptide sequence
(SEQ ID NO 3)
MSTPIEFHSFQDVHDLYEGGIKLPRDVISTIIPLPVIKELYRTDGQHI
LKFPQPHVVQVSQSAWMTDEEFAREMIAGVNPCVIRGLEEFPPKSNLD
PAIYGDQSSKITADSLDLDGYTMDEALGSRRLFMLDYHDIFMPYVRQI
NQLNSAKTYATRTILFLREDGTLKPVAIELSLPHSAGDLSAAVSQVVL
PAKEGVESTIWLLAKAYVIVNDSCYHQLMSHWLNTHAAMEPFVIATHR
HLSVLHPIYKLLTPHYRNNMNINALARQSLINANGIIETTFLPSKYSV
EMSSAVYKNWVFTDQALPADLIKRGVAIKDPSTPHGVRLLIEDYPYAA
DGLEIWAAIKTWVQEYVPLYYARDDDVKNDSELQHWWKEAVEKGHGDL
KDKPWWPKLQTLEDLVEVCLIIIWIASALHAAVNFGQYPYGGLIMNRP
TASRRLLPEKGTPEYEEMINNHEKAYLRTITSKLPTLISLSVIEILST
HASDEVYLGQRDNPHWTSDSKALQAFQKFGNKLKEIEEKLVRRNNDPS
LQGNRLGPVQLPYTLLYPSSEEGLTFRGIPNSISI
SLP1 DNA optimized encoding sequence (with
restriction sites 5′SmaI and 3′XhoI with stop
codon for cloning into pET47b with 6X histidine
tag
(SEQ ID NO 7)) (SEQ ID NO 4)
CCCGGGATGTTTAGTGCTGGTCACAAAATCAAAGGTACCGTGGTCCT
GATGCCGAAAAATGAACTGGAAGTCAACCCGGATGGTAGCGCCGTTG
ATAACCTGAATGCGTTCCTGGGTCGTAGCGTGTCTCTGCAGCTGATT
TCCGCCACCAAAGCAGACGCTCACGGCAAGGGTAAAGTTGGCAAAGA
TACGTTTCTGGAAGGTATTAATACCTCCCTGCCGACCCTGGGTGCCG
GTGAATCAGCTTTCAACATCCATTTCGAATGGGATGGTTCAATGGGC
ATTCCGGGCGCCTTCTACATCAAAAACTACATGCAGGTGGAATTTTT
CCTGAAAAGTCTGACCCTGGAAGCAATCTCCAATCAGGGTACGATTC
GTTTTGTCTGCAACTCGTGGGTGTATAATACCAAACTGTACAAAAGC
GTTCGCATCTTTTTCGCGAACCACACCTATGTTCCGAGCGAAACCCC
GGCACCGCTGGTTTCTTACCGTGAAGAAGAACTGAAAAGTCTGCGCG
GCAATGGTACCGGCGAACGTAAAGAATATGATCGCATTTATGACTAC
GATGTTTACAACGACCTGGGCAATCCGGATAAAAGCGAAAAACTGGC
CCGTCCGGTCCTGGGCGGTAGCTCTACCTTCCCGTATCCGCGTCGCG
GTCGTACCGGTCGTGGTCCGACCGTGACCGATCCGAACACCGAAAAA
CAGGGCGAAGTCTTTTATGTGCCGCGCGACGAAAATCTGGGCCATCT
GAAATCTAAAGATGCCCTGGAAATCGGTACCAAAAGTCTGTCCCAGA
TTGTGCAACCGGCGTTTGAAAGCGCCTTCGATCTGAAATCTACGCCG
ATTGAATTTCACTCCTTCCAGGACGTTCATGATCTGTATGAAGGCGG
TATCAAACTGCCGCGTGACGTCATTTCAACCATTATCCCGCTGCCGG
TGATCAAAGAACTGTACCGCACGGATGGTCAGCACATTCTGAAATTT
CCGCAACCGCATGTGGTTCAGGTTTCACAATCGGCGTGGATGACCGA
TGAAGAATTCGCGCGTGAAATGATCGCCGGCGTTAACCCGTGCGTCA
TTCGCGGTCTGGAAGAATTTCCGCCGAAAAGCAATCTGGACCCGGCA
ATCTATGGCGATCAGAGTTCCAAAATTACCGCTGACTCTCTGGACCT
GGATGGCTACACGATGGATGAAGCCCTGGGTAGTCGTCGCCTGTTTA
TGCTGGACTATCACGATATCTTCATGCCGTACGTGCGTCAGATTAAC
CAACTGAATTCTGCAAAAACCTATGCTACCCGTACGATCCTGTTTCT
GCGCGAAGACGGCACGCTGAAACCGGTTGCAATTGAACTGAGCCTGC
CGCATTCTGCTGGTGATCTGAGTGCCGCGGTGTCCCAGGTTGTGCTG
CCGGCAAAAGAAGGCGTTGAAAGTACCATCTGGCTGCTGGCGAAAGC
CTATGTTATTGTCAACGATTCATGTTACCATCAACTGATGTCGCACT
GGCTGAATACCCATGCAGCTATGGAACCGTTTGTTATCGCAACGCAT
CGCCACCTGTCTGTCCTGCACCCGATTTATAAACTGCTGACCCCGCA
TTACCGTAACAATATGAACATCAATGCACTGGCTCGCCAGAGTCTGA
TTAACGCGAATGGTATTATCGAAACCACGTTCCTGCCGTCAAAATAT
TCGGTGGAAATGTCATCGGCCGTTTACAAAAACTGGGTCTTTACCGA
CCAGGCACTGCCGGCTGATCTGATCAAACGTGGCGTCGCGATTAAAG
ATCCGAGCACCCCGCATGGTGTGCGTCTGCTGATTGAAGACTATCCG
TACGCGGCCGATGGCCTGGAAATCTGGGCAGCTATTAAAACCTGGGT
GCAGGAATATGTTCCGCTGTATTACGCACGCGATGACGATGTGAAAA
ATGACTCCGAACTGCAACACTGGTGGAAAGAAGCTGTTGAAAAAGGT
CATGGCGACCTGAAAGATAAACCGTGGTGGCCGAAACTGCAGACCCT
GGAAGATCTGGTGGAAGTTTGTCTGATTATCATTTGGATTGCCAGCG
CACTGCATGCCGCGGTGAACTTTGGTCAATATCCGTACGGCGGTCTG
ATTATGAATCGTCCGACCGCAAGCCGTCGCCTGCTGCCGGAAAAAGG
CACGCCGGAATACGAAGAAATGATCAACAACCATGAAAAAGCGTACC
TGCGCACCATCACGAGCAAACTGCCGACCCTGATTAGCCTGTCTGTT
ATCGAAATTCTGTCAACGCACGCGTCGGATGAAGTCTATCTGGGTCA
GCGTGACAACCCGCATTGGACCAGTGATTCCAAAGCGCTGCAGGCCT
TCCAAAAATTCGGCAACAAACTGAAAGAAATCGAAGAAAAACTGGTC
CGTCGCAACAATGATCCGAGCCTGCAGGGTAACCGTCTGGGTCCGGT
GCAACTGCCGTATACCCTGCTGTATCCGTCCAGTGAAGAAGGTCTGA
CGTTTCGTGGTATTCCGAACTCCATTTCCATCTGACTCGAG
SLP3 DNA optimized encoding sequence (with
restriction sites 5′NdeI and 3′EcoRI and 3′stop
codon for cloning into the pJex purple 424
vector from DNA2.0 Inc.
(SEQ ID NO 5)
CATATGCTGGGCGGCCTGCTGCACCGTGGTCATAAAATCAAGGGCA
CCGTGGTCCTGATGCGTAAGAACGTCCTGGATGTGAATAGCGTGAC
CTCGGTCGGCGGTATTATCGGCCAGGGTCTGGACCTGGTGGGTAGC
ACGCTGGATACCCTGACGGCCTTTCTGGGCCGCTCAGTGTCGCTGC
AACTGATCAGCGCAACCAAAGCAGATGCTAACGGCAAAGGCAAGCT
GGGCAAGGCGACGTTCCTGGAAGGCATTATCACCTCCCTGCCGACG
CTGGGTGCAGGCCAGTCAGCCTTTAAAATTAATTTCGAATGGGATG
ACGGCTCTGGTATTCCGGGCGCCTTCTACATCAAGAACTTCATGCA
GACCGAATTTTTCCTGGTCAGCCTGACGCTGGAAGATATCCCGAAT
CATGGCTCGATTCACTTTGTGTGCAACAGCTGGATCTACAATGCGA
AACTGTTCAAGTCCGATCGCATTTTCTTTGCCAATCAGACCTATCT
GCCGTCAGAAACGCCGGCACCGCTGGTTAAATACCGTGAAGAAGAA
CTGCACAACCTGCGTGGTGACGGTACCGGTGAACGTAAAGAATGGG
AACGCATCTACGATTACGACGTTTACAACGATCTGGGTGATCCGGA
CAAAGGCGAAAACCATGCGCGTCCGGTCCTGGGCGGTAATGACACC
TTTCCGTACCCGCGTCGCGGTCGTACCGGTCGTAAACCGACGCGTA
AGGATCCGAACAGCGAATCTCGCAGTAATGATGTGTATCTGCCGCG
TGACGAAGCCTTTGGTCACCTGAAAAGCTCTGATTTCCTGACGTAC
GGCCTGAAGTCCGTTTCACAGAACGTCCTGCCGCTGCTGCAAAGCG
CATTTGATCTGAATTTCACCCCGCGCGAATTTGATTCGTTCGACGA
AGTTCATGGTCTGTATAGCGGCGGTATTAAGCTGCCGACCGACATT
ATCTCTAAAATCAGTCCGCTGCCGGTGCTGAAGGAAATTTTTCGCA
CGGATGGCGAACAGGCTCTGAAGTTCCCGCCGCCGAAAGTCATCCA
AGTGTCGAAAAGCGCGTGGATGACCGATGAAGAATTTGCACGTGAA
ATGCTGGCTGGTGTTAACCCGAATCTGATTCGCTGTCTGAAGGATT
TCCCGCCGCGTTCCAAACTGGATTCACAGGTGTATGGTGACCACAC
CAGTCAAATCACGAAAGAACATCTGGAACCGAACCTGGAAGGCCTG
ACCGTTGATGAAGCTATTCAGAATAAACGTCTGTTTCTGCTGGATC
ATCACGACCCGATCATGCCGTATCTGCGTCGCATTAATGCGACCTC
GACGAAAGCGTACGCCACCCGCACGATCCTGTTCCTGAAGAACGAT
GGTACCCTGCGTCCGCTGGCCATTGAACTGAGCCTGCCGCATCCGC
AGGGTGACCAATCGGGTGCGTTTAGCCAGGTTTTCCTGCCGGCCGA
TGAAGGCGTCGAAAGTTCCATCTGGCTGCTGGCAAAAGCTTATGTG
GTTGTCAACGATTCTTGCTACCATCAGCTGGTGTCTCACTGGCTGA
ATACCCATGCAGTGGTTGAACCGTTTATTATCGCTACGAACCGCCA
CCTGTCTGTCGTGCATCCGATCTATAAACTGCTGCATCCGCACTAC
CGCGACACCATGAACATTAATGGTCTGGCGCGTCTGAGTCTGGTCA
ACGATGGCGGTGTGATTGAACAGACGTTTCTGTGGGGCCGTTATTC
TGTTGAAATGAGTGCCGTTGTCTACAAAGATTGGGTCTTCACCGAC
CAAGCACTGCCGGCAGACCTGATCAAGCGTGGTATGGCAATTGAAG
ATCCGTCCTGTCCGCACGGCATCCGTCTGGTGATTGAAGATTATCC
GTACACCGTTGACGGTCTGGAAATCTGGGATGCAATTAAAACGTGG
GTGCATGAATACGTTTTTCTGTACTACAAGTCTGATGACACCCTGC
GCGAAGACCCGGAACTGCAGGCGTGCTGGAAAGAACTGGTGGAAGT
TGGTCACGGCGATAAAAAGAACGAACCGTGGTGGCCGAAAATGCAA
ACCCGTGAAGAACTGGTTGAAGCGTGTGCCATTATCATTTGGACGG
CAAGCGCTCTGCATGCGGCCGTGAACTTTGGCCAGTATCCGTACGG
CGGTCTGATTCTGAATCGCCCGACCCTGTCTCGTCGCTTCATGCCG
GAAAAAGGCAGTGCTGAATATGAAGAACTGCGTAAAAATCCGCAGA
AGGCGTACCTGAAAACCATCACGCCGAAATTTCAAACCCTGATTGA
CCTGAGCGTGATCGAAATTCTGTCCCGCCATGCGTCAGATGAAGTT
TATCTGGGTGAACGTGACAACCCGAATTGGACCTCCGATACGCGTG
CACTGGAAGCTTTTAAGCGCTTCGGCAACAAACTGGCCCAGATCGA
AAACAAGCTGTCAGAACGTAACAACGATGAAAAGCTGCGTAATCGC
TGCGGCCCGGTGCAAATGCCGTATACCCTGCTGCTGCCGTCCTCAA
AAGAAGGTCTGACGTTCCGTGGTATCCCGAATAGCATTAGCATCTA
AGAATTC
Minilox optimized encoding sequence (with 5′NdeI
and 3′XhoI restriction sites and 3′stop
codon for cloning into pJexpress purple 424 vector
from DNA2.0 Inc.)
(SEQ ID NO 6)
CATATGTCTACGCCGATTGAATTTCACTCCTTCCAGGACGTTCAT
GATCTGTATGAAGGCGGTATCAAACTGCCGCGTGACGTCATTTCA
ACCATTATCCCGCTGCCGGTGATCAAAGAACTGTACCGCACGGAT
GGTCAGCACATTCTGAAATTTCCGCAACCGCATGTGGTTCAGGTT
TCACAATCGGCGTGGATGACCGATGAAGAATTCGCGCGTGAAATG
ATCGCCGGCGTTAACCCGTGCGTCATTCGCGGTCTGGAAGAATTT
CCGCCGAAAAGCAATCTGGACCCGGCAATCTATGGCGATCAGAGT
TCCAAAATTACCGCTGACTCTCTGGACCTGGATGGCTACACGATG
GATGAAGCCCTGGGTAGTCGTCGCCTGTTTATGCTGGACTATCAC
GATATCTTCATGCCGTACGTGCGTCAGATTAACCAACTGAATTCT
GCAAAAACCTATGCTACCCGTACGATCCTGTTTCTGCGCGAAGAC
GGCACGCTGAAACCGGTTGCAATTGAACTGAGCCTGCCGCATTCT
GCTGGTGATCTGAGTGCCGCGGTGTCCCAGGTTGTGCTGCCGGCA
AAAGAAGGCGTTGAAAGTACCATCTGGCTGCTGGCGAAAGCCTAT
GTTATTGTCAACGATTCATGTTACCATCAACTGATGTCGCACTGG
CTGAATACCCATGCAGCTATGGAACCGTTTGTTATCGCAACGCAT
CGCCACCTGTCTGTCCTGCACCCGATTTATAAACTGCTGACCCCG
CATTACCGTAACAATATGAACATCAATGCACTGGCTCGCCAGAGT
CTGATTAACGCGAATGGTATTATCGAAACCACGTTCCTGCCGTCA
AAATATTCGGTGGAAATGTCATCGGCCGTTTACAAAAACTGGGTC
TTTACCGACCAGGCACTGCCGGCTGATCTGATCAAACGTGGCGTCG
CGATTAAAGATCCGAGCACCCCGCATGGTGTGCGTCTGCTGATTGA
AGACTATCCGTACGCGGCCGATGGCCTGGAAATCTGGGCAGCTATT
AAAACCTGGGTGCAGGAATATGTTCCGCTGTATTACGCACGCGATG
ACGATGTGAAAAATGACTCCGAACTGCAACACTGGTGGAAAGAAGC
TGTTGAAAAAGGTCATGGCGACCTGAAAGATAAACCGTGGTGGCCG
AAACTGCAGACCCTGGAAGATCTGGTGGAAGTTTGTCTGATTATCA
TTTGGATTGCCAGCGCACTGCATGCCGCGGTGAACTTTGGTCAATA
TCCGTACGGCGGTCTGATTATGAATCGTCCGACCGCAAGCCGTCGC
CTGCTGCCGGAAAAAGGCACGCCGGAATACGAAGAAATGATCAACA
ACCATGAAAAAGCGTACCTGCGCACCATCACGAGCAAACTGCCGAC
CCTGATTAGCCTGTCTGTTATCGAAATTCTGTCAACGCACGCGTCG
GATGAAGTCTATCTGGGTCAGCGTGACAACCCGCATTGGACCAGTG
ATTCCAAAGCGCTGCAGGCCTTCCAAAAATTCGGCAACAAACTGAA
AGAAATCGAAGAAAAACTGGTCCGTCGCAACAATGATCCGAGCCTGC
AGGGTAACCGTCTGGGTCCGGTGCAACTGCCGTATACCCTGCTGTAT
CCGTCCAGTGAAGAAGGTCTGACGTTTCGTGGTATTCCGAACTCCAT
TTCCATCTGACTCGAG
Other embodiments and uses of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. All references cited herein, including all publications, U.S. and foreign patents and patent applications, are specifically and entirely incorporated by reference. The term comprising, where ever used, is intended to include the terms consisting and consisting essentially of. Furthermore, the terms comprising, including, and containing are not intended to be limiting. It is intended that the specification and examples be considered exemplary only with the true scope and spirit of the invention indicated by the following claims. | The invention is directed to the enhanced expression and purification of lipoxygenase enzymes. These enzymes are of wide-spread industrial importance, often produced in heterologous microbial systems. Preferably, the lipoxygenase produced by the methods of the invention is a plant-derived enzyme and expressed at high-levels in a microbial system that includes a protease-deficient host and one or more chaperone expression plasmids. The invention is also directed to amino acid and nucleic acid fragments of the lipoxygenase enzyme including fragments in expression constructs encoding all or a portion of one or more lipoxygenase genes. The invention is also directed to methods of manufacturing bread and other food and also non-food products with lipoxygenase manufactured by the methods of the invention. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the U.S. National Stage of International Application No. PCT/EP2010/055242, filed Apr. 21, 2010 and claims the benefit thereof. The International Application claims the benefits of European Patent Office application No. 09007792. EP filed Jun. 12, 2009. All of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The invention relates to an arrangement, comprising an electrical generator, a main exciter machine and an auxiliary exciter machine, and to a method for turning a shaft run which comprises a steam turbine and/or a gas turbine and/or a generator.
BACKGROUND OF INVENTION
[0003] A turbogenerator having a polyphase synchronous generator is normally used to produce electrical energy in a power station. The turbogenerator essentially comprises a gas turbine, a polyphase synchronous generator and an exciter current device, possibly as well as a steam turbine. The polyphase current which is produced by the generator is tapped off on the stator winding of the generator, while the rotor winding is excited with direct current to produce a magnetic field. It is known for the direct current to be provided via brushless rotating rectifier exciter machines, or via sliprings from a solid-state thyristor-controlled exciter device. A brushless rectifier exciter machine having external poles is coupled to the generator such that its rotor rotates with the generator shaft. In a situation such as this, the polyphase current which is first of all produced in the exciter machine can be rectified with the aid of rectifiers which rotate with the rotor shaft of the exciter machine. The direct current which is produced by a rectifier exciter machine such as this can be passed directly to the rotor of the generator, without sliprings.
[0004] In contrast to a turbogenerator having a steam turbine as a drive, a gas turbine cannot accelerate the turbogenerator on its own. In general, the turbogenerator is started up from so-called turning operation at a rotation speed of about 100 rpm to 200 rpm, for which purpose a hydraulic-oil drive is generally used. As is known, a gas turbine cannot be ignited until an adequate rotation speed of about 1000 rpm is reached and then being accelerated further up to the nominal rotation speed. A separate so-called starting motor can be used to reach this rotation speed limit, or the generator can be used as a frequency-control motor for acceleration.
[0005] The shaft runs in those power stations which comprise a steam and/or gas turbine as well as a generator, must be rotated at a low rotation speed after being decelerated from operation at rated rotation speeds, and this is also referred to as a turning, in order to prevent deformation of the shafts as they cool down.
[0006] In this case, the shaft run is moved by a hydraulic motor, which is operated by oil pressure and is designed for this purpose, at rotation speeds of about 2 rpm up to 70 rpm.
SUMMARY OF INVENTION
[0007] Use of oil for the hydraulic motor which is operated by oil pressure always results in a fire risk. The object of the invention is to specify an arrangement and a method by means of which a shaft run in a power station can be turned without having to use an external hydraulic motor, which is operated by oil pressure, in this case.
[0008] This object is achieved by an arrangement comprising an electrical generator, a main exciter machine and an auxiliary exciter machine, wherein the auxiliary exciter machine is designed to produce electrical voltage during normal operation and to be used as a turning motor during turning operation.
[0009] During normal operation, the auxiliary exciter machine is a permanent-magnet synchronous machine which is fitted as a component of the rotating exciter device at the end of the generator-side shaft run. During normal operation, the auxiliary exciter machine is in the form of a synchronous generator, which produces the voltage for the field winding of the main exciter machine.
[0010] The invention now proposes that the auxiliary exciter machine be in the form of a synchronous motor which drives the shaft run at the required turning rotation speeds of about 2 rpm to 70 rpm. There is therefore no need whatsoever for the hydraulic motor, which is operated by oil pressure, for the turning drive. Furthermore, the physical length of the machine casing can be made shorter overall.
[0011] The changeover of the auxiliary exciter machine, which first of all operates as a synchronous generator, to a synchronous motor which drives the shaft run is carried out by switching the terminals of the auxiliary exciter machine to an appropriate polyphase feeder. This polyphase feeder produces a variable-frequency, variable electrical voltage. The auxiliary exciter machine therefore becomes a synchronous motor whose rotation speed can be set by the polyphase feeder and which provides the required turning rotation speeds of about 3 rpm to 100 rpm.
[0012] For the purposes of the invention, it is advantageous for an appropriate rotation speed signal to be emitted to the turbine tachogenerator, in order to control the rotation speed.
[0013] Further advantageous developments are specified in the dependent claims.
[0014] In a first advantageous development of the electrical generator, the main exciter machine and the auxiliary exciter machine are therefore coupled to one another via a shaft which transmits torque. For the purposes of the invention, this therefore advantageously avoids the use of a gearbox or similar torque-transmitting elements.
[0015] In a further advantageous development, the main exciter machine has a stator winding which is supplied with electric current from the auxiliary exciter machine.
[0016] The object relating to the method is achieved by a method for turning a shaft run which comprises a steam turbine and/or a gas turbine and/or a generator, wherein the auxiliary exciter machine which is required for production of a magnetic field is operated as a turning motor.
[0017] According to the invention, in the method, the auxiliary exciter machine is supplied with electrical voltage via a polyphase feeder, with the polyphase feeder producing a variable-frequency, variable electrical voltage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] One exemplary embodiment of the invention will be explained in more detail with reference to the following drawings, in which:
[0019] FIG. 1 shows an overview of an arrangement;
[0020] FIG. 2 shows an outline circuit diagram of a turbogenerator with a rotating brushless exciter machine
DETAILED DESCRIPTION OF INVENTION
[0021] FIG. 1 shows a steam turbine 1 , an electrical generator 2 , a main exciter machine 3 and an auxiliary exciter machine 4 . The steam turbine 1 comprises a rotor, which is not illustrated in any more detail, comprising a plurality of rotor blades, as well as a casing which has a plurality of stator blades. The rotor is borne such that it can rotate about a rotation axis 5 . A gas turbine can be arranged to transmit torque in alternative embodiments, in addition to the steam turbine 1 . The electrical generator 2 is arranged on the steam turbine 1 , such that torque is transmitted. The electrical generator 2 has a rotor, which has a rotor winding 19 , as well as a stator, which has a stator winding 22 . The rotor winding 19 is supplied with an electrical voltage from the main exciter machine 3 , leading to a magnetic field, which leads to an induced voltage in the stator winding 22 because of the rotatable movement about the rotation axis 5 . The auxiliary exciter machine 4 and the main exciter machine 3 are likewise coupled to one another such that torque is transmitted.
[0022] A rectifier and a voltage regulator 6 are arranged between the auxiliary exciter machine 4 and the main exciter machine 3 , rectified with electrical voltage transmitted by the auxiliary exciter machine 4 , and adapting the level of the electrical voltage. During normal operation, that is to say when the shaft run is rotated at a frequency of 3000 rpm or 3600 rpm, a changeover switch 7 , for normal operation is in the position N. As soon as the shaft run has to be decelerated from the comparatively high rotation speeds to low rotation speeds, the changeover switch 7 is moved to the position T for turning operation, thus allowing a connection to a polyphase feeder 8 with a controller. The polyphase feeder 8 produces an electrical voltage, with the level of the electrical voltage and the frequency of the electrical voltage being variable and adjustable. The auxiliary exciter machine 4 therefore becomes a synchronous motor, which drives the shaft run at the required turning rotation speed, which is between 3 rpm and 100 rpm. The actual rotation frequency N act and the nominal rotation frequency N nom are provided as input variables for the polyphase feeder 8 , in order to control the auxiliary exciter machine, which is in the form of a turning motor. Finally, the polyphase feeder 8 is supplied with electrical power via the electrical power supply system.
[0023] FIG. 2 shows an outline circuit of the turbogenerator with a rotating brushless exciter machine 10 . The outline circuit diagram shows the electrical generator 2 with a brushless rotating rectifier exciter machine 10 , which comprises an auxiliary exciter machine 11 and a main exciter machine 12 .
[0024] Both the generator 2 and the rectifier exciter machine 10 have stationary components 13 and rotating components 14 . A current is induced in an auxiliary exciter winding 16 in the auxiliary exciter machine 11 by a rotating permanent magnet 15 and is supplied to a voltage regulator 17 , to which a stator winding 18 of the main exciter machine 12 is connected. Instead of supplying voltage from auxiliary exciter winding 16 to the voltage regulator 17 , a voltage supply can alternatively be provided from a power supply system, which is not illustrated, to the voltage regulator 17 . The stator winding 18 produces a field which induces a current in a rotor winding 19 in the main exciter machine 12 , which current is rectified by a rotating rectifier 20 . This rectified current is supplied to a rotor winding 21 in the electrical generator 2 , which is fitted as a rotating field winding on the rotor 9 , which is not illustrated here. A polyphase current is therefore produced in a stator winding 22 of the generator 2 , and can be fed into a power supply system, which is not illustrated. The voltage regulator 17 is connected to the stator winding 22 via a current transformer 23 and a voltage transformer 24 . The outline circuit diagram shown in FIG. 2 shows normal operation, in which the auxiliary exciter machine is in the form of a permanent-magnet synchronous machine. According to the invention, the auxiliary exciter machine 11 is operated via the polyphase feeder and the changeover switch 7 as a synchronous motor, which moves the shaft run at the required turning rotation speeds. | An assembly including an electric generator and a steam turbine and an excitation device is provided. The excitation device is designed such that during nominal operation the auxiliary excitation machine is designed as permanently excited synchronous machine and the auxiliary excitation machine is designed as a synchronous motor or turning gear motor in a turning gear operation. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
The present application claims priority to (is a national stage filing of) PCT Application PCT/GB2009/000932 filed Apr. 9, 2009, which claims priority to British Patent Application No. GB0815192.0 filed Aug. 20, 2008 and British Patent Application No. GB0806811.6 filed Apr. 15, 2008. The entirety of each of the aforementioned references is incorporated herein by reference for all purposes.
BACKGROUND OF THE INVENTION
The present invention relates to an inlet for a fluid tank such as a vehicle fuel tank. In particular, the present invention relates to an anti-siphon inlet for a vehicle fuel tank.
The theft of fuel by siphoning from the fuel tanks of vehicles, and in particular commercial road vehicles, is a recognized problem. It is known to fit vehicles with a lockable fuel tank filler cap to prevent unauthorized access to the tank inlet. However, since the fuel filler cap is accessible it is vulnerable to tampering and can often be forced open by the determined thief. In addition, it is not always practical to fit a vehicle with a lockable fuel filler cap.
This problem has been addressed in the prior art by provision of a fluid tank inlet incorporating structure to prevent insertion of a siphon tube into the tank. For example, WO2006/048659 discloses an anti-siphon fluid tank inlet assembly comprising a tubular inlet body which in use is secured to the normal tank inlet so that its distal end extends a short distance in to the tank. The tubular inlet is designed to receive a conventional fuel dispensing nozzle. A conically shaped baffle is provided at the distal end of the tubular inlet to prevent insertion of a siphon tube through the tubular inlet and into the tank below. Both the tubular wall and the conical baffle are provided with apertures sized to allow the egress of fuel but block insertion of a siphon tube of any practical diameter. The inlet is designed so that fuel hitting the conical baffle either passes through the apertures in the baffle or is deflected towards apertures in the tubular body.
With such anti-siphon inlets, fuel can only be siphoned to the extent that the fuel level is above the base of the conical baffle. It is therefore desirable for the tubular body to be as short as possible. However, the shorter the tubular body the more prone the inlet becomes to the problem of “backflow”. That is, if fuel does not flow through the inlet at a minimum rate, fuel can well up within the inlet and either spit out of the inlet or cause sufficient back-pressure to activate the filler nozzle automatic shut-off mechanism thereby interrupting fuel delivery.
Hence, there exists a need in the art for systems and methods to mitigate the aforementioned limitations.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to an inlet for a fluid tank such as a vehicle fuel tank. In particular, the present invention relates to an anti-siphon inlet for a vehicle fuel tank.
According to a first aspect of the present invention there is provided a fluid tank inlet device comprising:
a tubular inlet body having a central bore defined by a tubular wall and having an axis; the tubular wall defining an open proximal end for receiving fuel; a plurality of apertures provided through the tubular wall for egress of fuel; wherein the distal end of the tubular body is blocked by a baffle defining a baffle surface facing into the bore of the tubular body, wherein at least a portion of the baffle surface is inclined at an acute angle relative to the axis to deflect fuel towards apertures in the tubular wall; and wherein the baffle surface is at least substantially free from apertures.
The It has been found that apertures provided in the baffle of known inlet structures such as that described in WO2006/048659 referenced above hinder rather than improve fluid flow through the inlet. This is believed to be the result of turbulence induced in the fuel by the presence of apertures in the baffle. In accordance with the present invention elimination of apertures in the baffle reduces turbulence and directs all fluid flow to the apertures in the tubular wall. For a given length of tubular body, the invention improves fluid flow and increases the speed of flow through the inlet that can be achieved without encountering problems due to backflow. Accordingly, the rate of fuel delivery can either be speeded up or the length of the tubular body can be reduced for a given fuel delivery rate. The latter feature is of particular benefit as by reducing the length of the tubular body the amount of fuel potentially exposed to theft by siphoning is reduced.
In accordance with some embodiments of the present invention there are no apertures at all through the baffle. However, an improvement over the prior art can be expected simply by reducing the number of apertures through the baffle. Accordingly embodiments of the present invention preferably have at least about 75% of the area of the baffle surface free from apertures. That is if the baffle is provided with one or more apertures, the apertures preferably do not take up more than about 25%, and preferably no more than 10%, of the baffle surface area. Some embodiments of the invention have no apertures through at least said inclined portion of the baffle surface, and may have no apertures at all through the baffle surface. In other embodiments of the invention, the baffle may comprise a single bore. In some embodiments the bore may extend parallel to the axis, whereas in other embodiments the bore may extend at an angle to the axis. The bore may open at one end to any appropriate portion of the baffle surface, however, preferably, the bore will open at one end to the apex of the baffle.
The inclined portion of the baffle surface (which may be the whole of the baffle surface) is preferably defined by a surface of revolution around an axis, which is preferably the axis of the tubular body. A surface of revolution will be understood to be generated by rotating a line around an axis (the line may meet the axis at the apex of the surface). The line may be a straight line so that the surface is conical, or may be curved. A convex curve will for instance generate a domed surface, whereas a concave curve will generate a horn shaped surface. The inclined portion of the baffle surface may be truncated, in that it is flattened below the apex of a surface of revolution. However, in preferred embodiments of the invention the inclined portion of the baffle surface rises to an apex. The apex preferably lies on the axis of the tubular body.
The terms “dome” and “domed” are used herein to refer to a surface of revolution (truncated or otherwise) generated by a convex curved line, and covers any curve including for instance the arc of a circle, a parabola or any convex curve.
In some embodiments of the invention the inclined portion of the baffle surface may be defined by a surface of revolution centered on an axis offset from and/or angled to the axis of the tubular body. In yet other embodiments of the invention the inclined portion of the baffle surface need not be defined by a surface of revolution, but preferably still rises to an apex and most preferably an apex lying on the axis of the tubular body.
The baffle may have a substantially uniform thickness, with a surface facing away from the bore of the tubular body which has substantially the same configuration as the baffle surface facing the bore of the tubular body. Alternatively the baffle may be a solid block with a surface facing away from the bore of the tubular body which is substantially normal to the axis of the tubular body.
The whole of the baffle surface may be inclined at said acute angle, so that the inclined surface extends to the tubular wall at an acute angle to the tubular wall. The angle of inclination of the baffle surface relative to the axis may decrease towards the tubular wall so that the baffle may for instance meet the tubular wall at an angle of between 0 and 25 degrees. Alternatively the inclined portion of the baffle surface may be bordered by a substantially non-inclined portion at its periphery which meets the tubular wall substantially at right angles (so that the tubular wall is substantially perpendicular to a peripheral border portion of the baffle surface). However, in preferred embodiments the peripheral edge region of the baffle surface is radiused so that it curves outwardly towards the tubular wall.
The baffle may be formed integrally with the tubular body, for instance by casting or machining, or may be formed separately from the tubular body and subsequently fitted thereto.
Both the tubular body and the baffle are preferably fabricated from metal or other strong material that resists puncture by anyone trying to circumvent the anti-siphon protection of the baffle.
According to a second aspect of the present invention there is provided a fluid tank inlet device comprising:
a tubular inlet body having a central bore defined by a tubular wall and having an axis; the tubular wall defining an open proximal end for receiving fuel; a plurality of apertures provided through the tubular wall for egress of fuel; wherein the distal end of the tubular body is blocked by a baffle defining a baffle surface facing into the bore of the tubular body, wherein at least a portion of the baffle surface is inclined at an acute angle relative to the axis to deflect fuel towards apertures in the tubular wall; and wherein the height of the baffle from its base to its apex is at least about 25% of the length of the tubular body.
The length of the tubular body may for instance be regarded as the length to which it will in use extend into the tank inlet. It will be appreciated that the “apex” of the baffle may not be a point, but may be flattened or rounded. In preferred embodiments of the second aspect of the invention the height of the baffle is at least about 35%, and most preferably at least about 40% of the length of the tubular body. In some embodiments of the invention the height of the baffle is between 45% and 55% of the length of the tubular body.
The baffle may have a configuration according to any of the possible embodiments of the first aspect of the present invention mentioned above. Similarly, the first and second aspects of the invention may be combined so that the baffle is at least substantially free from apertures.
This summary provides only a general outline of some embodiments of the invention. Many other objects, features, advantages and other embodiments of the invention will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
A further understanding of the various embodiments of the present invention may be realized by reference to the figures which are described in remaining portions of the specification. In the figures, like reference numerals are used throughout several figures to refer to similar components. In some instances, a sub-label consisting of a lower case letter is associated with a reference numeral to denote one of multiple similar components. When reference is made to a reference numeral without specification to an existing sub-label, it is intended to refer to all such multiple similar components.
FIG. 1 is a side view of an embodiment of an anti-siphon inlet according to the present invention;
FIG. 2 is a perspective view from one end of the embodiment of FIG. 1 ;
FIG. 3 is a perspective view from the other end of the embodiment of FIG. 1 ;
FIG. 4 is a schematic drawing showing the relative dimensions of an embodiment of the present invention;
FIG. 5 is a perspective view from one end of a further embodiment of the present invention; and
FIG. 6 is a cross section through a baffle in accordance with the embodiment of the invention shown in FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to an inlet for a fluid tank such as a vehicle fuel tank. In particular, the present invention relates to an anti-siphon inlet for a vehicle fuel tank.
Referring first to FIGS. 1 to 3 of the drawings, the illustrated anti-siphon inlet is designed for installation in the inlet of a vehicle fuel tank (not shown) and comprises a cylindrical body 1 having an axis X and depending from an attachment means or mounting structure 2 at its proximal end. The inlet commonly comprises a length of pipe which leads to the fuel tank. The anti-siphon inlet is received by the fuel-tank and/or the inlet pipe. The distal end of the tubular body 1 is closed by a domed baffle 3 whereas the proximal end of the tubular body 1 is open to receive a conventional fuel dispensing nozzle.
The attachment means 2 comprises a collar 4 adapted to seat over the cylindrical neck of a conventional fuel tank inlet. Bayonet lugs 5 extend radially outward from a radially thickened annular portion la of the tubular body 1 towards the collar 5 . The bayonet lugs 5 are adapted for engaging conventional bayonet fittings provided on a fuel tank inlet to receive a conventional fuel filler cap. Internally, the mounting structure 2 is provided with recesses 6 to receive the bayonet lugs of a conventional filler cap. Accordingly, the anti-siphon inlet is designed to be fitted to the inlet neck of a conventional fuel-tank inlet, and closed with a conventional fuel-filler cap. If necessary, the collar 4 may be fixed to the inlet tank neck, for instance using a suitable adhesive. Additionally, or alternatively, the inlet may be secured in the inlet tank neck by grub screws extending outwardly from the tubular body through holes 7 and engage the internal surface of the inlet neck.
The tubular body 1 is provided with a plurality of fuel flow apertures comprising holes 8 distributed around an upper portion of the tubular body 1 , and elongate slots 9 distributed around a lower portion of the tubular body 1 .
The baffle 3 defines a domed surface 3 a facing into the bore of the tubular body 1 which rises from its base at the distal end of the tubular body 1 to an apex on the axis of the tubular body 1 . The domed surface 3 a of the baffle 3 is defined by a surface of revolution of a curved line rotated about the axis of the tubular body 1 . The baffle 3 is a solid block so that its bottom surface 3 b is circular and planar.
The baffle 3 extends approximately 50% along the length of the tubular body 1 in the illustrated embodiment, and is entirely free from apertures. The length of the tubular body is its extent between its distal end and its proximal end where it joins the mounting structure 2 .
In use, a conventional fuel dispensing nozzle is simply inserted into the open end of the tubular body through the mounting structure 2 . Fuel flow from the filler nozzle is deflected by the domed baffle 3 towards the apertures in the tubular body, and in particular towards the elongate slots 9 . Accordingly, all fluid flow is through apertures in the tubular body 1 , and no fluid flows through the end of the tubular body which is closed by the baffle 3 .
Whereas conventional wisdom suggests that the baffle 3 should be provided with fluid flow apertures, the present inventors have found that fluid flow through the inlet is in fact enhanced by eliminating such apertures so that fuel can flow only through apertures in the tubular body 1 . That is, it has been found that apertures provided in the baffle 3 (as for instance taught by WO2006/048659 referenced above) do not provide any significant fluid flow but rather increase turbulence in the fluid within the inlet which increases the tendency of fuel to well up within the inlet and reduces the efficiency and speed of fluid flow through the inlet. For instance the present invention allows the length of the tubular body to be reduced (thereby reducing the volume of fuel potentially susceptible to theft) whilst permitting typical fuel dispensing rates.
FIG. 4 is a schematic cross-section through a tubular body 1 of an anti-siphon inlet according to the present invention revealing the cross-sectional profile of a domed baffle 3 . It will be appreciated that FIG. 4 is a simplified drawing intended to exemplify the profile of a baffle 3 in accordance with the present invention, and the relative dimensions of the baffle 3 and tubular body 1 . In one example of this embodiment, the length L of the tubular body is 68 mm and the height H of the domed baffle 3 is 31 mm. The domed surface 3 a of the baffle 3 is defined by revolution of a curved line about the axis X of the tubular body, the curve of the line being an arc of a circle with a radius R of 43 mm. The base of the baffle 3 curves radially outwards with a radius r of 5 mm. This outward curvature of the base of the baffle 3 improves fuel flow.
It will be appreciated that in other embodiments of the invention the dimensions of the baffle, and the dimensions of the baffle relative to the dimensions of the tubular body 1 , may vary from those illustrated in FIGS. 1 to 4 . Similarly, the profile of the domed surface 3 a of the baffle 3 may vary from that illustrated. However, it is preferred that the baffle extends to a height of more than about 25% of the length of the tubular body 1 , and more preferably more than about 35% of the length of the tubular body 1 . Such a height, coupled with the curvature of the surface, greatly hinders insertion of a siphon tube of any significant size into the inlet. For instance, for a siphon tube approaching the size of a conventional fuel filler nozzle, it would be difficult if not impossible to insert the siphon tube into the inlet body 1 past the apex of the baffle 3 . This raises the level of fuel below which siphoning is practically possible, thereby limiting the amount of fuel that might be siphoned from a full fuel tank. For instance, with the known anti-siphon inlet described in WO2006/048659 referenced above, it is possible to insert a relatively large siphon tube to the base of the conical baffle and accordingly siphon fuel down to a level reaching the bottom of the inlet.
In addition, the domed baffle 3 according to the present invention is advantageously resistant to tampering. A method of circumventing known anti-siphon inlets, as for instance described in WO2006/048659 referenced above, is to knock the baffle out of the tubular body, or puncture the baffle, for instance using a hammer and chisel. With the present invention, the curved outer surface of the baffle 3 makes it difficult for a chisel to gain purchase on the surface of the baffle thereby providing improved resistance to this form of attack. Furthermore, since there is no requirement to provide apertures in the baffle 3 , the baffle can be constructed as a solid block as illustrated in FIGS. 1 to 3 , which increases the strength of the baffle as compared with a conical baffle “plate” as for instance described in WO2006/048659.
FIGS. 5 and 6 show a further embodiment of the invention in which the baffle 3 additionally comprises an axial bore 10 which passes from the apex of the domed surface 3 a to the bottom surface 3 b . As stated above, an advantage of the present invention is that, due to a reduction in turbulence in the fluid within the inlet, the length of the tubular body may be reduced, for a given fuel dispensing rate, compared to known anti-siphon inlets. The reduction in length of the tubular body is advantageous in that it limits the amount of fuel that might be siphoned from a full fuel tank.
As fuel is delivered to the fuel tank via the anti-siphon inlet, the fuel displaces air in the fuel tank, which to prevent pressure build up, must return to the atmosphere via the fuel inlet and hence the anti-siphon inlet. Due to the close proximity between the tubular body and the fuel inlet pipe within which it is received, airflow from the fuel tank via the holes 8 and slots 9 to the atmosphere is restricted. It is thought that the restriction in airflow results in pressure build-up within the fuel tank which opposes the ingress of the delivered fuel and hence reduces the maximum achievable fuel inlet rate.
It has been found that in some applications the addition of the bore 10 improves the rate of fluid flow through the anti-siphon inlet whilst filling the fuel tank. As such, the bore 10 provides a conduit through which any displaced air in the fuel tank can pass to the atmosphere without any significant impedance due to fuel flow in the opposite direction. The improved flow of displaced air out of the fuel tank leads to an improved achievable flow rate of fuel into the tank. This embodiment may be of particular use in cases where the entire length of the tubular body is received within the inlet pipe.
In one example of this embodiment of the invention the diameter D of the curved baffle surface is 49 mm and the diameter B of the bore 10 is 4.7 mm. As a result, the area of the base of the curved baffle surface is approximately 1885 mm2 and the cross-sectional area of the bore 10 is approximately 17.35 mm2. As such it is preferable that the cross-sectional area of the bore is approximately 2 orders of magnitude less than the area of the base of the baffle surface. It is preferable that the relative cross-sectional area of the bore 10 is small enough such that a siphon pipe cannot fit through the bore 10 and/or such that the volume of fuel which may pass through the bore 10 is not sufficient so as to significantly restrict the outward flow of air via the bore 10 . Increasing the relative cross-sectional area of the bore 10 will permit a greater flow of displaced air through the bore 10 and as such will enable a greater fuel supply rate.
The bore 10 is additionally countersunk 11 at the end opening to the bottom surface 3 b of the baffle 3 . The countersink 11 aids the passage of air through the baffle bore 10 in a direction towards atmosphere as it reduces friction and turbulence that would otherwise occur at the opening to a bore 10 which has not been countersunk. It will be appreciated that the presence of the countersink 11 is desirable, however, in some embodiments it may be omitted.
It will be appreciated that many modifications may be made to the embodiments of the invention described above. For instance, the mounting structure 2 may vary from that illustrated and may have any form suitable for attachment to the inlet of a vehicle fuel tank (or any other tank) to which the anti-siphon inlet is to be fitted. For instance, in some embodiments a simple radially extending flange provided at the proximal end of the tubular body 1 may be sufficient, particularly for example where the tank inlet does not have a cylindrical neck but is simply an aperture in a wall of the tank.
Similarly, it will be appreciated that the configuration of apertures provided through the tubular body 1 may vary significantly from that illustrated. For instance, a different array of apertures such for instance as described in WO2006/048659 may be provided.
It will also be appreciated that the detailed dimensions and configurations of the domed baffle 3 may vary from that illustrated without departing from the present invention.
In conclusion, the invention provides novel systems, devices, methods and arrangements for anti-siphon inlets. While detailed descriptions of one or more embodiments of the invention have been given above, various alternatives, modifications, and equivalents will be apparent to those skilled in the art without varying from the spirit of the invention. For example, while anti-siphon inlets adapted for fitting to vehicle fuel tanks have been discussed, one or ordinary skill in the art will recognize applications to other fluid tanks or containers. Therefore, the above description should not be taken as limiting the scope of the invention, which is defined by the appended claims. | This invention relates to inlet devices that include, for example, a tubular inlet body having a central bore defined by a tubular wall and having an axis. The tubular wall defines an open proximal end for receiving fuel. A plurality of apertures are provided through the tubular wall for egress of fuel. The distal end of the tubular body is blocked by a baffle defining a baffle surface facing into the bore of the tubular body, wherein at least a portion of the baffle surface is inclined at an acute angle relative to the axis to deflect fuel towards apertures in the tubular wall; and wherein the baffle surface is at least substantially free from apertures. | 1 |
RELATION TO OTHER APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/159,589, filed on Mar. 12, 2009.
BACKGROUND OF THE INVENTION
[0002] Currently, deployment and retrieval of downhole devices such as pumps and production pipes requires a rig, which can be costly. Further, wellbore tubulars tend to be made of metals which may corrode and are rigid, leading to less flexible installation procedures.
[0003] Over the past 10 years, the application of non-metallic materials in flowlines such as in those used wellbores has proven itself an alternative to metallic flowlines. Metallic materials tend to be less resistant to corrosion and/or chemicals and their rigidity is a factor to be taken into consideration during installation and use.
SUMMARY
[0004] A system is disclosed that uses a non-metallic, substantially continuous, flexible tube comprising a flexible, non-metallic, e.g. resin-based, substantially continuous production tube that can be wellbore deployed and retrieved without the need of on site rigs. Reusability is enhanced since the tube can be retrieved and redeployed in the wellbore. The system's components can be placed inside existing pipes for work in old wells where removal of the existing tube is not economical.
[0005] Non-metallic materials such as thermoplastics have high chemical resistance, depending on material chosen, and are typically imperative to corrosion. Tubes comprising such non-metallic materials may also be spoolable, thereby increasing installation rates and flexibility. Such systems may also require fewer personnel and less time to deploy equipment and tube in a well. Systems as claimed herein can be easily insulated for special applications.
[0006] Connectors for the tube are dimensioned and configured to allow for sealing the downhole tools to the production tube. Additionally, an interface to a tool such as a downhole pump may be provided to allow downhole processes, e.g. dewatering and/or chemical injection.
[0007] The system may be used to replace workover rigs and metallic pipes for the production of hydrocarbon from wellbores.
[0008] In certain embodiments, an onsite power generator will provide a clean alternative to existing diesel burning generators and will typically use a furnace, boiler, steam engine and electrical power generator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The various drawings supplied herein are representative of one or more embodiments of the present inventions.
[0010] FIG. 1 is a diagram of an exemplary system embodiment;
[0011] FIGS. 2 and 3 are perspectives in partial cutaway of an exemplary tube illustrating embedded umbilical and/or electrical cables;
[0012] FIG. 4 is an exemplary plan view of a tube with filters; and
[0013] FIG. 5 is an exemplary plan view of a tube with deformable material.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0014] As used herein, “tube” will be understood by one of ordinary skill in these arts to include a production pipe, an injection pipe, a portion of a tubular to be used within a wellbore, a portion of a tubular to be used within another tubular, or the like.
[0015] Referring now to FIG. 1 , rigless intervention and production system 10 comprises flexible, non-metallic, substantially continuous tube 20 and connector 30 .
[0016] Tube 20 comprises a high temperature tolerant, non-metallic material such as a carbon-enhanced, resin-based thermoplastic, a fluoropolymer, a polyemide material, or the like, or a combination thereof. Kevlar® or other similar materials may be used as part of the tube wall to strengthen tube 20 such as to improve pressure collapse and burst properties.
[0017] In typical embodiments, a predetermined portion of tube 20 is dimensioned and configured to be deployed within wellbore 100 , with the predetermined portion of tube 20 further comprising first connection end 24 disposed distally from fluid outlet 22 . Tube 20 is typically dimensioned and configured into continuous lengths to reach a desired wellbore depth, typically from around between 6,000 feet to around 10,000 feet. In typical embodiments, tube 20 can withstand a maximum working pressure of around 15,000 psi (1,034 bar).
[0018] Referring additionally to FIGS. 2 and 3 , tube 20 may further comprise umbilical 26 and/or electrical cable 27 which may be disposed about a predetermined portion of tube 20 , such as about an interior or exterior surface of tube 20 , or at least partially embedded into tube 20 . In certain configurations, umbilical 26 may further comprise electrical cable 27 .
[0019] Annulus 28 of tube 20 is typically dimensioned and configured to allow fluids to be pumped into wellbore 100 .
[0020] Connector 30 is typically attached to first connection end 24 and dimensioned and configured to sealably attach tube 20 to tool 110 which is deployable within wellbore 100 , e.g. pump 110 a (not specifically shown in the figures), downhole gauge 110 b (not specifically shown in the figures), sensors 110 c (not specifically shown in the figures), or the like, or a combination thereof. Tools 100 such as downhole gauge 110 b may be used to optimize production from wellbore 100 . For example, downhole gauge 110 b may be dimensioned and configured to measure pressure of injected water near the bottom of wellbore 100 , temperature of injected water near the bottom of wellbore 100 , or the like, or a combination thereof. As used herein, “wellbore” and “well” may be used synonymously, as the context requires.
[0021] Sensors 110 c may be embedded into tube 20 such as during the manufacturing process. These sensors 110 c may comprise induction system sensors for formation evaluation and fluid evaluation; radio frequency identification sensors (RFID); pressure and temperature sensors, or the like, or combinations thereof. Sensors 110 c may be operatively connected to cable 27 , e.g. using wired or wireless connections, umbilical 26 , or to a cable disposed outside tube 20 . Fiber wire 28 may also be embedded or otherwise disposed inside tube 20 and used for sensing downhole data such as data regarding production status, fluid configuration, fluid flow, fluid density, microseismic data, strain, pressure, temperature, or the like, or a combination thereof. As will be apparent to one of ordinary skill in these arts, sensor 110 c may be a plurality of sensors 110 c embedded at a corresponding plurality of locations in tube 20 or gathered into less than a corresponding plurality of locations in tube 20 . Sensors 110 c may further comprise one or more coils dimensioned and configured to provide formation evaluation data, data communications, or the like, or a combination thereof.
[0022] In certain embodiments, tube spooler 40 is operatively connected to tube 20 , i.e. tube 20 may be spooled and/or unspooled from tube spooler 40 . Tube spooler 40 may comprise a power cable spooler or a combination of a power cable and a tube spooler.
[0023] Vehicle 130 may be part of rigless intervention and production system 10 and dimensioned and configured to accept tube spooler 40 . One or more tube spoolers 40 and/or power cable spoolers may be located in the same unit for deployment, e.g. vehicle 130 .
[0024] In currently contemplated embodiments, vehicle 130 comprises mast 132 and controller 134 . Controller 134 is operatively in communication with tube spooler 40 . Controller 134 controls the tension on tube 20 , depth of tube 20 into wellbore 100 , as well as control the starting and stopping of tube spooler 40 . Controller 134 may be an electro-hydraulic controller, an electronic controller, or the like, or a combination thereof.
[0025] Rigless intervention and production system 10 may further comprise power generator 50 . Typically, power generator 50 is a steam-powered electricity generator disposed at or near a surface location of wellbore 100 . Power generator 50 may be in fluid connection with fluid outlet 22 to allow use of water from wellbore 100 obtained through fluid outlet 22 to be turned into steam to provide power for power generator 50 . In currently envisioned embodiments, power generator 50 may be dimensioned and configured to use natural gas to generate heat to boil the water into steam for use by power generator 50 . The water and natural gas may be obtained from wellbore 100 , transported from a remote location, or the like, or a combination thereof.
[0026] Injector 60 may be present and operatively in fluid communication with tube 20 and used at wellhead 102 for the deployment of the system in wellbore 100 . In these embodiments, injector 60 is dimensioned and configured for injection of fluids into wellbore 100 from the surface through a predetermined portion of tube 20 . These fluids are typically usable for water injection suitable for well desalination or chemical injection.
[0027] Tube stop 120 , which may include devices such as packers, may be deployed in wellbore 100 to secure tube 20 to a predetermined location in wellbore 100 , such as near well perforations.
[0028] In further embodiments, a tool such as packoff unit 130 or tube hanger (not shown in the figures) is dimensioned and adapted to secure tube 20 inside wellbore 100 near wellhead 102 . Tool 130 would typically be attached to the casing wall.
[0029] In certain embodiments, tube 20 further comprises a material disposed about an outer surface of tube 20 . This material may be disposed along one or more predetermined lengths of tube 20 that match predetermined geological zone 104 in wellbore 100 that needs to be isolated. The material is configured and adapted to swell when in contact with a fluid, such as hydrocarbon or other fluids such as water, such that the material swells and seals the area between the outside of flexible non-metallic continuous tube 20 and well casing 104 or a geological formation when the material gets in contact with the activating fluid. For embodiments where the geographical zone comprises a plurality of zones in wellbore 100 , the material may be disposed along different lengths of tube 20 where each such length matches one of the geological zones. This configuration can be used to isolate a zone in wellbore 100 where metallic production tube may be leaking. In this case, tube 20 can be deployed through the production tube and the production would then continue through tube 20 as opposed to the original production tube.
[0030] By way of example and not limitation, in certain embodiments, isolation material such as rubber formation isolation material can be attached to packoff unit 130 , tube 20 , or both, either permanently or removably. This material may be swell when in contact with a fluid, such as hydrocarbon or other fluids such as water, such that the material swells and seals the area between the outside of flexible non-metallic continuous tube 20 and well casing 104 or a geological formation when the material gets in contact with the activating fluid.
[0031] In the operation of preferred embodiments, rigless intervention and production system 10 may be used for wellbore operations.
[0032] In one exemplary embodiment, rigless intervention and production system 10 is used for dewatering by deploying a predetermined portion of a flexible, non-metallic, substantially continuous tube 20 within wellbore 100 ; attaching first connection end 24 to pump 110 a ; and using pump 110 a to introduce water from wellbore 100 into an annulus of tube 20 . Pump 110 a may be attached to first connection end 24 prior to deploying tube 20 and pump 110 a into wellbore 100 .
[0033] In a further exemplary embodiment, power generator 50 , which is in fluid communication with the annulus of tube 20 , may be used to generate electricity using water introduced to power generator 50 via tube 20 .
[0034] Once so deployed, production of hydrocarbons through the annulus of tube 20 may be allowed. Further, water or chemicals may be injected into wellbore 100 through tube 20 .
[0035] Referring additionally to FIG. 4 , in certain contemplated embodiments, control of sand or other particulate matter within wellbore 100 may be accomplished using tube 20 or a portion of tube 20 . A control depth of a production pipe within wellbore 100 is determined, where the control depth may be the result of sand or other unwanted solids being present. In these embodiments, tube 20 is fashioned with one or more filters 21 disposed at a predetermined length of tube 20 and then tube 20 deployed into wellbore 100 . Filters 21 are dimensioned and adapted to filter a solid such as sand from fluid being produced in wellbore 100 . Deploying tube 20 to the control depth positions filter 21 in wellbore 100 at the control depth production of the fluid is the allowed through filter 21 , such as into tube 20 . Tube 20 with filter 21 may also be a standalone unit deployed with standard metallic pipe.
[0036] Referring additionally to FIG. 5 , in certain contemplated embodiments, tube 20 may further comprise deformable material 23 . By way of example and not limitation, piezoelectric material can be molded onto tube 20 , which itself may comprise a suitable plastic, and deformed to allow or impede the flow of hydrocarbons into tube 20 when electrical current is exerted onto the material. The piezoelectric material may be enhanced with nanotubes dimensioned and configured to control the flow of fluids being produced in wellbore 100 . Tube 20 with deformable material 23 may also be a standalone unit deployed with standard metallic pipe.
[0037] The foregoing disclosure and description of the inventions are illustrative and explanatory. Various changes in the size, shape, and materials, as well as in the details of the illustrative construction and/or a illustrative method may be made without departing from the spirit of the invention. | A system which may be used to replace workover rigs and metallic pipes for the production of hydrocarbon from wellbores uses a non-metallic, substantially continuous, flexible tube comprising a flexible, non-metallic, e.g. resin-based, substantially continuous production tube that can be wellbore deployed and retrieved without the need of onsite rigs. The system's components can be placed inside existing pipes for work in old wells where removal of the existing tube is not economical. The tubes may also be spoolable, thereby increasing installation rates and flexibility. Connectors for the tube may be dimensioned and configured to allow for providing and/or sealing downhole tools to the production tube. In certain embodiments, an onsite power generator will provide a clean alternative to existing diesel burning generators and will typically use a furnace, boiler, steam engine and electrical power generator. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to a retaining mechanism and, in particular, such a mechanism suitable for, but not limited to, retaining an article (e.g. a liquid dispenser) with a base member.
Various retaining mechanisms have been devised for releasably engaging an article to a base, e.g. for the releasable engagement of a liquid dispenser with a base member. For the purpose of discouraging unauthorized removal of the liquid dispenser from the place of use, the dispenser is usually provided with a protrusion with a spherical end, which does not allow the dispenser to support itself on an ordinary support surface, e.g. a sink counter top. However, it is found that after a certain period of use, the dispenser may get loosed from the base member, so that it is necessary to fit the dispenser again into the base member. It is therefore an object of the present invention to provide a retaining mechanism in which the aforesaid shortcoming is mitigated, or at least to provide a useful alternative to the public.
It should be pointed out that although a liquid dispenser is here shown as an embodiment of the present invention, it should be understood that the present invention can find its application in, e.g. the releasable engagement and locking of any other utensil, e.g. a pair of pliers or a pair of scissors, to a base member.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention, there is provided a retaining member for releasably retaining an article, wherein said retaining member includes at least one engagement member, at least one locking mechanism, and at least one body member having a central longitudinal axis, wherein said at least one engagement member is movable radially relative to said central longitudinal axis of said body member between an engaged position and a disengaged position, wherein said at least one engagement member, when in said engaged position, is closer to said central longitudinal of said body member than when at said disengaged position, wherein said locking mechanism includes at least one ring member, wherein said ring member is movable relative to said body member in a first direction to a locking position to lock said article against disengagement from said retaining member, and wherein said ring member is movable relative to said body member in a second direction to a unlocked position to unlock said article, and wherein, when said engagement member is in said inner position and said ring member is in said unlocked position, said article is engageable with and disengageble from said retaining member.
According to a second aspect of the present invention, there is provided a container with a body member and a protrusion extending from said body member, wherein said protrusion includes at least two grooves on its outer surface.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will be described by way of examples only, and with reference to the accompanying drawings, in which:
FIG. 1 shows a side view of a liquid dispenser with a protrusion forming part of the present invention;
FIG. 2 shows a side view of a first embodiment of a base portion forming part of the present invention;
FIG. 3 shows the liquid dispenser shown in FIG. 1 engaged with the base portion shown in FIG. 2, and attached as a whole to a support surface;
FIG. 4 is a part sectional view of the liquid dispenser and base portion shown in FIG. 3 in which the liquid dispenser is locked with the base member;
FIG. 5A is a sectional view of the base portion taken along the line V—V of FIG. 2 in which the locking pins are in the locking position;
FIG. 5B is a sectional view of the base portion taken along the line V—V of FIG. 2 in which the locking pins are in the unlocked position;
FIG. 6 is a side view of a second embodiment of a base portion, forming part of the present invention;
FIG. 7 is a side view showing the liquid dispenser shown in FIG. 1 engaged with the base portion shown in FIG. 6, and attached as a whole to a support surface;
FIG. 8 is a part sectional view of the liquid dispenser and base portion shown in FIG. 7 in which the dispenser is not locked with the base portion;
FIG. 9 is a part sectional view of the liquid dispenser and base portion shown in FIG. 7 in which the dispenser is locked with the base portion;
FIG. 10 is a side view showing the liquid dispenser shown in FIG. 1 engaged with a third embodiment of a base portion (forming part of the present invention), and attached as a whole to a support surface; and
FIG. 11 is a part sectional view of the liquid dispenser and base portion shown in FIG. 10 in which the liquid dispenser is locked with the base portion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a liquid dispenser, e.g. for dispensing liquid soap, constituting an article of the present invention is shown and generally designated as 10 . The dispenser 10 includes a body 12 for containing the liquid, with a conventional manually actuated pump and spout assembly 14 threaded to the upper end of the body 12 . Formed at and extending from a lower end 16 of the body 12 is a protrusion 18 . As can be seen in FIG. 1, the protrusion 18 is generally cylindrical in shape with two groove portions 20 , 22 on its outer surface 23 . It can be seen that the while the surface of the groove portion 20 is substantially planar, the surface of the groove portion 22 is generally concave. At the distal end of the protrusion 18 is a part-spherical portion 24 . It can be seen that, with such an arrangement, the dispenser 10 cannot self-support itself on an ordinary support surface, e.g. a desk top or sink counter top.
Shown in FIG. 2 is a first embodiment of a base portion according to the present invention, and generally designated as 100 . The base portion 100 includes a body portion 102 and a ring 104 , which is rotatable or swivelable relative to the body portion 102 about a common central longitudinal axis L—L. The outer surface of the ring 104 is corrugated to enhance gripping by a hand of a user for rotation/swiveling. The body portion 102 is open on its upper end 106 , through which the protrusion 18 of the dispenser 10 can enter and be received within an internal cavity of the body portion 102 . As shown in FIG. 3, the dispenser 10 may thus be engaged with the base portion 100 , so that the dispenser 10 can be supported upright on a support surface 108 . At the bottom end of the base portion 100 may be provided an adhesive tape, or some other adhesive material, which serves to secure the base portion 100 to the support surface 108 .
FIG. 4 shows in more detail the mode of engagement between the dispenser 10 and the base portion 100 . As can be seen, the protrusion 18 of the dispenser 10 is received within an internal cavity of the base portion 100 . The part-spherical portion 24 of the protrusion 18 sits on a substantially correspondingly shaped and sized concave trough on the inner bottom end of the base portion 100 .
As shown in FIG. 4, there is a set of upper pin assemblies 110 (of which only one is shown in FIG. 4) and a set of lower pin assemblies 112 (of which, again, only one is shown in FIG. 4 ). In this particular embodiment, there are three upper assemblies 110 , and three lower pin assemblies 112 . Referring first to the set of lower pin assemblies 112 , each such assembly 112 includes a lower pin 114 and a lower spring 116 , which biases the respective lower pin 114 radially towards the inner cavity of the base portion 100 . Such an arrangement ensures that when the dispenser 10 is engaged with the base portion 100 in the position as shown in FIG. 4, the lower pins 114 are engaged and snap-fitted with the groove portion 22 , so that the dispenser 10 is releasably engaged with the base portion 100 . If the dispenser 10 is not locked with the base portion 100 (in a manner to be discussed below), the dispenser 10 may be disengaged from the base portion 100 by being pulled upward and away from the base portion 100 . In this way, the lower pin 114 will be pushed radially outward against the biasing force of the lower spring 116 , thus allowing the dispenser 10 to be disengaged from the base portion 100 .
As to the upper pin assemblies 110 , each such assembly 110 includes an upper pin 118 , an upper spring 120 , and a head portion 122 integrally formed with the upper pin 118 . In a manner to be discussed below, the upper pin 118 may be moved radially inwardly, and against the biasing force of the upper spring 120 , to the position as shown in FIG. 4, to engage the groove portion 20 . In this inner position, due to the shape of the upper pin 118 and the surface of the groove portion 20 , the dispenser 10 is locked, i.e. prevented from being disengaged from the base portion 100 , even if the dispenser 10 is pulled upward and away from the base portion 100 .
FIG. 5A shows the upper pins 118 in the inner locking position. In this position, each of the head portion 122 of the pin 118 is actuated by a cam surface 124 on the inner surface of the ring 104 , which cam surface 124 pushes and retains the upper pin 118 in its inner position to engage with the groove portion 20 . When the ring 104 is rotated in the direction shown by the arrow A relative to the rest of the base portion 100 , the cam surfaces 124 will come out of engagement with the respective head portion 122 . As the upper springs 120 bias the respective upper pin 118 radially away from the longitudinal axis L—L of the base portion 100 , to its outer position (as shown in FIG. 5 B), the upper pins 118 will be disengaged from the groove portion 20 to unlock the dispenser 10 , thus allowing the dispenser 10 to be disengaged from the base portion 100 . The ring 104 may be turned/rotated in the direction shown by the arrow B to again lock the dispenser 10 to the base portion 100 . It can be seen that the present invention provides a simple yet effective locking feature which can be used in a large variety of applications.
FIG. 6 shows a second embodiment of a base portion generally designated as 200 . As in the first embodiment of base portion 100 discussed above, this base portion 200 also includes a body portion 202 and a ring 204 . The main difference in this base portion 200 is that a shaft 206 extends from its bottom end. The distal end of the shaft 206 is threaded so that it can be threadedly engaged with a nut 208 .
As shown in FIG. 7, the shaft 206 may be received through a bore hole of a support surface 210 , and the nut 208 secured against the bottom side of the support surface 210 , so as to secure the dispenser 10 and the base portion 200 to the support surface 210 . FIGS. 8 and 9 show the mode of engagement of the dispenser 10 with the base portion 200 in, respectively, the unlocked and locked configuration. It can be seen that the mode of engagement and locking are the same as in the first embodiment discussed above.
FIGS. 10 and 11 show a third embodiment of a base portion 300 engaged with the dispenser 10 , which base portion 300 includes a body portion 308 and a ring 310 . The main difference between this base portion 300 and the base portion 200 is that, in this base portion 300 , the upper surface 302 and the lower surface 304 are non-parallel, i.e. they are inclined to each other. As shown in these two figures, the dispenser 10 can still assume an upright position although it is secured to a slanted support surface 306 . Alternatively, the dispenser 10 may assume an appropriately slanted position when it is secured to a horizontal support surface. It can be seen in FIG. 11 that the mode of engagement and locking are the same as in the first and second embodiments discussed above.
It should be understood that the above only describe examples of how the present invention may be carried out, and that various modifications and/or alterations may be made thereto without departing from the spirit of the invention hereof. | A mechanism for releasably retaining an article, e.g. a liquid dispenser, with a base portion is disclosed, in which the dispenser includes a protrusion releasably engageable with the base portion, and the base portion includes locking means adapted to prevent disengagement of the dispenser from the base portion, and the locking means includes a ring which is movable, e.g. by rotation or swiveling action, relative to the base portion to lock or unlock the dispenser from said base portion. | 1 |
FIELD OF THE INVENTION
The present invention relates to the continuous production of cast polyurethane foams, including rigid, semirigid and flexible polyurethane foams.
BACKGROUND OF THE INVENTION
Polyurethane foams are widely used as materials from which articles such as mattresses, seat cushions, and thermal insulators are fabricated. Such polymeric foam materials are ordinarily manufactured by a casting process in which a mixture of liquid polyurethane-foam-generating reactants are deposited in a mold. As used herein, the term "mold" includes both stationary molds for batch casting and translating or otherwise moveable molds for continuous casting. Evolution of a gas causes the reactants to foam. For some foam formulations, the reactants themselves react to evolve sufficient gas; in others, a blowing agent is mixed with the reactants to provide gas evolution. Continued gas evolution causes the foam to expand to fill the mold. The foam becomes increasingly viscous as the reactants polymerize, ultimately curing into a polyurethane foam casting shaped by the mold.
Slabs of polyurethane foam approximately rectangular and round in cross section are conventionally cast in a translating channel-shaped mold. Such molds typically include a belt conveyor forming the bottom of the mold and a pair of spaced-apart, opposing side walls, which can be fixed or translatable at the speed of the conveyor. The mold sides and bottom are generally lined with one or more sheets of flexible-web such as kraft paper or polyethylene film. The sheets of mold liner are ordinarily withdrawn from rolls and continuously translated along the mold channel at the same speed as the belt of the conveyor. A liquid foam-generating reaction mixture is deposited on the mold bottom in a zig-zag pattern from a nozzle positioned above the mold which is reciprocated back and forth across the width of the mold. Typically, as the foam expands, the reaction mixture will merge into a uniform slab of foam.
If fresh reaction mixture is deposited on top of foam generated from previously deposited reactants, the resulting cured foam will have an uneven surface and nonuniform density, which is undesirable for most applications. By continuously translating the mold liner, the reaction mixture is continuously carried away from the pouring area below the pouring nozzle, which reduces the tendency for fresh reaction mixture to cover previously deposited mixture.
Propitious selection of conveyor speed can prevent production of undesirable foam products. A range of speeds can be established for a particular reaction mixture formulation. Minimum speed is achieved when liquid reaction mixture is evenly distributed on the bottom of the mold and does not flow in a direction opposite to that of the mold and conveyor. Selection of an appropriate speed requires consideration of the chemical reaction occuring subsequent to the depositing of liquid mixture in the mold. During residence in the mold, the liquid mixture foams and cures. Because economy necessitates maximum product height, lower speeds are preferred during the foaming portion of the reaction to attain such heights.
To reduce further the tendency of the liquid reactants to flow back under the pouring nozzle and to assist the "zig-zags" of reaction mixture to merge uniformly, it is customary to incline a pouring board, the surface under the nozzle, from horizontal so that the bottom liner slopes downward in the direction of translation. The maximum angle of inclination is different for different foam formulations, such as polyester polyurethane foams.
Also, problems arise if the mold bottom slopes downward along its entire length. Conventional continuous slab molds are quite long, typically in excess of 60 feet, to provide for integrity of the foam. Building a translatable mold of this length inclined from horizontal is significantly more expensive than building a translatable mold of the same length which is horizontal, because, for example, the building housing and the super structure supporting the inclined mold would require a higher investment. Moreover, it is especially expensive to provide for changing the angle of inclination of the entire mold to compensate for differing viscosities among the various foam formulations. Thus some continuous slab molds have horizontal belt conveyors for most of the length of the mold bottom, but have relatively short inclined and adjustable pouring boards located beneath the pouring nozzles. The expansion and rise of the foam generally takes place on the sloping pouring board.
A second reason for providing a pouring board which makes an angle with respect to the belt conveyor concerns the cross-sectional shape of the slab cast the the mold. As the foam expands and rises in the mold, it encounters the sides of the mold. If the mold-side liners are being translated substantially parallel to the mold bottom, the expanding foam experiences a shear force which resists its rise along the sides. This shear force results in a rounding of the top of the rectangular slab to form a crown or crest of convex shape, much like a loaf of bread. For most applications such rounded portions are unusable and must be discarded as scrap. Thus, the more nearly rectangular the cross section of the slab, i.e., the flatter the top, the more economical is the casting process. U.S. Pat. No. 3,325,823 describes one method known and used commercially for making flat top blocks of polyurethane foam.
If, over the length the foam travels as it expands, the mold bottom liner and the two mold side liners are translated, not in parallel, but at an angle with respect to one another, the mold side liner can have a velocity component relative to the mold bottom in the direction of the expansion of the foam which can compensate for the shear force which resists the rise of the foam. Guiding the mold-bottom liner across an inclined pouring board, which is located between the side walls of a slab mold and intersects the mold-bottom conveyor at an angle, can provide such a compensating velocity component when the foam expansion is carried out over the length of the pouring board and mold-side liners are translated parallel to the mold-bottom conveyor. The angle of intersection which ordinarily leads to polyurethane foam slabs having the most nearly rectangular cross sections is about 10° for typical foam formulations and production conditions. Unfortunately, if the pouring board is sloped about 10° from horizontal, freshly deposited reaction mixture tends to flow forward and under already-deposited reaction mixture, as discussed above, leading to foam slabs of nonuniform density or otherwise imperfect.
Although it is possible to construct a continuous slab mold with a pouring board inclined from horizontal by an angle of 4.5° and intersecting the belt conveyor at 10°, the belt conveyor in such a case is normally inclined upward by an angle of 5.5°. See, for example, U.S. Pat. No. 3,325,823. As noted above, however, inclined translatable molds are more expensive than comparable horizontal molds.
U.S. Pat. No. 3,786,122 discloses a process for producing polyurethane foam slabs which employs a horizontal, channel-shaped mold having at its forward end an inclined "fall plate" which makes an angle of significantly greater than 4.5° from horizontal. The problem of reaction mixture flowing down the inclined fall plate is obviated by prereacting the reaction mixture prior to introducing it onto the fall plate. The prereacting step is carried out in a trough which opens onto the upper edge of the fall plate. Liquid foam reactants are introduced onto the bottom of the trough and the foam which is generated is allowed to expand upwards in the trough and spill over onto the fall plate. The foam continues to expand as it is carried down along the fall plate by a translating bottom sheet. Because the prefoamed reaction mixture exiting the trough is more viscous than the initial liquid reaction mixture, the fall plate can be inclined at a greater angle from horizontal than a pouring board in a conventional polyurethane-foam slab mold.
An additional result of introducing prefoamed reaction mixture into the mold is that relatively high foam slabs can be produced as compared with conventional processes. The height to which foam rises can be thought of as being divided into two components, a first component is the result of the expansion of the foam below a horizontal plane passing through the point at which the reactants begin to foam and is determined by the decline and length of the pouring board, and a second component is the result of the rise of the foam above the horizontal plane.
Economies result from producing high slabs because, the thicker the foam slab, the less is the loss from discarding the skin or rind which generally coats polyurethane foam castings. With a conventional slab mold, if the rate of introduction of reaction mixture is kept constant and the rate of translation of the mold liner is reduced, the height of the foam slab tends to increase because more foam-generating reactant is deposited per unit length. However, because the rate of gas evolution remains essentially constant, the rising of the foam takes place over a linear distance, in addition to rising to a greater height, which gives the rising foam a steeper slope. If the rate of translation is slowed sufficiently, this slope becomes so steep that the expanding foam, particularly the youngest and most fluid portion, becomes unstable and tends to slip and shift, which results in cracks and other imperfections in the cured foam.
This problem of instability of rising foam is reduced in the process of U.S. Pat. No. 3,786,122 by introducing into the translating mold prefoamed reaction mixture which is sufficiently viscous as to be able to sustain a relatively steep slope of the pouring board as it completes its expansion. Thus the first component which determines the height of the foam can be increased. In addition to permitting higher foam slabs to be cast by reducing the translation speed of the mold liner, this process permits the use of slab molds shorter than those of conventional processes, because the slab moves a shorter distance during the curing time.
In practice, however, the process of U.S. Pat. No. 3,786,122 suffers from a number of drawbacks. The prefoamed reaction mixture introduced into the mold must be quite fluid, because the foaming mixture rising in the trough must, by gravity flow, spill over a weir structure and onto the fall plate of the mold. Thus prefoamed reactants which are too viscous to flow freely such as the polyester type cannot normally be used. This limits the height of slabs which can be obtained by the process.
SUMMARY OF THE INVENTION
The present invention is directed to a process for the production of large dimension polyester-derived polyurethane foam products. Those products exceed heights of forty (40) inches. Such heights substantially exceed those of the prior art for rectangular blocks and are accomplished through the use of a slow-rise polyester-derived polyurethane foam formulation. Specifically, the formulation utilizes particular quantities of amine catalyst and surfactant so that the rise time of the modified formulation exceeds 90 seconds. Use of such slow-rise formulations avoids prior art problems of excessive throughputs and conveyor speeds, effects advantages in fabrication and results in increased product yield.
Another embodiment of the present invention is directed to the use of a slow-rise formulation with an apparatus utilizing a specific pouring board arrangement onto which slow-rise liquid polyurethane formulations are deposited. The arrangement consists of pouring boards having multiple segments, each at a different angle. In a preferred embodiment, the pouring board comprises two segments with a first segment, located where the formulation is deposited, having an angle about 8° to 10° from horizontal and a second segment having an angle about 25° to 30° from horizontal. The second segment is adjacent a conveying means. In another embodiment of the present invention, a pouring board having three sections is utilized. Each of the aforementioned pouring board arrangements in combination with the slow-rise polyester-derived polyurethane formulation effects a polyurethane foam product that is substantially rectangular in cross-section.
BRIEF DESCRIPTION OF THE DRAWINGS
Several preferred embodiments of the invention are described below with references to the accompanying drawings, in which:
FIG. 1 is an elevation and partial section of an embodiment of the present invention for producing slabs of polymeric foam of substantially rectangular cross-section; and
FIG. 2 is also an elevation and partial section of a modification of FIG. 1 wherein a segmented pouring board is depicted for producing polymeric foam slab of rectangular cross section.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, an apparatus for producing slabs of free-rising polyester-derived polyurethane foam having a substantially rectangular cross section is illustrated. Such apparatus is suitable for use with the process of the present invention. The apparatus includes a depositing means 11 for depositing the polyurethane foam generating reaction mixture and forming a continuous slab mold 12. Depositing means 11 usually includes a conventional mixing head 15. In general, the mixing head 15 has first and second mixing head inlets 13 and 14 for introducing polymeric foam reactants into mixing head 15 which has an outlet connected to depositing means 11.
Depositing means 11 directs the polyurethane foam generating reaction mixture from the interior of the mixing head to the slab mold 12. Nozzle 16 is positioned above a pouring surface 22 of pouring board 17. Nozzle 16 can be reciprocated across the width of the mold 12 by conventional reciprocation means. A first edge 18 of pouring board 17 is adjacent a surface of a conventional belt conveyor 19, which is used to form a mold-bottom surface 20. That surface is preferably substantially horizontal.
A mold-bottom liner 21 made of a flexible-web such as Kraft paper is supplied from a roll shown in the drawing and is guided over pouring surface 22 down past first edge 18 onto mold-bottom surface 20 of the belt conveyor 19. The mold-bottom liner 21 is continuously translated with translating belt conveyor 19.
First and second mold-side walls are positioned adjacent to mold-bottom surface 20 and are preferable perpendicular to surface 20. First mold-side wall 23 is illustrated. A mold-side liner 24, also made of a flexible-web such as Kraft paper or polyethylene film, is positioned flat against the first mold-side wall 23 and is drawn from a roll shown in the drawing. The second mold-side wall and a complementary mold-side liner are now shown but are positioned on the opposite side of belt conveyor 19 in a manner identical to its described counterpart. First and second mold-side liners and the mold-bottom liner define a channel-shaped mold for casting foam slabs, which preferably have a substantially rectangular cross-section. Means are provided for guiding and translating the side liners and bottom-liner in a parallel relationship. Of course, the rates of translation of the three liners are equal and identical to the rate of translation of belt conveyor 19.
Pouring surface 22 is substantially planar and makes an angle α, which in accord with the slow-rise polyester-derived polyurethane foam formulations of this invention should be no greater than 15° from horizontal. The angle of inclination α of the pouring surface 22 can be changed to accommodate variations in the viscosity of the reaction mixture.
Although a planar pouring board 17 is illustrated in FIG. 1, in certain applications it can be advantageous to employ pouring boards having segments such as that shown in FIG. 2, each segment being inclined at a different angle from horizontal. FIG. 2 shows a pouring board consisting of two segments, a first segment 25 located adjacent pouring nozzle 16 and having an angle β from horizontal and a second segment 26 abutting first segment 25 and adjacent to belt conveyor 19 having an angle γ from horizontal. When using the slow-rise polyurethane foam formulation of the present invention to obtain a rectangular block 40 inches in height, the first segment 25 should be about 7 feet in length and have an angle β of from about 9 degrees to 12 from horizontal. Second segment 26 should be about 3 feet in length and have an angle from about 25 degrees to about 30 degrees from horizontal. Such a pouring board arrangement can be used to make slabs of rectangular cross-section of about 40 inches in height.
Further segmented pouring boards are within the purview of the subject invention. Alternatively, a curved pouring board could be used if desired.
In accordance with the process of the subject invention, a first component A enters the mixing head 15 via mixing head inlet 13 and a second component B simultaneously enters mixing head 15 via mixing head inlet 14. These components are mixed and the mixture travels through deposit means 11 to nozzle 16 to be deposited on inclined pouring surface 22. The mixture is normally deposited at a constant rate and at ambient conditions. The components of the mixture react to form a polyurethane foam slab. As the mixture is deposited on surface 22, it continuously translates along with the mold liners and the conveyor. The conveyor normally translates at a constant speed.
Slow-rise formulations of polyester-derived polyurethane are necessary to the process of the subject invention. Typical formulations are exemplified hereinafter. The criticallity of these formulations resides in the amount of amine catalyst and surfactant added to the foam formulation. Slow-rise formulations of the subject invention require relatively small quantities of amine catalyst and surfactant so that the rise time of the particular foam formulation exceeds ninety (90) seconds.
The use of relatively smaller amounts of amine catalyst and surfactant to attain foam products of increased height is demonstrated by the comparison provided in Examples I through X hereinafter.
EXAMPLES
The following examples are illustrative of the ease with which polyester-derived polyurethane foam may be produced in accordance with the process of this invention:
EXAMPLE I
A slab of polyester-derived polyurethane foam was cast continuously using a conventional reciprocating mixing head, illustrated in FIG. 1. The following formulation was mixed in the head:
______________________________________ Parts by Weight______________________________________Ingredient-Component APolyester E-280 (Mobay 100.00Chemical Company)Surfactant DC-1312 (Dow 1.00Chemical Company)Y-6721 (Union Carbide) 0.50Water 4.15Amine Catalyst ESN 2.70(Union Carbide)Ingredient-Component BTD-80 (Mobay Chemical Company) 47.49______________________________________
The ingredients of Component A, comprising the polyester component, were premixed and pumped as a single stream into the mixing head. Component B, comprising the toluene diisocyanate component, was separately and simultaneously pumped into the head. Then the two components were mixed at ambient temperature. The combined feed rate of the blended components was about 16.1 pounds/minutes. The resulting mixture was deposited at a constant rate on a pouring board inclined at an angle of 5.7 degrees from horizontal, a normal angle for free-rising polyester-derived polyurethane foam formulations. Consonant with FIG. 1, the mold was channel-shaped with parallel sidewalls, spaced apart about 18 inches. The mold was lined with Kraft paper, all of which translated at a constant speed of about 5.1 foot/minute.
The molded foam slab was of good quality and was about 14 feet in length. The slab was 18 inches wide and had a 15 inch center height and 12.5 inch shoulder height. The average height of the slab was 13.3 inches.
EXAMPLE II
The purpose of this example was to obtain a slab height which exceeds the previous example by reducing the amount of amine catalyst and to obtain increased stability by modifying the surfactant system. The amount of the amine catalyst ESN in Example I was decreased to 1.35 parts by weight and the surfactant DC-1312 was reduced to 0.5 parts by weight. Otherwise, Example II was identical to Example I.
The polyurethane foam produced was of good quality. A slab of approximately 10 feet was made and was 18 inches wide. The slab had a 16.5 inch center height and a 14 inch shoulder height. These dimensions showed an improvement in block height over the previous example.
EXAMPLE III
This example was the same as Example II except that the angle of the pouring board was changed to about 8.6 degrees from horizontal. The product had a center height of 16.75 inches and a shoulder height of 14.5 inches. Accordingly, the shoulder height was 87% of the center height.
EXAMPLE IV
This example duplicates Example II, except the angle of the pouring board was about 11.5 degrees from horizontal. Here, the foam product had a center height of 19 inches and a shoulder height of 17 inches. Consequently, the shoulder height was 89% of the center height.
EXAMPLE V
This example is a duplication of Example II except the reaction mixture was poured on a board inclined at an angle of about 15 degrees from horizontal. Here the blended ingredients began to "run down" the pouring board indicating that a 15 degree angle was too great, and consequently, an undesirable product was obtained.
EXAMPLE VI
The purpose of this experiment was to determine the commercial feasibility of producing foam products with a substantially round cross-section of a diameter of about forty (40) inches at reduced amine catalyst levels. The formulation employed was:
______________________________________ Parts by Weight______________________________________Ingredient-Component APolyester F-203 (Hooker 100.00Chemical Company)Silicone Surfactant L-532 1.50(Union Carbide)Black Paste-287 (Custom 1.86Chemical Company)Catalyst B-16 (Lonza) 0.09Water 3.90Catalyst ESN (Union Carbide) 1.60Ingredient-Component BTD 80 (Mobay ChemicalCompany) 46.96______________________________________
The cream time for the formulation was more than nine (9) seconds and the rise time was more than ninety (90) seconds. The round foam product was produced according to the method described and claimed in U.S. Pat. No. 3,325,573 employing a throughput of 180 pounds/minute.
The slower formulation showed no evidence of instability and the foam product obtained was essentially round in cross section.
EXAMPLE VII
This experiment states conditions to produce a round polyurethane foam product whose height will exceed fifty (50) inches. This example follows the process of Example VI, except that the angle of the pour board should be about 6 degrees from horizontal and its length should be about 20 feet. The conveyor speed and feed rate should be adjusted for this experiment to about 18 feet/minute and 468 pounds/minute, respectively. A satisfactory product with an essentially round cross section whose height exceeds fifty (50) inches should be obtained.
EXAMPLE VIII
This example states conditions to produce rectangular foam products whose height would be greater than forty (40) inches. The formulation to be utilized in this experiment is the formulation of Example VI. The product should be produced in a manner similar to that of Examples II to IV except that the total feed rate of about 342 pounds/minute and the conveyor speed should be about 22 feet/minute. Furthermore, the pouring board should have an angle of about 6.5 degrees from horizontal. The product in theory will have a density of 1.82 pounds/cubic foot and its height will exceed forty (40) inches.
EXAMPLE IX
The purpose of this experiment was to determine whether a two-segment pouring board, each segment having a different angle, could flatten the top of the rectangular foam product. This experiment reproduced Example II except that the first segment of the board had an angle of about 10 degrees from horizontal and the second segment had an angle of 30 degrees from horizontal. The foam product had a center height of 18.5 inches and a shoulder height of 17.75 inches. Thus, the shoulder height was 97% of the center height. These results indicate that in order to produce products having heights exceeding forty (40) inches, a throughput of less than 300 pounds/minute and a pouring board whose length of about 10 feet should be required.
EXAMPLE X
Example IX was reproduced here except that the pouring board was further segmented. The pouring board consisted of three segments. The first segment next to the pouring point of the board, had an angle of about 12 degrees followed by a second segment having an angle about 1.5 degrees and having a third and last segment having an angle about 36 degrees. A foam product was obtained having a center height of 15 inches and a shoulder height of 14.5 inches. The three section pouring board arrangement showed a significant flattening effect, that is, a shoulder height which is 97% of the center height.
It is not intended to limit the present invention to the specific embodiments described above. Other changes may be made in the process and apparatus specifically described herein without departing from the scope and teachings of the instant invention, and it is intended to encompass all other embodiments, alternatives and modifications consistent with the present invention. | A process is diclosed for the production of large dimension polyester-derived polyurethane foam. A preferred embodiment of the invention is continuous production of polyurethane foam slabs having a height exceeding forty inches. Such heights are obtained through use of a slow-rise foam formulation. Slabs having a substantially rectangular or round cross section can be obtained using segmented inclined pouring boards. The slow-rise formulation is deposited on one inclined segment and moves down it and another segment more steeply inclined to effect the production of both rectangular or round slabs. | 1 |
BACKGROUND OF THE INVENTION
[0001] Solutions comprising oxidizing agents, such as hypohalous acids, such as sodium hypochlorite, or bleach, render nucleic acid molecules unamplifiable by known nucleic acid amplification methods such as Strand Displacement Amplification (SDA), Polymerase Chain Reaction (PCR) (U.S. Pat. Nos. 4,683,195 and 4,683,202), Ligase Chain Reaction (LCR) (EP 0320308) Transcription Mediated Amplification (TMA), 3SR, Nucleic Acid Sequence Based Amplification (NASBA) (U.S. Pat. No. 5,409,818), Rolling Circle Amplification (U.S. Pat. No. 6,280,949) and others. Contact of the sodium hypochlorite solution, for example, with a nucleic acid molecule chlorinates the nucleic acid molecule causing permanent destabilization of the double helix structure. The resulting chemically modified molecule no longer can be replicated by enzymatic means, and thus, the nucleic acid molecule is rendered unamplifiable (U.S. Pat. No. 5,612,200).
[0002] In general, such hypohalous acids destabilize nucleic acids by halide transfer to amino groups on DNA causing oxidative damage (Shishido et al., Redox Rep (2000) 5(4):243-7). Hence, for example, sodium hypochlorite solutions are commonly used to wash and rinse surfaces areas where nucleic acid amplification reactions are conducted. Such washes and rinses can and are referred to as nucleic acid decontamination procedures. Commonly, such surfaces include laboratory bench tops, floors and walls, as well as surfaces of instruments and equipment in laboratories where such nucleic acid amplification reactions are conducted.
[0003] However, it is also known that, oftentimes, such sodium hypochlorite washes and rinses do not render all nucleic acid molecules unamplifiable. Furthermore, the washing and rinsing with sodium hypochlorite solution do not remove either amplifiable or unamplifiable nucleic acid molecules from the treated surface.
[0004] Thus, there is recognized in the art, a need for a more effective nucleic acid decontamination and removal composition and method.
SUMMARY OF THE INVENTION
[0005] To address that recognized need in the art, the present invention comprises a solution of a nucleic acid oxidizing agent and a surfactant. It has been found that the use of this solution is more effective to provide nucleic acid decontamination and removal than conventional sodium hypochlorite solutions.
[0006] In one aspect a solution for removing and helix-destabilizing nucleic acids on surfaces is envisaged comprising a blend of surfactant for suspending and a nucleic acid oxidizing agent for destabilizing nucleic acids by oxidation, rendering such unamplifiable. Surfaces treated with such a solution for an appropriate period of time have greater than about 50% of the amplification detectable nucleic acids destabilized and removed. More preferably, at least 90% of the amplification detectable nucleic acids destabilized and removed.
[0007] In another aspect, the surfactant may comprise higher fatty acid alkali soaps and organic builder salts such that anionic, non-ionic, ampholytic or zwitterionic detergents are formed. In a related aspect, such detergents may comprise sodium alkylaryl sulfonate, alcohol sulfate, phosphate and carbonates. Oxidizing agents include, but are not limited to, HOBr, HOI, HOCI and other hypohalous acids. Other oxidizing agents include, but are not limited to, peroxides, such as H 2 O 2 and perioxynitrite.
[0008] A preferred oxidizing agent is a hypochlorite. Hypochlorites include, but are not limited to sodium, lithium, calcium and dibasic magnesium hypochlorite.
[0009] The ratio of surfactant to oxidizing agent can be varied such that a sufficient oxidizing agent availability is maintained to cause at least 50% of contaminating nucleic acids to become oxidized and thus rendered unamplifiable. Preferably greater than 50% of nucleic acids are rendered unamplifiable and removed. It is preferred that more than 60%, 70%, 80% or more than 90% of nucleic acids are rendered unamplifiable and removed.
[0010] In another aspect, the solution is exposed to surfaces for such a time as to remove detectable nucleic acids and oxidize sufficient nucleic acid molecules, resulting in a decontaminated surface.
[0011] In another aspect, the invention envisages a kit comprising surfactant and oxidizing agent as separate components. These separate components are to be mixed just prior to contacting suspect surfaces such that the resulting solution may decontaminate these surfaces, where contaminating nucleic acids are rendered suspensable and unamplifiable by oxidation (e.g., chlorination) and nucleic acids are removed by contact with admixed components.
[0012] Methods of decontaminating surfaces comprising contacting such surfaces with a solution are also envisaged. In a related aspect, a surface suspected of being contaminated with nucleic acids is treated for a time with the solution to suspend, oxidize and destabilize undesired nucleic acids. Such methods include contacting surfaces for at least 30 seconds and as long as until the composition of interest dries on the surface. The solution of interest finds use at normal, ambient temperature, such as between about 20° C. to about 40° C. but can be used at colder or warmer temperatures. The treated surface is followed with an aqueous rinse (e.g., but not limited to, deionized water) to rehydrate and to remove the solution and nucleic acids, which is then followed by wiping and rinsing of said contacted surface such that at least 50% of the contaminating nucleic acids are oxidized and removed, and preferably greater than 90% of contaminating nucleic acids are oxidized and removed from the surface.
[0013] These and other advantages associated with the present invention and a more detailed explanation of preferred embodiments is described below.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The term “unamplifiable” and grammatical variations thereof, herein means that a nucleic acid can no longer be replicated by enzymatic means.
[0015] The term “solution” or “non-particulate solution” and grammatical variations thereof, herein means an essentially single-phase liquid system. However, as well known in the art, at saturating levels of surfactant there may be particulate precipitation of said surfactant. Under these circumstances, such a saturated solution and particularly the fluid phase is considered a non-particulate solution for the purposes of the instant invention.
[0016] The term “surfactant” or “surface acting agent” herein means that any compound that reduces surface tension when dissolved or suspended in water or water solutions, or which reduces interfacial tension between two liquids, or between a liquid and a solid. In a related aspect, there are at least three categories of surface active agents: detergents, wetting agents, and emulsifiers; all use the same basic chemical mechanism and differ, for example, in the nature of the surfaces involved.
[0017] The term “nucleic acid halogenating” or oxidizing agent” and grammatical variations thereof, herein means an element, compound, composition and the like that halogenates or oxidizes nucleic acids, wherein such halogenation or oxidation prevents complementary base pairing of the strands and alters the structure of the nucleic acid such that amplification of single-stranded and double-stranded nucleic acids cannot occur.
[0018] The term “detergent” and grammatical variations thereof, herein means an emulsifying agent or surface active agent made usually by action of alkali on fat or fatty acids and consisting essentially of sodium or potassium salts of such acids. In a related embodiment, the term may include any of numerous synthetic water-soluble or liquid organic preparations that are chemically different from soaps but are able to emulsify oils, hold dirt in suspension, and act as wetting agents.
[0019] The term “helix destabilizing” and grammatical variations thereof, herein means an effect on the double helix of nucleic acids such that complementary base pairing cannot be maintained between nucleic acid strands treated with the surfactant/oxidizing agent solution.
[0020] The term “amplification detectable” and grammatical variations thereof, herein means nucleic acid present at a concentration such that detection is capable following nucleic acid amplification.
[0021] Amounts of solid reagents are expressed as w/v, for example, grams per milliliter or grams per liter. Amounts of liquid reagents are expressed as v/v, for example, milliliters per liter.
[0022] The invention relates to a new composition of matter and nucleic acid decontamination procedure using such composition of matter. The composition of matter is a combination of a surfactant (e.g., detergent) and a nucleic acid oxidizing agent (e.g., hypohalous acid). Although virtually any surfactant is useful, anionic detergents are preferred. For example, one such anionic detergent is a proprietary blend of sodium linear alkylaryl sulfonate, alcohol sulfate, phosphates and carbonates known as ALCONOX®. ALCONOX® is available as a powdered detergent. A similar detergent, LIQUINOX®, also is useful in the present invention.
[0023] In a preferred embodiment, the oxidizing agent is hypochlorite and in a more preferred embodiment, the hypochlorite is sodium hypochlorite.
[0024] The concentration of surfactant is between about 0.1% and saturation. A preferred amount is from about 0.2% to about 10%. A suitable amount is from about 0.5% to about 5%. A preferred range is from about 0.6% to about 1%. When ALCONOX® is used as the surfactant, the final concentration of ALCONOX® is preferably about 0.75% w/v.
[0025] The concentration of oxidizing agent is between about 0.01% and 10%. A preferred range is from about 0.05% to about 5%. A suitable amount is from about 0.1% to about 3%. In the case where the oxidizing agent is sodium hypochlorite, the hypochlorite concentration is between about 0.01% and about 5%, preferably about 0.05% to about 3%, and preferably between about 0.1% to about 2%. In a related embodiment, the final concentration of hypochlorite is 1%.
[0026] Water-soluble salts of the higher fatty acids, i.e., “soaps,” are useful surfactants in the blends of solution disclosed herein (see also U.S. Pat. No. 4,123,377). This class of surfactants includes ordinary alkali metal soaps such as the sodium, potassium, ammonium and alkanol ammonium salts of higher fatty acids containing from about 8 to about 24 carbon atoms and preferably from about 10 to about 20 carbon atoms. Soaps can be made by direct saponification of fats and oils or by the neutralization of free fatty acids. Particularly useful are the sodium and potassium salts of the mixtures of fatty acids derived from coconut oil and tallow, i.e., sodium or potassium tallow and coconut soaps.
[0027] Another class of anionic surfactants includes water-soluble salts, particularly the alkali metal, ammonium and alkanolammonium salts, of organic sulfuric reaction products having in their molecular structure an alkyl group containing from about 8 to about 22 carbon atoms and a sulfonic acid or sulfuric acid ester group. (Included in the term “alkyl” is the alkyl portion of acyl groups.) Examples of this group of synthetic surfactants which can be used in the present solutions are the sodium and potassium alkyl sulfates, especially those obtained by sulfating the higher alcohols (C 8 -C 18 carbon atoms) produced by reducing the glycerides of tallow or coconut oil, sodium and potassium C 8 -C 20 paraffin sulfonates, and sodium and potassium alkyl benzene sulfonates, in which the alkyl group contains from about 9 to about 15 carbon atoms in straight chain or branched chain configuration, e.g., those of the type described in U.S. Pat. No. 2,220,099, and 2,477,383, incorporated herein by reference.
[0028] Other anionic surfactant compounds useful herein include the sodium alkyl glyceryl ether sulfonates, especially those ethers or higher alcohols derived from tallow and coconut oil, sodium coconut oil fatty acid monoglyceride sulfonates and sulfates; and sodium or potassium salts of alkyl phenol ethylene oxide ether sulfate containing about 1 to about 10 units of ethylene oxide per molecule and wherein the alkyl groups contain about 8 to about 12 atoms.
[0029] Other useful anionic surfactants herein include the water-soluble salts of esters of α-sulfonated fatty acids containing from about 6 to 20 carbon atoms in the ester group; water-soluble salts of 2-acyloxy-alkane-1-sulfonic acids containing from about 2 to 9 carbon atoms in the alkane moiety; alkyl ether sulfates containing from about 10 to 20 carbon atoms in the alkyl group and from about 1 to 30 moles of ethylene oxide; water-soluble salts of olefin sulfonates containing from about 10 to 20 carbon atoms in the alkyl group and from about 1 to 30 moles of ethylene oxide; water-soluble salts of olefin sulfonates containing from about 12 to 24 carbon atoms; and β-alkoxy alkane sulfonates containing from about 1 to 3 carbon atoms in the alkyl group and from about 8 to 20 carbon atoms in the alkane moiety.
[0030] Preferred water-soluble anionic organic surfactants herein include linear alkyl benzene sulfonates containing from about 11 to 14 carbon atoms in the alkyl group; the tallow range alkyl sulfates; the coconut range alkyl glyceryl sulfonates; and alkyl ether sulfates wherein the alkyl moiety contains from about 14 to 18 carbon atoms and wherein the average degree of ethoxylation varies between 1 and 6.
[0031] Specific preferred anionic surfactants for use herein include: sodium linear C 10 -C 12 alkyl benzene sulfonate; triethanolamine C 10 -C 12 alkyl benzene sulfonate; sodium tallow alkyl sulfate; sodium coconut alkyl glyceryl ether sulfonate; and the sodium salt of a sulfated condensation product of tallow alcohol with from about 3 to about 10 moles of ethylene oxide.
[0032] It is to be recognized that any of the foregoing anionic surfactants can be used separately herein or as mixtures. Mixtures of anionic surfactants which can be used in the present detergent compositions can be taken from the sodium and potassium alkyl sulfates, especially those obtained by sulfating the higher alcohols (C 8 -C 18 carbon atoms) produced by reducing the glycerides of tallow or coconut oil, sodium and potassium C 8 -C 20 paraffin sulfonates, sodium and potassium alkyl benzene sulfonates, in which the alkyl group contains from about 9 to about 15 carbon atoms in straight chain or branched chain configuration, and the sodium salt of a sulfated condensation product of tallow alcohol with from about 2 to about 10 moles of ethylene oxide. Nonionic surfactants include the water-soluble ethoxylates of C 10 -C 20 aliphatic alcohols and C 6 -C 12 alkyl phenols.
[0033] Semipolar surfactants useful herein include water-soluble amine oxides containing one alkyl moiety of from about 10 to 28 carbon atoms and 2 moieties selected from the group consisting from 1 to about 3 carbon atoms; water-soluble phosphine oxides containing one alkyl moiety of about 10 to 28 carbon atoms and 2 moieties selected from the group consisting of alkyl groups and hydroxyalkyl groups containing from about 1 to 3 carbon atoms; and water-soluble sulfoxides containing one alkyl moiety of from about 10 to 28 carbon atoms and a moiety selected from the group consisting of alkyl and hydroxyalkyl moieties of from 1 to 3 carbon atoms.
[0034] Ampholytic surfactants include derivatives of aliphatic or aliphatic derivatives of heterocyclic secondary and tertiary amines in which the aliphatic moiety can be straight chain or branched and wherein one of the aliphatic substituents contains from about 8 to 18 carbon atoms and at least one aliphatic substituent contains an anionic water-solubilizing group.
[0035] Zwitterionic surfactants include derivatives of aliphatic quaternary ammonium, phosphonium and sulfonium compounds in which the aliphatic moieties can be straight or branched chain, and wherein one of the aliphatic substituents contains from about 8 to 18 carbon atoms and one contains an anionic water-solubilizing group.
[0036] It is further envisaged to use common laboratory surfactants and detergents to practice the instant invention such as, but not limited to, the Tween series, the octylphenol series (Triton), tergitol detergents (NP series), sodium laureth sulfide (SDS), Brij detergents and niaproff anionic detergents. Useful builders herein include any of the conventional inorganic and organic water-soluble builder salts, as well as various water-insoluble and so-called “seeded” builders.
[0037] Inorganic detergency builders useful herein include, for example, water-soluble salts of phosphates, pyrophosphates, orthophosphates, polyphosphates, phosphonates, carbonates, bicarbonates, borates and silicates. Specific examples of inorganic phosphate builders include sodium and potassium tripolyphosphates, phosphates, and hexametaphosphates. The polyphosphonates specifically include, for example, the sodium and potassium salts of ethylene diphosphonic acid, the sodium and potassium salts of ethane 1-hydroxy-1, 1-diphosphonic acid, and the sodium and potassium salts of ethane-1,1,2-triphosphonic acid. Examples of these and other phosphorous builder compounds are disclosed in U.S. Pat. Nos. 3,159,581; 3,213,030; 3,422,021; 3,422,137; 3,400,176; 3,400,148; 4,019,998 and 4,019,999, incorporated herein by reference. Sodium tripolyphosphate is an especially preferred, water-soluble inorganic builder herein.
[0038] Non-phosphorous containing sequestrants can also be selected for use herein as detergency builders. Specific examples of non-phosphorus, inorganic builder ingredients include water-soluble inorganic carbonate, bicarbonate, borate and silicate salts. The alkali metal, e.g., sodium and potassium, carbonates, bicarbonates, borates (Borax) and silicates are particularly useful herein.
[0039] Water-soluble, organic builders are also useful herein. For example, the alkali metal, ammonium and substituted ammonium polyacetates, carboxylates, polycarbonates, succinates, and polyhydroxysulfonates are useful builders in the present compositions and processes. Specific examples of the polyacetate and polycarboxylate builder salts include sodium potassium, lithium, ammonium and substituted ammonium salts of ethylene diamine tetraacetic acid, nitrilotriacetic acid, oxydisuccinic acid, mellitic acid, benzene polycarboxylic acids and citric acid.
[0040] Other preferred non-phosphorous builder materials (both organic and inorganic) herein include sodium carbonate, sodium bicarbonate, sodium silicate, sodium citrate, sodium oxydisuccinate, sodium mellitate, sodium nitrilotriacetate, and sodium ethylenediaminetetraacetate, the mixtures thereof.
[0041] Preferably, the blend is solvated in an aqueous solution, however, other solvents are contemplated as useful for the present invention. For example alcohols, such as ethanol, methanol, propanol, isopropyl alcohol, butanol and the like can be used. Such non-water solvents can serve as the sole solvent, or if miscible, can be combined with water. The composition of interest can include a buffer to facilitate solvation and to yield a solution of reduced acidity or alkalinity.
[0042] The composition of interest also contains a nucleic acid oxidizing agent agent. The agent oxidizes nucleic acids and thereby prevents proper complementary base pairing. The agent also alters the nucleic acid so that amplification thereof is not possible. Suitable oxidizing agents include, but are not limited to, hypohalous acids. Suitable hypohalous acids include HOBr, HOI and HOCI. Other agents include, but are not limited to, peroxides, such as H 2 O 2 and perioxynitrite.
[0043] A preferred oxidizing agent is hypochlorite.
[0044] Hypochlorites (bleach) useful in the blend of the present invention include sodium, lithium, calcium and di-basic magnesium. Sodium hypochlorite is preferred.
[0045] Certain oxidizing agents yield alkaline solutions, as do many surfactants. Thus, for example, hypohalous acids, such as sodium hypochlorite, yield solutions with pH values well greater than 7. However, higher pH values also can impact nucleic acid stability and thus, can be beneficial.
[0046] In another embodiment, the combination of surfactant and oxidizing agent is such that inactivation and the removal of greater than 50% of the contaminating nucleic acids occurs in at least about 30 seconds. In a related embodiment, the contact time is sufficient to cause more than 90% of the contaminating nucleic acid to be rendered unamplifiable and removed.
[0047] In a related aspect, when the surface is in contact with the solution for at least about 2 minutes, greater than about 50% of contaminating amplification detectable nucleic acids are removed. Further, 2 minutes contact time is sufficient to cause about 95% of the contaminating amplification detectable nucleic acids to be rendered unamplifiable and removed.
[0048] The use of a surfactant/oxidizing agent solution allows virtually no redeposition of removed (and unwanted) nucleic acid molecules. More specifically, it is believed that when a surfactant is used during decontamination procedures, nucleic acid molecules, including target molecules as well as amplicons are lifted from a surface, solubilized and are not redeposited. Contact of the oxidizing agent solution with a nucleic acid molecule oxidizes the nucleic acid molecule causing permanent destabilization of the double helix structure and rendering nucleic acids unamplifiable. Solubilized nucleic acids are more accessible to the oxidizing agent. The resulting chemically modified molecule can no longer be replicated by enzymatic means and thus the nucleic acid molecule is rendered unamplifiable. The surfactant/oxidizing agent solutions of the present invention not only render nucleic acid molecules unamplifiable, but also easily removable from surfaces.
[0049] Use of the surfactant/oxidizing agent solutions of the present invention involves the application of such solutions to surfaces. Preferably the surfaces are soaked with the solution. The solution is left on the surface for a period of time, for example, at least about 30 seconds, preferably for about one minute and more preferably more than about two minutes up through the time of having the solution of interest dry on the surface. Then the surface is wiped with an aqueous solution, such as water, water/alcohol mixture and the like, which optionally can be buffered, to remove the nucleic acid molecules. The surfaces should be rinsed with water or like solvent and wiped to remove any residual surfactant/oxidizing solution and nucleic acid molecules remaining.
[0050] The solution can be contacted with a surface at room temperature that generally is in the range of 220-28° C., and more generally 24-26° C. However, the solution is effective at temperatures varying from 0° C. to about 97-99° C. The optimal temperature is adjustable depending on the surfactant and oxidizing agent used. Suitable additives, such as buffers and salts, can be added to ensure use of the solution at warmer or colder temperatures. In a related embodiment, the preferred temperature for contamination removal is between about 10° C. and about 40° C.
[0051] Sodium hypochlorite alone has limitations in being only about 50% effective in removing DNA. Experimental evidence shows that application of a conventional sodium hypochlorite solution to a nucleic acid amplification instrument contaminated with target nucleic acid molecules did not fully remove the nucleic acid molecules causing such contamination. However, the use of a detergent (ALCONOX®)/sodium hypochlorite solution in accordance with the present invention eliminated the nucleic acid molecules causing contamination to a greater degree. The detergent/bleach solution was applied to the same instrument after use of bleach alone for comparison. Similarly, environmental data has been generated from laboratories where nucleic acid amplification reactions are conducted showing that use of a surfactant/oxidizing agent solution in accordance with the present invention results in decreased nucleic acid contamination as compared to the application of a conventional sodium hypochlorite solution.
[0052] It is preferred that the solutions be prepared shortly before use. Thus, various types of pre-packaging of an appropriate amount of surfactant and oxidizing agent are envisioned. Such pre-packaging may facilitate dissolving of the surfactant, oxidizing agent or both into solution, and may comprise a vehicle for delivery of the components into the solution, such as a dissolvable vehicle. The present invention also comprises a kit containing appropriate amounts of surfactant and oxidizing agent in separate containers for mixing prior to application.
[0053] In one embodiment, a kit comprising a separate container consists essentially of a surfactant and a separate container consisting essentially of oxidizing agent in concentrations such that when admixed, a non-particulate solution for removing and helix destabilizing contaminating nucleic acids on amplification reaction surfaces is generated. In a related embodiment, when the surfaces are contacted with the decontaminating solution the undesired nucleic acids are rendered unamplifiable by oxidation and greater than about 50% of amplification detectable nucleic acids are removed.
[0054] In another embodiment, the kit comprising a separate container consisting essentially of a higher fatty acid alkali metal soap, organic builder salts and a separate container consisting essentially of oxidizing agent.
[0055] The following non-limiting examples illustrate the efficacy and advantages associated with the solution for certain surfaces in accordance with the present invention. It is understood that these examples are for illustration purposes only and that alternative embodiments are contemplated as within the scope of the present invention.
EXAMPLES
Example 1
Effectiveness of Bleach/ALCONOX Solution in Removing DNA Environmental Contamination
[0056] A preferred protocol involves taking a set of pre-cleaning swabs, cleaning the area with 1% sodium hypoochlorite/0.75% ALCONOX® detergent solution, and taking a set of post cleaning swabs. Swabs generally are processed on the day of collection but can be held and used within 4-6 days of collection if stored at 2-27° C. The swab is placed into a suitable vessel, such as a test tube, containing a diluent, such as a standard nucleic acid amplification buffer solution, and swirled in the diluent for about 5-10 seconds. The swab is expressed on the inside wall of the vessel to remove as much of the liquid containing any nucleic acids collected in the swab into the liquid diluent. The swab is discarded and the tube vortexed. A sample is taken for detection of nucleic acid by an amplification method.
[0057] This experiment used a pre-test/post-test design to evaluate the effectiveness of 1% sodium hypochlorite/0.75% ALCONOX® detergent solution as a DNA decontamination agent. In the pre-test, contaminated areas were swabbed 10 times to assess the degree of contamination. These areas were then treated with 1% sodium hypochlorite/0.75% ALCONOX® detergent solution and 10 post-test swabs were collected. Presence of nucleic acid was by the strand displacement method using the BDProbeTec™ ET test kit to detect Chlamydia trachomalis (CT) and Neisseria gonorrhoeae (GC) nucleic acids. The swab diluent provided in the kit was used. A 50% reduction in the frequency of positive contamination monitoring swabs was considered to be an indicator of effective decontamination. A CT/GC score of <2000 is considered negative for the strand separation assay as performed.
[0058] Data from the contaminated areas are summarized in TABLE 1, below.
TABLE 1 CT/GC Contaminated Areas, 6 Areas, 20 Swabs from each Area. CT-GC/20 CT-GC/20 Area Swabs Before Swabs After % Reduction 1 7/20 0/20 100% 2 8/20 0/20 100% 3 6/20 0/20 100% 4 5/20 0/20 100% 5 9/20 0/20 100% 6 10/20 1/20 1 90% Overall 45/120 1/120 99.60%
[0059] [0059] TABLE 2 Breakdown of Data Before Cleaning. Area Before GC Before CT 1 7/10 0/10 2 8/10 0/10 3 6/10 0/10 4 2/10 3/10 5 9/10 0/10 6 10/10 0/10
[0060] Acceptance criterion for this validation called for at least a 50% reduction in the frequency of positives in contamination monitoring samples. Each individual test area as well as the pooled data sets met this criterion.
[0061] These data demonstrate that 1% sodium hypochlorite/0.75% ALCONOX® detergent solution is an effective agent for the removal of DNA amplification products form laboratory surfaces and equipment.
Example 2
Use of Peroxide as the Oxidizing Agent
[0062] Hydrogen peroxide was used in combination with ALCONOX®. Two different concentrations of hydrogen peroxide were used, 1% and 3% in distilled water, with the detergent used at the same concentrations.
TABLE 3* Performance with Hydrogen Peroxide. Before After Swab # Condition** CT GC CT GC 1 A 2086 7 47 9 2 A 5181 48 159 98 3 B 0 21633 663 1 4 B 7845 21586 309 148 Pos. Ctrl. 33796 53673 16488 36667 Neg. Ctrl. 420 288 378 177
Example 3
Performance of Swab Testing for Amplicons before and after Cleaning
[0063] An ALCONOX® and bleach solution was used to clean an instrument directed to operate with the SDA amplification assay. The solution was prepared by adding 600 ml of a commercial bleach solution (5% sodium hypochlorite) was added to a 3.5 L container followed by 22.5 g of ALCONOX®. Warm water (qs to 3000 ml) was added to produce the final solution that was used to wipe down the suspected contaminated surfaces of the instrument. The washing procedure was repeated three to four times, the solution and towels were changed after each wash, before the certain areas were swabbed.
[0064] Swabs were dipped into swab sample diluent and then swabbed over different locations that were previously shown to be contaminated with amplicons. Bleach, detergent and water were added as in Example 1. The procedure for wiping the surfaces was also as provided in Example 1, except that the procedures were repeated 4 times instead of 3. Amplicon monitoring using dipped swabs was as described in Example 1.
[0065] Data from the contaminated areas are summarized in TABLE 4, below.
TABLE 4* CT/GC Contaminated Areas Before and at Final Cleaning. Before Cleaning After Cleaning Swab # Location CT GC CT GC 1 Matrix Stand 38 17599 301 31 2 Printer-Right 3018 280 195 106 Side 3 Printer-Top 8 8046 38 95 4 Lysis Rack Top, 657 10675 20 21 Handles 5 Heat Blocks-Left 2895 13630 1 140 Side 6 Heat Blocks- 2012 3472 21 14 Right Side 7 Heat Blocks-Heat 162 7542 153 86 Spike 8 Heat Blocks-Pre- 6 25095 0 0 Warm 9 Heat Blocks- 76 18483 60 7 Front Surface 10 Lysis Block-Top 36 13994 13 5 11 Lysis Block- 0 12142 163 70 Sides 12 Black Cord 95 28947 31 29 13 Power Cord to 18 10772 157 65 Printer 14 Printer Cable 0 16266 407 105 15 Black Cord 1 7123 563 144 16 Black Cord 118 12409 7 46 Pos. Ctrl. 20977 35914 23157 18075 Neg. Ctrl. 44 98 559 144
[0066] Peripherals from the instrument were found to be contaminated. After thoroughly cleaning each piece of equipment with the solution of interest, no amplicon contamination was found.
Example 4
Environmental Swab Testing on an Instrument
[0067] Various areas on the instrument and peripherals were swabbed and tested using the CT/GC SDA assay. After results were collected, the instrument and peripherals were cleaned using an ALCONOX@ and bleach solution. The procedure was as in Example 1, except that the procedure was repeated 2×.
[0068] Data from the contaminated areas are summarized in TABLE 5, below.
TABLE 5* CT/GC Contaminated Areas from the Field. Before Cleaning After Cleaning Swab # Location CT GC CT GC 1 Latch 296 2362 102 0 2 Front Deck 124 7899 30 100 3 Right Outside 134 9925 60 61 4 Heat Block-Rt. 2184 159 0 4 Side
[0069] After through cleaning with the solution of interest, all tested areas of the equipment were found to be contamination free.
Example 5
Additional Testing
[0070] An SDA instrument was tested for contamination and decontamination. Fourteen areas were swabbed with a 1% solution hypochlorite. Ten areas were tested after cleaning with a solution of interest as prepared in Example 1.
[0071] Of the fourteen sites tested with bleach alone, 7/14 were positive for GC and 0/14 were positive for CT. On the other hand, none of the ten areas cleaned with a solution of interest contained CT or GC nucleic acids.
Example 6
Additional Testing
[0072] Another instrument was tested as described in the above examples. Although twelve sites were tested before cleaning, three of the sites were inside the machine and were not cleaned and tested following exposure to the solution of interest.
TABLE 6 GC CT # of Areas Swabbed Before Instrument Cleaning 12 9/12 3/12 Same Instrument, # of Areas Swabbed After Instrument Cleaning (3X) 9 1/9 0/9 Same Instrument, # of Areas Swabbed After Instrument Cleaning (1X additional) 9 0/9 0/9
[0073] It will be understood that various modifications may be made to the embodiments disclosed herein. Therefore, the above description should not be construed as limiting, but merely as exemplifications of preferred embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.
[0074] All patents and references cited herein are explicitly incorporated by reference in their entirety. | A solution is disclosed which is useful in removing contaminating nucleic acids from various surfaces, including areas such as laboratory bench tops, floors and walls, as well as surfaces of instruments and equipment in laboratories where nucleic acid amplification reactions are conducted. Further, methods and kits are provided that afford effective decontamination and removal of nucleic acids from such surfaces. | 2 |
This application is a continuation of application Ser. No. 07/370,827, filed June 23, 1989, abandoned, which is a divisional of allowed grandparent application Ser. No. 07/240,193, filed Sep. 6, 1988, now U.S. Pat. No. 4,905,632.
BACKGROUND OF THE INVENTION
The present invention relates to a safeguard arrangement for a plant, and particularly to a safeguard arrangement for a plant for securing the safety of personnel for maintenance when a test with any people being admitted or maintenance is executed.
In a plant such as a thermal power plant, the inspection and maintenance of plant auxiliaries are conducted properly for maintaining sound operations of the plant, and it is indispensable, on the occasion, to secure the safety of the maintenance personnel in terms of both mind and body thereof. A sudden motion of some peripheral apparatus in the course of the maintenance, for instance, frightens the personnel, and also exposes them to serious danger, just causing casualty in some cases, when they work at a height. Such matters as stated above must be avoided without fail.
On the occasion of maintenance of plant auxiliaries, therefore, warning tags for prohibiting operations are usually put on the operation switches of said auxiliaries and the peripheral apparatuses so as to prevent the erroneous operation of said switches by any operator other than the maintenance personnel concerned. Besides, a process control system is known wherein the delivery of a control instruction from a process control unit to a process apparatus is prohibited by operating a switch for maintenance and inspection provided in a process input/output device on the occasion of the maintenance and inspection of the process control system, as described in Japanese Patent Laid-Open No. 91507/1984.
Among the plant auxiliaries, there are units, such as a condenser waterbox, a feed water heater, a coal pulverizer, a fan, a motor and a pump, which have a so-called lid, such as a manhole, a hatch or a cover, which is opened for internal on-the-spot maintenance. In many cases, moreover, a plurality of these auxiliaries are installed in juxtaposition to obtain a prescribed output, and therefor it sometimes happens that a part of the auxiliaries is stopped and subjected to the maintenance while a partial loaded operation is executed. On the occasion of the maintenance of the stopped auxiliary, apparatuses on the entrance and exit sides thereof are closed, a rotary machine is stopped, the inflow of a fluid is checked, and the fluid located inside is discharged, before the maintenance is executed. However, if an apparatus on the entrance or exit side is opened on the rotary machine is driven erroneously on the occasion, a great injury is to be inflicted on the personnel working inside.
In terms of the safeguard regarding such auxiliaries as mentioned above, the method relying on the manual operations of the warning tag for prohibiting operation and the switch for maintenance and inspection according to the above-described prior art can not eliminate the possibility of forgetting to set the warning tag, to operate the switch for maintenance and inspection, or the like, and it can also be imagined that an operation switch is operated erroneously by a person not knowing that a given auxiliary is under maintenance. These failures cause the problem that the maintenance personnel are imperiled by the operation of the auxiliary under maintenance or a related apparatus.
SUMMARY OF THE INVENTION
As is seen from the above description, an object of the present invention is to prevent the personnel engaged in the maintenance of a plant apparatus from being imperiled by unexpected motion of the plant apparatus due to an erroneous operation.
The aforesaid object is attained by providing a lid opening detector which detects whether a lid, such as a cover, a hatch or a manhole, to be opened for entrance into a plant auxiliary on the occasion of the maintenance thereof is opened or not, and by delivering a signal to prohibit the operation of the plant auxiliary or an attached apparatus located in the corresponding spot when it is detected by said detector that the cover, the hatch or the manhole is opened.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a fundamental construction of the present invention;
FIG. 2 and 3 show an example of installation of a maintenance state detector for a manhole;
FIG. 4 is a system diagram related to a condenser;
FIG. 5 shows an example of application of a safeguard arrangement to a condenser waterbox;
FIG. 6 is a system diagram related to a feed water heater;
FIG. 7 shows an example of application of the safeguard arrangement to the feed water heater;
FIG. 8 is a system diagram related to a coal pulverizer;
FIG. 9 shows an example of application of the safeguard arrangement to the coal pulverizer;
FIG. 10 is a system diagram related to a forced draft fan;
FIG. 11 shows an example of application of the safeguard arrangement to the forced draft fan;
FIG. 12 is a schematic view of a pump and a motor;
FIG. 13 shows an example of application of the safeguard arrangement to the pump and the motor; and
FIG. 14 shows another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will be described hereunder, taking a thermal power plant as an example and using FIGS. 1 to 13.
FIG. 1 shows a fundamental construction of a safeguard arrangement 1. In this arrangement, a lid opening detector 2 detecting that a lid, such as a cover, a hatch or a manhole, is opened is provided, an opening detection signal 3 from said detector 2 is inverted by an NOT circuit 4, an operation permission signal 5 thus obtained and a starting (opening) operation signal 7 from an operation switch 6 are given to an AND circuit 8, and an auxiliary 10 is started by an output signal 9 only when the aforesaid operation permission signal 5 and the aforesaid starting (opening) operation signal 7 are effectuated simultaneously. Interlocking of the lid opening detection signal 3 is not necessary for a stop (closure) side signal of the operation switch 6.
FIGS. 2 and 3 show an example of installation of a cover opening detector in a manhole. In this figure, numeral 100 denotes a part of the wall of a plant auxiliary 10. A cover therefor 102 being opened (FIG. 3), maintenance personnel go in and out through a manhole 101. The cover 102 is fitted rotatably to the wall 100, and a lever 103 of the cover opening detector 2, e.g. a microswitch, fixed on the wall 100 and a part of the cover 102 engage with each other so as to detect the opening of the cover 102. FIG. 2 shows the state wherein the manhole cover 102 is closed. In this case, the lever 103 of the cover opening detector 2 is pressed by the manhole cover 102, and the detector 2 does not deliver an output. FIG. 3 shows the state wherein the manhole cover therefor 102 is opened, and the lever 103 of the cover opening detector 2 is released in this case. Judging from the state that the lever 103 is therefor released, the cover opening detector 2 determines the plant auxiliary 10 to be in the state of maintenance and delivers an output. While the opening is detected from the engagement of the rotating manhole cover with the microswitch in this example, adequate detecting means other than the above can also be adopted. In addition, while the opening of the cover is detected in this case, it is also effective to determine the opening from the disengagement of an opening locking mechanism fitted to the cover and to deliver an output on the basis of the determination.
The following is a description therefor of a concrete embodiment of the present invention. FIG. 4 shows an example wherein condenser waterboxes 11 and 12 of a thermoelectric power plant are cited as plant auxiliaries. The degree of vacuum of a condenser under a rated load is maintained at a prescribed value by using the two waterboxes 11 and 12, and in this state, valves 13, 14, 221 and 222 are opened, while valves 15 and 16 are closed. Moreover, cooling water such as seawater is made to flow in the directions of arrows shown in the figure, and thereby turbine exhaust not shown in the figure is cooled down to be condensed.
While the maintenance of these waterboxes is conducted also with the plant stopped for a long term as is the case with periodical inspection, a higher degree of danger is brought about when one of them is subjected to maintenance while the other is operated, with a plant output halved. These conditions increase the possibility of erroneous operation of valves and the like related to the stopped waterbox. In order to subject the waterbox A 11 to maintenance while leaving the waterbox B 12 operated in this figure, for instance, all of a waterbox A inlet valve 13, a waterbox A outlet valve 14, a waterbox bypass valve 15 and a waterbox bypass valve 16 are put beforehand in a full-closed state so as to isolate the waterbox A 11 from the cooling water flowing through the waterbox B 12 and from the one flowing on the upstream side of the waterbox A inlet valve 13 and on the downstream side of the A outlet valve 14, and the cooling water in the waterbox A 11 is discharged. On the occasion when the waterbox A 11 is subjected to maintenance actually, any of a waterbox A entrance cover 17, a waterbox A entrance manhole 18, a waterbox exit cover 19 and a waterbox A exit manhole 20 is opened, and maintenance personnel enter a maintenance spot therethrough.
In this figure, numeral 222 denotes an inlet valve on the waterbox B side, 221 an outlet valve, 224 and 226 waterbox manholes, and 223 and 225 waterbox covers, and cover opening detectors are fitted to all of the manholes and covers respectively.
FIG. 5 shows an example of application of a safeguard arrangement in the maintenance of the condenser waterbox A 11 shown in FIG. 4. Cover opening detectors 21, 22, 23 and 24 are provided for a waterbox A entrance cover 17, a waterbox A entrance manhole 18, a waterbox A exit cover 19 and a waterbox A exit manhole 20 respectively, and a waterbox A maintenance signal 26 is effectuated by an OR circuit 25 when any one of said detectors 21, 22, 23 and 24 detects the state of maintenance. Besides, a push button 27 for signaling the waterbox A being under maintenance, or the like, which is operated by maintenance personnel on the spot at the start of the maintenance may also be provided in addition to the aforesaid detectors.
In the case when the waterbox A maintenance signal 26 is effectuated, a waterbox A operation permission signal 29, which is obtained by inverting said maintenance signal 26 by an NOT circuit 28, is not effectuated. Therefore, opening operation instruction signals 34, 35, 36 and 37 for a waterbox A inlet valve 13, a waterbox A outlet valve 14, a waterbox bypass valve 15 and a waterbox bypass valve 16 are not effectuated even if any of operation switches 30, 31, 32 and 33 corresponding to said valves 13, 14, 15 and 16 respectively is operated for opening, and consequently all of the aforesaid valves 13, 14, 15 and 16 do not make opening operation. An identical opening therefor operation prohibiting circuit may also be provided for/ an automatic opening operation circuit, such as a sequencer, as well as for the aforesaid operation switches 30, 31, 32 and 33. In this case, the switches 30 to 33 may be regarded as the automatic opening operation circuit such as the sequencer. Moreover, the state that the waterbox A 11 is under maintenance currently may be shown by an indication lamp provided on each of the operation switches 30, 31, 32 and 33, or on a display screen of a computer, in response to the waterbox A maintenance signal 26, so as to inform an operator that the part concerned is under maintenance.
In the same way as in the case of the abovestated waterbox A 11, a safeguard arrangement for maintenance of the waterbox B 12 is constructed as follows. A waterbox B entrance cover 225, a waterbox B entrance manhole 226, a waterbox B exit cover 223 and a waterbox B exit manhole 224 of FIG. 4 are provided with cover opening detectors 227 to 230 (FIG. 5) respectively, and when any one of said detectors 227 to 230 detects the state of maintenance, a waterbox B maintenance signal 233 is effectuated by an OR circuit 232. Besides, a push button 231 for signaling the waterbox B being under maintenance, which is operated by maintenance personnel on the spot at the start of the maintenance, is also provided in addition to the aforesaid detectors 227 to 230.
In the case when the waterbox B maintenance signal 233 is effectuated, a waterbox B operation permission signal 235, which is obtained by inverting the aforesaid maintenance signal 233 by an NOT circuit 234, is not effectuated. Therefore opening operation instruction signals 238, 239, 36 and 37 for a waterbox B inlet valve 222, a waterbox B outlet valve 221, the waterbox bypass valve 15 and the waterbox bypass valve 16 are not effectuated even if any of operation switches 236, 237, 32 and 33 corresponding to said valves 222, 221, 15 and 16 respectively is operated for opening, and consequently all of the aforesaid valves 222, 221 15 and 16 do not make opening operation.
According to the present embodiment, the opening operation of all the valves 13, 14, 15 and 16 connected to the waterbox A 11 can be prohibited during the maintenance of the waterbox therefor A 11. Even if any of the operation switches 30, 31, 32 and 33 is operated for opening erroneously by an operator or if the central sequencer (computer) outputs an opening signal by any reason, therefore, the inflow of cooling water into the waterbox A 11 can be prevented, and this produces an effect that such a personal accident as maintenance personnel being immersed in water or drowned to death is prevent from occurrence. During the maintenance of the waterbox B, likewise, the opening operation of all the valves 222, 221, 15 and 16 connected to the waterbox B 12 can be prohibited, and therefore the inflow of the cooling water into the waterbox B 12 can be prevented, even if any of the operation switches 236, 237, 32 and 33 is operated for opening erroneously by the operator. The characteristic feature of this embodiment is that the valves 15 and 16 bypassing the two waterboxes are locked in the maintenance of either of the waterboxes since they are common to the two.
FIG. 6 shows a system of feed water heaters 111 and 112 which are plant auxiliaries, and feed water from a condenser can be supplied to a boiler through three routes, the two feed water heaters 111 and 112 installed in juxtaposition and a bypass valve 240 opened during the operation of the heaters. These feed water heaters are given an extracted steam from a turbine through an extraction stop valve 115 and heat the feed water. Numeral 113 denotes a feed water inlet valve and 114 a feed water outlet valve. In this case, a system A consisting of 111, 114a, 115a and 113a and a system B consisting of 112, 114b, 115b and 113b are independent of each other, and there is no apparatus that must be locked when either of the systems is subjected to maintenance, as is the case with the example of FIG. 4. Therefore, a description will be made hereunder only on the system A, and the one on the system B will be omitted.
In order to subject the feed water heater A 111 to maintenance while leaving the feed wa heater 112 in the state of operation, in the present feed water system, the feed water heater A feed water inlet valve 113a, the feed water heater A feed water outlet valve 114a and the feed water heater A extraction stop valve 115a are put in a full-closed state, while other valves are put in an opened state, and thereby the feed water heater 111 is isolated from the feed water and extracted steam flowing in and out of the feed water heater B 112. When the feed water heater A 111 is put under maintenance, a feed water heater A manhole 116a is opened, and maintenance personnel enter the spot of maintenance therethrough.
FIG. 7 shows an example of application of the safeguard arrangement in the maintenance of the feed water heaters shown in FIG. 6, and a description will be made only on the maintenance of the system A. The feed water heater A manhole 116a is provided with a cover opening detector 117a, and a feed water heater A maintenance signal 120a is effectuated by an OR circuit 119a when the state of maintenance is detected by said detector 117a or when a push button 118a for signaling the feed water heater A being under maintenance is operated on the spot by maintenance personnel. Said push button 118a may not be provided. In the case when the feed water heater A maintenance signal 120a is effectuated, a feed water heater A operation permission signal 122a, which is obtained by inverting said maintenance signal 120a by an NOT circuit 121a, is not effectuated. Therefore opening operation instruction signals 126a, 127a and 128a for the feed water heater A feed water inlet valve 113 a, the feed water heater A feed water outlet valve 114a and the feed water heater A extraction stop valve 115a are not effectuated even if any of operation switches 123a, 124a and 125a corresponding to said valves 113a, 114a and 115a respectively is operated for opening, and consequently all of the aforesaid valves do not make opening operation. Besides, interlocking of a cover opening detection signal for an operation signal for closure of the operation switches 123a, 124a and 125a is unnecessary.
According to the present embodiment, the opening operation of all the valves connecting to the feed water heater A 111 can be prohibited during the maintenance of the feed water heater A. Even if any of the operation switches 123a, 124a and 125a is operated for opening erroneously by an operator, accordingly, the inflow of feed water or an extracted steam into the feed water heater A 111 can be prevented, and this produces an effect that such a personal accident as maintenance personnel being burnt, scalded or drowned to death by the feed water or extracted steam of high temperature and high pressure is prevented from occurrence.
FIG. 8 shows an example of a coal pulverizer as a plant auxiliary. Herein the coal pulverizer 38 is an apparatus for supplying pulverized coal as a fuel to a boiler 241. One boiler 241 is provided with a plurality of coal pulverizers 38, and the coal supplied from a coal feeder 41 is crushed by a rotor into pulverized coal, and then the pulverized coal is supplied to the boiler by carrier air 242. The figure shows an example of a coal pulverizer having two systems of a and b. In order to subject the inside of a coal pulverizer 38a of the system a to maintenance while leaving a coal pulverizer 38b of the system b in the state of operation, in the coal pulverizer 38 stated above, a coal gate 40a checking the flow of coal from a coal bunker 39a into a coal feeder 41a is closed, a coal feeder motor 42a for casting coal from the coal feeder 41a into the coal pulverizer 38a is stopped, a coal pulverizer motor 43a for pulverizing the coal cast in from the coal feeder 41a is stopped, a primary air damper 44a checking the inflow of hot primary air 242, the carrier air, into the coal feeder 41a is closed, and a coal pulverizer outlet damper 45a checking the backflow of a flame in a furnace and that of pulverized coal from another coal pulverizer is closed so that the coal pulverizer 38a be isolated from the coal, primary air, flame and pulverized coal flowing thereinto, and a rotor 46a in the coal pulverizer 38a is stopped. On the occasion when the inside of the coal pulverizer 38a is subjected to maintenance, any of coal pulverizer hatches 47a provided in a plurality is opened, and maintenance personnel enter the spot of maintenance therethrough.
FIG. 9 shows the safeguard arrangement in the maintenance inside the coal pulverizer 38 shown in FIG. 8, and since both systems a and b are based on the same logic, a description will be made hereunder only on the example of the system a. Each of the coal pulverizer hatches 47a in a plurality is provided with a hatch opening detector 48a, and a coal pulverizer maintenance signal 51a is effectuated by an OR circuit 49a when the opened state of the hatches is detected by any one of said detectors 48a provided in a plurality or when a push button 50a for signaling the coal pulverizer being under maintenance is operated on the spot by the maintenance personnel. Said push button 50a may not be provided.
In the case when the coal pulverizer maintenance signal 51a is effectuated, a coal pulverizer operation permission signal 53, which is obtained by inverting said maintenance signal 51a by an NOT circuit 52a, is not effectuated. Therefore opening operation instruction signals 59a, 62a and 63a for the coal gate 40a, the primary air damper 44a and the coal pulverizer outlet damper 45a are not effectuated even if any of operation switches 54a, 57a and 58a corresponding to said apparatuses respectively is operated for opening, and consequently all of the aforesaid apparatuses do not make opening operation.
Even if either of operation switches 55a and 56a corresponding to the coal feeder motor 42a and the coal pulverizer motor 43a respectively is operated for starting, start instruction signals 60a and 61a for said motors are not effectuated, and consequently neither of these motors is started.
According to the present embodiment, the opening and starting operations of all of the auxiliaries 40a, 42a, 43a, 44a and 45a related to the coal pulverizer 38a can be prohibited during the maintenance of the coal pulverizer. This produces effects that such personal accidents as maintenance personnel being buried in the coal flowing into the coal pulverizer 38a, as the personnel being burnt or scalded by the hot air, flame or pulverized coal flowing into the coal pulverizer 38a and as the personnel being caught in and, in the worst case, caused to death by the rotation of the rotor 46a, owing to the erroneous operations of either of the operation switches 54a and 55a, either of the operation switches 57a and 28a, and the operation switch 56a, by an operator, respectively, are prevented from occurrence.
FIG. 10 is a system diagram of forced draft fans and auxiliaries related thereto for supplying air to a boiler, which are taken as one example of the plant auxiliaries. In order to subject the inside of a forced draft fan 131a of a system A to maintenance while leaving a forced draft fan of a system B in the state of operation, in a forced draft fan system composed of a plurality thereof, a forced draft fan motor 132a is stopped, and a forced draft fan outlet damper 133a checking the backflow of air from the other forced draft fan is closed. On the occasion, a forced draft fan vane 134a is opened in the lowest degree. When the inside of forced draft fan 131a is subjected to maintenance, a forced draft fan manhole 135a is opened, and maintenance personnel enter the spot of maintenance therethrough.
FIG. 11 shows an example of application of a safeguard arrangement in the maintenance of the inside of the forced draft fan 131a shown in FIG. 10. The forced draft fan manhole 135a is provided with a cover opening detector 136a, and a forced draft fan maintenance signal 139a is effectuated by an OR circuit 138a when the opened state is detected by said detector 136a or when a push button 139a for signaling the forced draft fan being under maintenance is operated on the spot by the maintenance personnel. Said push button 137a may not be provided.
When the forced draft fan maintenance signal 139a is effectuated, a forced draft fan operation permission signal 141a, which is obtained by inverting said maintenance signal 139a by an NOT circuit 140a, is not effectuated. Therefore a start instruction signal 145a for the aforesaid motor 132a is not effectuated even if an operation switch 142a corresponding to the forced draft fan motor 132a is operated for starting, and consequently the motor 132a is not started. Even if either of operation switches 143a and 144a corresponding to a forced draft fan outlet damper 133a and the forced draft fan vane 134a respectively is operated for starting, opening operation instruction signals 146a and 147a for said auxiliaries are not effectuated, and consequently all of these auxiliaries do not make opening operation.
According to the present embodiment, the starting and opening operations of all the auxiliaries 132a, 133a and 134a related to the forced draft fan 131a can be prohibited during the maintenance of the forced draft fan. This produces effects that such personal accidents as maintenance personnel being caught in a movable element of the forced draft fan 131a and as the personnel being tumbled down or caught in the movable element, caused to death in the worst case, by the reverse rotations of the forced draft fan motor 142a and the vane 144a due to the backflow of air into the forced draft fan 131a, owing to erroneous operations of either of the operation switches 142a and 144a and the operation switch 143a by an operator, respectively, are prevented from occurrence.
FIG. 12 is a schematic view of a motor and a pump as plant auxiliaries. While the rotating elements of a motor 64 and a pump 65 are protected by casings or the like, a shaft coupling the motor 64 and the pump 65 together and a rotating shaft 66 in the end part or a bearing element 67 for supporting said rotating shaft 66 are covered with a plurality of rotary element covers 68. These covers 68 are removed on the occasion of maintenance of the motor 64, the pump 65, the rotating shaft 66 or the bearing element 67, and therefore the rotating shaft 66 and the bearing element 67 are exposed.
FIG. 13 shows an example of application of safeguard arrangement in the maintenance of the motor 64, the pump 65, the rotating shaft 66 or the bearing element 67 shown in FIG. 12.
Each of the rotary element covers 68 in a plurality is provided with a cover opening detector 69, and a pump or motor maintenance state signal 72 is effectuated by an OR circuit 70 when the state of maintenance is detected by any one of said detectors 69 provided in a plurality or when a push button 71 for signaling the pump or the motor being under maintenance is operated on the spot by maintenance personnel. Said push button 71 may not be provided.
In the case when the pump or motor maintenance state signal 72 is effectuated, a motor start permission signal 74, which is obtained by inverting said maintenance state signal 72 by an NOT circuit 73, is not effectuated. Therefore a start instruction signal 76 for the motor 64 is not effectuated even if an operation switch 75 corresponding to the motor 64 is operated for starting, and consequently all of the motor 64, the pump 65, the rotating shaft 66 and the bearing element 67 do not rotate but remain at a standstill.
According to the present embodiment, the rotating motions of all the elements can be prohibited when any of the motor 64, the pump 65, the rotating shaft 66 and the bearing element 66 is subjected to maintenance, and this produces an effect that such a personal accident as maintenance personnel being caught in a rotating element is prevented even if an operation switch 75 is operated erroneously by an operator.
According to the present invention, it is possible to detect automatically that some plant apparatus and auxiliaries are under maintenance and thereby to prevent dangerous motions of relevant apparatuses due to erroneous operations, and therefore personal accidents can be prevented from occurrence.
The ideas described above with reference to figures ranging to 13 are premised on the thought that "peripheral apparatuses are stopped or closed", and accordingly the technological value thereof is derived from checking the start or opening of the peripheral apparatuses on the occasion of maintenance. In a plant, the stoppage or closure of the peripheral apparatuses is confirmed generally before maintenance is started. If it should be missed that some apparatuses are in the state of operation or opened, checking of the start or opening will lose its meaning, and safety can not be secured. In order to avoid this missing, it is effective to stop or close apparatuses forcibly when the state of maintenance (the release of locking of a cover or the opening of the cover mentioned with reference to FIGS. 2 and 3) is detected. However, this measure is not based on the thought that the occurrence of a dangerous state is prevented (i.e. the thought equivalent to that stated with reference to FIG. 1), but based on the thought close to that of averting the dangerous state quickly. It is desirable, therefore, to take the following three-step measure.
1. The state of closure or stoppage of peripheral apparatuses is confirmed without fail before maintenance is commenced.
2. The state of maintenance is detected and a forced stop or closure signal is delivered to the apparatuses.
3. The state of maintenance is detected and a start or opening checking signal is delivered to the apparatuses.
Next, the basic thought of the method of forced stop or closure stated in the above item 2 will be described by using FIG. 14.
Numeral 2 in FIG. 14 denotes a cover opening detector. The detail thereof is the same with that of the detector described with regard to FIGS. 2 and 3, and it gives an output 3 when a cover 102 is opened or when the locking of the cover is released. However, the arrangement of FIG. 14 is premised on an assumption that an apparatus is opened or operated, and it is intended to make switching over to the safety side. Therefore it can be assumed that a transient state of danger appears and thereby a measure is delayed, if the opening of the cover is detected on the occasion. It is preferable, accordingly, that the release of locking is detected. The output 3 is turned to be a stop or closure signal 9 through an OR circuit 8, and thereby an operation of stopping or closing the apparatus 10 is conducted. Besides, a stop (closure) instruction 6 of an operation switch 6 may also be impressed on the OR circuit 8.
The circuit of FIG. 14 is applicable also to concrete interlocking circuits of FIGS. 5, 7, 9, 11 and 13, and by applying both ideas of FIG. 1 and FIG. 14, a double safeguard arrangement can be obtained.
According to the present invention described above, the safety of maintenance personnel on the occasion of maintenance can be secured. | A safeguard arrangement for a plant, which comprises a plant auxiliary provided with a lid and so designed that the lid is opened for maintenance of the inside thereof, switching means installed on a piping connected to said plant auxiliary, and driving means to give a driving output to the switching means in response to an opening or closing instruction signal for said switching means, and which is employed when operations for maintenance of the aforesaid plant auxiliary are executed, is provided additionally with lid opening detecting means to detect the opening of the lid of the afore-said plant auxiliary or the release of locking means thereof, in gearing with either of them, and checking means to check the opening of the aforesaid switching means on the basis of the opening instruction signal for the switching means when it is detected by said lid opening detecting means that the lid is opened or to be opened. | 5 |
FIELD OF INVENTION
The invention relates to a composition for forming optical layers particularly for use in the manufacture of optical recording media.
BACKGROUND OF THE INVENTION
In response to the demand for more reliable and higher capacity data storage and retrieval systems, there is considerable activity in the research and development of so-called optical disk recording systems. These systems utilize a highly focused modulated beam of light, such as a laser beam, which is directed onto a recording layer which is capable of absorbing a substantial amount of the light. The heat thusly produced causes the light-absorbing material in the areas struck by the highly focused laser beam to change chemically and/or physically, thus producing a concomitant change in optical properties, e.g., transmissivity or reflectivity, in the affected area. For readout, the contrast between the amount of light transmitted or reflected from the unaffected parts of the absorbing layer and from the marked areas of the layer is measured. Examples of such recording systems are disclosed throughout the literature and in numerous U.S. Patents such as U.S. Pat. Nos. 3,314,073 and 3,474,457. In recording data, a rotating disk having a light-absorptive recording layer is exposed to modulated radiation from a laser source. This radiation is passed through a modulator and appropriate optics, and the highly focused laser beam is directed onto the disk which forms by chemical and/or physical reaction of the light-absorbing layer a series of very small marks along a circular path within the light-absorptive layer. The frequency of the marks is determined by the modulator inputs. Using laser beams with a focused spot diameter of 1 μm or less, data can be stored at a density of 10 8 bits/cm 2 or higher.
The simplest optical disk medium consists merely of a dimensionally stable solid substrate on which is coated a thin layer of light-absorptive material such as a metal layer. When the light-absorptive layer is struck by an intense beam of coherent light, such as from a laser source, the light-absorptive material is either vaporized and/or thermally degraded, thereby producing a very small marked area which exhibits different transmissivity or reflectivity than the adjacent unmarked layer. Multilayer antireflection structures, such as those disclosed in U.S. Pat. No. 4,305,081 to Spong and U.S. Pat. No. 4,270,132 to Bell, increase the absorption of the laser beam which also gives better read/write contrast than with the use of simple single layer media. Therefore, for purposes of obtaining better power efficiency, sensitivity and readout response of the record, it has been preferred to use multilayer antireflective structures.
There are two basic types of multilayer antireflective structures, one of which is basically a bilayer structure and the other a trilayer structure. In bilayer media, the substrate is coated with a very smooth, highly reflective material such as aluminum, on top of which is coated a layer of moderately light-absorptive material which is preferably of a thickness corresponding to about λ/4n, where λ is the wavelength of the recording light source and n is the refractive index of the light-absorptive layer. In trilayer media, the substrate is likewise coated with a first layer of very smooth highly reflective material on which is coated a second layer of transparent material. Atop the transparent second layer is coated a thin third layer of strongly light-absorptive material. The combined thickness of the transparent and absorptive layers is preferably adjusted to be about λ/4n. In both types of structures, the adjustment of certain layer thicknesses according to the wavelength of light and refractive index of the layer is for the purpose of minimizing the amount of light reflected from the unmarked areas and maximizing the amount of light reflected from the marked areas, thus producing a higher playback signal amplitude. A detailed discussion of the three types of disk construction is given by A. E. Bell in Computer Design. Jan. 1983, pp. 133-146 and the references cited therein. See especially Bell and Spong, IEEE Journal of Quantum Electronics, Vol. QE-14, 1978, pp. 487-495.
It will be realized, of course, that the terms "bilayer" and "trilayer" refer only to the fundamental optical layers and do not exclude the use of ancillary layers. In particular, it is essential in most instances to have a polymeric layer which serves two important functions: (1) the layer must be optically smooth in order to provide an optically suitable foundation for the overlying reflective layer; and (2) the layer must have good adhesion to the underlying substrate as well as the overlying reflective layer. Furthermore, these properties must persist under all the environmental conditions which may exist as the medium is used and stored.
PRIOR ART
U.S. Pat. No. 4,188,433, Dijkstra et al.
Dijkstra et al. disclose a laser beam recording medium in which the energy absorbing recording layer is protected by a cured layer of UV-curable lacquer which serves as an adhesive layer and an overlying layer of transparent resin. The lacquer is preferably a mixture of protic acrylic acid esters such as hydroxyalkyl or aminoalkyl acrylates. The overlying resin layer can be made of any of several transparent resins, including poly(methylmethacrylate).
U.S. Pat. No. 3,665,483, Becker et al.
This patent is directed to a laser beam recording medium in which the energy-absorbing recording layer is protected with an overlying transparent layer of SiO 2 . It is disclosed that if the SiO 2 is thick enough, it can displace surface dust and dirt from the focal plane of the laser beam.
U.S. Pat. No. 3,911,444, Lou et al.
The Lou et al. patent is directed to a laser beam recording medium in which the energy-absorbing recording layer is coated upon an underlying layer of poly(alkyl methacrylate) or fluorinated polyethylene.
U.S. Pat. No. 4,300,143, Bell et al.
The Bell et al. patent is directed to an optical recording medium in which the recording layer is protected by an adjoining transparent layer of organic or inorganic material.
U.S. Pat. No. 4,477,328, Broeksemer et al.
This patent discloses a liquid coating for use on optical recording disks comprising a solution of acrylate or methacrylate oligomers and photoinitiator having a viscosity of 1000-15000 cP. Preferred oligomers are indicated to have a molecular weight of 300-1000. Only alkylene-bis(phenoxyalkylacrylate) and alkylene-bis(phenoxyalkylmethacrylate) are disclosed.
U.S. Pat. No. 4,492,718, Mayer et al.
The Mayer patent discloses rotation coating of optical disk substrates with compositions containing acrylate prepolymers, a mixture of triacrylate monomer, monoacrylate monomer, surfactant and initiator. One composition is disclosed which contains only a high molecular weight acrylate oligomer, 2-ethylhexyl acrylate, surfactant and initiator. No compositions are disclosed which use oligomers having molecular weights below 1000.
BRIEF DESCRIPTION OF THE INVENTION
In a primary aspect, the invention is directed to an optical coating composition comprising a solution of:
a. liquid hydroxy-lower alkyl monoacrylate having dissolved therein
b. oligomer having a molecular weight of at least 500; and
c. 0.05-10% wt. photoinitiator system, the liquid uncured solution having a viscosity of at least 10 cP and surface tension of less than 36 dynes/cm at coating temperature and the solid cured composition having a transmissivity of at least 88% to light having a wavelength of 488-830 nm and a pencil hardness of at least 2B.
In a second aspect, the invention is directed to
(1) applying to the substrate a liquid layer of the above-described coating composition at a temperature such that the viscosity of the composition is 10-100 cP; and
(2) exposing the coated layer to actinic radiation for a time sufficient to effect substantially complete photohardening of the acrylic monomer.
In a third aspect, the invention is directed to an optical recording medium comprising:
a. a dimensionally stable substrate;
b. a layer of light-absorptive material; and
c. an optical layer coated on layer b. by the method described above.
Except as the terms are applied to specifically named compounds, the terms "acrylic" and "acrylate" are intended herein to encompass both acrylic (R 2 C═C--) and methacrylic ##STR1## moieties.
DETAILED DESCRIPTION OF THE INVENTION
A. Photohardenable Monomer
In applicant's copending U.S. patent application Ser. No. 760,947, filed concurrently herewith, it is disclosed that suitable monomers for making optical coating compositions must meet each of the following five criteria:
(1) No less than 4 carbon atoms in the ester group;
(2) Mutual solubility with the oligomer;
(3) Liquidity at room temperature; and
(4) Monofunctionality.
Because the composition of the invention contains no volatile solvents and because the acrylate monomer also serves as the dispersion medium for the oligomer and the photoinitiation system and since the composition must be liquid at whatever temperature it is coated and preferably at room temperature, the monomer must also be liquid at ambient room temperature. All of the hydroxy-lower alkyl acrylates used herein are liquid at room temperature.
Notwithstanding the general criticality of molecular size with respect to the number of carbon atoms in the monoacrylates of that corresponding application, it has been found quite unexpectedly that monofunctional acrylates having fewer than four carbon atoms are nevertheless quite useful so long as they are substituted with at least one hydroxy group. Thus, suitable primary monofunctional acrylate monomers include the following:
hydroxymethyl acrylate
hydroxymethyl methacrylate
1-hydroxyethyl acrylate
2-hydroxyethyl acrylate (HEA)
1-hydroxyethyl methacrylate
2-hydroxyethyl methacrylate (HEMA)
1-hydroxypropyl acrylate
2-hydroxypropyl acrylate (2-HPA)
3-hydroxypropyl acrylate
1-hydroxypropyl methacrylate
2-hydroxypropyl methacrylate
3-hydroxypropyl methacrylate
1-hydroxyisopropyl acrylate
2-hydroxyisopropyl acrylate
1-hydroxyisopropyl methacrylate
2-hydroxyisopropyl methacrylate
dihydroxymethyl acrylate
dihydroxymethyl methacrylate
1,2-dihydroxyethyl acrylate
1,2-dihydroxyethyl methacrylate
1-methyl-2,2-dihydroxyethyl acrylate
1-methyl-2,2-dihydroxyethyl methacrylate
1-hydroxymethyl-2-hydroxyethyl acrylate
1-hydroxymethyl-2-hydroxyethyl methacrylate
2,2-dihydroxyethyl acrylate
2,2-dihydroxyethyl methacrylate
1-methyl-1,2-dihydroxyethyl acrylate
1-methyl-1,2-dihydroxyethyl methacrylate
3,3-dihydroxypropyl acrylate
3,3-dihydroxypropyl methacrylate
1,3-dihydroxypropyl acrylate
1,3-dihydroxypropyl methacrylate
2,2-dihydroxypropyl acrylate
2,2-dihydroxypropyl methacrylate
1,2-dihydroxypropyl acrylate
1,2-dihydroxypropyl methacrylate
1,1-dihydroxypropyl acrylate
1,1-dihydroxypropyl methacrylate
All of the above-listed monomers are liquid at room temperature and are compatible with (mutually soluble in) the oligomer and initiator components of the compositions of the invention.
As is pointed out in the above-referred copending application, polyfunctional acrylates are not suitable except in small amounts for the reason that the photohardened monomers incur excessive shrinkage and thus degrade adhesion. Despite their unsuitability as primary monomers, multifunctional acrylate monomers and solid monofunctional acrylate monomers can be used in quantities up to about 10% wt. of the total monomer content so long as they meet the other criteria listed above. It is, however, preferred to use not more than about 5% wt.
B. Oligomer
The oligomer component of the composition is a primary tool to adjust the physical properties of the composition. In particular, it is a means for adjusting the viscosity of the coating composition and to adjust the hardness and other physical properties of the photohardened layer. Thus, so long as the oligomer is completely soluble in the acrylic monomer, its chemical composition is not narrowly critical. Thus, polyacrylates, epoxy resins, polyurethanes, aminoplast resins and phenolic resins can all be used as the oligomer component of the compositions of the invention. As used herein, the term "oligomer" refers to either linear or nonlinear polymers having from 2 to 10 repeating units.
When acrylate oligomers are used, they may be either monofunctional or polyfunctional. thus they can be oligomers of any of the above-described monofunctional acrylate monomers or they can be oligomers of acrylate monomers which do not meet the above-described five criteria. For example, suitable monomers that do not meet these criteria are:
1,4-butanediol dimethacrylate,
1,6-hexanediol diacrylate,
1,6-hexanediol dimethacrylate,
n-laural acrylate,
n-lauryl methacrylate,
methyl methacrylate,
2-methoxymethylethyl acrylate,
neopentylglycol dimethacrylate,
octodecyl acrylate,
octadecyl methacrylate,
polyethyleneglycol dimethacrylate,
tetrahydrofurfural acrylate,
trimethylolpropane triacrylate,
tripropyleneglycol diacrylate,
1,5-pentanediol diacrylate,
N,N-diethylaminoethyl acrylate,
ethylene glycol diacrylate,
1,4-butanediol diacrylate,
diethylene glycol diacrylate,
1,3-propanediol diacrylate,
decamethylene glycol diacrylate,
decamethylene glycol dimethacrylate,
1,4-cyclohexanediol diacrylate,
2,2-dimethylol propane diacrylate,
glycerol diacrylate,
glycerol triacrylate,
pentaerythritol triacrylate,
2,2-di(p-hydroxyphenyl)-propane diacrylate,
pentaerythritol tetraacrylate,
2,2-di(p-hydroxyphenyl)-propane dimethacrylate,
triethylene glycol diacrylate
polyoxyethyl-2,2-di(p-hydroxyphenyl)-propane dimethacrylate
di-(3-methacryloxy-2-hydroxypropyl) ether of bisphenol-A,
di-(2-methacryloxyethyl) ether of bisphenol-A,
di-(3-acryloxy-2-hydroxypropyl) ether of bisphenol-A,
di-(2-acryloxyethyl) ether of bisphenol-A,
di-(3-methacryloxy-2-hydroxypropyl) ether of tetrachloro-bisphenol-A,
di-(2-methacryloxyethyl) ether of tetrachlorobisphenol-A, di-(3-methacryloxy-2-hydroxypropyl)
ether of tetrabromo-bisphenol-A,
di-(2-methacryloxyethyl) ether of tetrabromobisphenol-A,
di-(3-methacryloxy-2-hydroxypropyl) ether of 1,4-butanediol,
di-(3-methacryloxy-2-hydroxypropyl) ether of diphenolic acid,
triethylene glycol dimethacrylate, polyoxypropyltrimethylol propane triacrylate (462)
ethylene glycol dimethacrylate
butylene glycol dimethacrylate
1,3-propanediol dimethacrylate
1,2,4-butanetriol trimethacrylate
2,2,4-trimethyl-1,3-pentanediol dimethacrylate
pentaerythritol trimethacrylate
1-phenyl ethylene-1,2-dimethacrylate
pentaerythritol tetramethacrylate trimethylol propane trimethacrylate and 1,5-pentanediol dimethacrylate.
Epoxy resins that can be used in the composition include those having the formula ##STR2## where b is a positive integer of about 1 to 4. Preferably, the epoxy resin is the polymerization product of epichlorohydrin and bisphenol-A. In a preferred epoxy resin, R 2 in the above formula is ##STR3## Typical of these preferred epoxy resins is Epon 828® having an equivalent weight of about 185-192, manufactured by Shell Chemical Company, Houston, TX and DER 331 having an equivalent weight of about 182-190, manufactured by The Dow Chemical Company, Midland, MI. The equivalent weight is the grams of resin that contain one gram equivalent of epoxide.
An epoxy novolac resin that can be used in the composition has the formula ##STR4## where d is a positive integer of about 1-2. Preferred epoxy novolac resin are DEN 431 where d has an average value of 0.2, DEN 438 where d has an average value of 1.6 and DEN 439 where d has an average value of 1.8. These resins are also manufactured by The Dow Chemical Company.
A wide variety of liquid cross-linking resins can be used as the oligomeric component for the invention, including thermosetting resins such as aminoplast resins, phenolic resins, blocked polyisocyanates and masked isocyanates.
The aminoplast resins used may be alkylated methylol melamine resins, alkylated methylol urea, and similar compounds. Products obtained from the reaction of alcohols and formaldehyde with melamine, urea or benzoguanamine are most common and are preferred herein. However, condensation products of other amines and amides can also be employed, for example, aldehyde condensates of triazines, diazines, triazoles, guanadines, guanamines and alkyl- and aryl-substituted derivatives of such compounds, including alkyl- and aryl-substituted ureas and alkyl- and aryl-substituted melamines. Some examples of such compounds are N,N'-dimethyl urea, benzourea, dicyandiamide, formaguanamine, acetoguanamine, ammeline, 2-chloro-4,6-diamino-1,3,5-triazine, 6-methyl-2,4-diamino-1,3,5-triazine, 3,5-diaminotriazole, triaminopyrimidine, 2-mercapto-4,6-diaminopyrimidine, 3,4,6-tris(ethylamino)-1,3,5-triazine, and the like.
While the aldehyde employed is most often formaldehyde, other similar condensation products can be made from other aldehydes, such as acetaldehyde, crotonaldehyde, acrolein, benzaldehyde, furfural, glycols and the like.
The aminoplast resins contain methylol or similar alkylol groups, and in most instances at least a portion of these alkylol groups are etherified by a reaction with an alcohol to provide organic solvent-soluble resins. Any monohydric alcohol can be employed for this purpose, including such alcohols as methanol, ethanol, propanol, butanol, pentanol, hexanol, heptanol and others, as well as benzyl alcohol and other aromatic alcohols, cyclic alcohol such as cyclohexanol, monoethers of glycols such as Cellosolves and Carbitols, and halogen-substituted or other substituted alcohols, such as 3-chloropropanol and butoxyethanol. The preferred aminoplast resins are substantially etherified with methanol or butanol.
The phenolic resins which may be used herein are formed by the condensation of an aldehyde and a phenol. The most used aldehyde is formaldehyde, although other aldehydes, such as acetaldehyde, can also be employed. Methylene-releasing and aldehyde-releasing agents, such as paraformaldehyde and hexamethylene tetramine, can be utilized as the aldehyde agent if desired. Various phenols can be used; for instance, the phenol employed can be phenol itself, a cresol, or a substituted phenol in which a hydrocarbon radical having either a straight chain, a branched chain or a cyclic structure is substituted for a hydrogen in the aromatic ring. Mixtures of phenols are also often employed. Some specific examples of phenols utilized to produce these resins include p-phenyl-phenol, p-tert-butylphenol, p-tert-amylphenol, cyclopentylphenyl and unsaturated hydrocarbon-substituted phenols, such as the monobutenyl phenols containing a butenyl group in ortho, meta or para position, and where the double bond occurs in various positions in the hydrocarbon chain. A common phenol resin is phenol formaldehyde.
Particularly preferred types of phenolic resins are the alkyl ethers of mono-, di- and tri-methylol phenols. Various forms of these resins are described in U.S. Pat. Nos. 2,579,329, 2,579,330, 2,579,331, 2,598,406, 2,606,929, 2,606,935 and 2,825,712. These materials are sold under the tradename Methylon® resins by General Electric Co., Schenectady, NY.
Blocked organic polyisocyanate may be used as the oligomeric component herein. The conventional organic polyisocyanates, as described above, which are blocked with a volatile alcohol, ε-caprolactam, ketoximes or the like, so that they will be unblocked at temperatures above 100° C. may be used. These curing agents are well known in the art.
A masked polyisocyanate may also be used as the curing agent. These masked polyisocyanates, as is known in the art, are not derived from isocyanates but do produce isocyanate groups upon heating at elevated temperatures. Examples of useful masked polyisocyanates include diaminimides ##STR5## adiponitrile dicarbonate, and the like. C. Photoinitiation System
Suitable photoinitiation systems are those which are thermally inactive but which generate free radicals upon exposure to actinic light at or below 185° C. These include the substituted or unsubstituted polynuclear quinones which are compounds having two intracyclic carbon atoms in a conjugated carbocyclic ring system, e.g., 9,10-anthraquinone, 2-methylanthraquinone, 2-ethylanthraquinone, 2-tert-butylanthraquinone, octamethylanthraquinone, 1,4-naphthoquinone, 9,10-phenanthrenequinone, benz(a)anthracene-7,12-dione, 2,3-naphthacene-5,12-dione, 2-methyl-1,4-naphthoquinone, 1,4-dimethylanthraquinone, 2,3-dimethylanthraquinone, 2-phenylanthraquinone, 2,3-diphenylanthraquinone, retenequinone, 7,8,9,10-tetrahydronaphthacene-5,12-dione, and 1,2,3,4-tetrahydrobenz(a)anthracene-7,12-dione. Other photoinitiators which are also useful, even though some may be thermally active at temperatures as low as 85° C., are described in U.S. Pat. No. 2,760,863 and include vicinal ketaldonyl alcohols such as benzoin, pivaloin, acyloin ethers, e.g., benzoin methyl and ethyl ethers; α-hydrocarbon-substituted aromatic acyloins, including α-methylbenzoin, α-allylbenzoin and α-phenylbenzoin. Photoreducible dyes and reducing agents disclosed in U.S. Pat. Nos. 2,850,445, 2,875,047, 3,097,096, 3,074,974, 3,097,097, and 3,145,104, as well as dyes of the phenazine, oxazine, and quinone classes, Michler's ketone, benzophenone, 2,4,5-triphenylimidazolyl dimers with hydrogen donors including leuco dyes and mixtures thereof as described in U.S. Pat. Nos. 3,427,161, 3,479,185 and 3,549,367 can be used as initiators. Also useful with photoinitiators and photoinhibitors are sensitizers disclosed in U.S. Pat. No. 4,162,162. The photoinitiator or photoinitiator system is present in 0.05 to 10% by weight based on the total weight of the dry photopolymerizable layer.
E. Formulation
In formulating the coating compositions of the invention, the order of mixing is not important. In general, they can be formulated most easily by adding the oligomer, which may be either a viscous liquid or a soft solid, and the photoinitiator system, which is normally solvent, to the liquid monomer and then agitating the mixture well to effect complete solution of all the components. This is the procedure which was used to prepare each of the coating compositions which are described in the examples.
As indicated above, it is important that the viscosity of the coating composition be suitable for the coating method by which it will be applied. When the composition is applied to a substrate by spin coating, the viscosity of the solution should be 10-100 centipoises (cP). However, if the composition is applied by other means, its viscosity can be much higher. For example, if the composition is applied by curtain coating, the viscosity might be as high as 3000 cP. The viscosity of the coating composition can be adjusted by changing the relative amounts of monomer and oligomer. The amount of oligomer may be as low as only about 1% wt. of the composition when low viscosity coating methods are used, but they may also be as much as 50% wt. for high viscosity coating methods. The photoinitiator system does not exert any significant effect on solution viscosity.
Another important property of the composition of the invention is its surface tension, which must be less than 30 dynes/cm in order to obtain proper wetting of the substrate with the coating. In many instances the solution of monomer, oligomer and initiator will have the proper surface tension. However, in those instances where the solution has too high surface tension, it can be lowered by the addition of a small amount of a soluble nonionic surfactant. Fluorinated glycol-type oligomers such as oligomers of fluorinated acrylate esters have been found to be most suitable for this purpose. Many others may, however, be used as well. Even when all of the foregoing monomer criteria are carefully observed, it is still necessary to formulate the composition to ensure that the cured composition has a hardness of at least 2B. The reason for this is that cured coatings softer than 2B have poor substrate adhesion.
The composition of the invention can in exceptional instances contain dispersed finely divided solids, e.g., polymeric solids, so long as the index of refraction of the solids matches that of the cured matrix in which they are dispersed. Such particles must, however, be very small, on the order of 100 Å or less. The inclusion of such materials can advantageously be used to reduce shrinkage of the coatings still further.
F. Test Procedures
In the examples, the following described test procedures were used:
1. Viscosity
Procedure 1: 1.2 ml of material is introduced into a Wells-Brookfield Model RVT Ser. No. 27814 microviscometer fitted with constant-temperature water bath. All measurements are made at 25° C. After a 1 minute temperature equilibration period, three viscosity readings are recorded at 1 minute intervals. The procedure is repeated for two additional 1.2 ml aliquots for a total of nine readings. All readings are taken at 100 RPM. The material viscosity is reported as the average of the nine readings.
Procedure 2: 8.0 ml of material is introduced into a Brookfield Model LVTD Ser. No. A01770 digital viscometer fitted with "small adaptor," LV spindle, and Endocal Model RTE-9DD refrigerated circulating bath. All measurements are made at 25° C. After a 3 minute temperature equilibration period, a single viscosity reading is recorded at each of the following spindle speeds: 60, 30, 12, 12, 30, 60 RPM. The procedure is repeated for one additional 8.0 ml sample or a total of twelve readings. The material viscosity is reported as the average of the twelve readings.
2. Filtration Procedure
Batches of material are filtered through 0.1 μm nominal and 0.2 μm absolute polypropylene filters arranged in series. Filters are cartridge-type purchased from Membrama, Inc., Pleasanton, CA 94566. Pressure ≦5 psi is required for the filtration process.
3. UV Curing and Percent Transmission of Films
The material is cast onto 8"×12" double weight window pane glass using an 8 mil doctor blade (4" wide). The material is cured on a conveyorized UV source (˜6 ft/minute; ˜6 j/cm 2 ) without a nitrogen blanket. Photospeed is indicated as the number of passes of the UV lamp a sample requires to completely cure. Films are carefully peeled from the glass surface, cut to ˜2"×2", and placed in a Perkin-Elmer Model 330 spectrophotometer for percent transmission determination. Percent transmission is recorded at 632.8 nm, 780 nm, and 830 nm. Six measurements at each wavelength are recorded. The film is removed and reinserted into the sample compartment between each measurement. The instrument is zeroed prior to each insertion of the film sample. The % T is read off the digital display. The percent transmission at each wavelength is reported as the average of the six measurements.
4. Surface Tension
Approximately 50 ml of material is poured into a 4-ounce clear straight-shoulder glass jar for use in the surface tension measurement. Six measurements are made at room temperature according to the instruction manual for the Fisher Model 21 Surface Tensiomat. The surface tension (dynes/cm) is reported as the average of the six measurements.
5. Percent Photoinitiator
A 1 mm path length quartz spectrophotometer cell is filled with material and inserted into the sample compartment of Perkin-Elmer Model 330 spectrophotometer zeroed at 340 nm (absorption mode). An empty 1 mm cell is placed in the reference compartment. The optical density (OD) of the material is read off the digital display. The optical density at 350 nm is directly proportional to the percent photoinitiator as follows:
______________________________________OD % Photoinitiator (Irgacure 651)______________________________________3.195 2.682.940 2.46______________________________________
6. Index of Refraction
Index of refraction of both solutions and films are measured according to the instructions provided for a Fisher Abbe Refractometer cooled at 20° C. using a temperature-controlled water bath.
7. Pencil Hardness
In this text, pencil leads of increasing hardness values are forced against a coated surface in a precisely defined manner until one lead mars the surface. Surface hardness is defined by the hardest pencil grade which just fails to mar the painted surface.
Leads, softest to hardest, are as follows: 6B, 5B, 4B, 3B, 2B, B, HB, F, H, 2H, 3H, 4H, 5H, 6H, 7H, 8H, 9H.
Begin testing using a Gardco® pencil hardness gage and the hardest pencil. Grasp the holder firmly and bring the tube end down onto the test surface. Rotate until the selected pencil is nearest the operator and then incline the assembly downward until the lead point and the tube end are simultaneously in contact with the surface. This defines the correct lead angle of 45° to the surface. Push the gage forward (away) about one-half inch. Observe the pencil track. Sufficient pressure must have been applied either to cut or mar the film or to crush the sharp corner of the lead. If neither marring nor crushing is observed, repeat the test with greater pressure applied until a definite observation is made. If crushing of the hardest lead should occur, the film is extremely hard and is beyond the measuring range of the test. If scratching or marring of the film occurs, proceed with the next softer pencil grade and repeat the testing process until a test lead is found which crushes and does not mar the film. This is the pencil hardness of the film.
In the examples, the listed numbers and abbreviations refer to particular proprietary materials as indicated below:
A. Epoxy (acrylated epoxy) Oligomer
The following numbers refer to Celrad oligomers: 3201, 3500, 3600, 3700, 3701, 3702, 3703.
B. Acrylate (acrylated acrylate) Oligomer
The following number refers to Celrad oligomer: 6700.
C. Urethane (acrylated urethane) Oligomer
The following number refers to a urethane oligomer: UV 783.
The following numbers refer to Celrad oligomers: 1700, 7100.
D. Surfactant
FC-430 Fluorad FC-430
In the examples the following qualitative designations are used for the flexibility, adhesion and surface texture measurements.
______________________________________Flexibility: 1 Flexible 2 Moderately flexible 3 Moderately brittle 4 BrittleAdhesion: 1 Poor 2 Fair 3 Good 4 ExcellentSurface Texture: 0 None 1 Slight 2 Some 3 Pronounced/crazed______________________________________
EXAMPLES
EXAMPLES 1-27
Several series of compositions were prepared and tested in the manner described hereinabove. In particular, these series were designed to show the efficacy of the hydroxy-lower alkyl acrylates with a variety of oligomeric substances at various concentrations.
______________________________________Example Numbers Oligomer Type______________________________________ 1-19 Epoxy20-21 Acrylate22-27 Urethane______________________________________
The data on the coatings produced therefrom are given in Table 1 which follows:
TABLE 1__________________________________________________________________________ EFFECT OF COMPOSITIONAL VARIABLES ON COATING PROPERTIES__________________________________________________________________________EXAMPLE NO. 1 2 3 4 5 6 7 8__________________________________________________________________________Coating CompositionMonomer 1 Composition HEMA HEMA HEMA HEMA HEMA HEMA HEMA HEA % Wt. 76.9 76.9 76.9 57.7 76.9 76.9 71.0 71.0Monomer 2 Composition -- -- -- -- -- -- -- -- % Wt. -- -- -- -- -- -- -- --Oligomer 1 Composition 3201 3600 3700 3701 3702 3703 3201 3201 % Wt. 19.2 19.2 19.2 38.5 19.2 19.2 26.5 26.5Oligomer 2 Composition -- -- -- -- -- -- -- -- % Wt. -- -- -- -- -- -- -- --Photoinitiator % Wt. 3.8 3.8 3.8 3.8 3.8 3.8 2.5 2.5Surfactant Composition -- -- -- -- -- -- -- -- % Wt. -- -- -- -- -- -- -- --Coating PropertiesUncured LiquidViscosity, cP 16.9 22.7 23.1 107 23.9 25.0 19.6 avg. 15.3Surface Tension, dyne/cm -- 38.9 39.0 -- 38.4 38.5 38.4 --Cured Solid CoatingHardness H 3H HB H HB H HB FFlexibility -- 4 4 4 4 -- 1 1Adhesion 4 4 4 4 4 4 4 4Surface Texture 0 1 1 0 1 1 1 0No. of Passes to Cure 2 2 2 1 2 2 2 1__________________________________________________________________________EXAMPLE NO. 9 10 11 12 13 14 15 16 17__________________________________________________________________________Coating CompositionMonomer 1 Composition HEA HEA HEA HEA HEA HEA HEA HEA HEA % Wt. 65.8 65.6 65.0 71.0 78.3 78.3 76.9 76.9 76.9Monomer 2 Composition -- -- -- -- -- -- -- -- -- % Wt. -- -- -- -- -- -- -- -- --Oligomer 1 Composition 3201 3201 3201 3701 3702 3703 3600 3700 3600 % Wt. 32.0 31.9 31.6 26.5 19.2 19.2 19.2 19.2 19.2Oligomer 2 Composition -- -- Parlon-5 -- -- -- -- -- -- % Wt. -- -- 1.0 -- -- -- -- -- --Photoinitiator % Wt. 2.2 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5Surfactant Composition -- -- -- -- -- -- -- -- FC-430 % Wt. -- -- -- -- -- -- -- -- 1.0Coating PropertiesUncured LiquidViscosity, cP 22.1 21.8 Incompatible 28.2 16.9 17.5 -- -- --Surface Tension, dyne/cm -- -- -- -- -- -- -- --Cured Solid CoatingHardness 2B 2B < 3B H H HB H H-2H HFlexibility -- 1 1 1 0 1 1 1Adhesion -- 3 4 4 2 4 4 4Surface Texture 0 1 3 1 3 3 3 0No. of Passes to Cure 2 1 1 1 1 1 1 1__________________________________________________________________________EXAMPLE NO. 18 19 20 21 22 23 24 25 26 27__________________________________________________________________________Coating CompositionMonomer 1 Composition HEA 2-HPA HEMA HEA HEA HEA HEMA HEMA HEA HEA % Wt. 64.1 78.0 76.9 76.9 76.9 76.9 76.9 82.0 82.0Monomer 2 Composition HDODA* -- -- -- -- -- -- -- -- % Wt. 16.7 -- -- -- -- -- -- -- --Oligomer 1 Composition 3600 3600 6700 6700 UV893 UV783 1700 7100 7100 1700 % Wt. 16.0 19.5 19.2 19.2 19.2 19.2 19.2 15.5 15.5Oligomer 2 Composition -- -- -- -- -- -- -- -- -- -- % Wt. -- -- -- -- -- -- -- -- -- --Photoinitiator % Wt. 2.1 2.5 3.8 2.5 3.8 3.8 3.8 3.8 3.8 2.5Surfactant Composition FC-430 -- -- -- -- -- -- -- -- -- % Wt. 0.8 -- -- -- -- -- -- -- --Coating PropertiesUncured LiquidViscosity, cP 13.2 19.7 33.2 23.7 27.0 26.7 39.5 36.7 12.6 24.2Surface Tension, dyne/cm -- -- -- -- -- -- -- -- -- --Cured Solid CoatingHardness H H H H <4B <4B H H B 2BFlexibility 1 1 -- 1 0 0 4 4 1 1Adhesion 4 3 4 4 1 1 4 4 2-3 3Surface Texture 0 3 1 3 0 0 1 0 1 1No. of Passes to Cure 1 1 2 1 5 3 3 2 1 1__________________________________________________________________________ *1,6-hexanedioldiacrylate
Examples 1-19 all exhibited excellent adhesion of the compositions using hydroxy-lower alkyl acrylates with epoxy oligomers. Likewise, Examples 20 and 21 showed excellent adhesion of the composition using hydroxy-lower alkyl acrylates with acrylate oligomers. Examples 22 and 23, in which the oligomer was a urethane, did not show good adhesion because the cured coatings were too soft. However, Examples 24-27 in which HEMA was used as the monomer showed quite good hardness and thus excellent adhesion.
______________________________________Glossary of TradenamesTradename Goods Source______________________________________Celrad Acrylated Celanese Corp. oligomers New York, NYFluorad Fluorinated Minnesota Mining and acrylate Manufacturing Company ester oligomer St. Paul, MNUV Acrylated Thiokol Corp.(Urithane) urethane Danvers, MA oligomers______________________________________ | An optical coating composition comprising a C 1-3 hydroxyalkyl monofunctional acrylate monomer having dissolved therein an oligomer having a molecular weight of at least 500 and a photoinitiator system. | 8 |
The present invention relates generally to magnifying devices and more particularly to hand-held viewers that allow objects to be manipulated through a range of viewing positions while being observed under magnification.
BACKGROUND OF THE INVENTION
The study of biology and other natural sciences commonly involves microscopes and magnifying glasses to view small objects of interest. Relatively inexpensive microscopes are known for educational use by children. Some such devices may be used indoors and outdoors.
One hand-held magnifying device is described in U.S. Pat. No. 4,737,016. The '016 patent discloses a hand-held magnifying device having a small body that includes a fixed magnifying lens. A slidable adjusting tube is positioned near the lens for focusing. The adjusting tube is adapted to receive an object-supporting slide or panel (carrying an object of interest) so that the slide or panel is perpendicularly oriented to the adjusting tube. The end portion of the slide or panel, which may be formed to provide a transparent enclosure to hold an insect or the like, is positioned in alignment with the lens. By sliding the adjusting tube relative to the body of the device and in a direction parallel to the axis of view, the distance between the object and the lens is varied to bring the object into focus. The adjusting tube may be rotated about its axis to move the object being viewed from left to right within the field of view. The slide may be inserted more or less deeply into the adjusting tube to position the object relative to the lens in a rectilinear manner.
The device of the '016 patent has several drawbacks. First, the '016 viewer is difficult to use in that the plunger can easily be inadvertently pressed or moved while an object is being viewed, causing the object to move out of focus. Second, the object holder cannot be angled relative to the axis of view to permit the user to easily focus on part of the object that does not present itself "full-face" in front of the lens. Third, the object holder of the '016 device has to be moved in each direction separately when positioning an object in front of the lens, which does not allow for fluid, three-dimensional movement of the object mount. Because the '016 device requires considerable manual dexterity to focus and to manipulate the object holder, it is difficult for children to use, particularly when the object observed is a moving object.
SUMMARY OF THE INVENTION
The present invention solves these problems and provides an improved hand-held viewer for viewing various living and inanimate objects under magnification. The inventive hand-held viewer comprises an elongate body having a proximal end adapted for grasping and a distal end having a bore extending transversely therethrough which houses a magnifying lens. The magnifying lens is slidably adjustable within the bore for focusing on a plurality of focal planes. In a presently preferred embodiment, the magnifying lens of the viewer is connected to a gear mechanism for moving the lens, using a conveniently located thumb-wheel on the body, allowing the user (especially children) to smoothly focus the lens.
The hand-held viewer also has a pivotable and swivelable object mount for holding and positioning an optically transparent object holder in a variety of orientations in the field of view. In a presently preferred embodiment, the object mount includes a ball joint arrangement that allows the object mount to be pivoted right, left, up and down so that the object may viewed in focus from different distances and angles relative to the axis of view. Because the ball joint is mounted on a slidable pin, the ball joint arrangement allows the user to move an object of interest from one point to another through three dimensions in an intuitive and natural motion. The movement of the object holder can be readily accomplished with one hand, leaving the other hand free to hold and focus the hand-held viewer. The objects are conveniently held for observation in a suitable object holder, such as a transparent case or on a microscope slide or the like. The object mount of the inventive hand-held viewer also may be used to view film strips, 35 mm slides, mounted specimens sealed in plastic or cellophane, or the like.
In a presently preferred embodiment of the invention, a section of the handle is removable to gain access to the interior of the body where the transparent case can be stored when not in use.
The hand-held viewer also preferably includes a light-reflective background screen. In a presently preferred embodiment, the reflective background screen, which is angled about 45° relative to the axis of view, has a white plastic surface which reflects light and presents a bright background for viewing of film strips, 35 mm slides, or objects mounted on a transparent support.
The object mount and the background screen assembly of the inventive hand-held viewer are each removable from the elongate body or handle. For example, the background screen may be removed to view 35 mm slides, film strips or other objects with direct light, instead of reflected, indirect light. And, to view very large objects, both the background screen and the object holder may be removed to allow the inventive hand-held viewer to be used as a magnifying glass or field microscope.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of a hand-held viewer in accordance with the present invention;
FIG. 2 is a side elevation view of the hand-held viewer (partially cut-away to show the optics housing), with the background screen assembly, the object mount assembly and the handle segment detached from the body of the viewer;
FIG. 3 is a cross-sectional view of the hand-held viewer of FIG. 1 showing the gear mechanism for focusing;
FIG. 4a is a top view of the object mount inserted into the mounting receptacle (shown in cross section) and showing in phantom lines the orientation of a mounted 35 mm slide or microscope slide;
FIG. 4b is a side view of the object mount of FIG. 4a;
FIG. 4c is a top view of the object mount of FIG. 4a showing a slide strip mounted therein.
FIG. 4d is a side view of the object mount of FIG. 4c;
FIG. 5 is an exploded view in perspective of the background screen assembly of the handheld viewer of FIG. 1;
FIG. 6 is an exploded view of the optics housing of the hand-held viewer of FIG. 1;
FIG. 7 is a perspective view of an object case suitable for mounting between the arms of the object mount depicted in FIG. 4a; and
FIG. 8 is a perspective view of an object clip assembly including an alligator type clip.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2, a hand-held viewer of the present invention includes an elongate outer body 5 having a handle portion 7 at the proximal end. A bore 9 extends transversely to and through the longitudinal dimension of the body 5 near the opposite distal end 8 of body 5. An optics housing 11, including a magnifying lens 13, is mounted within bore 9. The optics housing is slidable within bore 9 for focusing the lens on an object. In a preferred embodiment of the present invention, the body 5 of the hand-held viewer has a generally Y-shaped configuration, with the base of the "Y" forming handle 7, one arm 15 of the "Y" extending above the focusable field of view to accommodate optics housing 11, and the other shorter arm 17 extending in a direction generally below the focusable field of view. A screen assembly 19 is connected to arm 17 through an opening 18 at the end of arm 17 so as to position a background screen 21 within the field of view. A pivotable and swivelable object mount assembly 23 extends between the arms 15, 17 for holding an optically transparent object holder, such as an object case 25 (FIG. 7) or microscope slide 29 (FIGS. 4a and b). Object mount assembly 23 may also be used for holding a photographic medium, such as film strip slide 28 or 35 mm slide 30 (see FIGS. 4a-d) in the field of view of the lens.
As shown in FIG. 3, body 5 comprises two mirror-image parts 5a and 5b. In a presently preferred embodiment, body parts 5a and 5b are connected to one another by a plurality of pins 59 and complementary receptacles 61 strategically positioned at points near the periphery of the body which frictionally engage each other when the body parts 5a and 5b are mated edgewise. As will be appreciated, the body parts 5a and 5b alternatively may be joined using a snap-fit arrangement or other means known in the art including sonic welding, cementing and the like.
Object mount assembly 23 is attached to the body 5 at crotch 16 and extends between the arms 15, 17 of the body. Referring to FIGS. 1, 2 and 4a-d, in a particularly preferred embodiment of the present invention, the object mount assembly 23 comprises a yoke 27 with spaced-apart arms 27a and 27b positioned to hold transparent case 25, microscope slide 29, film strip slide 28, 35 mm slide 30, or the like. To accommodate microscope slide 29, arms 27a and 27b of the yoke include slots 27' extending longitudinally. The slots 27' provide a gap that is sized to frictionally secure a microscope slide 29 or 35 mm slide 30 near its lateral edges, with the central portion of the slide centered side-to-side within the yoke. To accommodate film strip slide 28, slots 27' have an incrementally reduced gap 27" near the base 27c of yoke 27 to position the film strip substantially perpendicular to the axis of view V.
Where the viewed object dictates use of object case 25, depicted in FIG. 7, such as when the object to be viewed is not planar or mounted on a slide (e.g., an insect or spider), the arms of yoke 27 are provided with opposing tabs 31 to engage the endwalls of transparent object case 25. The arms 27a and 27b are spaced apart by an amount that is slightly less than the length of object case 25 and are resiliently deflectable so that tabs 31 on arms 27a and 27b are spring-biased against the endwalls 32 of object case 25. With reference to FIG. 7, a particularly preferred object case 25 includes (i) a container portion having a bottom wall 62, a pair of upstanding sidewalls 64, 66 and a pair of upstanding endwalls 68, 70; and (ii) a lid, sized to mate with the container portion, having a top wall 72, with airholes 74 therethrough, a pair of upstanding sidewalls 76, 78 and a pair of upstanding endwalls 80, 82. The endwalls 68, 70, 80 and 82 of the container and lid are slightly recessed relative to the edges of top wall 72, bottom wall 62 and respective sidewalls 64, 66, 76 and 78 to form a raised lip 84 around the perimeter of the endwalls. Lip 84 prevents object case 25 from accidentally sliding out of yoke 27 because arms 27a and 27b will not easily separate far enough to permit the lip to slide past tabs 31. Additionally, opposing shoulders 34 are provided on arms 27a and 27b of the yoke to stabilize object case 25 when object case 25 is fully inserted therein so that a wall of object case 25 (e.g., 64, 66 62, or 72) abuts and engages shoulders 34.
A particularly preferred embodiment of a pivotable object mount assembly 23 has a ball joint arrangement, with a ball member 33 located at and integrally molded to the base 27c of yoke 27. Ball member 33 is rotatable within a socket member 35 formed on adjoining base plate 37. The back side 37a of base plate 37 includes an elongate pin member 39 extending perpendicularly therefrom to facilitate attachment of the object mount assembly 23 to housing 5. In a preferred embodiment, and as shown in FIG. 1, the ball joint assembly allows the yoke, and the object captured by it, to be pivoted in any direction left, right, up or down through a range of positions up to an angle of about 25° relative to the yoke's centered position, as well as to turn 360° circularly about the axis extending between arms 27a and 27b. By "centered position" it is meant that yoke 27 is positioned directly under the lens with arms 27a and 27b being equidistant from the axis of view V, and the plane defined by arms 27a and 27b is perpendicular to the axis of view V, as shown in FIG. 1. As will be appreciated, a three-dimensional range of motion of yoke 27 is provided in this embodiment, as the yoke is both pivotably adjustable (analogous to the range of motion of a joystick) as well as slidably adjustable along the axis of pin 39, which is perpendicular to axis of view V. In addition, pin 39 can be rotated within receptacle 41, although that range of motion is also available by rotating yoke 27 within ball and socket members 33, 35. Thus, an object of interest held by yoke 27 within the field of view may be placed in a plurality of positions and viewed from different angles, with the maximum degree of pivoting depending in part upon the dimensions of the socket and ball attached to the yoke. With this range of motion, essentially all points within transparent object case 25 or on a slide may be viewed.
Another embodiment of an object mount is shown in FIG. 8. In this embodiment, an object clip assembly 123 includes a ball joint arrangement similar to that of object mount assembly 23 with ball member 33 being seated in socket 35. Ball member 33 is attached to one side of a disk 134, and a shaft 137 extends from the opposite side of disk 134 and terminates in an alligator-type clip. The alligator clip includes a bottom jaw 139 and a top jaw 141 which is spring biased against bottom jaw 139. Bottom jaw 139 includes a pair of handles 143 for pivoting and swiveling object clip assembly 123 through a range of positions analogous to those of object mount assembly 23. In this embodiment of the present invention, object clip assembly 123 is used to hold within the field of view of the lens 13 relatively rigid and larger objects (e.g., a piece of wood or a leaf) than can be contained within object case 25.
Object mount assembly 23 (or object clip assembly 123) is slidingly attached to the hand-held viewer of the invention by pressing pin 39 into mating sleeve or receptacle 41. As seen in FIGS. 2 and 3, receptacle 41 is positioned in an interior space of housing 5 so that it is aligned with the opening 16a at crotch 16 to receive pin 39. As best seen in FIG. 3, receptacle 41 is positioned between internally formed top wall 42a, bottom wall 42b, side walls 42c and 42d, back walls 42e and 42f and front wall 42g. Complementary halves of the walls 42a-g are provided on each half of the body 5 (i.e., on the inside of body parts 5a and 5b) so that the walls are completed, and receptacle 41 is caged therebetween, when body parts 5a and 5b are joined. Side wall 42d is radiused to form a bore having a diameter slightly larger than the outer diameter of receptacle 41 when body 5 is assembled. Thus, "complementary radiused walls," as used herein, means walls that, when mated edgewise, form a bore. Receptacle 41 includes a radially projecting tab 45 that "locks" into an opening in top wall 42a when the two halves of body 5 are assembled. This prevents relative rotation of receptacle 41 when the pivotable object mount is manipulated. As shown in cross section in FIGS. 4a-d, receptacle 41 preferably is slightly overbored (relative to the diameter of pin 39) and lined with a length of resiliently compressible material 44, such as the loop portion of hook and loop fastener material, frictional nylon or other suitable fabric for providing slightly frictional resistance to the sliding of pin 39 within receptacle 41. Pin 39 may be longer than receptacle 41 to accommodate the sliding adjustment along the axis of pin 39 while maintaining a substantial length of pin 39 within the bore of receptacle 41. When the viewer is not being used, object mount 23 may be detached from receptacle 41 for storage.
Turning to FIG. 5, a presently preferred embodiment of the invention also includes a detachable screen assembly 19 which, as noted above, mates with opening 18 in housing arm 17 to properly locate the screen assembly 19 in the field of view of lens 13. Screen assembly 19 preferably is sized to completely fill the field of view. Screen assembly 19 comprises: (i) a disk-shaped base 19a having a raised annular lip 19a' extending substantially around the periphery thereof and defining a centrally located cavity 24 in base 19a; (ii) a disk-shaped, reflective background screen 21 that is sized and shaped to seat on lip 19a'; and (iii) a circular frame member 19b that mates with base 19a to hold the circumferential edges of background screen 21 between base 19a and circular frame member 19b. Base 19a and circular frame member 19b may be mated to capture background screen 21 using a suitable adhesive or other bonding method such as ultrasonic welding. Background screen 21 is preferably a rigid, light-reflective plastic structure such as may be provided by a white, plastic disk.
With reference to FIGS. 2 and 5, base 19a and circular frame member 19b each have with spacer arms 20a and 20b respectively, which extend radially therefrom to position the background screen within the field of view. To facilitate attachment of screen assembly 19 to arm 17, tongue members 22a and 22b extend from spacer arms 20a and 20b and terminate with ridges 26a and 26b. Tab members 22a and 22b each terminate in resiliently deflectable fingers spaced apart from one another and include ridges 26a and 26b. The ridges frictionally engage the interior surface of arm 17 so as to provide attachment when screen assembly 19 is installed on arm 17. Optionally, detents may be provided on the interior surface of arm 17 to reversibly engage ridges 26a and 26b.
With further reference to FIGS. 2 and 3, in a particularly preferred embodiment of the present invention, a gear assembly advances and retracts optics housing 11 within bore 9 of the viewer. The gear assembly allows a user to easily focus lens 13 using the thumb of the same hand that grasps handle 7. The gear assembly includes a first gear member 51, a second gear member 53 and a third gear member 55. First gear 51 has a knurled circumferential edge 51' to facilitate operation by the thumb of the user . A small pinion gear 51a is coaxially aligned and integrally formed with first gear member 51. The small pinion gear 51a has a diameter of approximately 2 centimeters. First gear member 51, which has a diameter of approximately 3 centimeters at its knurled edge, is mounted on pin 63 positioned perpendicularly to the interior of body 5. A portion of the circumferential edge 51' of the first gear member protrudes through a slot in housing 5 for access by the user and manual operation of the gear mechanism.
The second gear member 53 is approximately 21/2 centimeters in diameter and also has a small pinion gear 53a (approximately 1 centimeter in diameter) coaxially aligned with and integrally formed with second gear 53. Second gear member 53 is mounted on pin 65 positioned perpendicularly to the interior of body 5.
The third gear member 55 is a linear gear (or rack) which is attached to the outer surface 50 of optics housing 11. The teeth of third gear member 55 are aligned parallel to the axis of view V. Third gear member 55 is approximately 3 centimeters in length. In a preferred embodiment, third gear member 55 is integrally molded to a spacer fin 55a, which in turn is integrally molded to optics housing 11 so that the teeth of third gear member 55 are located about 1.5 centimeters from the outer surface 50 of the optics housing.
The interrelationship and cooperation of the various gears that comprise the gear assembly are such that first pinion gear 51a operatively engages second gear member 53, and second pinion gear 53a operatively engages linear gear member 55. Thus, when first gear 51 is manually rotated by the user, the relative rotation is translated through first pinion gear 51a, second gear member 53, and second pinion gear 53a into linear movement of the third gear member 55. Because third gear member 55 is connected to optics housing 11, the optics housing 11 moves linearly along the axis of view V to permit the focusing of lens 13.
Referring to FIG. 6, the optics assembly 11 of the hand-held viewer comprises a lens 13, a generally cylindrical, hollow housing 11a having an enlarged upper portion 11b that is rounded to form an eye piece, and an annular flange 11c. Lens 13 has an outer diameter that is essentially the same as the outer diameter of housing 11a. Lens 13 fits into annular flange 11c, which in turn fits onto the bottom of tube 11a to capture lens 13 within the housing 11. Flange 11c may be connected to the lower end of housing 11a by cement, threads, or other suitable means. Convex magnifying lens 13 is formed from a optically transparent material (e.g., glass, polycarbonate, etc.). The magnification or "power" of lens 13, which depends in part on the convexity of the lens as known in the art, will preferably be between about 4× and 7×, with a presently preferred magnifying lens 13 having a power of about 7×.
As mentioned above, the optics housing is slidable within bore 9. With further reference to FIG. 3, body 5 has internally formed, radiused walls 9a and 9b and side walls 9c and 9d, which together define an upper bore 9U sized to slidingly receive the housing 11a of optics assembly 11. Body 5 also has internally formed, radiused walls 9e and side walls 9f, 9g and 9h, which together define a lower bore 9L sized to slidingly receive annular flange 11c. Annular flange 11c has an outer diameter that slides within lower bore 9L, but is too large to enter incrementally reduced upper bore 9U. The diameter of eye piece 11b is larger than the diameter of upper bore 9U. Thus, eye piece 11b and flange 11c act as mechanical "stops" for the linear movement of optics assembly 11 and define the focusing limits of optics assembly 11. Thus, the optics assembly 11 remains within bore 9 when the viewer is focused.
In a particularly preferred embodiment of the present invention, a handle segment 10 is detachable, using frictional, detent or other well known means, to expose the interior space within the handle 7. This is best seen in FIG. 2. Handle segment 10 has an L-shaped tab 12 having a ridge 12a at its free end which reversibly engages a detent (not shown) on the inside surface of handle 7. Thus, handle segment 10 snap-fits into place to complete the handle 7. The outer surface of handle segment 10 has a plurality of grooves 14 to provide a friction surface to facilitate removal of handle segment by sliding it rearwardly. The interior space within handle 7 of the viewer is available to store an object case 25 and/or microscope slides 29.
Handle 7 also includes an eyelet 48 at its distal end for attachment of a neck strap 49 for carrying the inventive hand-held viewer.
The various parts of the hand-held viewer of the invention can be preferably made by an injection molding process using a suitable plastic such as ABS (acrylonitrile butadiene styrene), HIPS or the like, as well known in the art.
The foregoing describes a particularly preferred embodiment of the invention. It will be apparent to those skilled in the art that modifications may be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited except as may be necessary in view of the appended claims. | A hand-held viewer for producing a magnified image of an object has a pivotable and swivelable object mount so that an object of interest may be positioned in a plurality of orientations within the viewable area and at different distances from the lens. One presently preferred object mount comprises a yoke with spaced apart arms having slots running along their length for mounting a microscope slide or a photographic slide such as film strips or 35 mm positives. The hand-held viewer desirably includes a detachable background screen assembly to provide a contrasting background against which to view the photographic slide or other object. In a preferred embodiment, the lens may be focused by rotating a thumb-wheel within and extending partially through the body of the viewer. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a planetary grinder for abrading floor surfaces with a rotating circular planar surface tool and more particularly to the planetary drive mechanism of the planetary grinder.
2. Description of the Related Art
Presently available disk floor abrading machines have separate means for rotating the planet disk and the screeding disks mounted thereon which requires a complicated and difficult to maintain mechanism for providing power to the screeding disks and the planetary disk.
In some designs there are multiple gears or multiple belts needed to drive the planet disk and the screeding disks. Other designs have counter-rotating screeding disks which add complications to the design.
Some disk floor abrading machines expose their working mechanisms to dust, debris or abraded particles which reduce the life of the machine due to extra wear on the parts. Other machines have hard to reach parts for making adjustments or repairs.
It is desirable to have a simple to make, simple to maintain, low cost and reliable means to power the screeding disks and the planetary disk of a planetary grinder without exposing the working mechanism to dust, debris and other particles.
SUMMARY OF THE INVENTION
The planetary grinder has a top cover plate for supporting a motor and a transmission on its top surface, for easy access, for maintenance and repair and to keep the motor and transmission free from dust and debris resulting from the floor screeding process. The planetary grinder has a rotating planetary disk driven from the transmission's output shaft under the cover plate for supporting a plurality of rotating screeding disks. The driving mechanism for the screeding disks is sandwiched between the top cover plate and the planetary disk to protect the bearings and belts therebetween from dust and debris. The bearings for the transmission shaft and the screeding disks are sealed to further protect the parts from excess wear due to dust and debris. The top cover plate has a stationary gear attached for engaging a single toothed belt to drive the screeding disks. The belt engages the stationary gear such that, as the planetary disk rotates, the belt turns the pulleys on the screeding disk shafts to rotate the screeding disks at a speed in proportion to the rotation speed of the planetary disk. The screeding disks can be rotated in the opposite direction from the rotation of the planetary disk to counter the torque created thereby and make the planetary grinder easier to control by the user.
The planetary disk assembly is easy to remove from the transmission's output shaft to expose all the moving parts in the mechanism for cleaning, maintenance and repair or replacement of the parts. The design is simple to repair, having only one belt which drives all the screeding disks.
A plurality of adjustment pulleys are used adjacent the screeding disk pulleys to adjust the belt tension. Balancing blocks are used to balance the rotating planetary disk.
The wheels supporting the planetary grinder are set back from the planetary disk by arms which allow the planetary disk to be tilted perpendicular to the floor to expose the cutting tools and the screeding disks for ease of access during maintenance or repair.
OBJECTS OF THE INVENTION
It is an object of the invention to provide an easy to maintain and easy to repair planetary grinder.
It is an object of the invention to provide an external transmission on top of the housing.
It is an object of the invention to provide an external motor on top of the housing.
It is an object of the invention to provide sealed bearings on all the shafts to protect them from dust and debris.
It is an object of the invention to have the drive mechanism sandwiched between a top cover plate and the planetary disk to protect the drive mechanisms from dust and debris.
It is an object of the invention to have the top cover plate support a stationary gear constituting a main driving gear.
Other objects, advantages and novel features of the present invention will become apparent from the following description of the preferred embodiments when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the planetary grinder.
FIG. 2 is a perspective view of the planetary grinder with the drive disk tilted up.
FIG. 3 is a perspective view of the planetary disk without any parts mounted thereon.
FIG. 4 is a perspective view of the planetary disk with the drive mechanism installed thereon.
FIG. 5 is a perspective view of an alternative drive mechanism with a different belt tightening method.
FIG. 6 is a perspective view of the planetary scrubber shaft with break way pins unassembled.
FIG. 7 is a perspective view of the planetary scrubber shaft with break way pins assembled.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The planetary grinder 10 is shown generally in FIG. 1 . It has a motor 12 which is preferably an electric motor and a transmission 14 attached to the motor 12 . Although an electric motor is preferred, any kind of motor or engine for providing power can be used. The transmission 14 is attached to the top of a housing 20 . Wheel mounts 22 are attached to the top of the housing 20 on each side of the transmission 14 and have arms 24 pivotally attached to the wheel mounts 22 . T-bolts 25 are used to secure, either locked down or pivotally, the housing 20 in place relative to arms 24 to position the plane of the housing top 20 parallel to the floor to be worked on or perpendicular to the floor for maintenance of the screeding disks 50 . The length of the arms 24 are preferably longer than the height of the motor 12 and the transmission 14 such that when the housing 20 is tilted perpendicular to the floor, the top of the motor 12 will clear the axle housing 26 at the end of the arms 24 . Wheels 30 are attached to axles in the axle housing 26 . The housing 20 sits close to the floor for a low profile of the planetary grinder 10 , allowing the planetary grinder 10 to get under objects, such as shelving, while screeding the floor.
Handle mounts 32 are attached to the axle housing 26 for pivotally attaching a handle shaft 38 to the axle housing 26 by brackets 36 having adjustment apertures 31 and pin 35 for selecting an aperture in handle mount 32 to set the handle shaft 38 at the desired angle for operation of the planetary grinder 10 . The handle shaft 38 pivots about bolt 37 through an aperture in brackets 36 and an aperture in handle mounts 32 .
The length of the handle is adjustable as shaft 42 telescopes inside of handle shaft 38 and can be fixed at a desired length by T-bolt 40 engaging threads on handle shaft 38 and pressing against shaft 42 .
A handle 45 on the top end of shaft 42 allows the user to push, pull or steer the planetary grinder 10 .
The planetary disk 60 is driven by the output shaft of the transmission 14 and rotates while supporting screeding disks 50 , which also rotate. The screeding disks 50 move in circles relative to the planetary disk 60 as the screeding disks 50 rotate on their axles. Hence, the floor experiences rotating screeding disks 50 engaging it while driven in a circular pattern by the planetary disk 60 while the planetary grinder 10 being pushed back and forth over the floor on wheels 30 . The floor is therefore engaged by a plurality of screeding disks 50 having a cutting tool or abrading tool rotating to cover all portions of the floor as the planetary grinder 10 is maneuvered over the floor.
Sandwiched between the planetary disk 60 and the housing 20 is the drive mechanism which rotates the screeding disks 50 . All of the moving parts for rotating the screeding disks 50 are mounted on the planetary disk 60 and are sandwiched between the planetary disk 60 and the housing 20 , thus sealing all the bearings and the oils associated therewith above the planetary disk 60 so that the floor is protected from oil, grease and dirt emanating from the drive mechanism. The working mechanism is all contained between the planetary disk 60 and the housing 20 within a small height, making for a low profile planetary grinder.
The hub 62 on planetary disk 60 rotatingly engages stationary gear 65 by use of a bearing 68 . A snap ring 67 is used to quickly and easily detach the hub 62 and thus the planetary disk 60 from the stationary gear 65 . A gear mounting plate 69 attaches to drive gear 65 by bolts in apertures 61 . Drive gear 65 is attached to the undersurface of the housing 20 by bolts 63 through housing 20 inserted into threaded apertures 61 in the gear mounting plate 69 attached to stationary gear 65 , thus keeping the stationary gear 65 fixed in place while the planetary disk 60 rotates. When bolts 63 are removed housing 20 and gear mounting plate 69 are quickly easily detached and the working mechanism is exposed for ease of repair and maintenance. The ease of maintenance and repair reduces downtime making the planetary grinder 10 more efficient.
Hub 62 is attached to the output of shaft of transmission 14 such that planetary disk 60 rotates when the motor 12 is on and the transmission 14 is engaged. With planetary disk 60 rotating and stationary gear 65 fixed, belt 70 transmits power to the screeding disk pulleys 74 which connect to the screeding disks 50 by an axle passing through screeding disk apertures 64 in the planetary disk 60 . In this manner the motor 12 rotates both the planetary disk 60 and the screeding disks 50 with a simple, easy to adjust, easy to maintain mechanism. As shown, a single endless belt 70 has teeth that engage the stationary gear 65 and the screeding disk pulleys 74 . Although a toothed belt 70 is shown, a chain drive, a v-belt or other means for transmitting power maybe used to connect the stationary gear 65 to the screeding disks 50 by way of screeding disk pulleys 74 .
Alternatively, a belt 70 with teeth on both sides may be used such that the idler pulleys 72 have the benefit of a geared pulley and the teeth of the belt 70 engaging. Also with a double-sided toothed belt, the belt can be moved from one side of the screeding disk pulley 74 to the opposite side causing the screeding disk 50 to spin the opposite direction. Using this method for selecting the spin direction of the screeding disks 50 , planetary grinders having four screeding disks can have two screeding disks spinning in one direction and two screeding disks spinning in the opposite direction.
As shown, when planetary disk 60 rotates in direction of arrow 80 , the screeding disk 50 will rotate in the opposite direction of arrow 82 , thus providing stability of the planetary grinder 10 by having planetary disk 60 counter-rotating to the direction of rotation of the screeding disks 50 which engage the floor with an abrading tool.
It is preferable to use sealed bearings on the idler pulleys 72 and the screeding disk pulleys 74 to keep oils from landing on the floor and to protect the bearings from dust and other particles. Sandwiching the idler pulleys 72 and the screeding disk pulleys 74 and the driving mechanism between the planetary disk 60 and the housing 20 helps to keep the abraded flooring material, dust, dirt and other particles from interfering with the drive mechanism and getting into the bearings, on the belts, and on the moving parts, which will cause wear on the parts.
As shown in FIG. 4 , idler pulleys 72 are on adjustment bars 90 having adjustment slots 92 and adjustment bolts 94 for locking the adjustment bars 90 in place. In this manner belt 70 can be easily installed and the tension thereon adjusted, making it easy to change belts if needed. Adjustment blocks 96 and 98 can be used in conjunction with adjustment bolt 99 and tension springs 95 to move the adjustment bars 90 for balancing the planetary disk 60 as it spins. The tension springs 95 help keep a desired tension on belt 70 . Adjustment blocks 96 , 98 maybe of different weights to help balance planetary disk 60 .
It is preferred to have a break-a-way safety clutch plate 85 with a pin 86 made of plastic or metal, such that if a nail or other object is struck by a screeding disk 50 or an abrading tool attached thereto, the pin 86 will shear, so damage to the planetary grinder 10 will be prevented and the safety of the operator will be enhanced. FIG. 6 and show the break-a-way safety clutch plate 85 with break-a-way pin 86 for insertion into apertures 89 on screeding disk connectors 87 .
A shroud 52 is provided on housing 20 to block debris, dust and abraded material from leaving the area under the drive disk and to aid in vacuuming when a vacuum is attached. There can be one or more ports in the shroud 52 for connection to a vacuum system attached to the planetary grinder 10 . The ports may be in various locations around the shroud 52 . A vacuum dust collection bag may be attached to the handle shaft 38 . The shroud 52 can be attached with a hook and loop fastener such as VELCRO® for ease of height adjustment and can be long enough to engage the floor for vacuum efficiency and confining debris and dust. In addition to the vacuum, a water dispenser can be added to inject water under the shroud 52 to help keep the dust down.
The motor 12 and transmission 14 being on top of the housing 20 make it easy to repair, replace or maintain the motor 12 and transmission 14 . Similarly, the belt 70 , pulleys 72 , 74 and the stationary gear 65 are easily accessible and adjustable for ease of maintenance and repair. The hub 62 can be easily removed from the stationary gear 65 with the use of a gear puller.
Planetary disk 60 can be balanced with all parts installed thereon by use of a bubble balance and balance weights such as used on car wheels.
In an alternative embodiment shown in FIG. 5 the tension belt 70 can be regulated by springs 101 which connect pin 102 attached to planetary disk 60 to pin 103 on pivotable idler bracket 105 having idler wheel 106 which pivots about aperture 110 which has a fastener connecting it to planetary disk 60 . A guide slot 120 in pivotable idler bracket 105 may be used to help align the pivotable idler bracket 105 when a pin is used in aperture 125 on planetary disk 60 .
Different sized planetary disks 60 can be used with different sized motors and different transmissions. Similarly different pulley wheel sizes and belts may be used to control the speeds of the screeding disks 50 . The screeding disks 50 may have different cutting or abrading tools attached depending on the cutting, polishing, sanding or other operations to be performed.
One advantage of using a belt drive with screeding pulleys 74 and idler pulleys 72 is that the size of the pulley wheels can be easily changed thus changing the ratios of the stationary gear 65 to the gear on the screeding disk pulley 74 and thus the rational speed of the screeding disks 50 on the floor. The higher the ratio of the screeding disk gear to the drive stationary gear 65 , the smoother the operation of the grinder. The ratios can be on the order of 4.3 to 1 and 7 to 1. Thus a quick and easy change of pulleys can change the performance of the grinder 10 depending on floor materials, and cutting tools used giving the belted grinder greater versatility over gear-to-gear grinders.
Another advantage of the belt drive planetary grinder is the ability to change from a screeding disk 50 with the axle centered in the disk to an off-center stationary gear 65 for eccentric screeder disks 50 , which may be preferred for wood floors. The screeder disks 50 can be quickly and easily changed by removing the belt 70 from the screeder disk pulley 74 and inserting an eccentric screeder disk 50 and its associated pulley and the replacing the belt. Similarly, satellite disks may be used on a screeder disk and the disks easily changed.
Wheels 30 are preferably placed close enough together so that they are within the diameter of the housing 20 . The planetary grinder 10 can then be used along walls without the wheels 30 interfering when the housing 20 is adjacent to the building's wall. The screeding disks 50 come close to the edge of the planetary disk 60 to screed the floor as close to a wall as possible. The wheels 30 being close together allows the planetary grinder 10 to walk straight down a wall and have greater pivot maneuverability.
Shaft 42 or handle 45 can have the planetary grinder controls, such as the motor on/off switch, mounted thereon.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | A planetary grinding machine having a simple design with a minimal number of parts, which are all easily accessible for maintenance and repair is disclosed. The machine has a rotating planetary disk with rotating screeding disks attached. The planetary disk is driven by a shaft extending through a top housing cover plate, which supports a transmission driven by a motor. As the planetary disk rotates, a single belt engages a stationary gear on the cover plate and pulleys on screeding disk shafts to turn the screeding disks as the planetary disk is turned. The belts and pulleys for the drive mechanism are sandwiched between the planetary disk and the top cover to protect the mechanisms from dust and debris. The bearings are sealed to prevent dust and debris from entering and oil from escaping. The bearings, being on the inside of the planetary disk, keep oil from landing on the floor. | 5 |
TECHNICAL FIELD
The invention relates generally to the field of networking. More specifically, it relates to the use of the Address Resolution Protocol (ARP) and to ensuring that only a single and consistent reply is generated in response to each ARP request.
BACKGROUND
The Address Resolution Protocol (ARP), used in TCP/IP networks such as the Internet, provides to requesting hosts a mapping between an IP address and a media access control (MAC) address. A host which needs to learn the MAC address for a given IP address broadcasts an ARP request containing the IP address to all routers and hosts in a network. The requests are received by adapters at the hosts; it is an adapter that owns an IP address and a corresponding MAC address. The requesting host learns the MAC address corresponding to an IP address by virtue of an ARP reply to an ARP request. An ARP reply is sent from the host that owns the corresponding adapter, or in some cases an adapter is arranged to perform ARP processing and it responds to ARP requests instead of the host. Such an adapter is called an offload adapter. In the remainder of this specification, host will be used to refer to both hosts that perform some kind of data processing in the traditional sense and to routers that route messages between networks or to nodes that perform both functions,
A host that owns multiple IP addresses that receives an ARP request will reply to the request only if the IP address in the request is the IP address of the adapter or if the adapter is explicitly configured to reply for the requested IP address.
A “real” IP address is one that is associated with a physical adapter. An adapter often supports thousands of network sessions with other hosts. If the adapter fails, all of the active sessions using the IP address associated with the adapter will also fail. Virtual IP addresses (VIPAs) were conceived to mitigate this problem. A VIPA is an IP address that is associated with a host, rather than with a physical adapter. Messages can be addressed to real IP addresses or to VIPAs. If a host contains multiple adapters, IP traffic addressed to a VIPA can be routed through any of the adapters. In this way, a host can provide fault tolerance after an adapter failure by routing the VIPA traffic over a different physical adapter. Virtual IP addressing is described in detail in U.S. Pat. No. 5,923,854, the contents of which are incorporated by reference herein.
There are two types of physical adapters, a host adapter in which the host does all of the ARP request processing for the adapter and an offload adapter that does its own ARP request processing.
For ease of expression, in the remainder of this document letters such as A, B, C, X, etc. other than V designate physical adapters. The letter V denotes a virtual IP address. IP-A represents the IP address of adapter A; MAC-A represents the MAC address of the adapter A associated with IP-A. IP-V denotes the virtual IP address V. VIPA and IP-V actually refer to the same thing—an IP address assigned to a host. Both of these designations are used interchangeably in this specification.
The traditional approach of ARP processing has a number of deficiencies. If adapters A and B are on the same physical network (i.e., all adapters on the network receive all ARP requests that any one of them receives) and both are owned by the same host, the host will not reply to ARP requests for IP-A received over adapter B. The host expects to reply to the request received over adapter A. This is a simple and effective way of preventing the generation of multiple replies to a single ARP request. However, it also means that no ARP reply will be generated if adapter A fails or is inactive. This means that adapters cannot serve as backups for one another. If a host owns IP-V and an ARP request for the MAC address assigned to IP-V arrives on adapter A, the host will not reply to the request, unless the owner has explicitly configured the system to do so. In the latter VIPA situation, if adapters A and B are on the same physical network, and A is assigned to IP-V, (explicitly configured to perform proxy ARP for IP address V), and adapter A fails, the host will no longer reply to ARP requests for V, even though it could send an ARP reply for V via adapter B. This often results in unsuccessful ARP requests.
The problem of providing backup adapters for offload adapters is even more difficult. For offload adapters, the host owning the offload adapter never sees an ARP request received over the offload adapter and the host likely has no knowledge of the MAC address of the offload adapter. If the offload adapter only replies to ARP requests containing its IP address, then it cannot provide any backup support for other adapters.
To address these limitations, a host could reply to any ARP request it receives over any adapter for any IP address owned by the host. However, when multiple adapters are on the same physical network, this will result in the host sending multiple ARP replies to a single ARP request and each will contain a different MAC address. This results in a flip-flopping of MAC addresses in the network for a single IP address. This, in turn, causes serious problems for network monitoring software. This flop-flopping of MAC addresses can also lead to odd traffic behavior and performance degradation.
To prevent multiple ARP replies when offload adapters are not involved, a host might implement a mechanism such that when the host first receives an ARP request over adapter A, it saves a timestamp and replies to the request. If within a short time it receives the same ARP request over adapter B, the host knows that an ARP response has recently been sent; so it ignores the ARP. Communication software in the Berkley Software Distribution uses this approach. A host might also implement such a technique to prevent multiple ARP replies for VIPAs. However, this timestamping solution still produces a flip-flopping of MAC addresses in a network. This is because there is a race as to which adapter A or B first receives an ARP request.
Therefore, there is a need for a solution that provides exactly one ARP reply with a consistent MAC address for any ARP request in an environment in which a host uses multiple adapters to address the same physical network, without the need for any user configuration.
SUMMARY OF THE INVENTION
Two embodiments are disclosed. The first embodiment is applicable to networks that do not contain VIPAs and offload adapters. The second implementation allows both types of physical adapters (host and offload) and VIPAs to coexist.
The First Embodiment
When an adapter (A) becomes active, the owning host sends an ARP advertisement into the network over adapter A that associates the MAC address for adapter A (MAC-A) with an IP address (IP-A). This advertisement is received by all hosts in the network and they update their ARP cache table to map IP-A to MAC-A accordingly. If the advertisement is also received at the sending host over a different adapter B, then the host knows that adapter B is on in the same physical network as adapter A. Therefore, B can be designated as a backup adapter for A and A can be designated as backup adapter for B. The host maintains a backup adapter field for each adapter owned by the host where this information is maintained. When the host discovers that adapter B is in the same network as adapter A, it queries the backup adapter field. If no backup adapter has been designated for A, then the host sets B as the backup adapter for A. Likewise, the host queries the backup adapter field for adapter B and sets A as the backup adapter for B if no backup adapter has already been designated.
If adapter A fails or becomes inactive, the host resets the backup adapter field for any adapter it owns for which A is marked as the backup adapter. If a backup adapter B has been designated for A, the owning host also sends an ARP advertisement associating MAC-B with IP-A. This advertisement causes each host in the network to update their ARP cache table to map IP-A to MAC-B. This allows network connections originally served via adapter A to continue non-disruptively over adapter B and it also provides access to the host for subsequent new connections. Whenever the host receives an ARP request for A on adapter B, the host replies to the request with MAC-B.
When adapter A later becomes active, the host sends a gratuitous ARP advertisement that maps IP-A to MAC-A. This allows adapter A to re-assume responsibility for responding to ARP requests for IP-A.
The Second Embodiment
The first embodiment depends on the host receiving ARP requests to determine what networks its adapters are on. Therefore, it does not function properly in networks that include offload adapters, because it does not receive ARP requests for these adapters. The adapters handle the ARP processing.
To solve the problems for offload adapters, the invention uses a different technique to determine what adapters of a host are on the same networks. This technique also works for host adapters and is further arranged to accommodate VIPAs as well. In each host, the first adapter A to become active is designated as being in a first physical network (PNET 1 ). The identification assigned to the network is arbitrary. It is only necessary to differentiate each separate network for the benefit of the host. For each subsequent adapter B to become active on a host, the host sends a packet over one of the adapters of each network already known to the host with a hop count of one. In the case of the second adapter to become active, the packet would be sent over adapter A. In the preferred embodiment the packet is an ICMP (Internet Control Message Protocol) echo request, although it could be any type of packet that allows a hop count of one. The hop count of one ensures that the packet will not be forwarded off of the network by a network router. The packet will be received by adapter B only if A and B are in the same physical network on which it is sent. Therefore, if the packet is received over adapter B, it is known that adapters A and B are in the same physical network. If this occurs, adapter B is marked as being in the same network PNET 1 as adapter A. If the packet is not received over adapter B, as evidenced by an eventual timeout function, then it is known that adapter B is in a different physical network as A. In this event, adapter B is marked as being in a new network PNET 2 . In general, the algorithm to determine in which network each offload adapter resides can be stated as follows. When an adapter becomes active at a host, send a data packet with a hop count of one over one adapter that resides in each different physical network known by the host and, if the packet returns on a different adapter, add the newly active adapter to the same physical network to which the receiving adapter belongs. If the packet does not return on a different adapter, create a new physical network at the host and add the new adapter to that network. If the new adapter also happens to be an offload adapter, then the host registers the IP address in the adapter. This causes the adapter to associate the IP address with the adapter MAC address known to the adapter and also to transmit an ARP advertisement into the network. If the new adapter is a host adapter, the host sends the advertisement itself. To handle VIPAs, after the first adapter on a host becomes active, it is initially marked as owning ARP responsibility for all virtual IP addresses owned by the host for the physical network in which the adapter is located.
When an adapter A becomes inactive in the second embodiment, if there are other active adapters in the physical network to which A belongs, then one of the remaining adapters B in that physical network is designated to have the responsibility for replying to ARP requests for IP-A. If B is a host adapter, the host sends a gratuitous ARP advertisement request mapping IP-A with MAC-B. If B is an offload adapter, the host registers IP-A in adapter B. This causes adapter B to associate its MAC address MAC-B with IP-A; the offload adapter also sends the gratuitous ARP advertisement. In either case, other network hosts update their ARP caches so that connections to IP-A will continue non-disruptively over adapter B. The host next determines if adapter A is marked as owning responsibility for VIPAs. If it is, then that marking is removed and adapter B is marked as owning VIPA ARP responsibility for that physical network. If B is a host adapter, then for each VIPA known to the host, it sends a gratuitous ARP advertisement into the network associating IP-V with MAC-B. If B is an offload adapter, the host registers IP-V with the adapter for each known VIPA and the adapter sends the advertisements into the network. Thereafter, when the host or an offload adapter on the host receives an ARP request for A or V, the host or offload adapter replies to it with the MAC address of B. When adapter A again becomes active, adapter A will re-assume ownership of ARP replies for IP address A.
The claims of this application are directed to the processing of ARP requests directed to VIPAs.
BRIEF DESCRIPTION OF THE DRAWING
In the Drawing,
FIG. 1 is used to explain the problems and solutions of the invention; the Fig. shows a block diagram of a host containing three adapters, two of which are connected to first network and the third being connected to a different network;
FIG. 2 pertains to the first embodiment and shows the steps executed by a host when an adapter becomes active at the host;
FIG. 3 pertains to the first embodiment and shows the steps executed by a host when it receives an ARP advertisement message;
FIG. 4 pertains to the first embodiment and shows the steps executed by a host when an adapter becomes inactive;
FIG. 5 pertains to the first embodiment and shows the steps executed by a host when it receives an ARP request for the MAC address of an adapter associated with an IP address;
FIG. 6 pertains to the first embodiment and shows the steps executed by a host when it receives a reply to an ARP request it sent;
FIG. 7 pertains to the second embodiment and shows the steps executed by a host when an adapter becomes active at the host;
FIG. 8 pertains to the second embodiment and shows the steps executed by a host when it receives an ICMP echo request;
FIG. 9 pertains to the second embodiment and shows the steps executed by a host when a timeout occurs at a host after the host sends an ICMP echo request in an attempt to determine in what network a newly active adapter belongs;
FIG. 10 pertains to the second embodiment and shows the steps executed by an offload adapter when the adapter receives an ARP request for the MAC address associated with an IP address;
FIG. 11 pertains to the second embodiment and shows the steps executed by a host when it receives an ARP request over adapter B for the MAC address associated with IP-A;
FIG. 12 pertains to the second embodiment and shows the steps executed by a host it receives a reply to an ARP request;
FIG. 13 pertains to the second embodiment and shows the steps executed by a host when it receives an ARP advertisement;
FIG. 14 pertains to the second embodiment and shows the steps executed by a host when an adapter becomes inactive.
DETAILED DESCRIPTION
FIG. 1 shows a block diagram of a host containing three adapters, two of which are connected to first network and the third being connected to a different network. This Fig. illustrates the problems associated with ARP processing and helps explain the invention. The host shown in the Fig. contains three adapters D, E and F. Adapters D and E are attached to the same network, which in the Fig. is illustratively assumed to be a token ring LAN TR 1 . TR 1 has attached to it workstations WS 1 , WS 2 and WS 3 . Adapter F is attached to a different network identified as token ring LAN TR 2 . TR 2 has attached to it workstations WS 4 , WS 5 and WS 6 . In conventional ARP processing, although adapters D and E are on the same network, if D fails or becomes inactive for any reason, the host (or adapter E if it is an offload adapter) will not respond to ARP requests for D received over adapter E. This prevents E from being a backup for D, and vice versa. If the host did respond to such ARP requests for D, then without additional processing ARP replies would be generated for both adapters D and E in the normal situation, thereby resulting in multiple and inconsistent ARP replies. Assume further that the host of FIG. 1 has one or more virtual IP addresses (VIPAs) V assigned to it and that D has responsibility for responding to ARP requests for VIPAs. In this case, for the same reason as above, if D fails or becomes inactive, the host will not respond to ARP requests for V received over E.
Therefore, the invention is directed to solving the problem of providing backup adapters when two or more adapters on the same network, and to do it in a way that results in one and only one reply to an ARP request. Further, the invention is adapted to solve this problem for host adapters, offload adapters and VIPAs.
The First Embodiment
FIG. 2 pertains to the first embodiment in which a system contains only host adapters and specifically to the steps executed by a host when an adapter X becomes active at the host. The first embodiment relies on the receipt of ARP advertisement messages to determine the network that adapters are on. The adapter control block maintained in memory for each adapter is modified to contain a backup adapter field. This field is cleared by step 202 for the adapter X which is becoming active. Next, step 204 sends an ARP advertisement over the new adapter X. This advertisement maps IP-X to MAC-X. All hosts that are on the same network as adapter X will receive the ARP advertisement.
FIG. 3 shows the steps executed by every host on the same network as X when the host receives the ARP advertisement from FIG. 2 . Step 304 determines the IP address of the adapter over which the host received the advertisement. Step determines the IP address S of the new sending adapter X from the advertisement message. Step 307 determines if S is owned by this host. If the answer is no, then this host needs to update its ARP cache with the mapping contained in the advertisement. Thus, step 309 performs this by mapping IP-S from the advertisement with the MAC contained in the advertisement. If step 309 determines that S is owned by this host, then this host must determine if it received the advertisement over a adapter other than the one on which it was sent. If so, the receiving adapter is on the same network as the sending adapter X. Thus, step 308 determines if IP-R equals IP-S. If they are equal, the advertisement is ignored. If they are unequal, step 310 determines if the receiving adapter R has a backup adapter marked in the adapter control block. If it doesn't have a backup adapter, step 312 marks S as the backup adapter for R. Next, step 314 determines if S has a backup adapter. If not, then R is marked as the backup adapter for S at step 316 . This ends the processing of an ARP advertisement. Every host receiving the advertisement has updated its ARP cache and the sending host has determined if adapters S and R can act as backup adapters for each other. When an adapter X becomes inactive for any reason, then if X has a backup, all hosts must be told of backup. Also, if X is marked as backup for one or more another adapters in the host owning X, then the control blocks pertaining to the other adapters must be updated to remove X as backup. Step 402 of FIG. 4 determines if adapter X has a backup adapter Y. If so, then step 404 sends an ARP advertisement over adapter Y mapping IP-X to MAC-Y. Step 406 locates all adapter control blocks in the host owning X and clears the backup adapter field in any that has X marked as backup.
Sometimes a host sends an ARP request into a network to request the host owning an adapterX with IP address IP-X to reply with its MAC address MAC-X. FIG. 5 shows the steps executed by a host when it receives an ARP request associated with IP-A over adapter B. Step 502 determines if IP-A equals IP-B. That is, 502 determines if the request is received over the same adapter as the IP address contained in the request. If the answer is yes, step 506 returns a conventional ARP reply over the adapter mapping IP-A to MAC-A. If the answer is no, conventional hosts will not generate a reply. However, step 504 of the invention determines if a backup adapter B is marked in the A control block. If not, nothing more can be done. However, if A has a backup, step 505 determines if adapter A is active. If it is, then it is assumed that a reply will be made to the request that is received over adapter A. Thus, no further processing is done on this request. However, If adapter A is not active, then step 506 sends an ARP reply to the requester mapping IP-A to MAC-B.
FIG. 6 shows the steps executed by a host when it receives a reply to an ARP request. At step 602 , the ARP cache maintained by the host receiving the reply conventionally updates its ARP cache to associate the IP address in the reply to the MAC address in the reply.
The Second Embodiment
The second embodiment relies principally on sending and receiving ICMP (Internet Control Message Protocol) messages with a hop count of one to determine which of separate networks contain specific adapters. This embodiment is also arranged to handle offload adapters and VIPAs.
FIG. 7 is the initial figure of the second embodiment and shows the steps executed by a host when an adapter X becomes active at the host. X should regain ownership of its IP address if another backup adapter has been previously given responsibility (IP-X associated with MAC Y). Step 702 determines if a backup adapter is specified in the adapter X control block. If the answer is yes, step 708 determines if the backup adapter is an offload adapter. If that answer is yes, at step 710 the host sends a command to the adapter X to un-register IP-X with MAC-Y. This causes the adapter X to remove any association of IP-X with MAC-Y. Step 704 clears the backup adapter field in the X control block so that no other adapter is marked as backup for X. Any possible backup adapter for X will be determined dynamically shortly. Step 706 determines if X is an offload adapter. If it is, step 712 sends a command to the adapter X to register IP-X with MAC-X. This causes the adapter to send an ARP advertisement into the network containing this association. If the adapter is not an offload adapter, step 714 sends the advertisement into the network itself. Next begins the operation of determining what adapters are on what network. Step 716 determines if this adapter X is the first adapter to become active on this host. If there are no other active adapters on this host, then this host knows of no other network other than the network on which X is located, so there is no need to determine the network to which X belongs relative to other active adapters. In this case, step 724 creates a new and first network control block for a network PNET-X (where X in this case is 1) and links the network control block to the adapter X control block. All that is known now is that adapter X is active and that it resides in some network designated as PNET- 1 . Since X is the only active adapter on this host, it is marked at step 726 as owning all virtual IP addresses adapters on this host for this physical network. An alternative when an adapter becomes active is to assign VIPA responsibility to any one of the adapters known to the host at that time. Step 728 determines if X is an offload adapter. If so, step 730 sends a message to adapter for each VIPA owned by the host, Each message maps IP-V with the adapter X. As a result, adapter X sends an ARP advertisement message into the network mapping each IP-V to its MAC address MAC-X. If the adapter is not an offload adapter, step 732 sends the ARP advertisements into the network itself.
Returning to step 716 , if there are active adapters on this host other than X, then it is desired to determine on which, if any, of these networks X resides. For each physical network known to the host (as evidenced by network control blocks created by the host) step 718 selects one adapter and sends an ICMP message to that adapter via the new adapter X. The ICMP message is marked with a hop count of one to prevent routers and other hosts from transmitting the packet off of the physical network. In the preferred embodiment, the ICMP message used is an echo request, although any message with a hop count of one can be used. Also, step 718 saves the IP address of each selected destination adapter in a list. When all of the echo requests have been sent at step 718 , step 720 starts a timer. The IP address of the new adapter X is included in the timer setup as a parameter to be delivered if a timeout occurs. That is the end of this processing. The network occupied by adapter X will be determined by a reply to the echo request or a timeout of the timer activated by step 720 .
FIG. 8 shows the steps executed by a host if and when it receives an ICMP echo request. If a request is received over an adapter on the list from 718 , then it is known that the adapter X over which the message was sent in the same network as the adapter receiving the message. Step 802 determines if this receiving host sent the ICMP echo request. If it did not, then the echo request offers no information as to what networks the adapters on this host belong. Therefore, the echo request is processed in the conventional way at step 808 . If the echo request was sent by this receiving host, step 804 determines if this request contains an IP address that is on the list generated at step 718 . If the answer is no, then again the echo request is just processed conventionally at step 808 . If the IP address is on the list, it is now known that the adapter X, whose IP address is in the echo request, is in the same network as the receiving adapter. Step 806 sets the network field of the adapter X control block to point to the same network to which the receiving adapter points. Since an adapter can only be in one network, step 807 cancels the timer initiated at 718 . Processing of the echo request is completed by step 808 . It is now known which of the active adapters on this host has the capability of acting as backup for the new adapter. An actual backup adapter is not selected at this time. That decision is reserved in the preferred embodiment until it is necessary. This is discussed below with respect to FIG. 14 .
FIG. 9 shows the steps executed by a host as a result of a timeout initiated at step 720 . A timeout means that the newly active adapter X from FIG. 7 is not in any network presently known to the host. Therefore, the host needs to create a new network control block and link this adapter into it. The IP address of the new adapter X is delivered to step 900 when the timeout occurs. Step 902 determines if the adapter X control block is already linked to a network control block. If it is, then the timeout is ignored. If it is not, step 902 branches control at 904 to step 723 of FIG. 7 to create a new network identification PNET-X for this adapter and to link the adapter control block to the new PNET network control block.
FIG. 10 shows the steps executed by an offload adapter B when it receives an ARP request for the MAC address associated with an IP address IP-A. Step 1002 determines if the host has registered the address IP-A with the offload adapter. If the host has not so registered, the adapter ignores the ARP request. Otherwise, the adapter responds at step 1004 with an ARP reply mapping IP-A to MAC-B.
FIG. 11 shows the steps executed by a host when it receives an ARP request over adapter B for the MAC address associated with IP-A. Step 1102 compares IP-A with IP-B to determine if the request is received over the same adapter to which the request pertains. If so, then step 1106 replies to the ARP request in the conventional way mapping IP-A to MAC-A. If IP-A does not match IP-B, step 1104 determines if adapter B is marked as a backup for adapter A. If it is, then again step 1106 replies to the request, but in this case it maps IP-A to MAC-B. At 1104 , if adapter B is not marked as backup for adapter A, step 1108 determines if IP-A is a VIPA address. If IP-A is a VIPA address, then step 1110 determines if adapter B is designated as owning responsibility for VIPAs for that physical network. If it is, then step 1106 replies to the ARP request, mapping MAC-B to the virtual IP address IP-A.
FIG. 12 shows the steps executed by a host it receives a reply to an ARP request for the MAC address associated with IP-A. Step 1202 updates the ARP cache of the host in a conventional way to map the MAC address in the reply to the IP address in the reply.
FIG. 13 shows the steps executed by a host when it receives an ARP advertisement. Step 1302 also updates the host ARP cache table in a conventional way.
FIG. 14 shows the steps executed by a host when an adapter X becomes inactive. Step 1402 determines if there is another adapter on this host that also is in the same network as adapter X. This is determined by examining the network control blocks that are linked to the adapter control blocks for adapters that share the same network. If there is no other sharing adapter, no further processing is necessary. If there is, ARP caches and backup indications maintained by this host and other hosts need to be updated. Step 1406 picks the sharing adapter B or one of the sharing adapters B if there are more than one to backup adapter X and updates the backup field in the adapter X control accordingly. Step 1408 determines if adapter B is an offload adapter. If so, step 1410 registers IP-X with adapter B to cause the adapter to advertise to the network a mapping of IP-x to MAC-Y. Otherwise, the host performs the advertising at step 1416 . Step 1412 determines if adapter X has been designated as owning responsibility for VIPAs. If not, then processing is complete. If yes, step 1418 marks the backup adapter B as now owning VIPA responsibility. Step 1420 now determines if adapter B is an offload adapter. If so, step 1422 registers IP-V with the backup adapter B for each VIPA known to the host. This causes adapter B to broadcast an ARP advertisement to the network for each of these VIPAs mapping it to MAC-B. If adapter B is not an offload adapter, at step 1424 the host sends these advertisement messages into the network to complete the processing required for this inactive adapter X. | The invention ensures that a single and consistent reply is made to an ARP request in a system of connected IP networks. When an adapter becomes active, the relative network on which it resides is determined by transmitting control packets over it and all other adapters known to the host and observing if and where responses are returned to the adapters. One adapter on a network is designated as active. If the same network contains other adapters, they are marked as standby adapters for the purpose of responding to ARP messages. Special processing is provided for offload adapters that perform there own ARP processing. | 7 |
TECHNICAL FIELD
The present disclosure relates generally to catalytic converters used in motor vehicles.
BACKGROUND
Catalytic converters are used in motor vehicles for exhaust gas treatment to reduce harmful emissions in the exhaust gas. There are various known types of catalytic converters, such as three-way catalytic converters, unregulated oxidation catalytic converters and SCR catalytic converters.
In SCR catalytic converters, so-called selective catalytic reduction (SCR: Selective Catalytic Reduction) is used as a method for the reduction of nitrogen oxides. The chemical reaction in an SCR catalytic converter is selective, thus the nitrogen oxide (NO, NO 2 ) is reduced, while undesired side reactions, such as oxidation of the sulfur to sulfur dioxide, are largely suppressed.
In internal combustion engines used in motor vehicles, the reduction of nitrogen oxides by the SCR method proves to be difficult because there exist varying operating conditions, which makes the dosage of reducing agents difficult.
A reducing agent is dosed for the operation of SCR catalytic converters, whereby a NO x sensor value is controlled after SCR. The NO x sensor has a cross-sensitivity to NH 3 . If overdosing takes place in the system, then a so-called NH 3 slip is the result after the SCR reaction, or increased NO x emissions arise again after the SCR if a slip catalyst is used in the system after the SCR.
The NO sensor therefore presents ambiguity in a characteristic curve. Therefore, it cannot be predictably differentiated whether the dosage is too low and whether NO x emissions are present, or whether the dosage is too high and a NH 3 slip or increased NO x emission is present due to NH 3 conversion in the slip catalyst.
The problem described does not occur when only low NO x conversion rates are required through the SCR catalytic converter. Then the conversion in the system is far from the maximum possible conversion with the so-called slip limit. However, high conversion rates must be achieved for fuel-saving engine tuning and efficient utilization of the catalytic converter.
Another way to resolve the ambiguity of the characteristic curve is to introduce artificially small changes in the dosage quantity of the reducing agent. By appropriate evaluation of the NO x value after the SCR, the presence of an NH 3 slip can be detected. Such an approach is described in DE 10 2009 012 092 A1.
Such an evaluation, however, only works when the system is in a steady state; thus the existence of an NH 3 slip is only detected after a certain delay.
SUMMARY
In the present disclosure, a method for dynamic breakthrough detection is proposed, whereby an NH 3 slip or increased NO x emission can be identified quickly during operation through NH 3 conversion in the slip catalyst. In the proposed method, it is not necessary to wait for a stationary operating point of the SCR catalytic converter. It is also not necessary to carry out a special variation of the dosage quantity of the reducing agent for the method, while the regular operation of the SCR control system remains in a steady state.
In the exemplary method for dynamic detection of breakthrough or NH 3 slip of an SCR catalytic converter operating in an exhaust gas after-treatment system, the dosage rate of a reducing agent that is added to the exhaust gas stream upstream of the SCR catalytic converter is calculated by using a model of the dynamic behavior of the SCR catalytic converter, in which parameters are used that are dependent on one or more operating parameters of the SCR catalytic converter, e.g. temperature or exhaust gas mass flow, for at least one linear sensor characteristic curve which maps the region of normal operation and at least one linear sensor characteristic curve which maps the region of the breakthrough or NH 3 slip, or, respectively, an expected value of the conversion rate is determined. This expected value is compared with a real conversion rate value determined by an NO sensor arranged downstream of the SCR catalytic converter. A control variable is calculated for each of the characteristic curves for adjustment of the actual conversion rate to the expected value in each case, and the characteristic curve is selected for which the smallest control value was calculated. If this is a characteristic curve that maps the region of the breakthrough or NH 3 slip, this indicates a breakthrough or NH 3 slip, and this information can be fed back to the control of the dosage of the reducing agent.
The proposed method can be used both in exhaust gas treatment systems without an additional slip catalyst for the oxidation of NH 3 after the SCR catalytic converter, as well as in systems that have such a slip catalyst.
In addition to the detection of an NH 3 slip, the maximum achievable conversion rate can also be determined at the operating point of the SCR catalytic converter under consideration. The maximum conversion rate of the SCR catalytic converter so determined can also be used to monitor the SCR catalytic converter, e.g. for the monitoring of catalyst aging.
Furthermore, an arrangement suitable for implementing the method is also proposed herein. The arrangement comprises at least a transfer element, at least a memory unit in which the sensor characteristics are stored, at least a controller and an evaluation logic. A dynamic model can be used as the transfer element, comprising, for example, a PT 1 element, a PT 1 element with dead time (Tt) or a PT 2 element. A PI controller, an adaptive controller or an adaptive PI controller may be used, for example, as a controller.
DETAILED DESCRIPTION OF THE DRAWINGS
Further advantages and embodiments of the disclosure will be apparent from the description and the accompanying drawings.
It is understood that the features mentioned above and those still to be explained may also be used not only in each of the given combinations, but in other combinations or alone while remaining within the scope of the present disclosure.
The disclosure is schematically illustrated by means of embodiments in the drawings and will be described below with reference to the drawings.
FIG. 1 shows an abstract representation of the dynamic behavior of an SCR catalyst;
FIG. 2 shows examples of sensor characteristic curves for various maximum conversion rates;
FIG. 3 shows an example of a general model of the dynamic behavior of an SCR catalytic converter subdivided into sub-models;
FIG. 4 shows schematically an example of an observer structure used in the described method;
FIG. 5 shows schematically an embodiment of the described method.
DETAILED DESCRIPTION
FIG. 1 shows an abstract representation of the dynamic behavior of an SCR catalytic converter, whereby a transfer element 1 is implemented in this case as a PT 1 element with dead time (Tt), adaptively with parameters depending on a catalyst temperature. The input quantity is the alpha dosage rate; the output quantity is the eta conversion rate. Sensor behavior is shown as a characteristic curve with a break point at a maximum conversion, whereby the cross-sensitivity of the sensor to NH 3 is reflected in a negative gradient of the characteristic curve in the breakthrough region. The parameters can be determined by step attempts in order to determine a target conversion or from model calculations. The sensor characteristic curve is stored in a memory unit 2 . The control of the dosage rate is affected via a controller 3 ; in the case illustrated, this is an adaptive PI controller.
FIG. 2 shows sensor characteristic curves for various maximum conversion rates. The curves are each composed of two sub-lines, a sub-line with a positive slope for normal operation and a sub-line with a negative slope for the breakthrough region. The changeover point between the normal operation and the breakthrough region, identified as the maximum of the characteristic curve, is dependent on the respective maximum conversion rate of the catalyst. Curves for maximum reaction rates of 0.8, 0.9 and 1.0 are shown in FIG. 2 .
All possible normal operation and breakthrough region variations with various maximum conversion rates are combined into a general model for the described method. The general model is subdivided into corresponding linear sub-models, each composed of the time behavior (PT 1 , PT 1 and dead time, or PT 2 ) and a linear characteristic curve, while the sub-models are transformed into linear control models. An associated observer structure is designed for each sub-model, and a dosage quantity is determined based on the corresponding model calculation, which leads to exact matching of the model and reality. A PI observer is used in order to reach steady-state accuracy. The observer control variables obtained for the different linear sub-models are compared. The model with the lowest observer control variable best matches the real behavior of the system. This model is selected and provides information on whether a breakthrough is present and what the maximum conversion rate of the real system is. In the selection, it should be noted that each model, whose maximum conversion rate corresponds to the current actual conversion rate, is excluded, because a distinction between normal operation and breakthrough operation is not possible with the current actual conversion rate.
FIG. 3 shows an example of a general model transformed into linear sub-models. It includes a sub-model for normal operation and three sub-models for the breakthrough, each with different maximum conversion rates, respectively shown with transfer element 1 and sensor characteristic curves stored in the memory unit 2 . The output equations for the sub-models in the breakthrough region is a straight line which does not pass through the origin. The slope of the line results from the cross-sensitivity of the NO x sensor to NH 3 and its y-axis intercept from its slope and the maximum conversion.
FIG. 4 shows an observer structure 5 used in the described method, and comprising a transfer element 1 , a memory unit 2 with sensor characteristic curves and a controller 3 . The sub-model observed is compared to the real conversion, whereby the observer 5 of the control corresponds to the real conversion with a PI controller for steady-state accuracy, while the control action of the observer 5 establishes the correspondence between the actual conversion and the conversion calculated in the sub-model. FIG. 5 shows schematically an embodiment of the described method. The control variables of the observer 5 calculated in the sub-model used are compared through an evaluation logic 4 . The sub-model with the smallest observer control variable is the one that shows the best correspondence with the real system. This sub-model is selected and it is thereby determined whether a breakthrough is present and what the maximum conversion rate of the SCR catalytic converter is.
The system so described makes it possible to detect a breakthrough of the SCR catalytic converter or the NH 3 slip, and to determine the maximum conversion rate of the SCR catalytic converter without an artificial excitation of the system being required. The automatic excitations resulting from the operation of the system with a controller are sufficient. The method only requires low computational effort, as only simple linear models and PI controllers need to be calculated, while no complex model calculations are required. | A method and an arrangement for dynamic breakthrough detection is proposed. The arrangement comprises at least a transfer element, at least a memory unit in which sensor characteristic curves, at least a controller and an evaluation logic are stored. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] This invention generally relates to fencing systems. More particularly, the invention relates to mounting brackets useful for installing horizontal rails to vertical posts. Specifically, the invention relates to a bracket for mounting a rail to a post in confined spaces and to a cover plate that snaps around the bracket once the rail has been retained within the bracket.
[0003] 2. Background Information
[0004] It has become more common in recent years to use either vinyl or plastic products for constructing fences for yards or deck railings. While vinyl fencing is aesthetically pleasing and easy to maintain, the material poses somewhat of a problem for the contractor who must connect the various components together. It is especially problematic to connect horizontal vinyl rails to vertically extending posts in confined spaces.
[0005] There is therefore a need in the art for an improved bracket assembly for attaching horizontal rails to vertical posts.
SUMMARY OF THE INVENTION
[0006] The mounting bracket assembly of the present invention comprises a bracket that is secured to a vertical fence post and a cover plate that is snap-fitted over the bracket after the rail has been retained within the bracket. The bracket is preferably substantially U-shaped and is mounted in such a way that it is open at a top end. The rail is dropped into the U-shaped bracket and fasteners are used to secure the rail within the bracket. The cover plate is snap fitted over the bracket after the rail has been retained therein so as to conceal the fasteners. The cover plate provides an aesthetically pleasing finish to the connection between the post and rail.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The preferred embodiments of the invention, illustrative of the best mode in which applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.
[0008] FIG. 1 is a front elevational view of a deck railing incorporating the mounting bracket assembly of the present invention;
[0009] FIG. 2 is a partial perspective view of a rail secured to a post using a first embodiment of a mounting bracket assembly in accordance with the present invention;
[0010] FIG. 3 is an exploded perspective view of the rail and post shown in FIG. 2 ;
[0011] FIG. 4 is a rear view of the cover plate being snap-fitted over the bracket;
[0012] FIG. 5 is a rear view of the bracket and cover plate through line 5 - 5 of FIG. 2 ;
[0013] FIG. 6 is a partial cross-sectional bottom view of the cover plate and bracket;
[0014] FIG. 7 is an enlargement of the highlighted area of the cover plate and bracket from FIG. 5 ;
[0015] FIG. 8 is a side view through line 8 - 8 of FIG. 5 ;
[0016] FIG. 9 is a top view through line 9 - 9 of FIG. 5 ;
[0017] FIG. 10 is a cross-sectional front view of a post with two rails connected thereto by way of bracket assemblies in accordance with the present invention;
[0018] FIG. 11 is a perspective view of a second embodiment of bracket assembly in accordance with the present invention;
[0019] FIG. 12 is a rear view of the bracket assembly shown in FIG. 11 ; and
[0020] FIG. 13 is a perspective view of the bracket of the bracket assembly of FIG. 11 .
DETAILED DESCRIPTION OF THE INVENTION
[0021] Referring to FIGS. 1&2 , there is shown a section of a deck railing 10 including a post 12 , mounted to deck planking 14 , and having a plurality of rails 16 secured thereto. A plurality of balusters 18 extend between the upper and lower rails 16 . Rails 16 are secured to post 12 by way of mounting bracket assemblies in accordance with the present invention and generally indicated at 20 .
[0022] Referring to FIGS. 3-9 , there is shown a rail 16 connected to a post 12 by way of the mounting bracket assembly 20 in accordance with the present invention. Bracket assembly 20 comprises a bracket 22 and a cover plate 24 .
[0023] In accordance with a specific feature of the present invention, bracket 22 has a back wall 26 , a peripheral outer wall 28 extending outwardly away from the back wall 26 and having an opening 30 formed therein. Opening 30 preferably extends entirely across one end of bracket 22 . Peripheral outer wall 28 is substantially U-shaped with the opening 30 therein extending from side section 28 a across to side section 28 b ( FIG. 3 ). Back wall 26 of bracket 22 is also substantially U-shaped. Back wall 26 and peripheral outer wall 28 of bracket 22 substantially define a U-shaped receptacle 27 into which rail 16 may be received. Bracket 22 is complementary shaped and sized to receive an end of rail 16 therein. The distance between side sections 28 a and 28 b is therefore substantially equal to the width “A” of rail 16 ; and the distance between end section 28 c and edge 29 is substantially equal to the height “B” of rail 16 . It should, however, be understood that the bracket could alternatively be sized and shaped to receive rail 16 therein when it is turned through 90 degrees. In that instance, the distance between side sections 28 a and 28 c would have to be substantially equal to the height “B” of rail 16 and the distance between end section 28 c and edge 29 would have to be substantially equal to the width “A” of rail 16 . No matter which way rail 16 is to be oriented, an end of rail 16 is received within receptacle 27 in bracket 22 . So, as is shown in FIG. 3 , rail may be dropped or slid vertically into receptacle 27 through opening 30 (i.e., in the direction of arrow “C”) or, if space provides, may be slid horizontally into receptacle 27 in the direction of arrow “D”. Bracket 22 has a longitudinal axis “E-E” that runs substantially parallel to post 12 and a horizontal axis “F-F” that runs perpendicular to post 12 .
[0024] Back wall 26 of bracket 22 defines a plurality of first apertures 32 therein. A plurality of first fasteners 34 are received through first apertures 32 to secure bracket 22 to a side wall 36 of post 12 . Peripheral outer wall 28 defines a plurality of second apertures 38 therein. Second apertures 38 are provided to receive second fasteners 40 therethrough in order to secure rail 16 in shear within bracket 22 . Side sections 28 a , 28 b of peripheral outer wall 28 preferably are also each provided with a flange 42 which extends from an outer edge 44 of bracket 22 through to a short distance inwardly from back wall 26 thereof. Flanges 42 preferably taper forwardly from back wall 26 through to outer edge 44 ( FIG. 3 ). Outer edge 44 of peripheral outer wall 28 is preferably beveled and the beveling may include a front end 42 a of flanges 42 . End section 28 c ( FIG. 4 ) of peripheral outer wall 28 may also be provided with a pair of spaced apart ridges 46 thereon and a pair of notches 48 are provided at a top end of back wall 26 . The purpose of ridges 46 and notches 48 will be described hereinafter.
[0025] Cover plate 24 is complementary shaped to surround bracket 22 and, more specifically, to encompass peripheral outer wall 28 thereof, including spanning the opening 30 between side sections 28 a and 28 b . Consequently, because bracket 22 is substantially U-shaped, cover plate 24 is substantially rectangular in shape. Cover plate 24 comprises a perimeter wall 50 that has a top end 50 a , a bottom end 50 b and sides 50 c and 50 d which together define an interior cavity 52 into which bracket 22 is received. The exterior surface of perimeter wall 50 may be provided with a decorative profile so as to give railing 10 a more decorative appearance. A slot 54 extends from a front edge 56 of cover plate 24 through to a back edge 58 thereof. The cover plate 24 is manufactured in such a way that it can flex and sides 50 c and 50 d can be pulled apart from each other as shown in FIG. 4 . Tabs 60 are provided on each of sides 50 c , 50 d proximate back edge 58 thereof. As may be seen from FIG. 5 , tabs 60 are positioned so that when cover plate 24 is snap-fitted over bracket 22 , tabs 60 slide behind flanges 42 . Tabs 60 will then be positioned between flanges 42 and side wall 36 of post 12 . Cover plate 24 also has a lip portion 62 extending inwardly a short distance perimeter wall 50 . Outer edge 44 of bracket 22 abuts lip portion 62 when cover plate 24 is snap-fitted around bracket 22 . A pair of tapered tabs 64 are also provided on bottom end 50 c alongside slot 54 , with the widest part of tabs 64 being positioned proximate back edge 58 of cover plate 24 . Tabs 64 are positioned to interlock with ridges 46 on bracket 22 . Second tabs 66 are disposed on the interior surface of top end 50 a of being positioned proximate back edge 58 of cover plate 24 . Each second tab 66 further includes a downwardly extending projection 68 disposed proximate back edge 58 .
[0026] Bracket assembly 20 is used to connect rail 16 to post 12 in the following manner. The installer selects the position on side wall 36 of post 12 where he wishes to install bracket 22 . Back wall 26 is placed in abutting contact with side wall 36 , preferably with opening 30 being position at the top of bracket 22 . Fasteners 34 , which are preferably stainless steel screws, are used to secure bracket 22 to post 12 .
[0027] Rail 16 is then dropped into receptacle 27 defined by bracket 22 peripheral outer wall 28 . The end 70 ( FIG. 10 ) of rail 16 preferably is pushed into abutting contact with rear wall 26 of bracket 22 . Second fasteners 40 , which are preferably stainless steel screws, are then used to secure rail 16 within bracket 22 .
[0028] Cover plate 24 is then positioned around bracket 22 . In order to do this, side sections 50 c and 50 d of cover plate 24 are pulled apart ( FIG. 4 ) and then cover plate 24 is moved downwardly over bracket 22 . As the inner surface of the top end 50 a of cover plate 24 engages edge 29 of bracket 22 , projections 68 on cover plate 24 slide into notches 48 on bracket 22 . The installer releases side sections 50 c , 50 d , which then snap inwardly toward each other and around bracket 22 . When this occurs, tabs 60 slide behind flanges 42 . The installer then engages side sections 50 c and 50 d of cover plate 24 proximate bottom end 50 b and gently pushes side sections 50 c , 50 d inwardly toward each other. This causes tabs 64 to slide over ridges 46 , thereby locking cover plate 24 in place. It should be noted that when in this position, cover plate 24 cannot slide outwardly away from post 12 and along rail 16 . This is because projections 68 are engaged in notches 48 and tabs 60 are disposed behind flanges 42 . Furthermore, side sections 50 c and 50 d cannot easily be moved outwardly away from each other because the tabs 64 are interlocked with ridges 46 . Back edge 58 of cover plate 24 lies in abutting contact with side wall 36 of post 12 , and lip 62 is in abutting contact with front edge 56 of bracket 22 . All fasteners, 34 and 40 are hidden from view by cover plate 24 and the connection between rail 16 and post 12 is aesthetically pleasing. As may be seen from FIG. 10 , a second bracket 22 and its associated cover plate 24 may be secured to one of the other side walls of post 12 .
[0029] When cover plate 24 is positioned around bracket 22 , cover plate 24 lies substantially at right angles to the horizontal axis “F-F” of bracket 22 and substantially axially aligned with longitudinal axis “E-E” of bracket 22 .
[0030] In order to unlock tabs 64 from ridges 46 a thin object, such as the end of a flathead screwdriver can be inserted between a bottom wall of rail 16 and the inner surface of lip 62 and a small downward force is applied. Once tab 64 is disengaged from bracket 22 , then side sections 50 c and 50 d are moved arcuately outwardly away from each other so that tabs 60 slide outwardly from behind flanges 42 . Cover plate 24 is then slid slightly upwardly so that projections 68 slide out of slots notches 48 . Cover plate 24 is then completely disengaged from bracket 22 , each one of bottom sections 50 b needs to be individually lifted over substantially prevents this arcuate motion from occurring without a reasonable amount of force being applied thereto.
[0031] Referring to FIGS. 11-13 , there is shown a second embodiment of bracket assembly in accordance with the present invention and generally indicated at 120 . Bracket assembly 120 is adapted to be used in association with a rail 116 . Rail 116 is substantially T-shaped in cross-section and is adapted to be received within a bracket 122 mounted on a post 112 . Bracket 122 includes a substantially T-shaped back wall 126 and a substantially U-shaped peripheral outer wall 128 which terminates in a flange 172 at the base of the crossbar 174 of the “T” shape on the back wall 126 . All other components of bracket assembly 120 are substantially the same as those of bracket assembly 20 . Bracket 122 is secured to post 112 by fasteners 134 . Rail 116 gets dropped into the opening 130 between side sections 128 a and 128 b . The underside 176 a of the flanges 176 on rail 116 abuts flange 172 on bracket 122 . Fasteners (not shown) are then screwed into the side walls 116 a of rail 116 . Cover plate 124 is then snap fitted around bracket 122 by pulling the side sections 150 c and 150 d apart from each other and moving cover plate 124 downwardly until the interior surface of top end 150 a engages upper edge 129 of bracket 122 . Cover plate 124 interlocks and is secured to bracket 122 in the same manner as cover plate 24 and bracket 22 .
[0032] It will be understood that while the figures illustrate bracket 22 secured to side wall 36 of post 12 with the opening 30 at the top so that rail 16 may be slid vertically into bracket 22 in the direction of arrow C, bracket 22 may be placed in any other desired orientation, e.g. with opening 30 effectively facing the front or back of the railing, or at an angle to the vertical, or even downwardly. The latter orientation is the least favored only for the reason that the end section 28 c of bracket 22 assists in carrying the load of rail 16 and if opening 30 is disposed facing the deck planking 14 , then the load of rail 16 is effectively carried by the fasteners 40 , instead of a combination of the fasteners 40 and end section 28 c.
[0033] Furthermore, while a generally rectangular shaped rail and bracket assembly; and a generally T-shaped rail and bracket assembly have been illustrated and described herein, it will be understood that the complementary bracket and rail assembly can be of any desired shape and configuration without departing from the spirit of the present invention.
[0034] In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.
[0035] Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described. | A bracket assembly for securing a rail to a post. The bracket assembly includes a bracket that is secured to the post and a spring-biased cover plate. The cover plate includes a perimeter wall that includes a slot which extends from its front edge through to its back edge. A portion of the perimeter wall terminates adjacent either side of the slot. These portions of the perimeter are movable relative to each other. The bracket includes a back wall with a peripheral outer wall extending upwardly and outwardly away therefrom. The peripheral wall defines a rail receiving receptacle into which an end of a rail is placed. The rail is preferably secured in position by a plurality of fasteners inserted through the rail and into the housing. Once the end of the rail is retained in the bracket, the terminal portions of the perimeter wall are arcuately separated from each other and the cover plate is snap-fitted over the peripheral outer wall of the bracket. | 4 |
This is a continuation of co-pending Serial No. 113,374 filed on Oct. 23, 1987, which is a continuation of Serial No. 932,171, filed Nov. 18, 1986.
FIELD OF THE INVENTION
The invention relates to reclining lift chairs which are power actuated.
BACKGROUND OF THE INVENTION
Various recliner lift chairs are available which have been developed principally for the elderly and handicapped to assist them in moving into a standing position from a seated position. Further developments include adapting the elevator lift chairs to have a reclining mode with a foot rest which supports the legs in a reclined position. Various manual reclining chairs have been available as conventional furniture for some time. Heretofore power actuated bases and linkage systems have not been available to readily convert a conventional recliner chair into a powered recliner lift chair.
SUMMARY OF THE INVENTION
The invention provides a base and linkage system which is adapted to be readily attached to an existing manual recliner chair to convert the chair into a powered recliner lift chair. The base of the invention includes a simplified linkage which employs spaced linkage control plates which act as intermediate pivot points between the base and the driving linkage which lifts and tilts the chair. The control plates are readily attached by brackets mounted thereon to the lower hinge mounting rails of standard recliner hinge assemblies on reclining chairs. The existing fasteners which secure the reclining hinges to the chair are merely backed off a short distance and the slots in the control plates are readily positioned between the hinge and the chair frame. The driving linkage of the base is readily attached to the upper hinge linkage mounting rail. The power actuator drives the reclining linkage through the various ranges in the lift mode and reclining mode rather than driving portions of the seat or chair frame as in prior art power actuated recliner lift chairs. This reduces creaking which can occur as in the prior art recliner lift chairs when the lifting reclining forces are transmitted to certain spaced locations on the wooden frame rather than to the hinge.
The linkage control plates are rather large in area and are provided with surface that sweeps adjacent the longest link arms which connect the plates to the base to provide lateral stability to the link arms to minimize twisting or bending of the links.
A chair frame design is also provided in which the corners of the chair frame about the base frame are provided with recesses filled with foam to eliminate pinch points. The foam also provides a backing for the chair covering fabric over the recesses.
Further objects, features and advantages of the invention will become apparent from the disclosure.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic perspective of the chair parts of a recliner lift chair.
FIG. 1A is a fragmentary perspective view of the base of the invention.
FIG. 2 is a fragmentary side elevational view fragmentary section of a recliner lift chair in accordance with the invention in the recliner mode.
FIG. 3 is a side elevational view of the chair embodying the base of the invention with the chair in a partial reclining position.
FIG. 4 is a plan view of the base with a chair in the normal sitting position.
FIG. 5 is a front view of the base.
FIG. 6 is a view of the base along line 6--6 of FIG. 3.
FIG. 7 is a side elevational view of the chair in the lift mode.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure. The scope of the invention is defined in the claims appended hereto.
FIG. 1 shows a typical reclining chair with a seat 13, back 15 and foot rest 17.
FIGS. 1, 2 and 5 show side frames 10 and 11 of the reclining chair which have front vertical frame members 12 and rear vertical member 14 (FIG. 7) with lower ends 16 and 18 (FIG. 3). The front and rear vertical members 12 and 14 are interconnected by a generally horizontal extending tie frame members 20 and 20A (FIG. 7) which are fastened together to form a unit and provide for pockets 24 above the frame ends 16 and 18 which pockets are occupied by foam 30. A cross-frame member 22 interconnects the two side frames. The member 22, together with the front and rear frame members and member 20, provides said pockets 24 which are positioned over the horizontal base frame members 26 and 28 (FIGS. 6, 7). The pockets are filled with foam pads 30 as shown in FIG. 2 which are flush with the exterior of the frame members and flush with the bottom of the ends 16 and 18 and the frame 20. Hence the foam pads provide a back up for upholstery 95 (FIG. 6) and eliminates finger pinch points between the base frame and the base.
A conventional reclining chair which is not powered is typically provided with a hinge linkage 33 (FIG. 2) for purposes of controlling the reclining movement and position of the foot rest and seat and back assembly. The reclining hinge linkage 33 illustrated, is a Leggett & Platt 8500 two-way hinge which accommodates a seat and back rest 13 and 15 which are rigidly secured in fixed relationship. Alternatively a three-way hinge such as a Leggett & Platt Model No. 8254 could be employed wherein the back rest 15 is movable with respect to the seat 13.
The standard hinge 33 is provided with an upper mounting rail 32 and lower mounting rail 34 (FIGS. 1A, 2, 5). The mounting rails 32 are fixed to the side frame 35 of the seat 13 and the side rails 34 are normally fixed to the mounting blocks 37 on the chair side frame 10 and 11. Thus the seat and back rest are typically suspended between the side frames which remain in floor engagement through the connections of the hinge linkages to the chair side panels 10 and 11.
The base of the invention (FIG. 1A) includes the ground engaging frame 7. The frame includes two parallel frame members 27 interconnected at the rear by frame member 29 which has two leg portions 28 provided with feet 31. The frame portions 27 have outturned leg portions 26 at the front also provided with rubber feet 31. The frame portions are interconnected by a thin web portion 36 which provides flexibility in the base. The base is provided with a pair of spaced linkage control plates 40 which have an offset channel portion 42 which receives the lower mounting rail 34 of the reclining hinge. As illustrated in FIG. 5, assembly of the control plate to the existing reclining chair is accomplished by loosening the fasteners 43 which secure the hinge to the mounting blocks, sliding the slots 45 in the channel members over the fasteners and retightening the fasteners 43. The other connections of the base linkage to the chair will be subsequently described.
The linkage control plates 40 are connected to the base by a pair of elongated links 47 which are connected to upstanding tabs 49 on the base which are provided with outturned flanges 55 which provide support platforms for the lower rear edge of control plates when the chair is in the normal seat position in FIG. 5. Pivot 51 connects the arms or links 47 to the base and pivots 53 connect the links to the control plates 40.
The other connection between the base and the linkage control plates comprises a u-shaped frame 65 which has legs 56 and 57 (FIG. 6) which are connected to upstanding tabs 59 on web 36. Pivots 61 connect the legs 56 and 57 to the linkage control plates 40. The connection of the base to the upper hinge mounting rail 32 is provided by a pair of spaced driven links 70 connected to flying links 72. The connections of links 72 to the rails 32 is best shown in FIGS. 1A, 5 and 7 and is easily accomplished by removing the fastener 101.
Integral with the base is a conventional power actuator (FIG. 4) which includes a screw 80 which cooperates with a screw housing 82 that is pivotally connected to a clevis-like bracket 96 to power the driven links 70 which are connected by a cross-member 84 to which bracket 96 is joined. The screw is driven by a motor and a gear drive unit 86 which is swingably connected to the base by a pin 88.
The close proximity of elongated arms 47 to the linkage control plates 40 provides control over the arms so that shifting the chair will not bend or twist the arms 47.
In use the rear corner 90 of the linkage control plates rests on the outturned flange 55 of the flanges when the chair is in the normal sitting position illustrated in FIG. 3. Additionally the linkage is supported on the base frame in the collapsed FIG. 3 position with the arms 56 and 57 resting on the arms 27. By operating the power actuator from the at rest point of FIG. 3 to a second point as shown in FIG. 2, the seat 13 reclines relative to the chair frame. By operating the power actuator to a third point as shown in FIG. 7, the entire chair lifts. The base provided for the chair provides a readily attachable base with a linkage which uses the existing connections of the reclining hinge linkage to the chair for assembly of the base to the chair. This greatly facilitates assembly of the base to the chair. It can be readily done in the field without any special tools. | Disclosed herein is a lift base for converting a manual reclining chair to a powdered lift and reclining chair. The base is readily attached to the reclining hinge and drives the hinge parts as well as the chair frame. A simplified base linkage uses linkage plates as a common pivot mount for link connections inbetween the base and the chair. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to a device and a process for the production, transfer and installation of the coils into the stator of electrical machines, the interconnected coils being machine-fabricated in sets by means of semi-circular winding formers with wire chambers stepped in correct polarity and the formers being arranged axially extractably on carrying bars which are secured parallel to the rotational axis on rotary arms of a winding machine such that they allow themselves to be turned after release of a rotational lock, furthermore the winding diameters of the formers being equivalent to the cord lengths between the corresponding stator grooves, and the coil sets taken off the formers being installed into the stator by means of elastically spreadable installation strips inserted in groups between the groove heads.
In electrical machine construction, the working steps named and the means used for them are essentially dealt with as separate technologies. The result of this is that the production objective, namely fitting of the stator with wire coils, is only achieved at a high expenditure in terms of time and labor. Particular problems are presented by transportation of the wound coils to the stator without them losing their original shape. Usually, time-consuming secondary jobs and additional devices are necessary to prepare the densely wound coils such that they can be laid satisfactorily into the narrow stator grooves.
SUMMARY OF THE INVENTION
It is therefore the objective of the invention to facilitate stator fitting. The preparatory working steps are to be executed in such a way that installation of the coils is facilitated with the aid of known, tried-and-tested so-called installation strips and thus the time expenditure from winding the coil to concluding the installation operation can be reduced.
Another objective consists in being able to take the coils off the winding formers with a few manipulations, i.e. simplifying the adjustment facilities of the formers.
The exposed loose coils are to retain their shape so that the wire layers do not have to be ordered and the coil phase windings do not have to be fixed by binding with tapes or the like. In particular the invention endeavors to create flat coil phase windings which can be inserted particularly well into the installation strips.
Another objective is the production of multi-phase coil sets ordered in correct polarity which are connected to one another during the course of the winding operation by looped-over winding wires without separation points and the joint installation of these coil sets into the stator.
The invention intends in particular to increase the overall performance of small winding shops and repair workshops for electrical machines and achieve the same or a higher product quality without great financial investments and with less trained workers.
Starting out from a device of the type designated in the introduction, these objectives are achieved according to the invention by the fact that, for dimensionally stable transfer of the coil set from the winding machine to the stator, at least one of the two mutually opposite former sets is provided with a support element which, running radially in the former mid-axis and perpendicular to the former sectional plane, protrudes into the former-free space and the supporting faces of which are designed in mirror symmetry with the step profile of the former set, the step radii of the support element being equivalent to the winding radii of the former chambers and the supporting faces being arcs concentric to the winding axis of about 10° arc length. The turning of such a former set through 180° alone is enough to move the ready-wound coils into a receive-ready position. The coils are transported without dimensional loss together with the former sets and inserted into the installation strips. Only then are the former sets removed.
In this way, not only is the manual work of the winder simplified and speeded up, but the possibility of mechanizing the said operations in the series production of electrical machines is also created.
Further expedient structural details are described below. Brief reference is to be made here to the most important ones. The raised holding edge prevents slipping off of the coils from the supporting faces of the support element. The former sets may be designed variably with respect to the winding radii, for example by means of slip-on semi-circular insertion dishes. Of particular significance are arrangements according to which the former set can be separated from the support element, facilitating the insertion of the coil phase windings into the installation strips. With the aid of a second carrying rod, such a support element can be extracted together with the former set more easily from the former carrying rod.
The working process according to the invention has two variants which differ from each other according to whether the support element is secured to the associated former set or is separable from it. In one case, the former set is turned as long as it is still on the former carrying rod. In the other case, on the other hand, the turning movement is performed when both former sets have been extracted from the winding machine, the second carrying rod serving as a turning axis.
Finally, the invention proposes a particular installation strip group which is distinguished by the fact that the individual installation strips and, in particular, their individual tongues are of different lengths. The tongue ends are preferably spread such that they touch one another and thereby produce receiving spaces which facilitate the introduction of the coil phase windings. A further facilitation and simplification of work in this respect is achieved by the fact that in each case two installation strips assigned to a coil are marked by their own coloring.
BRIEF DESCRIPTION OF THE DRAWING
Details of the device according to the invention are diagrammatically represented as exemplary embodiments in the drawings, in which
FIG. 1 shows a side view of the former sets with the coils, partially in cross-section along line I--I of FIG. 2;
FIG. 2 shows the front view of FIG. 1 taken in cross-section along II--II of FIG. 1;
FIG. 3 shows a side view of the former sets with the coils in the vertex position of the support element;
FIG. 4 shows the front view of FIG. 3 in cross-section along line IV--IV of FIG. 3;
FIG. 5 shows the front view of the stator with fitted coils for a four-pole winding pitch with 36 grooves;
FIG. 6 shows a side view of FIG. 5;
FIG. 7 shows an enlarged plan view of the stator cross-section along line VII--VII of FIG. 5, elongated in the horizontal plane, with diagrammatically drawn-in installation strips, coils and support elements;
FIG. 8 shows the cross-section through a former chamber with insertion dish;
FIG. 9 shows a side view of another former set with the coils, taken in cross-section along line IX--IX of FIG. 10;
FIG. 10 shows the front view of FIG. 9, taken in cross-section along line X--X of FIG. 9;
FIG. 11 shows a side view of the support element separated from the former set in accordance with FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1-4 the drive shaft 1 of the winding machine has secured thereon in the usual way a rotary arm 2 on which the carrying rods 3, 3a for the winding former sets 4, 4a are attached. The latter are connected to be rotationally fixed to, but axially extractable from, their carrying rods and the axial displacement can be blocked by setting rings 5. The carrying rods 3, 3a are secured on the rotary arm 2 via one spacer 6 each which can be radially adjusted in a longitudinal groove 7 by actuation of a fixing screw 8 on the rotary arm 2. In addition, provided on the inner end of the carrying rod 3, 3a is a tightening screw 9 with which the rotatability of the carrying rod and of the former set can be arrested and released as required.
The wire coils 11a, 11b, 11c wound in the former chambers 10 are interconnected in correct polarity in a known way by wire connections so that they can be handled from here on as a unit and installed in the stator 12 (FIGS. 5, 6, 7). The former chambers 10 are widely shaped and the winding operation is controlled such that the coil phase windings are given a flat cross-section. This preparatory measure facilitates the following installation of the coils into the narrow stator grooves and the use of the known installation strips.
The former set 4 is provided with a support element 13 which is secured on the continuous former hub 14, or can be made integral with the latter, and which, extending perpendicular to the former sectional plane, projects into the former-free space. The supporting faces 16a, 16b, 16c of the support element, provided on both sides with raised holding edges 15, are designed mirror-symmetrically to the opposite former set 4, the winding radii also coinciding. The former hub 14 receiving the carrying rod 3 is arranged in the present example such that the axis of the carrying rod 3 runs at a short distance from the geometrical form axis 17 of the half-former.
The winding facility is shown in an operational state with ready-wound coil set. In order to implement then the intended transfer of the coils to the stator 12 such that the three-dimensional shape of the coil set and the flat coil cross-section are retained as exactly as possible, first of all the rotary arm 2 is swung far enough for the former set 4 to be in the upper vertex position shown. Then the rotational lock of the carrying rod 3 is lifted by release of the tightening screw 9, whereupon the carrying rod with the former set 4 and the support element 13 is turned through 180° and moved into the position according to FIGS. 3 and 4, the spacer 6 acting as a bearing for the carrying rod 3. This turning causes only the semi-circular coil heads to be released, whereas the vertical coil phase windings continue as before to be guided dimensionally stably in their former chambers 10 and are now suspended on the supporting faces 16a, 16b, 16c of the support element 13 so that the inherently rigid coil form is retained.
The finished coil sets can now be brought into the installation strips 18a, 19a, 20a (FIG. 6) for installation without the risk of deformation. For this purpose, the setting rings 5 are released so that the former sets 4, 4a can be axially detached simultaneously from their supporting rods 3, 3a and subsequently the entire former-coil complex is transportable. In this condition, the upper coil heads are securely suspended on the support element 13 by the weight of the coil whereas the vertical coil phase windings are positively held in the former chambers 10 of the upper former set 4 and of the lower former set 4a.
FIGS. 5, 6 and 7 show the arrangement of the installation strips 18a, 18b, 19a, 19b, 20a, 20b, the stator 12 being turned in its receiving bearing such that the groove group to be fitted is located in the lower vertex region symmetrical to the vertical mid-axis. As a preparatory step, the installation strips are inserted into the grooves 21 of the stator such that their head parts, consisting of the spread tongues 22a, 22b, protrude out of the stator grooves. In accordance with the three-dimensional shape of the stepped coil set, the lengths of the spread strip head parts are likewise stepped.
This produces an effective optical indication for the logical, quick matching of the strips with the variously lying coils of different sizes. As a further aid for reliable introduction between the spread tongues of the individual installation strips, each interacting strip pair is marked or colored by its own coloring, e.g. strips 18a, 18b red, strips 19a, 19b green and strips 20a, 20b blue. In addition, the angle of spread of the strip tongues is chosen such that the tongues of two neighboring strips can make a tangent to each other, so that the inadvertent pushing-in of a coil phase winding between two strips is avoided and completely accurate, reliable lining up of the entire coil set with the strips can be carried out in a short time.
According to FIGS. 5, 6, and 7, in this process the coil set suspended on the support element 13 is transferred directly into the spaces 23 of the spread head pieces of the installation strips 18, 19, 20 (a/b), so that the coils are now carried by these head pieces. This causes the upper former set 4 with the support body 13 to be relieved and it can be taken out of the coil set together with the lower former set 4a. Subsequently, the coils 11a, 11b, 11c are pushed in the direction of the arrows of FIG. 6 right up to the stator or far enough for them to reach the clamping region 24 of the installation strips.
The subsequent installation of the complete coil set into the stator can be performed in a known way, e.g. by the installation strips connected to a draw device being drawn axially through the stator bore and in the process drawing the coil phase windings into the grooves 21. The spreading spaces 23 of the installation strips, shown in FIG. 7, also facilitate attachment of the cover slides which can be installed by pushing over the coil phase windings.
After completion of the described groove fitting, the stator 12 is turned on further by the pole pitch, in the present example through 90°, until the groove group to be fitted is again located in the lower vertex position according to FIG. 5.
The dimensions of the groove graduated circle and of the graduation module determine the dimensions of the coil sets to be wound, in particular the cord lengths Sa, Sb, Sc. However, repair shops also receive stators on which the said cord lengths and the profiles of the coil chambers deviate from standard dimensions, so that a reprocessing of the wound coils or the procurement of special winding formers is necessary. As the deviations are usually only slight, the effort mentioned can be avoided by the formers in each case being adapted to the deviant cord length, e.g. Sa', in accordance with FIG. 8 by introducing one or more insertion dish 25, it being expedient to use a former set with the next smallest dimensions. The insertion dish 25 can be detachably connected to the basic former, for example by a plug cone 26.
In FIGS. 9 to 11, a further exemplary embodiment of a former set with support element is illustrated, which is particularly advantageous for multi-wired tiered windings. Parts coinciding with the first exemplary embodiment bear the same reference numbers.
FIGS. 9 and 10 show in a similar way to FIGS. 1 and 2 a former set 30 which is pushed onto the carrying rod 3 which is secured on the rotary arm 2 of the winding machine by the tightening screw 9. At the other end, the former set is axially secured by a setting ring 5.
The winding operation is concluded and the wire coils 11a, 11b and 11c lie flat in the former chambers 10. The coil set is moved into its upper vertex position, the downwardly suspended coil phase windings being guided through the wire chambers of the lower former set (not shown).
The support element 31 is an independent element, separated from the former set, and is provided with a receiver 32 which projects into the hollow interior space 33 of the formers where it is held positively, but detachably. This is achieved, for example, by two elastic guide strips 34 attached in the former, through which the receiver can be pushed in, producing a retaining tension which is sufficient to carry the support element 31.
The receiver 32 has a longitudinal bore which, with fitted receiver, aligns with the bores 35 in the outer walls of the former set, so that the carrying rod 3 inserted into the bores connects the former set 30 and the receiver 32 to the rotary arm 2.
Underneath the former longitudinal axis, the support element 31 is provided with a second profiled receiving bore 36 which serves for rotationally positive reception of a second carrying rod 37, which can be provided at one end with a retaining knob 38 and has at its inserting-side end a driving bolt 39 which is moved automatically into a transverse position and facilitates the extraction of the former set from the bearing rod 3, which remains on the rotary arm 2.
Before this extraction operation, the second bearing rod 37 has been pushed into the second receiving bore 36 (arrow E), so that this rod now carries the former set with the coils and the support element.
In this state, to facilitate further handling, the carrying rod 37 can be set down onto two bearing rails 40 (FIG. 11).
Subsequently, the support element 31 with its receiver 32 and the former set 30 is swung through 180° about the axis of the carrying rod 37 (arrow D) so that now, as shown in FIG. 11, the former set 30 assumes the lower vertex position and the support element 31 the upper vertex position, the wire coils 11a, 11b, 11c being lifted out automatically from the former chambers 10 of the formers and taken over by the wire chambers 41 of the support element 31. The former set 30 can now be detached from the receiver 32 and taken out of the region of the coil phase windings (arrow W, FIG. 11).
Once the other former set suspended at the bottom in the coil phase windings has been cleared away as well, the unhindered insertion of the coil phase windings into the installation strips already arranged in the stator can be carried out, the support element ensuring the three-dimensional shape and flat position of the coils. | A device and a process for the functionally combined production, transfer and installation of coils (11a, 11b, 11c) into the stator (12) of electrical machines using installation strips (18a to 20b) provided with spreadable tongues. A ready-wound coil set (11a, 11b, 11c) is taken off the winding machine with its formers (4, 4a), moved to the stator (12), maintaining the spatial stepping and the flat shape of the coil phase windings, transferred directly from the formers (4, 4a) into the installation strips (18a to 20b) inserted into the stator (12), and drawn into the stator (12) as a whole in a single operation. One of the two formers (4) is provided with a preferably detachable support element (13) which lifts the coil heads out of the former chambers by turning the former about the axis of its carrying rod (3). For easier introduction of the coil phase windings into the installation strips ( 18a to 20b), their strip tongues are arranged in different lengths and stepped. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of provisional U.S. Patent Application Ser. No. 61/175,115, filed on May 4, 2009
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] N/A
COPYRIGHT NOTICE
[0003] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyrights rights whatsoever.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to an apparatus for use with a suitcase, and more particularly to a travel organizer comprising a hanging shelf system that may be collapsed for transport within a suitcase and quickly removed and deployed in a hanging configuration to provide the traveler with access to clothing and other travel items.
[0006] 2. Description of Related Art
[0007] Luggage refers to various sizes and shapes of containers, suitcases, and travel bags used to transport personal items during travel. Historically, luggage was recognized as a large bulky container such as a trunk or storage locker. As technology advanced and individuals accelerated the rate of personal travel, such cumbersome containers were replaced by lighter-weight suitcases and travel bags. Improvements in suitcase design allowed for ease of transportability and use. Although several styles of suitcases exist today, most luggage has been designed for ease of use by the traveler. Popular models are rectangular-shaped, and provide an expandable handle and wheels that allow the traveler to roll, rather than carry, the luggage from one point to another. Generally, the interior of the suitcase features an empty volume of space which allows for maximizing the number of articles which may be stored. As such, the traveler must pack their individual items prior to the trip and then unpack upon arrival at the destination. As travelers are increasingly mobile, it is often inconvenient to pack and unpack at each destination. Accordingly, there exists a need for suitcase accessory devices designed to assist in the organization of contents.
[0008] The background art reveals a number of attempts directed to improving suitcase organization and storage. For example, U.S. Pat. No. 7,334,669, issued to Barker et al., discloses a rolling luggage system incorporating an expandable and collapsible shelf-containing compartment for organization of stored items within the luggage during travel.
[0009] In addition, the background art reveals a number of references directed to closet organizers. With respect to closet organization, prior art reveals many attempts to best utilize space. Many objects of prior art are directed at hanging shelf systems and/or hanging closets. For example, U.S. Pat. No. 6,732,659, issued to Poon discloses a hanging shelf system with a plurality of shelves. U.S. Pat. No. 2,533,333, issued to Kitson, discloses a collapsible and portable wardrobe featuring shelf and clothes-storage space, which may be rolled compactly for ease of transport. The wardrobe itself is portable, and securely latches to itself to maintain closure during transport. U.S. Pat. No. 2,244,887, issued to Manley, discloses a portable collapsible shelved cabinet wherein the stored articles are covered to protect them against outside elements, whereby the device is easily folded into a compact unit for transport. U.S. Pat. No. 2,440,192, issued to Cowan, discloses a hanging, dust-proof container for storing articles, which may be collapsed and transported for travel.
[0010] The references of the background art are primarily designed to organize items either within suitcase as disclosed by Barker, or in a hanging shelf system for permanent storage in a closet. The background art fails, however, to disclose a hangable travel organizer system designed for removable insertion and transport within a conventional suitcase. Accordingly, there exists a need for a travel organization system whereby the organizational element is easily collapsible for insertion and transport within a suitcase, and, upon reaching the desired destination, removable and hangable without requiring removal and replacement of the contents.
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention overcomes the limitations and disadvantages present in the art by providing a hanging shelf system travel organizer that is specifically adapted for use in combination with a suitcase. A travel organizer in accordance with the present invention comprises a hanging shelf system adapted to collapse to a size suitable for insertion within an article of luggage. The shelf system is configurable between a vertically expanded configuration when deployed wherein a plurality of shelves are disposed in vertically spaced relation for receiving clothing and other travel items, and a vertically compact, stowed configuration wherein the travel shelf apparatus is compactly configured for insertion into a suitcase for travel. When the user reaches his/her destination the travel organizer may be removed from the suitcase and hung in a closet in the vertically expanded configuration with spaced shelves thereby providing the traveler with ready access to the packed articles while eliminating the need to unpack and repack.
[0012] A hanging shelf system in accordance with the present invention is preferably provided with three storage compartments, each of which includes a supporting bottom surface configured to function as shelf. Each shelf preferably includes a lightweight yet sturdy rigid or semi-rigid horizontally disposed panel to provide structural support. The remaining structure is comprised of flexible, preferably mesh, fabric thereby allowing the apparatus to be selectively configured between a vertically expanded configuration wherein the shelves are maximally spaced, and a vertically collapsed configuration wherein the shelves are minimally spaced. In contrast to prior art, no structural support is provided. A pair of hooks is provided to allow the organizational apparatus to be hung from a closet rod. When suspended from the closet rod the travel organizer automatically deploys to the vertically extended configuration under the influence of gravity. By simply unhooking the entire apparatus from the closet rod, the user can collapse the system into the luggage. As the sides and rear of the apparatus are formed of flexible fabric, the apparatus will compact itself into a small volume of space, i.e., the interior of luggage. Upon arrival at the destination, the user can open the luggage, and lift the system by grasping the hooks and hanging in a closet or over a door frame. Because there is no need to empty the system prior to packing, all items remain organized in the shelving apparatus and ready for use in minimal time.
[0013] Accordingly, it is an object of the present invention to provide an improved travel organizer specifically designed for use with luggage.
[0014] Another object of the present invention is to provide such an apparatus which is adaptable for ease of transport in standard luggage.
[0015] Another object of the present invention is to provide such an apparatus adapted to allow for collapsibility.
[0016] Still another object of the present invention is to provide such an apparatus adapted to store clothes and other objects commonly transported in luggage.
[0017] Yet another object of the present invention is to provide such an apparatus adapted for continued organization of items in the apparatus upon arrival, where packing and repacking of items is not required.
[0018] These and other objects are met by the present invention which will become more apparent from the accompanying drawing and the following detailed description of the drawings and preferred embodiments.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0019] FIG. 1 is a front perspective view of a travel shelf system organizer in accordance with the present invention illustrated in relation to a suitcase;
[0020] FIG. 2 is a front perspective view illustrating the travel shelf system partially received within the suitcase;
[0021] FIG. 3 is a front perspective view thereof illustrating the travel shelf system fully received within the suitcase;
[0022] FIG. 4 is a front perspective view of an alternate embodiment travel shelf system having deployable and stowable support members; and
[0023] FIG. 5 is a front perspetive view thereof illustrating pivotal movement of the legs to the stowed configuration.
DETAILED DESCRIPTION OF THE INVENTION
[0024] With reference now to the drawings, FIGS. 1-3 depict a preferred embodiment of the present invention which comprises a shelf system and travel organizer apparatus, generally referenced as 10 , that is specifically sized and shaped to fit within a suitcase 11 . Suitcase 11 preferably includes an openable top closure configurable between a closed configuration and an open configuration. With the top in the open configuration the user is presented with access to the interior of the suitcase via a top opening having a length and a width.
[0025] Travel organizer 10 preferably comprises a collapsible shelf system sized for removable insertion within a suitcase. In a preferred embodiment, travel organizer 10 comprises an expandable and collapsible main body 12 having a top 12 a and a bottom 12 b . Main body 12 preferably includes three (3) storage surfaces or shelves, referenced as 14 , 16 , and 18 connected thereto and supported thereby. Shelf 14 forms a bottom shelf connected in proximity to the bottom of main body 12 . Shelf 18 forms a top shelf connected below the top 12 a of main body 12 . Shelf 16 forms a middle shelf and is disposed between bottom shelf 14 and top shelf 18 . Each shelf preferably includes a lightweight yet sturdy rigid or semi-rigid horizontally disposed panel to provide structural support. As used herein, the term “rigid” as applied to describe shelves 14 , 16 , and 18 , shall mean capable of retaining a generally planar shape while supporting a modest load of the type associated with a stack of folded clothing or other travel articles, namely a load between approximately 1.0 lbs and 10.0 lbs. for embodiments on the invention intended for general business or recreational travel. The term “rigid” should not be construed to mean absolutely rigid, e.g. without a degree of deflection or bending under an applied load. The present invention, however, may be adapted to handle greater loads in embodiments intended for the transport of other goods and/or industrial use. The present invention may further be configured with shelves that are generally flexible and not rigid.
[0026] Main body 12 is preferably fabricated from flexible sheet-like material, such as natural or synthetic fabric, e.g. cotton, nylon, polyester etc. The fabric may be woven or non-woven, and may further have water-resistant characteristics for maintaining the contents dry and/or for keeping wet contents in one compartment from wetting contents in another compartment. Main body 12 includes opposing side walls, referenced as 20 a and 20 b , and a rear wall 22 . An important aspect of the invention involves forming side walls 20 a and 20 b , and rear wall 22 , out of mesh material to allow the user to visually inspect the contents from the side or rear of main body 12 , while further providing ventilation.
[0027] Main body 12 is configurable between an expanded configuration wherein shelves 14 , 16 , and 18 , are disposed in maximally spaced generally parallel relation as illustrated in FIG. 1 , and a collapsed configuration wherein shelves 14 , 16 , and 18 , are disposed in minimally, substantially adjacent relation as illustrated in FIG. 3 . When in the expanded configuration, the vertical spacing between shelves is preferably approximately 8.0 inches. In addition, side walls 20 a and 20 b and rear wall 22 preferably project upward from top shelf 18 approximately 6.0 inches when in the expanded configuration so as to contain articles placed on top shelf 18 . As should be apparent, side walls 20 a and 20 b and rear wall 22 function to support shelves 14 , 16 , and 18 , while containing clothing and articles disposed thereon. The dimensions set forth herein in connection with the preferred embodiment may be altered (e.g. increased and/or decreased) within the scope of the present invention.
[0028] A pair of hooks 24 are attached to main body 12 along the top edges of side panels 20 a and 20 b by straps, 25 as best seen in FIG. 1 . Hooks 24 and straps 25 are preferably configurable between a retracted configuration for hanging main body 12 from a closet rod as seen in FIG. 1 , to an extended configuration (shown in phantom) for hanging main body 12 from a more elevated support structure, such as a door hook or door top edge. Hooks 24 function in the retracted and extended configurations to allow the main body 12 to be hung from a variety of supporting structures disposed at various heights upon removal from the suitcase. When packed in a suitcase, hooks 24 and straps 25 may be tucked into the side (as shown in FIG. 3 ) or folded over the top.
[0029] Travel organizer and shelf system 10 is primarily intended for use as a travel organizer that allows the user to pack travel articles, such as clothing, therein with the travel organizer disposed in the expanded configuration and then drop the system into a suitcase wherein travel organizer 10 is contained during travel as illustrated in sequence in FIGS. 1-3 . In that regard, the user may pack shelf system 10 , while main body 12 is hanging in a closet (or other support structure) from hooks 24 , in the expanded configuration. When hanging from hooks 24 in the expanded configuration, main body 12 forms a first compartment bounded at the bottom by shelf 14 , on the sides by side walls 20 a and 20 b respectively, at the rear by rear wall 22 , and on the top by the bottom surface of shelf 16 . A second compartment is bounded at the bottom by the top surface of shelf 16 on the sides by side walls 20 a and 20 b respectively, at the rear by rear wall 22 , and on the top by the bottom surface of shelf 18 . Finally, a third open-top compartment is bounded at the bottom by shelf 18 on opposing sides by side walls 20 a and 20 b , and at the rear by rear wall 22 , and provides a surface upon which folded clothing or other items may be placed. The present invention thus provides a travel organizer that allows a user to pack by simply placing clothing and the like on any one of the three shelves while the device hangs in a closet in an expanded configuration, after which the organizer may be placed in an article of luggage configured to a compact configuration for travel. Accordingly, a significant aspect of the present invention relates to sizing main body 12 , and particularly the length and width dimensions of shelves 14 , 16 , and 18 , to fit within a piece of luggage, suitcase, or other suitable travel container. Accordingly, the present invention includes the combination of a luggage shelf system 10 with a correspondingly sized suitcase. More particularly, the length and width dimensions of shelves 14 , 16 , and 18 , are sized to be slightly less than the corresponding length and width dimensions of the luggage intended for use therewith. Once the traveler reaches his or her destination the organizer is simply removed from the luggage and hung in a closet whereby the shelves vertically expand to allow for access to the packed items.
[0030] FIGS. 4 and 5 depict an alternate embodiment, shelf system 10 , which includes a collapsible support frame including left and right frame members, referenced as 30 a and 30 b . Opposing left and right support frame members 30 a and 30 b function to allow the system to be free standing and/or to stand within the body of a suit case. Support frame members 30 a and 30 b are each configurable between a deployed configuration and a stowed configuration as generally illustrated in FIGS. 4 and 5 . FIG. 4 illustrates a deployed configuration wherein frame members 30 a and 30 b are disposed in generally vertically adjacent relation with corresponding sides 20 a and 20 b to support main body 12 in the expanded configuration. At least one strap member 32 is provided for securing frame member 30 in the deployed configuration. In a preferred embodiment, strap member 32 includes an end adapted with hook and loop fastening by mating engagement with fastening element 33 . FIG. 4 depicts strap member 32 in art attached configuration, and FIG. 5 depicts strap member 32 in a detached configuration. In accordance with a preferred embodiment, each support member 30 is pivotally connected proximal the upper portion of the corresponding panel 20 to as to allow for pivotal movement of each support member as illustrated in FIGS. 4 and 5 . As should now be apparent, shelf system 10 may be supported in a free standing manner by support frame members 30 as illustrated in FIG. 4 , or compacted to the compact configuration within a suitcase with frame members 30 folded over the top thereof for compact transport within the suitcase. As should be apparent, the alternate embodiment shelf system 10 depicted in FIGS. 4 and 5 may also include the hooks 24 and straps 25 as disclosed with the preferred embodiment.
[0031] The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to a person skilled in the art. | A hanging shelf system and travel organizer is specifically adapted for use in combination with a suitcase wherein the shelf system is adapted to collapse to a size suitable for removable insertion within the suitcase. The shelf system is configurable between a vertically expanded configuration when deployed wherein a plurality of shelves and walls form storage compartments for receiving clothing and other travel items, and a vertically compact, stowed configuration wherein the travel shelf apparatus is compactly configured for insertion into a suitcase for travel. When the user reaches his/her destination the travel organizer may be removed from the suitcase and hung in a closet in the vertically expanded configuration with spaced shelves thereby providing the traveler with ready access to the packed articles while eliminating the need to unpack and repack. | 0 |
This is a division of application Ser. No. 955,117 filed Oct. 26, 1978.
INTRODUCTION
Heat exchangers incorporating apparatus of the present invention have been developed for use with large gas turbines for improving their efficiency and performance while reducing operating costs. Heat exchangers of the type under discussion are sometimes referred to as recuperators, but are more generally known as regenerators. A particular application of such units is in conjunction with gas turbines employed in gas pipe line compressor drive systems.
Several hundred regenerated gas turbines have been installed in such applications over the past twenty years or so. Most of the regenerators in these units have been limited to operating temperatures not in excess of 1000° F. by virtue of the materials employed in their fabrication. Such regenerators are of the plate-and-fin type of construction incorporated in a compression-fin design intended for continuous operation. However, rising fuel costs in recent years have dictated high thermal efficiency, and new operating methods require a regenerator that will operate more efficiently at higher temperatures and possesses the capability of withstanding thousands of starting and stopping cycles without leakage or excessive maintenance costs. A stainless steel plate-and-fin regenerator design has been developed which is capable of withstanding temperatures to 1100° or 1200° F. under operating conditions involving repeated, undelayed starting and stopping cycles.
The previously used compression-fin design developed unbalanced internal pressure-area forces of substantial magnitude, conventionally exceeding one million pounds in a regenerator of suitable size. Such unbalanced forces tending to split the regenerator core structure apart are contained by an exterior frame known as a structural or pressurized strongback. By contrast, the modern tension-braze design is constructed so that the internal pressure forces are balanced and the need for a strongback is eliminated. However, since the strongback structure is eliminated as a result of the balancing of the internal pressure forces, the changes in dimension of the overall unit due to thermal expansion and contraction become significant. Thermal growth must be accommodated and the problem is exaggerated by the fact that the regenerator must withstand a lifetime of thousands of heating and cooling cycles under the new operating mode of the associated turbo-compressor which is started and stopped repeatedly.
Confinement of the extreme high temperatures in excess of 1000° F. to the actual regenerator core and the thermal and dimensional isolation of the core from the associated casing and support structure, thereby minimizing the need for more expensive materials in order to keep the cost of the modern design heat exchangers comparable to that of the plate-type heat exchangers previously in use, have militated toward various mounting, coupling and support arrangements which together make feasible the incorporation of a tension-braze regenerator core in a practical heat exchanger of the type described.
Heat exchangers of the type generally discussed herein are described in an article by K. O. Parker entitled "Plate Regenerator Boosts Thermal and Cycling Efficiency", published in The Oil & Gas Journal for April 11, 1977.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to heat exchangers and, more particularly, to apparatus for providing thermal isolation and support of heat exchanger ducting members from the heat exchanger frame.
2. Description of the Prior Art
Arrangements are known in the prior for fastening together two different elements in a heat insulating mounting or for accommodating thermal growth between adjacent elements which are mounted together. For example, the Ygfors U.S. Pat. No. 3,690,705 discloses a device for rigidly connecting two metallic members together in heat-insulating relation. The arrangements disclosed in this patent depend upon a bushing constructed of a material having known heat insulating properties mounted between the two members.
The Young U.S. Pat. No. 3,710,853 discloses an arrangement of a radiator comprising two headers or tanks on opposite sides of a heat exchanging core. One of the tanks is fixed to the frame while the other is mounted to the frame by means of a shoulder stud extending through an enlarged hole in the frame to permit lateral movement of the stud. However, no thermal isolation of the radiator from the mounting frame is provided, the only concern being the accommodation of the different coefficients of expansion for the frame and the radiator. The arrangement of the Young patent depends upon flexible conduits, typically rubber hoses, for connection to the fluid passages of the radiator.
Devices of the type disclosed in these prior art patents may be suitable for apparatus of limited size, weight and thermal gradient. However, they are totally unsuitable for heat exchangers of the type here involved which include heat exchanger cores operating at temperatures in excess of 1000° F. supported in frames of conventional structural steel construction maintained at temperatures less than 150° F.
SUMMARY OF THE INVENTION
In brief, arrangements in accordance with the present invention comprise members for supporting heat exchanger ducts relative to the heat exchanger frame which serve to provide thermal isolation of the ducts from the associated frame members while accommodating axial and radial thermal growth and limited lateral movement. Thermal isolation with the required structural support is provided in accordance with an aspect of the invention by the use of thin walled metal members extending between the ducts and associated points of attachment to the frame. One such element is in the form of a thin walled cylinder with end plates threaded to receive mounting bolts. The cylinder is attached to a frame member (the cold structure) by a mounting bolt fitted into one end of the cylinder. The other end of the cylinder is constrained axially by means of a shoulder bolt threaded into the other end of the cylinder and extending through an oversized opening in a flange attached to the heat exchanger duct (the hot structure). This opening may be a radially aligned slot in the flange or a round opening larger than the body of the bolt but small enough to be engaged by the bolt head or a retaining washer mounted thereon. The threaded portion of the shoulder bolt is of lesser diameter than the shoulder portion, thereby insuring sufficient space between the end of the thin walled cylinder and the retaining portion (head or washer) to permit the duct flange to slide radially relative to the cylinder. Although the cylinder is of metal for structural strength, the thin walls of the cylinder have low thermal conductivity, thus providing the desired thermal isolation between the hot and cold structures.
Further thermal isolation with accommodation of thermal growth of the hot structure is also provided by circumferential bellows members having re-entrant collar portions developing an extended path length for heat travelling through the metal between the hot and cold structures. Duct flange members at opposite ends of the heat exchanger are provided for supporting the duct loading of attached piping and for balancing the internal pressure forces relative to the frame. These are tied together for dimensional stabilization of the heat exchanger by means of tie rods which extend through the space surrounding the heat exchanger core. Support pins extending through openings in ears or projections on the manhole flanges covering the blind ducts at the rear end of the heat exchanger serve to support these flanges and ducts while permitting several inches of axial growth of the core structure and internal duct passages connected thereto.
BRIEF DESCRIPTION OF THE DRAWING
A better understanding of the present invention may be had from a consideration of the following detailed description, taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective, partialy exploded view of a heat exchanger module in which embodiments of the present invention are utilized;
FIG. 2 is a perspective view of the heat exchanger module of FIG. 1, taken from the opposite end;
FIG. 3 is a sectional view of a portion of the heat exchanger module of FIGS. 1 and 2, illustrating one embodiment of the invention;
FIG. 4 is a view, partially broken away, taken along the line 4--4 of FIG. 3 and looking in the direction of the arrows;
FIG. 5 is a sectional view of a portion of the module of FIGS. 1 and 2, showing details of another embodiment of the present invention; and
FIG. 6 is a sectional view of another portion of the module of FIGS. 1 and 2, showing details of still another arrangement in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As presently constructed, heat exchangers utilizing arrangements in accordance with the present invention are fabricated of formed plates and fins assembled in sandwich configuration and brazed together to form core sections. These sections 10 are assembled in groups of six (referred to as "six-packs") as shown in FIGS. 1 and 2 to form a core 12 which, together with associated hardware, comprises a single heat exchanger module 20. A single module 20 may be joined with one or more other modules to make up a complete heat exchanger of desired capacity.
In the operation of a typical system employing a regenerator of the type discussed herein, ambient air enters through an inlet filter and is compressed to about 100 to 150 psi, reaching a temperature of 500° to 600° F. in the compressor section of an associated gas turbine (not shown). It is then piped to the regenerator module 20, entering through the inlet flange 22a (FIG. 1) and inlet duct 24a. In the regenerator module 20, the air is heated to about 900° F. The heated air is then returned via outlet duct 24b and outlet flange 22b to the combustor and turbine section of the associated turbine via suitable piping. The exhaust gas from the turbine is at approximately 1100° F. and essentially ambient pressure. This gas is ducted through the regenerator 20 as indicated by the arrows labelled "gas in" and "gas out" (ducting not shown) where the waste heat of the exhaust is transferred to heat the air, as described. The exhaust gas drops in temperature to about 600° F. in passing through the regenerator 20 and is then discharged to ambient through an exhaust stack. In effect, the heat that would otherwise be lost is transferred to the inlet air, thereby decreasing the amount of fuel that must be consumed to operate the turbine. For a 30,000 hp turbine, the regenerator heats 10 million pounds of air per day.
The regenerator is designed to operate for 120,000 hours and 5000 cycles without scheduled repairs, a lifetime of 15 to 20 years in conventional operation. This requires a capability of the equipment to operate at gas turbine exhaust temperatures of 1100° F. and to start as fast as the associated gas turbine so there is no requirement for wasting fuel to bring the system on line at stabilized operating temperatures. The use of the thin formed plates, fins and other components making up the brazed regenerator core sections contributes to this capability. However, it will be appreciated that there is substantial thermal growth in all three dimensions as a result of the extreme temperature range of operation and the substantial size of the heat exchanger units. As an example, the overall dimensions for the module 20 shown in FIGS. 1 and 2, in one instance, were 17 feet in width, 12 feet in length (the direction of gas flow) and 7.5 feet in height.
The core 12 is suspended from beams 16 by a suspension system which permits this thermal growth. Also, coupling is provided between the manifold duct portions 24a, 24b and the inlet and outlet flanges 22a, 22b by apparatus which isolates the external pipe loads at the flanges 22a, 22b from the heat exchanger core 12 while accommodating the thermal growth as described.
As indicated, particularly in FIG. 2, somewhat similar flange and duct arrangements are provided at the end of the module 20 opposite the air flanges 22a, 22b and ducts 24a, 24b. These comprise blind ducts such as 26 (FIG. 1) and manway flanges 28a, 28b with manhole covers 30a, 30b, and are provided for balancing the internal pressure forces on the manifold portions of the core 12 by means of tie rods 36 and to permit access to the manifold sections of the core 12 for inspection and maintenance.
The frame is maintained in thermal isolation from the heat exchanger core 12 and associated components which are operated at elevated temperatures to levels in excess of 1000° F. in a manner which insures that the temperature of the frame will not exceed 140° on a 100° day, thus permitting the frame to be constructed of low-cost structural steel while limiting the requirement for special high temperature materials essentially to the heat exchanger core 12.
It will be appreciated that the highest temperature in the module 20 is at the gas inlet side of the chamber surrounding the core 12. This chamber is thoroughly insulated by blankets and blocks of insulation, such as the insulation blanket 34 (FIG. 2). While this chamber contains exhaust gas at a pressure at or slightly above ambient, it will be appreciated that all parts of the frame 32 must be protected against possible leaks past the thermal blanket insulation 34 which might permit hot exhaust gas to escape and reach any portion of the frame 32.
The flanges 22a, 22b are fixed in position relative to the frame 32 and thermal growth is permitted to extend in the direction from left to right in the module as shown in FIG. 1. The pressure forces developed by the compressed air within the manifold portions of the core 12 are contained by tie rods 36 which extend through the gas chamber and fasten at opposite ends to the flanges 22a, 22b, 28a, and 28b as shown. However, since these tie rods 36 are of substantial length, approximately 18 feet, with the major portion of their length extending within the hot exhaust gas chamber, the tie rods 36 also experience thermal growth and provision must be made to accommodate this growth at the blind duct/manway flange end of the module 20 while providing the necessary support from the frame 32 of the weight of the structure at that end.
As noted above, the air leaving the regenerator module 20 through outlet flange 22b is at approximately 900° F. Thus the flange 22b is also close to this temperature. The flange is mounted to the adjacent structure of the frame 32 by means of thermal isolators 40, such as are shown in FIG. 3. Four such thermal isolators 40 are provided for each of the flanges 22a and 22b, spaced approximately 90° apart about the flanges 22a, 22b.
As particularly shown in FIGS. 3 and 4, the thermal isolator 40 comprises a thin-walled cylinder 42 fastened to end portions 44, 45, as by brazing or welding. The end portion 44 is threaded to receive a mounting bolt 46 extending through a frame member 48 and a plate 49 welded to the frame member 48. This is the cold end of the thermal isolator 40 and is rigidly affixed to the frame.
At the opposite end of the thermal isolator 40, the closed end portion 45 is threaded to receive a shoulder bolt 50 having a shoulder portion 52 which bears against the end portion 45 as the bolt 50 is threaded into the end portion 45 and prevents further tightening of the bolt 50 in the threaded opening, thus maintaining a selected minimum spacing between the head of the bolt 50 and the end portion 45.
The flange 22i provided with a slotted projection of ear 54 (FIG. 4) to receive the bolt 50. The minimum spacing between the head of the bolt 50 and the thermal isolator end portion 45 is sufficiently greater than the thickness of the ear 54 at this point to accommodate a washer 56 and maintain a gap of not less than 0.005 inches. Moreover, the positioning of the thermal isolator 40 on the frame member 48 relative to the flange 22 is such that a radial gap 58 of not less than 0.20 inches is maintained. This arrangement provides the desired support of the flange 22 with thermal isolation relative to the frame member 48 while accommodating radially directed thermal growth of the flange 22. That is, the flange 22 may expand radially outward to reduce the gap 58 as the flange 22 rises in temperature while the ear portion 54 slides relative to the bolt 50 and washer 56. Similar movement in the reverse direction is permitted as the flange 22 cools down after shutdown of the associated turbine.
Referring to FIG. 5, this is a sectional view taken in the vicinity of the circle inset in FIG. 2. It shows a support arrangement 60 for supporting the manway flange 28b whle accommodating thermal growth from the longitudinal expansion of the tie rods 36. This support arrangement 60 is represented in FIG. 5 as comprising a support pin 62 mounted on a frame member 64. A slotted extension 66 of the manway flange 28b encompasses the support pin 62 and moves outwardly (to the left) along the support pin 62 as the tie rods 36 extend in length due to thermal growth. Four such support arrangements 60 are provided for each of the flanges 28a, 28b, spaced at approximately 90° intervals about the periphery of the flange. Radial thermal growth is accommodated in a fashion similar to the forward end although temperature differences are somewhat less.
Also shown in FIG. 5 is a portion of the blind duct 26 suspended within a circumferential duct housing 70. The exterior surface 72 of the circumferential housing 70 is exposed, about its right-hand end as shown in FIG. 5, to the interior gas chamber of the module. A frame member 74 is shown adjacent this exterior surface 72 and insulation, such as the insulation 34 (FIG. 2), is placed in this region, but it has been omitted in FIG. 5 for simplicity. The space between the frame member 74 and the duct housing surface 72 is sealed by the circumferential member 76 which is shown comprising a bellows portion 78 and a collar portion 80. The collar portion 80 is a thin sheet fastened to the exterior surface 72 at one end and attached to the metal corrugated or bellows portion 78 at its other end. The bellows portion is joined to the frame member 74 at an end remote from its juncture with the collar portion 80. With the configuration as shown, the sealing member 76 provides thermal isolation between the duct housing surface 72 and the frame member 74 by virtue of being of thin metal cross-section and extended path length for heat which may be carried by this member. At the same time, the bellows portion 78 permits the member to accommodate the movement of the duct housing due to thermal growth of the tie rods 36. It also serves to accommodate radial thermal growth of the duct housing 70 and its external surface 72 as well as a certain amount of transverse displacement of the duct 26 and duct housing 70 relative to the axis thereof, all without any disruption of the sealing function performed by this thermally isolating, sealing member 76.
A similar arrangement, shown in FIG. 6, is provided for the air ducts 24a, 24b at the other end of the heat exchanger core 12. FIG. 6 is a sectional view comparable to the view of FIG. 5, but depicting an air duct 24 with its suspension housing 81 and external housing surface 82. The space between adjacent frame member 84 and the external surface 82 is sealed with a thermally isolating sealing member 86 which is shown comprising a corrugated or bellows portion 88 and a wishbone-shaped portion 90 formed of a pair of conical sheets 92 and 94. The member 86 is a circumferential structure which encircles the duct 24 and the duct housing 81 with the plate 94 being attached at one edge to the exterior housing surface 82. Member 86 accommodates axial movement of the duct housing 82 relative to the frame member 84 as well as axial displacement and radial growth of the duct 24 and duct housing 81, while at the same time maintaining the desired thermal isolation between the hot structure of the surface 82 and the frame member 84 by virtue of the extended path length of the member 86.
As thus described, the arrangements in accordance with the present invention advantageously provide support with thermal isolation of various portions of a heat exchanger which is subject to extreme operating temperatures and repeated cycling between full operation and shutdown. The thermal isolation afforded by these arrangements in accordance with the present invention is such that the associated frame structure is maintained below a maximum temperature of approximately 140° F., well within acceptable temperatures for any metal suitable as frame structure. Particular thermal isolators in accordance with the present invention serve to transmit support loads from a hot component to the cold support structure. The isolator reduces the temperature rise, and the attendent decrease in strength, of the cold structure using a thin-walled cylinder of low thermal conductivity to restrict heat flow. These arrangements in accordance with the invention are adapted to accommodate thermal growth and anticipated displacement of the hot structures being supported, relative to the associated support frame members.
Although there have been shown and described herein specific arrangements of a heat exchanger support system providing for thermal isolation and growth in accordance with the invention for the purpose of illustrating the manner in which the invention may be used to advantage, it will be appreciated that the invention is not limited thereto. Accordingly, any and all modifications, variations or equivalent arrangements which may occur to those skilled in the art should be considered to be within the scope of the invention as defined in the appended claims. | Apparatus for supporting and constraining opposed end members of a heat exchanger frame structure while maintaining the high temperature portions of the heat exchanger thermally isolated from the frame and accommodating relative movement of the heat exchanger due to thermal growth. Thermal isolation with structural support is achieved by the use of strategically positioned, thin-walled metal members aligned in the direction of heat travel between high temperature portions of the heat exchanger and adjacent frame elements. Opposed portions of the heat exchanger are tied together by rods extending between them and secured thereto. Longitudinal growth of the heat exchanger core and associated ducting is accommodated by the provision of flange guides slidable on guide pins attached to the frame. | 5 |
FIELD OF THE INVENTION
The present invention relates in general to a category of golf equipment and in particular to two types of golf swing training devices.
BACKGROUND OF THE INVENTION
A dictum of golf technique is that the club face should remain parallel to and on the swing plane except near the impact point if the desired delayed hit is to be achieved. This preceding dictum means that the golfer must rapidly rotate the club shaft 90 degrees about its longitudinal axis in approximately 58 milliseconds just prior to impact given a club head velocity of 75 MPH. The delayed hit which is essential to a good golf swing requires the golfer to : (a) maintain a cocked wrist position until approximately the last 90 degrees of swing arc just prior to impact, (b) while in this cocked wrist position, the club face must be parallel to and on the swing plane, (c) and then in approximately 58 milliseconds, just prior to impact, rotate the club shaft so that the club face is perpendicular to the swing plane. The center of gravity of the club head which is approximately at the mid-point of the club head between the heel and toe extremities must be moved off of the swing plane by rotating the club shaft 90 degrees about its longitudinal axis in 58 milliseconds. The rotation of the club shaft is accomplished by the use of the golfer's pronator and supinator wrist muscles. The club head center of gravity, is experiencing high centrifugal forces during this critical 90 degrees (last arc segment before impact) of the swing arc.
Centrifugal force can be defined as, a n =v 2 /r. If we let r=4.04 feet and v=110 feet/second (75 MPH), we are looking at a centrifugal force of approximately 93 Gs. Due to the movement of the pivot point during the golf swing, it is expected that the G force would be considerably less than 93, but even with a G force of 50, the golfer is compelled to rotate the club shaft 90 degrees about its longitudinal axis in 58 milliseconds against this high G force which is resisting any reaction to move the club head center of gravity off of the swing plane. It is the wrist muscles, mainly the left wrist supinator muscle and the right wrist pronator muscle, that provides the reaction to rotate the club shaft about its longitudinal axis. An authority states that: "Every good golfer has his left wrist in this supinating position at impact." [Ben Hogan in Five Lessons The Modern Fundamentals Of Golf, pp 101, 102; A Fireside Book, Simon & Schuster, Inc. New York Copyright 1957 by Ben Hogan]. It is important to note that the authority Ben Hogan pages 101 and 103 strongly advises against pronation of a golfer's left wrist just before impact.
It is the intent of this invention's golf swing trainer to enhance the development of the golfer's left wrist supinator muscle and right wrist pronator muscle and the other muscles required to perform a good golf swing. The pronator muscle is defined as the right wrist muscle required to rotate the club shaft counterclockwise (for a right handed golfer) about its longitudinal axis, just prior to impact. The supinator muscle is defined as the left wrist muscle required to rotate the club shaft counterclockwise about its longitudinal axis, just prior to impact. Hereinafter, the pronator and supinator muscles maybe referred to as the delayed hit muscles. The delayed hit has already been defined as a special case condition existing through the last 90 degrees of the swing arc just prior to impact. Hence, there is a need for the golfer to develop his delayed hit muscles if he is to consistently achieve the delayed hit which is so essential to a good golf swing.
OBJECT OF THE INVENTION
To provide a golf swing training device that enhanced and accelerates the development of the golfer's delayed hit and other muscles required in the performance of a delayed hit golf swing.
To provide a golf swing training device that can be used by the golfer in between shots during the course of playing a round of golf wherein his practice swings will serve as a reminder of the importance of the delayed hit. Toward this end, the present invention's training device incorporates a standard grip and a straight shaft so that said training device conveniently fits into an ordinary golf bag tube.
To provide a golf swing training device wherein its swing weight does not depart too greatly from the golfer's accustomed swing weight. A correlation of swing weights between this training device and the golf club normally used by the golfer ensures that the golfer is not faced with two entirely different swing weight situations during his practice swing and actual golf swing. Using a trainer, in between golf shots, that has a large departure from the golfer's accustomed swing weight may well be detrimental to the golfer.
To provide a golf swing training device affording a very high axial moment of inertia. The golf swing training device of the present invention is configured to provide the maximum available axial moment of inertia consistent with its swing weight and form factor constraints. The training device head form factor is constrained to be approximately 4.0 inches along its longitudinal axis and 2 inches in height. The training device head bear some resemblance to an iron golf club head.
To provide a very high axial moment of inertia training device by ensuring that the toe weighted mass section is devoid of any holes to maximizes the air resistance presented by said mass sections during practice swings taken by the golfer. When using the training device of the present invention, the golfer will be forced to use his pronator and supinator muscles to overcome the additional torque generated by the air resistance.
To provide a training device that affords the maximum practical available axial moment of inertia about its longitudinal axis consistent with its weight and form factor by ensuring that the hosel and the interconnect between the hosel and toe mass section are configured to provide a low weight structure.
To provide a training device that is suitable for either a right or left handed golfer.
To provide a training device that is simple and economical to produce.
Some of the general objectives of the present invention is summarized as: to provide a golf swing training device that is uniquely structured and weighted so that it affords, a high axial moment of inertia training device, a swing weight that is consistent with the swing weight of an ordinary golf club, a high air resistance toe mass section to further enhance the delayed hit muscle development of the golfer, adjustability of the swing weight to accommodate the special needs of a golfer, utility so that either a right or left handed golfer is allowed to use said training device, a form factor bearing some resemblance to an iron golf club, and a configuration which allows said training device to conveniently fit into an ordinary golf bag tube so that it may be conveniently carried by a golfer while playing a round of golf.
To provide a golf swing training device comprised of a weighted implement configured to be attached to the toe extremity of a conventional golf club. Said weighted implement in combination with a conventional golf club becomes a trainer that enhances and accelerates the development of the golfer's delayed hit and other muscles required in the performance of the delayed hit golf swing.
To provide a configuration of said weighted implemented so that at least 75 percent of its weight is concentrated at the toe extremity of the conventional golf club. The concentration of weight location affords, in combination with the conventional golf club, a high axial moment of inertia golf swing trainer.
To provide said weighted implement with attachment means to readily attach or detach said weighted implement to or from a conventional golf club so that said weighted implement may be conveniently used by the golfer during a round of golf.
Prior art does not provide a golf swing training device that provides: a high axial moment of inertia (consistent with its weight), a structure that increases the axial moment of inertia due to air resistance created during a swing, a swing weight that is consistent with swing weights used by most golfers, a weight that is consistent with the weight of a golf club that is used by most golfers, adjustability of the training device swing weight to accommodate the special needs of a particular golfer, broad utility (may be used as a two-handed training device by either left or right handed golfers, and will fit into a standard golf bag tube), and economical construction.
In an embodiment of the present invention, the golf swing training device is comprised of a grip, a shaft, and a trainer head somewhat resembling a golf club head except that the trainer head lacks a ball striking face since the trainer head is not designed to strike a golf ball. This training device contains a concentration of weight at the opposite end of the hosel. The opposite end of hosel will be referred to as the toe end or toe extremity, wherein the hosel is the part that interfits with a shaft. The concentration of weight at the toe end of the training device head affords a high axial moment of inertia device. High axial moment of inertia is defined for the present invention as high rotational moment of inertia about the shaft longitudinal axis and is related to high torque about the shaft longitudinal axis. Because of its high axial moment of inertia, said training device will particularly enhance the development of the golfer's delayed hit muscles.
In a preferred embodiment of the present invention, the training device will provide a fixed swing weight of approximately F-0 on a prorhythmic swing weight scale. A typical swing weight of an ordinary golf club is approximately D-0 on this prorhythmic swing weight scale. This preferred embodiment of the training device has a swing weight of approximately 20 points above said ordinary golf club. This increase in swing weight, D-0 to F-0, will not appreciably affect the swing velocity of the golf swing. One intention of this invention is to provide a golf swing training device that enhances the development of the delayed hit muscles of the golfer but not at a sacrifice to the development of the golfer's other, including speed, muscles.
In another preferred embodiment of the present invention, the concentration of the weight at the toe end shall be adjustable to accommodate the particular needs of a golfer. The adjustability of the weight will accommodate the golfer's degree of muscle development and/or other special needs. If said training device is adjusted to equal the swing weight that the golfer normally uses, his golf swing velocity will not be affected, by a noticeable extra demand will be placed on the golfer's delayed hit muscles in the critical (delayed hit) zone because of the high axial moment of inertia uniquely afforded by the present invention's training device. Of course, additional weighting over and beyond the golfer's normal swing weight may be used to further enhance the development of the golfer's delayed hit and other muscles required for a delayed hit golf swing. The delayed hit is essential to any good golf swing.
The fundamental and unique concept of the present invention is to provide a golf swing training device that enhances the development of the so essential delayed hit muscles without sacrificing the development of the golfer's speed or other muscles required in the performance of a good solid golf swing. It is well known that club head velocity (speed) is required to obtain distance. Said concept of the present invention is realized by providing a high axial moment of inertia training device, but wherein the swing weight and weight of said training device is consistent with the golfer's accustomed swing weight and golf club weight.
SUMMARY OF THE INVENTION
To provide a golf swing training device that is uniquely structured and weighted so that is affords, a high axial moment of inertia training device, a swing weight that is consistent with a swing weight of an ordinary golf club, a high air resistance toe mass section to further enhance the delayed hit muscle development of the golfer, adjustability of the swing weight to accommodate the special needs of a golfer, utility so that either a right or left handed golfer is allowed to use said training device, a form factor bearing some resemblance to an iron golf club, and a configuration which allows said training device to conveniently fit into an ordinary golf bag tube so that it may be conveniently carried by a golfer during a round of golf.
This training device is approximately 38 inches long which is substantially the length of a number four iron golf club. This training device may be carried by the golfer during a round of golf to stimulate his delayed hit muscles in between golf shots. This method of use will serve as a mental reminder, to the golfer, as to the importance of the delayed hit. The delayed hit muscles are defined as the muscles required to very rapidly rotate the golf club shaft about its longitudinal axis just prior to impact. Said delayed hit muscles involve the right wrist pronator and left wrist supinator muscles. To achieve the so essential delayed hit, the golfer must rotate the golf shaft 90 degrees about its longitudinal axis in approximately 58 milliseconds given a club head velocity of 75 MPH. If a golfer is to achieve even a modicum of success, it is imperative that the golfer develops his delayed hit muscles.
The GOLF magazine, June 1991, "The Iron Men", pages 97 through 103 illustrates golf swings by three well known golf professionals. And in particular, bottom of pages 99, 101 and 103 illustrates the positions of their wrists (hands) through the critical swing arc segment (delayed hit zone) just before impact. It is clear from these illustrations that all three golf professionals have rotated their wrists (hands) approximately 90 degrees about the club shaft longitudinal axis in the critical delayed hit zone to obtain their desired results. It is clear from these illustrations that it is imperative for the golfer to develop his delayed hit muscles.
One golf swing training device of the present invention is a uniquely structured weighted (adjustable or fixed) device comprised of a grip, a shaft, and a training device head bearing some resemblance to an iron golf club except that it lacks a ball striking surface. This training device is not designed to strike a golf ball. To enhance the development of the delayed hit muscles, the present invention's training device simulates a golf club which exhibits high axial moment of inertia about its longitudinal axis. This feature is obtained by extensive toe weighting of the training device head. In one preferred embodiment, said extensive toe weighting is adjustable and may be tailored to the meet the needs of the golfer.
Another type of golf swing training device is a weighted implement which is readily attachable to the toe extremity of a conventional golf club. Said weighted implement may be left attached to the toe extremity of a conventional golf club during muscle development training sessions. For practice swings during a round of golf, the golfer attaches this weighted implement to the toe of the club which he intends to use on his next shot, takes a couple of practice swings, detaches this weighted implement and proceeds with his play. Attaching this weighted implement to the toe extremity dramatically increases the axial moment of inertia of the golf club, but at only a small increase in golf club swing weight, since substantially all of the weight of this weighted implement is attached to the toe extremity. Said weighted implement is configured to be usable on most golf club ranging from the driver to the number nine iron.
Using the high axial moment of inertia training devices of the present invention, the golfer will rapidly develop his delayed hit and other golf swing muscles. Additionally, use of these training devices between golf shots on the course will stimulate the delayed hit muscles and reminds the golfer of the importance of the delayed hit golf swing.
The unique features of the golf equipment that are considered characteristic of the present invention are set forth in the appended claims. The invention will readily be understood from the following description when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are frontal views of two prior art golf training clubs.
FIG. 3 is a frontal view of the fixed swing weight head of the present invention's golf swing training device.
FIG. 4 is a top view of the fixed swing weight head of the present invention's golf swing training device.
FIG. 5 is a frontal view of the adjustable swing weight head of the present invention's golf swing training device.
FIG. 6 is a top view of the adjustable swing weight head of the present invention's golf swing training device.
FIG. 7 is a frontal view of the weighted implement of the present invention's golf swing training device. Said weighted implement is uniquely positioned over the toe extremity of a conventional wood type golf club.
FIG. 8 is a view of the weighted implement as seen from the toe end of the conventional wood type golf club.
FIG. 9 is a view of the weighted implement as seen from above the conventional wood type golf club.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is frontal view of a prior art (U.S. Pat. No. 4,511,147) golf swing training club. This prior art golf swing training club features a head made from bent bar stock and formed to provide an open head to minimize the air resistance. The present invention's training device describes and claims features diametrically opposed to this prior art. The present invention's training device specifics a mass section surface area of at least 2 square inches to provide air resistance so that the golfer will be compelled to use his pronator and supinator muscles (delayed hit muscles) to overcome the additional torque generated by the air resistance created by its mass section's surface area. This additional torque experienced by the golfer will enhance and accelerate the development of his delayed hit muscles.
FIG. 2 is frontal view of a prior art (U.S. Pat. No. 4,529,204) training club for golfers. This prior art training club for golfers features a short pitching wedge shaft and a hand grip adapted to be grasped by one hand. The present invention's training device is preferably 38 inches long and features a standard two-handed grip. A standard pitching wedge is only 35.5 inches long. The purpose of the present invention's training device, is in part, to enhance the development of the golfer's right wrist pronator and left wrist supinator muscles (delayed hit muscles). Simultaneous development of the right wrist pronator and left wrist supinator muscles is not possible with only one hand grasping the training device. This prior art training club for golfers illustrates an adjustment means of its swing weight, but does not specify the location of this adjustment means relative to its shaft longitudinal axis. Therefore, it could be deduced that Yamakawa is not concerned with providing a trainer that exhibits high axial moment of inertia. The golf swing training device of the present invention is configured to provide the maximum available axial moment of inertia consistent with its swing weight and form factor constraints. The present invention specifies and claims that the weighted mass center of gravity is located at least 2.5 inches from its shaft longitudinal axis affording a high axial moment of inertia training device.
FIG. 3 is a frontal view of the fixed swing weight head of the present invention's golf swing training device. Said fixed swing weight head is comprised of a low weight hosel 10, a low weight interconnect 11, and a substantial mass section 12. The location of the mass section 12 center of gravity 14 relative to the hosel centerline is shown by dimension 15. In one preferred embodiment, the weight of the hosel 10 and interconnect 11 is two ounces and the weight of the mass section 12 is seven ounces. This head weight of nine ounces combined with a light-weight steel shaft, cut for a training device length of 38 inches, and a standard grip will afford a swing weight of approximately D-3 on a prorhythmic swing weight scale. This preferred embodiment meets the present invention's intent to provide a high axial moment of inertia training device consistent with ordinary swing weight and training device head form factor constraints. Said training device head form factor is constrained to be approximately 4.0 inches in length, measured along its longitudinal axis, with a height dimension of approximately 2.0 inches. A D-3 swing weight is consistent with a swing weight used by many golfers. Because the dimension 15 is specified to be at least 2.5 inches, this preferred embodiment of the present invention will afford a high axial moment of inertia device with a torque about its shaft axis of more than 17.5 in-oz.
The frontal surface area of the mass section 12 is specified to be at least 2.0 square inches. This surface area creates additional torque for the golfer to overcome during practice swings because of its air resistance. When using the training device of the present invention, the golfer will be forced to use his pronator and supinator muscles (delayed hit muscles) to overcome the additional torque generated by the air resistance of the mass section 12. This additional torque is over and beyond the torque generated by the unique structure of the present invention's high axial moment of inertia training device. The static torque of 17.5 in-oz becomes magnified in a dynamic situation involving high centrifugal forces. The golfer is compelled to rotate the club shaft against the effects of high centrifugal and air resistance forces and will quickly develop his delayed hit and other swing muscle by using the training device of the present invention.
FIG. 4 is a top view of the fixed swing weight head of the present invention's golf swing training device. This view also shows the interconnect 11 to be rather thin so that the weight of this interconnect is minimized. A highly rigid massive interconnect is not necessary since the training device is not intended to be used for striking a golf ball. Moreover, it is the intent of the present invention to provide a high moment of inertia training device by concentrating the available weight far away as practical from its hosel. It is not critical as to the type of materials used for the the present invention's training device but should preferably be of one piece economical construction.
FIG. 5 is a frontal view of the adjustable swing weight head of the present invention's golf swing training device. FIG. 6 is a top view of the adjustable swing weight head of the present invention's golf swing training device. Said adjustable swing weight head is comprised of a low weight hosel 20, a low weight interconnect 21, and a substantial mass section 22. This mass section 22 has an axial borethrough hole 23 to accommodate a bolt shaft 24. A bolt comprised of a head 27, a shaft 24, and nut 26 is used to mount additional weights, 28 and 29, to the mass section 22 to suit the needs of then golfer. These additional weights are made of tungsten steel, stainless steel, or any other suitable weighting materials. For the sake of brevity, locking or captive hardware is not discussed or shown. The location of the mass section 22 center of gravity 19 relative to the hosel centerline is shown by dimension 25. In one preferred embodiment, the combined weight of the hosel 20 and interconnect 21 is approximately two ounces and the weight of the mass section 22, not including any additional weights, is approximately 6.0 ounces. This mass section of 6 ounces should accommodate even the weakest of golfers.
This preferred embodiment meets the present invention's intent to provide a high axial moment of inertia training device consistent with swing weights commonly used and form factor constraints. Since the dimension 25 is specified to be at least 2.5 inches, this preferred embodiment of the present invention, without any additional weights, will afford a high axial moment of inertia device affording a torque of more than 15.0 in-oz about its hosel centerline. If additional weights were used to bring the combined mass section weight up to 8 ounces, then the torque about its hosel centerline would be 20.0 in-oz. The frontal surface area of the mass section 22 is specified to be at least 2.0 square inches. This surface area creates additional torque for the golfer to overcome during practice swings because of the air resistance generated by said surface area. When using the training device of the present invention, the golfer will be forced to use his pronator and supinator muscles (delayed hit muscles) to overcome the additional torque generated by the air resistance of the mass section 12. This additional torque is over and beyond the torque generated by the unique structure of the present invention's high axial moment of inertia training device. The static torque of 20.0 in-oz becomes magnified in a dynamic situation involving high centrifugal forces. The golfer is compelled to rotate the club shaft against the effects of high centrifugal and air resistance forces and will; therefore, quickly develop his delayed hit and other swing muscle by using the training device of the present invention.
FIG. 7 is a frontal view of the weighted implement of the present invention's golf swing training device. Said weighted implement is uniquely positioned over the toe extremity of a conventional wood type golf club 33. The toe extremity being the part a golf club head that is the farthest from the golfer as he takes his stance. In regards to weighted trainer attachments, prior art puts the attachment around the shaft of the golf club to increase the golf club swing weight. In this embodiment of the present invention, this weighted implement is comprised of two cords affording means to readily attach this weighted implement to a conventional golf club head. This weighted implement is designed to be readily carried by the golfer during the course of playing a round of golf. The golfer simply attaches this weighted implement to one of his golf clubs, preferably the club he intends to use on his next shot, and then takes a few practice swings to stimulate his delayed hit muscles. Additionally and importantly, practice swings with this weighted element will serve as a mental reminder to the golfer, of the importance of the delayed hit. Since this weighted implement is attached to the toe extremity, the golf club becomes a high axial moment of inertia training device.
In this preferred embodiment, said weighted implement will increase the swing weight of a driver club by approximately twenty points on the prorhythmic swing weight scale. In other words, a driver club with a swing weight of D-0 will become a F-0 swing weight club after the weighted implement is attached to its club head. Said weighted implement may be left attached to a golf club during training periods to enhance the development of the golfer's delayed hit muscles and other muscles required to perform a delayed hit golf swing. This increase of twenty points on the prorhythmic swing weight scale will not appreciably affect the swing velocity of the golfer's swing. The prior art weighting device (U.S. Pat. No. 3,716,239) modifies a golf club swing weight to a point where the swing weight can not be measured on a standard prorhythmic swing weight scale.
In regards to this embodiment of the present invention's weighted implement, the fundamental and unique concept is to provide a training device that affords high axial moment of inertia but without unduly increasing the swing weight of the golf club. This embodiment does not simply add weight around the shaft of the golf club to increase the golf club's swing weight but uniquely locates the weighted implement at the toe extremity of the club head to increase the axial moment of inertia of the golf club. The intent is to provide a training device wherein its swing weight does not depart too greatly from the golfer's accustomed swing weight yet places extra demands on the golfer's delayed hit muscles. A similarity of swing weights between this training device and the golf club normally used by the golfer ensures that the golfer is not faced with two entirely different swing weight situations during his practice swing and actual golf swing. Using a trainer, in between golf shots, that has a large difference in swing weights, between the trainer and the golf club, may well prove to be detrimental.
Referring to FIG. 7, the weighted implement body is secured to the club head, in this preferred embodiment, by using the attachment cords 31 and 32. These cords 31 and 32 are terminated with spring biased hooks 35 and 36. These cords 31 and 32 are sufficiently long to be wrapped around the hosel 34 two times and then return to the weighted implement body 30. Hooks 35 and 36 are used to attach the free end of the cords to hook receptacle 37 through 44. Hook 35 will be attached to either hook receptacle 37, 38, 39, or 40. Hook 36 will be attached to hook receptacle 41, 42, 43, or 44. The center of gravity 45 of the weighted implement body 30 location relative to the hosel centerline is shown by dimension 46. The inside surface of the weighted implement body 30, the surface that makes contact with the golf club, is coated with a resilient material to form a large contact surface area. This large contact surface area minimizes the movement of the weighted implement relative to the golf club during practice swings.
FIG. 8 is a view of the weighted implement as seen from the toe end of the conventional wood type golf club.
FIG. 9 is a view of the weighted implement as seen from above the conventional wood type golf club.
As discussed above, the considerations that contribute towards the attainment of the present invention's objective of providing a high axial moment of inertia training device are the location of the mass section center of gravity relative to the hosel centerline and the weight of the mass section. In FIG. 3, it is the distance 15 and the weight of the mass section 12 that is mainly controlling the torque about the hosel 10 centerline. In FIG. 5 and 6, it is the distance 25 and the combined weight of the mass section 22, bolt assembly 24, 26 and 27; and weights 28 and 29 that is mainly controlling the torque about the hosel 20 centerline.
While a preferred embodiment of the present invention has been shown for a particular design in the drawing and discussed herein, many modifications thereof may be made by a person skilled in the art without departing from the spirit and scope of the present invention.
For the purpose of the present invention:
A conventional golf club is defined as a golf ball striking implement used by the great majority of golfers, wherein said golf ball striking implement is comprised of a grip, a shaft, and a club head, wherein said club head is comprised of a body, wherein said body is comprised of at least a hosel and a toe extremity, wherein the hosel is the part that interfits with the shaft and the toe extremity is the part that is the farthest from the hosel. A straight shaft is defined as a shaft that is substantially straight from one end to the other end. A standard grip is defined as a grip that is substantially circular in cross-section, except that a continuous, straight, slightly raised rib may be incorporated along the full length of the grip, may be tapered but must not have any bulge or waist, and the axis of the grip must coincide with the axis of the shaft. The shaft longitudinal axis is identical to the hosel centerline. | This invention relates in general to a category of golf equipment and in particular to two golf swing training devices. The two golf swing training devices are primarily used to accelerate the development of the golfer's, particularly the wrist, muscles required to properly perform the golf swing. The first swing training device is a uniquely weighted device bearing some resemblance to an iron golf club. The second golf training device is a weighted attachment which is readily and quickly attached to the club head toe of a golf club. Both of these swing training devices simulate a golf club exhibiting very high axial moment of inertia. Since these swing training devices afford very high axial moment of inertia, rapid development and stimulation of the right wrist pronator and left wrist supinator muscles will be realized by the golfer. The delayed hit which is essential to any good golf swing places stringent demands on the golfer's wrist muscles just prior to impact. The attachment of the second golf swing training device to the golf club head is facilitated through use of a single or a plurality of leads wherein said leads are an integral part of the second training device. | 0 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to a durable and imaged flame-retardant nonwoven fabric that can be used for flame-retardant apparel and other related applications. There are numerous flame-retardant fibers commercially available. E. I du Pont de Nemours and Company provides flame-retardant aramid fibers sold under the trade names of NOMEX® and KEVLAR®. NOMEX® materials were developed for applications requiring dimensional stability and excellent heat resistance, and which do not flow or melt upon heating. Decomposition and charring does not proceed at a significant rate until well over 350° C. without melting. NOMEX® materials in fibrous form have been used in protective apparel and similar applications, and can be processed by conventional textile technology. Heretofore, comparable flame-retardant nonwoven fabrics have been expensive to manufacture, and have not been susceptible of imaging by high pressure water jet entangling. Specific examples of prior art materials are set forth below.
[0002] U.S. Pat. No. 4,199,642 discloses a flame resistant fiberfill batt consisting of polyester fiberfill and synthetic organic filamentary materials, including poly(m-phenylene isophthalamide) blended therewith that maintains its physical integrity when exposed to the flame from a burning match.
[0003] U.S. Pat. No. 4,463,465 discloses an aircraft seat cushion including a highly heat-sensitive urethane foam covered by a flexible matrix, which may comprise a NOMEX® fabric. A further gas barrier layer may also be provided, which can also be a NOMEX® fabric.
[0004] A wet-type survival suit is disclosed in U.S. Pat. No. 4,547,904, including inner and outer NOMEX® layers, which provide maximum protection against fire.
[0005] A fire-retardant panel is disclosed in U.S. Pat. No. 4,726,987 and No. 4,780,359 which includes one or more layers of NOMEX® fiber that may be combined with adjacent fibrous layers by needle punching.
[0006] U.S. Pat. No. 4,748,065 discloses a flame resistant fabric, wherein a spunlaced fabric formed of fibers, such as NOMEX®, is brush-coated with an aqueous slurry containing activated carbon particles. The resulting fabric was subsequently dried and softened by crepeing. Laminates, including spunlaced outer layers of NOMEX® fibers, are also disclosed.
[0007] A fire-blocking textile fabric is disclosed in U.S. Pat. No. 4,750,443, which includes three to seven nonwoven layers that are hydraulically needled to one another. Each layer may be formed of NOMEX® fibers; however, an outer woven layer may be provided to impart dimensional stability and abrasion resistance.
[0008] U.S. Pat. No. 4,937,136 discloses a laminate for use in fire protective garments. The laminate includes a nonwoven fabric comprised of a blend of wool and synthetic fibers capable of high temperature performance, such as NOMEX®. The laminate includes an outer shell, which may also be formed of NOMEX® and an intermediate moisture barrier layer.
[0009] An animal bed cover is disclosed in U.S. Pat. No. 5,226,384, which is formed of an aramid fabric sheet, e.g. KEVLAR® with a polyester fabric sheet laminated to it.
[0010] In U.S. Pat. No. 5,252,386, a fire retardant entangled polyester nonwoven fabric is disclosed. The patent states that the fabric has balanced tensile strength properties in the cross- and machine-directions and improved fire retardant properties by cross-stretching the entangled fabric, after the fabric has been wetted with an aqueous-based fire retardant composition, and drying the wetted fabric while maintaining it in its stretched state.
[0011] U.S. Pat. No. 5,279,879 discloses a flame-retarding nonwoven fabric formed of partially graphitized polyacrylonitrile fibers that are bonded by water jet needling. The fabric may be reinforced by warp-wise and weft-wise threads, and the fabric may be combined with a decorative fabric/material by adhesive securement.
[0012] U.S. Pat. No. 5,475,903 discloses a fabric that is formed by carding synthetic fibers, such as polyester fibers, cross-lapping the carded web to orient the fibers in the cross-direction, drafting the cross-lapped web to reorient certain of the fibers in the machine-direction, applying unbonded wood fibers to the top of the drafted web, and hydroentangling the resulting web to entangle the wood fibers with those of the polyester drafted web. A liquid fire-retardant composition is then applied to the hydroentangled web.
[0013] In U.S. Pat. No. 5,578,368, a fire-resistant material is disclosed, which includes a fiberfill batt, that may comprise polyester fibers, and a fire-resistant aramid fibrous layer like NOMEX®, at one, or both, faces of the batt. The aramid fiber layer may be joined to the fiberfill batt by hydroentangling.
[0014] U.S. Pat. No. 5,609,950 and No. 5,766,746 disclose a flame-retardant nonwoven fabric wherein fleece, including cellulose fibers having a flame-retardant containing phosphorus, is bonded by water jet entanglement.
[0015] In order to provide adequate protection to the skin from burn damage by heat and/or flame, currently available fabrics for flame retardant clothing rely upon high basis weights and bulks. A practical consequence of extended wear of articles made of these heavy fabrics is fatigue and potential dehydration due to poor air circulation. Blends of melamine fibers (BASF Corporation under the trade name of BASOFIL) with varying ratios of aramid fibers, as is disclosed in U.S. Pat. No. 5,560,990, hereby incorporated by reference, are known. It has been discovered that when a melamine/aramid fiber blend is hydroentangled and a 3-dimensional image imparted, thermal protection to the skin at lower basis weights are maximized, thereby providing significantly improved wearer comfort and safety.
SUMMARY OF THE INVENTION
[0016] The fabric of the present invention is a hydroentangled, imaged nonwoven fabric formed from a blend of melamine and aramid fibers. While the heat and flame-resistant properties of aramid fibers are well understood and appreciated, fabrics produced using these aramid fibers are known to be heavy in weight and low in air permeability. When converted into flame retardant apparel, fatigue due to heat and dehydration in instances of extended wear, are commonplace.
[0017] It has been discovered that the use of melamine fibers, when blended with aramid fibers in relative ratios of between 45 weight percent and 55 weight percent, and preferably about 50 weight percent, of the melamine fiber, provides improvement in Thermal Protective Properties (TPP). In a preferred embodiment, a carded staple fiber blend is hydroentangled by the use of high-pressure water jets followed by imaging on a three-dimensional surface to provide a fabric with a basis weight range of between 65 grams per square meter and 150 grams per square meter, a resultant air permeability greater than 65 CFM per gram fabric weight per cubic centimeter and a TPP rating greater than 11.4 cal-sec per square centimeter.
BRIEF DESCRIPTION OF THE DRAWING
[0018] [0018]FIG. 1 is a schematic representation of a production line upon which the process of the present invention is practiced and the fabric of the present invention is produced; and
[0019] [0019]FIGS. 2 a through 4 b are schematic representations of preferred three-dimensional imaging surfaces;
DESCRIPTION OF PREFERRED EMBODIMENTS
[0020] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated.
[0021] With reference to FIG. 1, therein is illustrated an apparatus for practicing the present method for forming a nonwoven fabric. The fabric is formed from a fibrous matrix which comprises a blend of melamine and aramid staple length. The fibrous matrix is preferably carded and subsequently airrandomized to form a precursor web, designated P.
[0022] [0022]FIG. 1 illustrates a hydroentangling apparatus for forming nonwoven fabrics in accordance with the present invention. The apparatus includes a foraminous forming surface in the form of belt 12 upon which the precursor web P is positioned for pre-entangling. Precursor web P is then sequentially passed under entangling manifolds 14 , whereby the precursor web P is subjected to high pressure water jets 16 . This process is one well-known to those skilled in the art and is generally as taught by Evans in U.S. Pat. No. 3,485,706, incorporated herein by reference.
[0023] The entangling apparatus of FIG. 1 further includes an imaging and patterning drum 18 comprising a three-dimensional image transfer device for effecting imaging and patterning of the now-entangled precursor web. After pre-entangling, the precursor web is then trained over a guide roller 20 and directed to an image transfer device 18 , where a three-dimensional image is imparted into the fabric. The web of blended fibers is juxtaposed to image transfer device 18 , and high pressure water from manifolds 22 is directed against the outwardly facing surface from jets spaced radially outwardly of image transfer device 19 . Image transfer device 18 and manifolds 22 may be formed, and operated, in accordance with the teachings of commonly assigned U.S. Pat. Nos. 5,098,764, 5,244,711, 5,822,823, and 5,827,597, the disclosures of which are expressly incorporated herein by this reference. It is presently preferred that the precursor web P be given a three-dimensional image suitable to provide the desired air permeability of the final imaged fabric. The entangled fabric can then be vacuum dewatered at 24 , and dried on drying cans 26 .
EXAMPLES 1-6
EXAMPLE 1
[0024] Using a forming apparatus as illustrated in FIG. 1, a nonwoven fabric was made in accordance with the present invention by providing a precursor web comprising a blend of 50 weight percent melamine fibers and 50 weight percent aramid fibers. The web had a basis weight of approximately 85 grams per square meter.
[0025] The fabric comprised BASF BASOFIL (assorted denier and staple length of between 0.5 and 4.0 inches) and Du Pont NOMEX® (1.5 denier and 2 inch staple length). Prior to patterning and imaging of the precursor web, the web was pre-entangled by a series of entangling manifolds such as diagrammatically illustrated in FIG. 1. FIG. 1 illustrates disposition of precursor web P on a foraminous forming surface in the form of belt 10 , with the web acted upon by sequential entangling manifolds 14 . In the present examples, each of the entangling manifolds included 127-micron orifices spaced at 40 per inch, with four of the manifolds successively operated at 100, 300, 600, and 800 pounds per square inch. The entangling apparatus of FIG. 1 further includes an imaging and patterning drum 18 comprising a three-dimensional image transfer device for effecting imaging and patterning of the now-entangled precursor web. The entangling apparatus includes three entangling manifolds 22 which act in cooperation with the three-dimensional image transfer device of drum 18 to effect patterning of the fabric. In the present example, the entangling manifolds 22 were each operated at 2500 pounds per square inch, 127-micron orifices spaced at 40 per inch, and at a line speed of 30 feet per minute.
[0026] The three-dimensional image transfer device of drum 18 was configured as a so-called “herringbone”, as illustrated in FIGS. 2 a and 2 b.
[0027] A resultant fabric had a basis weight of 91.1 grams per square meter, a bulk of 0.031 inches, and a machine-direction strip tensile strength of 62.3 grams per centimeter as measured on an INSTRON Testing Device. Air permeability was 281.1 CFM as measured by ASTM D737. The TPP (thermal protection property) for this material, as measured by the test protocol specified in the NFPA 1971, 1997 Ed. (section 6,10), was 11.8.
[0028] For this material, a value of air permeability to mass/volume of 79.6 CFM/gram/cc was obtained.
EXAMPLE 2
[0029] A fabric as made in the manner described in EXAMPLE 1, whereby in the alternative the three-dimensional image transfer device of drum 18 was configured as a so-called 33×28, a rectilinear pyramidal forming pattern having 33 lines per inch by 28 lines per inch configured in accordance with FIG. 13 of U.S. Pat. No. 5,098,764, except mid-pyramid drain holes are omitted. Pyramid height is approximately 1.5 mm, with the long axis of each pyramid being oriented in the machine direction.
[0030] A resultant fabric had a basis weight of 89.1 grams per square meter, a bulk of 0.030 inches, a machine-direction strip tensile strength of 57.9 grams per centimeter, an air permeability of 283.9 CFM and a TPP of 11.5.
[0031] For this material, a value of air permeability to mass/volume of 80.9 CFM/gram/cc was obtained.
EXAMPLE 3
[0032] A fabric as made in the manner described in EXAMPLE 1, whereby in the alternative the three-dimensional image transfer device of drum 18 was configured as a so-called 20×20, a rectilinear pyramidal forming pattern having 20 lines per inch by 20 lines per inch configured in accordance with FIG. 13 of U.S. Pat. No. 5,098,764, except mid-pyramid drain holes are omitted. Pyramid height is 0.025 inches, with the drain holes at the corners of each pyramid having a 0.02 inch diameter. Drainage area is 12.5% of the surface area.
[0033] A resultant fabric had a basis weight of 91.9 grams per square meter, a bulk of 0.030 inches, a machine-direction strip tensile strength of 62.0 grams per centimeter, an air permeability of 246.8 CFM and a TPP of 11.8.
[0034] For this material, a value of air permeability to mass/volume of 68.2 CFM/gram/cc was obtained.
EXAMPLE 4
[0035] A fabric as made in the manner described in EXAMPLE 1, whereby in the alternative the three-dimensional image transfer device of drum 18 was configured as a so-called “pique”, as illustrated in FIGS. 3 a and 3 b.
[0036] A resultant fabric had a basis weight of 87.2 grams per square meter, a bulk of 0.030 inches, a machine-direction strip tensile strength of 60.0 grams per centimeter, an air permeability of 241.5 CFM and a TPP of 11.9.
[0037] For this material, a value of air permeability to mass/volume of 70.3 CFM/gram/cc was obtained.
EXAMPLE 5
[0038] A fabric as made in the manner described in EXAMPLE 1, whereby in the alternative the three-dimensional image transfer device of drum 18 was configured as a so-called “diamond”, as illustrated in FIGS. 4 a and 4 b.
[0039] A resultant fabric had a basis weight of 88.5 grams per square meter, a bulk of 0.025 inches, a machine-direction strip tensile strength of 54.5 grams per centimeter, an air permeability of 241.5 CFM and a TPP of 11.5. For this material, a value of air permeability to mass/volume of 69.3 CFM/gram/cc was obtained.
COMPARATIVE EXAMPLE 6
[0040] A commercially available fabric was obtained in the form of Du Pont E89, type P-27.
[0041] Testing of this fabric under identical conditions as above gave results of a basis weight of 101.6 grams per square meter, a bulk of 0.028 inches, a machine-direction strip tensile strength of 61.2 grams per centimeter, an air permeability of 181.0 CFM and a TPP of 11.0.
[0042] For this material, a value of air permeability to mass/volume of 45.2 CFM/gram/cc was obtained.
[0043] Table 1 sets forth test data for the above-described fabrics.
TABLE 1 Modi- DuPont E fied Plain Rip- Dia- 89/P-27 Twill Weave stop Pique mond Mass per Unit 101.6 91.1 89.1 91.9 87.2 88.5 Area (gsm) Mass per Unit 4.0 3.6 3.5 3.6 3.4 3.5 Volume (cc) Bulk (mils) 28.3 31 30 30 30 25 Tensile Strength -- 61.2 62.3 57.9 62 60 54.5 MD Tensile Strength -- 62.3 26.1 26.8 28.2 26.8 28.9 CD TPP - Single Layer 11.0 11.8 11.5 11.8 11.9 11.5 (SD< Flame Resistance - 4.0 2.0 2.0 2.0 2.0 2.0 Vertical test Afterglow MD (sec) Flame resistance - 3.5 2.0 1.0 2.0 1.5 1.0 Vertical test Afterglow CD (sec) Normalized Air 45.2 79.6 80.9 68.2 70.3 69.3 Permeability (CFM/gram/cc) | The present invention is directed to a durable and imaged flame-retardant nonwoven fabric that can be used for flame-retardant apparel and other related applications. The fabric is formed by providing a precursor web consisting of a blend of melamine fibers and aramid fibers. The precursor web is hydroentangled on a three-dimensional image transfer device for formation of the fabric. The resultant fabric provides desirable air permeability and Thermal Protective Properties. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application is a U.S. National Phase application under 35 U.S.C. §371 of International Application No. PCT/KR2009/000520, filed on Feb. 3, 2009, entitled METAMATERIAL ANTENNA USING A MAGNETO-DIELECTRIC MATERIAL, which claims priority to Korean patent application number 10-2008-0015244, filed Feb. 20, 2008.
TECHNICAL FIELD
The present invention relates to a reduction in the size of an antenna using a magneto-dielectric material in a CRLH-TL antenna. More particularly, the present invention relates to a metamaterial antenna using a magneto-dielectric material, which is capable of reducing the size by magnetizing a dielectric material using an SRR in a CRLH-TL antenna implemented using a patch and vias.
BACKGROUND ART
Recently, active research is being done on the design of an antenna using a metamaterial. The metamaterial indicates material which has a specific unit structure periodically arranged and an electromagnetic property not existing in the natural world.
From among several kinds of metamaterials, a metamaterial having a randomly controllable dielectric constant magnetic permeability has been in the spotlight. Representatively, a material called ‘Negative Refractive Index (NRI)’ or ‘Left-Handed Material (LHM)’ has both the valid dielectric constant and the magnetic permeability of a negative value and complies with the left hand rule in the electric field, the magnetic field, and the electric wave traveling direction. If the metamaterial is applied to an antenna, the performance of the antenna is improved by the characteristics of the metamaterial.
A metamaterial structure applied to an antenna representatively includes a Composite Right/Left Handed Transmission Line (CRLH-TL) structure. A 0-th order resonant mode (i.e., one of the characteristics of the structure) is a resonant mode in which the propagation constant becomes 0. In the 0-th order resonant mode, the wavelength becomes infinite, and no phase delay according to the transmission of electric waves is generated. The resonant frequency of this mode is determined by the parameters of the CRLH-TL structure and thus very advantageous in a reduction in the size of an antenna because it does not depend on the length of the antenna.
Of course, an antenna can be made using a first order resonant mode. In this case, the antenna can be designed to have a very low resonant frequency, while having the same radiation pattern as a common patch antenna.
Recently, there is a growing interest in a magneto-dielectric material capable of increasing the magnetic permeability. As a conventional method of decreasing the size of an antenna, there is a method using a substrate of a high dielectric constant. However, the method is disadvantageous in that the efficiency of an antenna is reduced and the bandwidth is narrowed because energy is confined in the substrate of a high dielectric constant. Meanwhile, if a substrate having a high magnetic permeability is used, the above problems can be solved and also the antenna can be reduced in size.
In order to fabricate the magneto-dielectric material, a metal structure responding to an external magnetic field is inserted into a common substrate. A Split Ring Resonator (SRR) is chiefly used as the structure. Current is induced into the SRR by an external magnetic field, and a magnetic field is generated by the induced current. Accordingly, the magnetic permeability is changed in response to the external magnetic field. The magnetic permeability has a resonating characteristic. The magnetic permeability is 1 or higher in a band under a resonant frequency, a negative value between the resonant frequency and a plasma frequency, and a positive value 1 or fewer over the plasma frequency. The band used as the magneto-dielectric material is a region under the resonant frequency.
SUMMARY
The present invention has been made in view of the above problems occurring in the prior art, and an object of the present invention is to provide a reduction in the size of an antenna using a magneto-dielectric material in a CRLH-TL antenna, and more particularly, a metamaterial antenna using a magneto-dielectric material, which is capable of reducing the size by magnetizing a dielectric material using an SRR in a CRLH-TL antenna implemented using a patch and vias.
To achieve the above object, the present invention provides a metamaterial antenna using a magneto-dielectric material, comprising a substrate into which SRR (Split Ring Resonator) structures are inserted and in which the magneto-dielectric material is implemented; a patch of a CRLH-TL (Composite Right/Left Handed Transmission Line) structure, spaced apart from the substrate at a specific interval and formed on the upper side of the substrate; and a ground spaced apart from the substrate at a specific interval and formed on the lower side of the substrate.
Preferably, the magneto-dielectric material in which the substrate, the patch, and the ground are interconnected through vias is used.
Furthermore, the substrate comprises the SRR structures having two unit cells, and one unit cell of the SRR structures comprises eight SRRs radially disposed.
Furthermore, one unit cell of the SRR structures comprises six first SRR of a relatively long length radially, disposed in a longitudinal direction of the substrate 200 , and second SRRs of a short length, disposed in a horizontal direction of the substrate 200 . The first and second SRRs are formed to face each other on the upper and lower sides of the substrate.
Furthermore, both ends of the first and second SRRs formed to face each other on the upper and lower sides of the substrate are interconnected through vias penetrating the substrate.
Furthermore, a slot is formed at the central portion of the first and second SRRs formed on the lower side of the substrate.
Furthermore, the patch is an antenna of the CRLH-TL structure including two unit cells.
Furthermore, the patch is spaced apart from a microstrip line (i.e., a feed line) at a specific interval, coupled therewith, and supplied with power.
Furthermore, the present invention provides a wireless communication terminal including the metamaterial antenna.
As described above, the present invention relates to a reduction in the size of an antenna using a magneto-dielectric material in a CRLH-TL antenna. More particularly, the present invention can provide a metamaterial antenna using a magneto-dielectric material, which is capable of reducing the size by magnetizing a dielectric material using an SRR in a CRLH-TL antenna implemented using a patch and vias.
DESCRIPTION OF DRAWINGS
FIG. 1 is a diagram showing a metamaterial antenna using a magneto-dielectric material according to a preferred embodiment of the present invention;
FIG. 2 is a diagram showing a substrate made of a magneto-dielectric material according to a preferred embodiment of the present invention;
FIGS. 3( a ) and 3 ( b ) are diagrams showing SRR structures according to a preferred embodiment of the present invention;
FIG. 4 is a diagram showing the direction in which a magnetic field is generated in the antenna according to the preferred embodiment of the present invention;
FIG. 5 is a diagram showing a change in the magnetic permeability according to the frequency of a first SRR according to a preferred embodiment of the present invention;
FIG. 6 is a diagram showing a change in the magnetic permeability according to the frequency of a second SRR according to a preferred embodiment of the present invention;
FIG. 7 is a graph showing a return loss depending on whether the SRRs are used;
FIGS. 8( a ) and 8 ( b ) are diagrams showing the surface current of an SRR in a 0-th order resonant mode according to a preferred embodiment of the present invention;
FIG. 9 is a diagram showing the direction of a magnetic field generated in the antenna according to the preferred embodiment of the present invention;
FIG. 10 is a photograph showing an antenna actually fabricated using the SRR structures according to the preferred embodiment of the present invention;
FIG. 11 is a graph showing a measured return loss of the actually fabricated antenna and a simulated return loss; and
FIGS. 12( a ) and 12 ( b ) are diagrams showing a measured radiation pattern of the actually fabricated antenna.
DETAILED DESCRIPTION
In order to fully understand the present invention, operational advantages of the present invention, and the object achieved by implementations of the present invention, reference should be made to the accompanying drawings illustrating preferred embodiments of the present invention and to the contents described in the accompanying drawings.
Hereinafter, the preferred embodiments of the present invention are described in detail with reference to the accompanying drawings. The same reference numbers are used throughout the drawings to refer to the same parts.
FIG. 1 is a diagram showing a metamaterial antenna using a magneto-dielectric material according to a preferred embodiment of the present invention.
Referring to FIG. 1 , in the metamaterial antenna 100 of a CRLH-TL structure of the present invention, a magneto-dielectric material formed using SRR (Split Ring Resonator) structures 210 is used as a substrate 200 , and a patch 300 is formed on the substrate 200 .
More particularly, the metamaterial antenna 100 includes three layers. The patch 300 is formed on the highest layer, and the SRR structures 210 are formed in the middle layer using both the upper and lower sides of the substrate 200 . The lowest layer is operated as a ground 400 , and the three layers are interconnected through vias 500 .
The patch 300 is a CRLH-TL antenna implemented using two unit cells. Eight SRRs 211 and 212 per unit cell are formed at the bottom of the patch 300 , thus forming the SRR structure 210 and magnetizing a dielectric material. The dielectric material is used as the substrate 200 .
The dimensions of the metamaterial antenna 100 were L=25 mm, W=12.4 mm, and gap=0.2 mm. The radius of the via was 0.3 mm. The substrate was formed of Rogers RT/duroid 5880 substrate. The thickness of the upper and lower substrates was 1.55 mm (62 mil), the thickness of the middle substrate was 0.508 mm (20 mil), and the dimensions of the substrate was 55 mm in length and breadth. The antenna is supplied with power through a microstrip line 310 of 8 mm in width.
FIG. 2 is a diagram showing a substrate made of a magneto-dielectric material according to a preferred embodiment of the present invention. FIG. 3 is a diagram showing the SRR structures according to a preferred embodiment of the present invention.
Referring to FIGS. 2 and 3 , the SRR structure 210 includes a first SRR 211 having a relatively long length and a second SRR 212 having a short length. The 6 first SRRs 211 are radially disposed in the longitudinal direction of the substrate 200 , and the second SRRs 212 are disposed in the horizontal direction of the substrate 200 . FIG. 3( a ) shows the structure of the first SRR 211 , and FIG. 3( b ) shows the structure of the second SRR 212 .
The first and second SRRs 211 and 212 are symmetrically formed on the upper and lower sides of the substrate. Both ends of the SRRs 211 and 212 , facing each other on the basis of the substrate, are interconnected through the vias 500 penetrating the substrate.
Meanwhile, a slot 213 is formed at the central portion of the first and second SRRs 211 and 212 formed on the lower side of the substrate.
The dimensions of the SRR were L_large_srr=11 mm, L_small_srr=4.5 mm, w_srr=2 mm, gap_srr=0.2 mm, h_srr=1.55 mm, and via_r=0.3 mm.
FIG. 4 is a diagram showing the direction in which a magnetic field is generated in the antenna according to the preferred embodiment of the present invention.
In order for the SRR structures 210 to respond to a magnetic field, the SRR structures 210 and the magnetic field need to be disposed vertically.
Referring to FIG. 4 , in the CRLH-TL metamaterial antenna 100 implemented using the patch 300 and the vias 500 , a magnetic field is formed in the direction in which the magnetic field is rotated around the via 500 . Accordingly, it is effective to radially dispose the first and second SRRs 211 and 212 around the respective vias 500 .
The operating characteristics of the SRR were checked through simulations. In the simulations, CST Microwave Studio 2006B was used.
FIG. 5 is a diagram showing a change in the magnetic permeability according to the frequency of the first SRR according to a preferred embodiment of the present invention.
Referring to FIG. 5 , the first SRR 211 showed a resonant characteristic at a frequency of 4.37 GHz. It was checked that in a frequency lower than the frequency 4.37 GHz, a magnetic permeability value was 1 or higher and in a frequency higher than the frequency 4.37 GHz, a magnetic permeability value became a negative number and was changed to a positive number smaller than 1. The range of a frequency used as a magneto-dielectric material is a frequency band lower than the resonant frequency of the SRR, and a magnetic permeability value is 1 or higher in the above frequency band.
FIG. 6 is a diagram showing a change in the magnetic permeability according to the frequency of the second SRR according to a preferred embodiment of the present invention.
Referring to FIG. 6 , the second SRR 212 showed a resonant characteristic at a frequency of 7.91 GHz, and a change in the magnetic permeability of the second SRR 212 was the same as that of the first SRR 211 .
A change in the resonant frequency of the antenna was checked in the case in which the SRRs were not used in the CRLH-TL antenna and the case in which the SRRs were used in the CRLH-TL antenna. The patch 300 is spaced apart from the microstrip line 310 (i.e., a feed line) with a gap of 0.3 mm interposed therebetween, coupled with the microstrip line, and supplied with power.
TABLE 1
Presence of SRR
f −1 (GHz)
f 0 (GHz)
Yes
1.4224
2.0604
No
1.3209
1.5674
From Table 1, it can be seen that the case in which the SRRs were used has a reduction both in the 0-th order resonant frequency and the −1-st order resonant frequency, as compared with the case in which the SRRs were not used. In the case of the 0-th order resonant mode, there was an effect of a reduction in the frequency of 23.9%. In the case in which the SRRs were not used, the dimensions of the antenna were 0.1717λ 0 ×0.1717λ 0 ×0.0176λ 0 (where λ 0 is the wavelength in the free space). In the case in which the SRRs were used, the dimensions of the antenna were 0.1306λ 0 ×0.1306λ 0 ×0.0134λ 0 . Accordingly, there was an effect of a reduction in the area of about 42.14%.
FIG. 7 is a graph showing a return loss depending on whether the SRRs are used.
FIG. 8 is a diagram showing the surface current of the SRRs in the 0-th order resonant mode according to a preferred embodiment of the present invention.
FIG. 8( a ) shows current flowing into the upper side of the SRRs when seen from the top to the bottom, and FIG. 8( b ) shows current flowing into the lower side of the SRRs when seen from the bottom to the top. Current in the via 500 is directed from the patch to the ground 400 . When seen from the top to the bottom, the direction of a magnetic field is clockwise as shown in FIG. 9 . At this time, in the direction of current flowing into the SRRs, it can be seen that the direction of a magnetic field generated by the SRRs will become the same as a magnetic field generated by the vias 500 . Accordingly, the magnetic permeability is increased, but the resonant frequency of the antenna is reduced by an enhanced magnetic field.
FIG. 10 is a photograph showing an antenna actually fabricated using the SRR structures according to the preferred embodiment of the present invention.
Referring to FIG. 10 , the gap between the feed line and the patch 300 was set to 0.5 mm in order to match the antenna.
FIG. 11 is a graph showing a measured return loss of the actually fabricated antenna and a simulated return loss.
Referring to FIG. 11 , there is slightly a difference between the simulation result and the measured return loss, which can be seen as error occurring in a process of fabricating the antenna. When the antenna is fabricated, the portion of the via 500 is slightly protruded because of the SRR structure having an upper and lower plane type, and thus an opening is formed between the substrates 200 . It is determined that the error of a frequency band was generated in the return loss because of the error resulting from the opening. A measured bandwidth of the antenna was 1.883 to 1.892 GHz (0.48%).
FIG. 12 is a diagram showing a measured radiation pattern of the actually fabricated antenna.
FIG. 12( a ) indicates an E-plane in an x-z plane, and FIG. 12( b ) indicates an H-plane in the x-y plane.
The radiation pattern indicates a monopole radiation pattern which is the radiation pattern of a 0-th order resonant mode antenna. A measured gain of the antenna was 0.534 dBi, and measured efficiency thereof was 51.7%.
While an embodiment of the present invention has been described with reference to the accompanying drawings, the embodiment is only illustrative. Those skilled in the art will understand that a variety of modification and equivalent embodiments are possible from the present invention. Accordingly, a true technological protection range of the present invention should be defined by the technical spirit of the accompanying claims. | The invention relates to the size reduction of an antenna using a magneto-dielectric material for a CRLH-TL (Composite Right/Left Handed Transmission Line) antenna. In particular, the invention provides a small and low profile metamaterial antenna attained by performing SRR (Split Ring Resonator) magnetization on a dielectric material and applying the magneto-dielectric material to the CRLH-TL antenna that is composed of patches and vias. Even further, the invention provides a metamaterial antenna using a magneto-dielectric material, the antenna comprising: a substrate which is made up of a magneto-dielectric material and which has an SRR structure inserted thereto; patches with a CRLH-TL structure formed at a predetermined distance above the substrate; and a ground plane formed at a predetermined distance below the substrate. | 7 |
This application is a divisional of and claims the benefit of all prior filing dates claimed in U.S. application Ser. No. 09/894,996, filed Jun. 27, 2001, now U.S. Pat. No. 6,742,774, herein incorporated by reference in its entirety. U.S. application Ser. No. 09/894,996 claims the benefit of the prior filing date of U.S. Provisional Application No. 60/214,538, filed Jun. 27, 2000, herein incorporated by reference in its entirety. U.S. application Ser. No. 09/894,996 is also a continuation-in-part and claims priority of U.S. application Ser. No. 09/345,813, filed Jul. 2, 1999, now U.S. Pat. No. 6,391,082; of U.S. application Ser. No. 09/802,037, filed Mar. 7, 2001, now U.S. Pat. No. 6,471,392; and of U.S. application No. 09/853,448, filed May 10, 2001, now U.S. Pat. No. 6,723,999.
This application is a divisional of U.S. application Ser. No. 09/894,996, filed Jun. 27, 2001, which claims the benefit of the prior filing date of U.S. provisional patent application No. 60/214,538, filed Jun. 27, 2000, herein incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to materials processing involving a chemical and/or a physical action(s) or reaction(s) of a component or between components. More specifically, the present invention produces a gas-in-liquid emulsion in a reactor to continuously process relatively large quantities of materials.
2. General Background and State of the Art
Apparatus for materials processing consisting of coaxial cylinders that are rotated relative to one another about a common axis, the materials to be processed being fed into the annular space between the cylinders, are known. For example, U.S. Pat. No. 5,370,999, issued 6 Dec. 1994 to Colorado State University Research Foundation discloses processes for the high shear processing of a fibrous biomass by injecting a slurry thereof into a turbulent Couette flow created in a “high-frequency rotor-stator device”, this device having an annular chamber containing a fixed stator equipped with a coaxial toothed ring cooperating with an opposed coaxial toothed ring coupled to the rotor. U.S. Pat. No. 5,430,891, issued 23 Aug. 1994 to Nippon Paint Co., Ltd. discloses processes for continuous emulsion polymerization in which a solution containing the polymerizable material is fed to the annular space between coaxial relatively rotatable cylinders.
U.S. Pat. No. 5,279,463, issued 18 Jan., 1994, and U.S. Pat. No. 5,538,191, issued 23 Jul. 1996, both having the same applicant as the present invention, disclose methods and apparatus for high-shear material treatment, one type of the apparatus consisting of a rotor rotating within a stator to provide an annular flow passage. U.S. Pat. No. 5,538,191, in particular, at column 13, line 37, describes using the invention as a gas/liquid chemical reactor by enveloping the greater part of the liquid that clings to the periphery of the spinning rotor with a body of the reactant gas. The high peripheral velocity of the wetted, spinning rotor causes the gas to be in a highly turbulent state of surface renewal at its contact interface with the liquid film. However, this gas/liquid reaction method provides a relatively small gas/liquid contact area and is prone to considerable back-mixing (mixing in the longitudinal, axial or general flow direction) of the gas component thus providing an undesirably large residence time distribution (RTD), impairing the overall efficiency of the process.
Sparging gasses through liquids for reacting the gasses with the liquids is also known in the prior art, but also fails to provide adequate interfacial contact area between the liquid and gas.
It would be desirable to provide a large interfacial contact area between a liquid and a gas in an efficient continuous or batch type process.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a method and apparatus for producing a gas-in-liquid emulsion for providing increased interfacial contact area between the liquid and the gas for improved reaction of the gas with the liquid, or more rapid solution or reaction of a difficulty soluble or immiscible gas in or with a liquid. This invention provides a superior, more economical and more efficient way of contacting gases with liquids for the purpose of effecting reactions between them to be carried out as a continuous or batch type process.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a part elevation, part longitudinal cross sectional view of a complete reactor of the present invention;
FIG. 2 is a transverse cross-sectional view of a reactor showing the cylindrical members in a concentric configuration with gas and liquid inlets leading to the processing chamber;
FIG. 3 is a cross-sectional view of an eccentrically mounted embodiment of the reactor in which the longitudinal axes of the cylindrical members are displaced to give an annular passage that varies in radial width around its circumference, the reactor including a series of gas inlets along its length;
FIG. 4 is a cross sectional view of an eccentrically mounted embodiment of the reactor similar to FIG. 3 , but showing a gas inlet at the top of the reactor and fluid inlets along the bottom of the reactor; and
FIG. 5 is a diagrammatic representation of the gas-in-liquid emulsion further illustrating incident white light and light scattered by the gas bubbles.
DETAILED DESCRIPTION OF THE INVENTION
A reactor 8 is illustrated by FIGS. 1–4 , and described in greater detail in U.S. patent Ser. No. 09/802,037 entitled “Method and Apparatus for Materials Processing”, filed Mar. 7, 2001 and U.S. Pat. No. 5,538,191 entitled “Methods and Apparatus for High-Shear Material Treatment” both by the applicant of the present invention and both of which are hereby incorporated by reference in their entirety into the present disclosure. An annular cross section processing chamber 44 having an annular gap is formed between an outer cylindrical member or cylindrical tube 30 comprising a stator and a cylindrical rotor or inner cylindrical member 42 . Liquid and gas enter the processing chamber 44 through inlets 14 . The cylindrical members 30 , 42 rotate relative to each other producing a shear force on the liquid, gas and any other reactants as they are pumped through the processing chamber and out an outlet 52 at the downstream end of the processing chamber 44 .
Turning to FIGS. 1 and 2 in particular, reactants are fed from supply tanks 10 , 16 , 20 , respectively. Also shown are metering pumps 12 and 18 leading from the supply tanks 10 , 16 and into the inlet 14 . The reactants can be aqueous solutions and a gas such as carbon dioxide. The reaction can occur at room temperature and atmospheric pressure for example, although other temperatures and pressures can be chosen as appropriate.
The reactor comprises a baseplate 22 on which is mounted rotor bearing supports 24 , stator supports 26 and a variable speed electric drive motor 28 . The cylindrical member 30 , comprising the apparatus stator, is mounted on the supports 24 . A rotor shaft 40 extends between the supports 24 and is supported thereby, one end of the shaft being connected to the motor 28 . The shaft 40 carries the cylindrical member 42 , comprising the apparatus rotor. The processing chamber 44 is formed between the inner cylindrical surface 46 of the cylindrical member 30 and the outer cylindrical surface 48 of rotor 42 and face body 51 . The ends of the chamber are closed against leakage by end seals 50 that surround the shaft 40 .
In the embodiment of FIGS. 1 and 2 the cylindrical member 42 is shown with its axis of rotation roughly coincident, or concentric, with the longitudinal axis of the cylindrical member 30 . The processing chamber 44 is shown having a radial dimension of H.
In another embodiment, as illustrated in FIGS. 3 and 4 for example, the cylindrical member 42 has its axis of rotation not coincident with, but rather eccentric, relative to the longitudinal axis of the cylindrical member 30 . The processing chamber 44 has a smaller radial dimension G and a larger radial dimension H diametrically opposite. The processing chamber 44 is therefore circumferentially alternately convergent from the portion having the dimension H to the portion having the dimension G at which portion the surfaces 46 , 48 are spaced a minimum distance apart and the maximum shear is obtained in the flowing material; the chamber 44 is then divergent from the portion having the dimension G to the portion having the dimension H.
Rather than the horizontal orientation of FIG. 1 , the reactor can be configured vertically with the outlet 52 at the top. Other orientations can be used as well. Also, other inlet and outlet configurations can be used. For example, in FIG. 3 a series of inlets 14 positioned along the length of the reactor 8 and passing through the cylindrical member 30 supply gas into the processing chamber 44 . FIG. 4 shows an embodiment in which both the inlet (not shown) and outlet 52 are disposed at the lowermost part of the cylindrical member 30 , while the gas is fed into the processing chamber 44 by a separate inlet 146 . In a general embodiment, the reactants are pumped into the inlets 14 , through the processing chamber 44 and out an outlet. The inlets 14 and outlets 52 can be at opposite ends of the length of the processing chamber 44 to allow mixing and reacting along the length of the processing chamber 44 .
U.S. Provisional Application No. 60/214,538 entitled “Process for High Shear Gas-Liquid Reactions” to Holl filed on Jun. 27, 2000, which is hereby incorporated by reference in its entirety into the present disclosure, describes the use of the reactor 8 for gas/liquid reaction. The reactor emulsifies the gas into the liquid providing increased contact between the liquid and gas for more efficient reactions. The inventor of the present invention discovered that a gas-in-liquid emulsification can be created by narrowing the radial dimension between the surfaces 46 , 48 of the processing chamber 44 while rapidly rotating the rotor cylindrical member 42 relative to the stator cylindrical member 30 .
For the gas-in-liquid emulsification to occur, the radial dimension between the surfaces 46 , 48 of the processing chamber 44 should be approximately equal to or less than the combined thickness of the two laminar boundary layers back-to-back. As the material being processed flows in the processing chamber 44 a respective boundary layer forms on each of the surfaces 46 and 48 , the thickness of which is determined by the viscosity and other factors of the material being processed and the relative flow velocity of the material over the surface. The laminar boundary layer for a fluid flowing over a flat surface along a path length x, which in the invention is taken as one circumferential flow length around the rotor surface, may be determined by the equation:
δ = 4.91 N R
where N RX is the product of length x and the flow velocity divided by the kinematic viscosity.
In addition to having a radial dimension requirement, the peripheral speed of the rotor cylindrical member 42 relative to the stator cylindrical member 30 should exceed approximately four meters per second for the gas-in-liquid emulsification to occur. The upper limit on the peripheral speed is determined by the application. For example, too great a speed might destroy living microbes or long molecular chains. Also, too great a speed can subject the reactor 8 to unnecessary stress and strain.
The required radial dimension and peripheral speed can vary depending on conditions. The radial dimension requirement and peripheral speed required for the onset of the emulsification phenomenon can be determined experimentally for given reactants under specified conditions. The onset of this emulsification phenomenon is indicated by the appearance of a white colored turbidity of the fluid agitated in the processing chamber 44 . The stator cylindrical member 48 can, for observation purposes, be made of glass. The grayish-white to white, almost milk like turbidity
supply energy into the processing chamber 44 through a port 58 and window 60 as illustrated in FIGS. 2 and 3 . This use of energy is described in greater detail in U.S. patent Ser. No. 09/853,448 entitled “Electromagnetic Wave Assisted Chemical Processing” by Holl filed May 10, 2001 which is hereby incorporated by reference in its entirety into the present disclosure. The energy can also be used in combination with the Taylor-vortices free gas-in-liquid emulsion for additional reaction capabilities.
Also, the cooperating surfaces 46 and 48 in FIGS. 2 and 3 can be coated with a catalyst to facilitate a chemical or biological reaction that constitutes the processing step. The catalytic material can enhance chemical, biochemical or biocidal reactions in the processing passage.
Importantly, the reactor 8 can be quickly and thoroughly cleaned. Therefore, unlike the prior art, deposits forming and blocking the irradiation is not a problem. For example, even if the reactant is a sticky opaque substance, the surfaces 46 , 48 and window 60 are easily cleaned. By running the reactor 8 with clean water for enough time for the water to pass from the inlet 14 to the outlet 52 , substances clinging to the surfaces 46 , 48 and the window 60 are washed away. In most cases the surfaces of the processing chamber 44 are clean within five seconds. This efficient cleaning ability is due to the extremely hard sheer forces as the rotor cylindrical member 42 and stator cylindrical member 30 rotate relative to each other. In most cases, no contaminants will even form on the window 60 or surfaces 46 , 48 of the processing chamber 44 due to the hard sheer forces pulling the materials through the reactor 8 .
The gas/liquid reaction can be used in an oxygenation process, or an enzyme reaction process for example: Additionally, solids, such as catalytic powders, can be added to the processing chamber 44 to form a gas/liquid/solid emulsion to provide a gas/liquid/solid reaction which can also be enhanced by the applied electromagnetic or longitudinal pressure energy as described below.
Returning to FIG. 3 , the illustrated embodiment is intended for an enzyme reaction process, and the axis of rotation of the rotor cylindrical member 42 is eccentrically mounted relative to the longitudinal axis of the stator cylindrical member 30 , so that the radial processing chamber 44 differs in dimension circumferentially around the rotor. A heat exchange structure is provided having an outer casing 32 and heat exchange material 34 , since such processes usually are exothermic and surplus heat must be removed for optimum operative conditions for the microorganisms. A series of oxygen feed inlets 14 are arranged along the length of the stator and the oxygen fed therein is promptly emulsified into the broth, providing uniformly dispersed, micron-fine bubbles instead of being sparged therein with mm size bubbles of non-uniform distribution, as with conventional enzyme reaction systems. The carbon dioxide that is produced is vented from the upper part of the processing passage through a vent 56 . The reactor according to FIG. 3 is designed to operate continuously and provides a continuous and uniform CO 2 removal along the upper portion of the rotor which is constantly wetted with a film of broth of uniform mixedness of all ingredients. Also shown is the port 58 and window 60 as described with reference to FIG. 2 .
The apparatus of the invention is generically a reactor process and apparatus, and a reactor consists of the vessels used to produce desired products by physical or chemical means, and is frequently the heart of a commercial processing plant. Its configurations, operating characteristics, and underlying engineering principles constitute reactor technology. Besides stoichiometry and kinetics, reactor technology includes requirements for introducing and removing reactants and products, supplying and withdrawing heat, accommodating phase changes and material transfers, assuring efficient contacting among reactants, and providing for catalyst replenishment or regeneration. These issues are taken into account when one translates reaction kinetics and bench-scale data into the design and manufacture of effective pilot plants, and thereafter scale up such plants to larger sized units, and ultimately designs and operates commercial plants.
While the specification describes particular embodiments of the present invention, those of ordinary skill can devise variations of the present invention without departing from the inventive concept. | A reactor produces a gas-in-liquid emulsion for providing increased interfacial contact area between the liquid and the gas for improved reaction of the gas with the liquid, or more rapid solution or reaction of a difficulty to dissolve or immiscible gas in or with a liquid. The reactor is suitable for a continuous or batch type process. Rotor and stator cylindrical members are mounted for relative rotation one to the other and have opposing surfaces spaced to form an annular processing passage. The gap distance between the opposing surfaces and the relative rotation rate of the cylindrical members are such as to cause formation of a gas-in-liquid emulsion of the gas in the liquid, as the liquid and gas pass through the processing passage. | 2 |
This application is a 371 of PCT/EP98/06765, dated Oct. 24, 1998.
BACKGROUND OF THE INVENTION
Epoxy compounds have a wide field of application in the production of plastics, polymer foams, surface coatings, and coating materials. It is desirable for these substances to have a very high epoxy oxygen content, and at the same time the volatile component content must be as low as possible in order to prevent exudation (fogging) on the plastics parts. Finally, the products must be sufficiently heat-stable; i.e., at relatively high temperatures as encountered during the preparation of the polymers, there must be no unwanted crosslinking of the epoxides with one another and no increase in viscosity.
From the prior art it is known to subject epoxy compounds prepared by the performic acid process to neutral washing by repeated treatment with water or aqueous alkali and to remove catalyst residues together with the washing water. Normally, this is followed by the phases being separated, the washing water being stripped off or removed by centrifugation, and the residual moisture content in the product being removed by adding sodium sulfate or by vacuum drying. Alternatively, traces of acid can be removed from the epoxides by introducing gaseous ammonia, by neutralization with anhydrous sodium carbonate, by azeotropic distillation, or by the use of anion exchangers [cf. Chem. Ztg. 95, 684(1971)].
Although the measures of the prior art, and especially the known method of wet refining with alkali metal hydroxide solution, make it possible to reduce the number of washing steps, it is nevertheless the case that under these conditions, from epoxidized esters, for example, surface-active soaps having emulsifying properties may be formed, and phase separation is therefore retarded. At the same time, there is increased incidence of epoxy ring opening reactions, which reduce the epoxy oxygen content.
The object of the invention was therefore to provide a process for preparing heat-stable epoxides which is free from the disadvantages depicted.
BRIEF SUMMARY OF THE INVENTION
The present invention includes a process for preparing heat-stable epoxy compounds wherein epoxide compounds are washed, dried, treated with selected basic solids and filtered.
The invention provides a process for preparing heat-stable epoxy compounds in which olefinically unsaturated compounds are epoxidized in a manner known per se and the resulting oxirane compounds
a) are washed with water and/or aqueous alkali solution, and
b) the useful, organic phase is separated off and dried,
which comprises subsequently treating the useful organic phase with solid, basic aluminum oxides, aluminum hydroxides and/or alkali metal silicates and filtering it.
It has surprisingly been found that the epoxy compounds obtained in this way rather than by prior art workup processes have a higher epoxy oxygen content even after thermal exposure and have a reduced tendency to crosslink during storage and to develop an unwanted viscosity. At the same time, the proposed process reduces the number of washing steps, which results in a technical simplification and reduces the amount of wastewater. Furthermore, the invention includes the finding that higher yields are obtained when the epoxy compounds obtainable by the process of the invention are worked up by distillation.
DETAILED DESCRIPTION OF THE INVENTION
Epoxy Compounds
The selection of the epoxides to which the process of the invention can be applied is not critical per se. Preference is given to the use of epoxides of olefinically unsaturated fatty substances, such as, for example, epoxides of olefinically unsaturated triglycerides, fatty acid lower alkyl esters (i.e., esters of fatty acids having 6 to 22 carbon atoms with alcohols having 1 to 8 carbon atoms) and/or fatty alcohols. Particular preference is given to the use of epoxidized triglycerides based on soybean oil, linseed oil, rapeseed oil, sunflower oil, tall oil, cottonseed oil, groundnut oil, palm oil, or neat's-foot oil, it having been found optimal in terms of the color quality of the products to use epoxides having a high degree of epoxidation and a low iodine number. Epoxidized triglycerides are known substances which are used in other technical fields as so-called “epoxy plasticizers”. They are prepared by epoxidizing unsaturated fats and oils by the so-called “in situ performic acid process”, which is described in J. Am. Chem. Soc. 67, 412 (1945). Depending on the amount of peracid used, epoxidation converts some or all of the olefinic double bonds of the glyceridically linked fatty acids to oxirane rings. Particularly suitable are triglycerides having an iodine number in the range from 50 to 150, which on substantial epoxidation of the olefinic double bonds are converted to epoxides having an epoxy oxygen content of from 3 to 10% by weight. For technical reasons, preference is given to the use of epoxidized soybean oil and/or epoxidized soya fatty acid methyl ester. On the preparation of epoxidized fatty alcohols, cf. also D. Swern in J. Am. Chem. Soc. 66, 1925 (1944). In addition to the epoxidized fatty substances, which to a certain extent represent functionalized olefins, it is of course also possible to use conventional epoxidized olefins having 6 to 18 carbon atoms, whose epoxide group is either at the end or in the interior of the molecule. Typical examples are α-epoxides of decene, dodecene, tetradecene, hexadecene and octadecene, and of corresponding technical-grade mixtures of these olefins.
Basic Solids
For the refining of the epoxides, suitable basic solids include aluminum oxides, aluminum hydroxides and also alkaline silicates such as, for example, Primisils, Celatoms or Celites. The amount of these substances used can be from 0.5 to 5, preferably from 1 to 3% by weight, based on the epoxides.
Refining
To refine the epoxides they are first of all washed, one particularly advantageous embodiment of the process of the invention consisting in treating the substances only once or twice with an equal amount by weight of water or alkali solution. Washing more times than this, as described in the prior art, is unnecessary from the standpoint of further refining. The term “alkali solution” is to be understood as referring, for example, to aqueous sodium hydroxide or sodium carbonate solutions having a solids content in the range from 1 to 15% by weight. After washing, phase separation takes place by decanting, the useful organic phase being dried in a manner known per se. Subsequently, the basic solids are added and, after stirring, the mixture is filtered until the product appears to be pure.
EXAMPLE
Epoxidized soybean oil was purified by the following processes:
(P1) Washing 5 times with an equal amount by weight of water, phase separation, and vacuum drying of the organic phase.
(P2) Washing 5 times with an equal amount by weight of water, then washing with an equal amount by weight of 2% strength by weight sodium hydroxide solution, phase separation, and vacuum drying of the organic phase.
(P3) Washing 5 times with an equal amount by weight of water, then washing with an equal amount by weight of 2% strength by weight sodium carbonate solution, phase separation, and vacuum drying of the organic phase.
(1) Washing twice with an equal amount by weight of water, phase separation, vacuum drying of the organic phase, addition of 0.5% by weight of basic aluminum oxide hydrate, and filtration.
Subsequently, the epoxy oxygen content and the Brookfield viscosity (RVT viscometer, 20° C., spindle 1, 10 rpm) was determined immediately and after storage at 150° C. for 24 h. The results are collated in Table 1. Example 1 is in accordance with the invention, Examples P1 to P3 serve for comparison.
TABLE 1
Stability and viscosity
Properties
P1
P2
P3
1
Epoxy oxygen content
[% by wt.]
immediate
6.65
6.55
6.75
6.85
after 24 h, l50° C.
6.25
6.20
6.45
6.70
Viscosity [mPas]
immediate
580
580
585
590
after 24 h, 150° C.
880
760
650
630 | A process for refining epoxy compounds, wherein the process comprises: (a) providing a washed and dried organic phase comprising at least one epoxide compound; (b) contacting the organic phase with at least one basic solid selected from the group consisting of aluminum oxides, aluminum hydroxides and alkali metal silicates; and (c) separating the organic phase and the at least one basic solid, is disclosed. | 2 |
TECHNICAL FIELD
The present invention generally relates to buoys and, in particular, to station keeping sonobuoys.
BACKGROUND
Sonobuoys are equipped with electronic sensors to both gather data and transmit that data. Sonobuoys have been used to detect and locate submerged submarines. They have also been used in military and private applications to take measurements regarding the environment such as water temperature, current flow, etc. Sonobuoys can be free-floating, anchored or station-keeping. For more useful collection of data, it is desirable for the sonobuoys to be either anchored or station-keeping in order to collect data from relatively the same location. Station-keeping buoys are preferred in situations where an extended anchor would not be desirable or practical.
Station-keeping buoys, however, consume power quickly through the propulsion system used to keep the buoy in the same geographic location. This rapid power consumption prevents the station-keeping buoy from operating for extended periods of time. Additionally, sonobuoys used by the Navy are often launched through a small tube (i.e. typically a tube with an 8 inch diameter). The typical shape of the sonobuoys is, accordingly, cylindrical. Any deployable sonobuoys must, therefore, conserve this cylindrical shape in order to be launched from existing tubes.
For the reasons stated above, and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for a deployable station-keeping buoy which can be launched from existing launch tubes and which significantly reduces power consumption allowing the buoy to operate for extended periods of time.
SUMMARY
The above-mentioned problems and other problems are resolved by the present invention and will be understood by reading and studying the following specification
In one embodiment, an articulating sonobuoy is provided. The articulating sonobuoy comprises a plurality of section, and a plurality of joints connecting each of the plurality of section to adjacent sections, wherein each of the plurality of sections self-aligns by rotating about one or more of said plurality of joints changing the shape of the buoy from a stowed configuration to a streamlined deployed configuration.
In another embodiment, an articulating sonobuoy is provided. The articulating sonobuoy comprises a plurality of section, joint means for connecting said plurality of sections to adjacent sections, and folding means for folding said plurality of sections about said joint means such that the buoy has at least two configurations, wherein the at least two configurations include an initial stowed configuration and a deployed configuration.
In yet another embodiment, an articulating sonobuoy is provided. The articulating sonobuoy comprises a plurality of sections, each section being a cross-sectional piece of a streamlined airfoil shape, and a plurality of joints connecting each of the plurality of sections to adjacent sections, wherein rotation of each of the plurality of sections about the plurality of joints changes the shape of the buoy from a cylindrical stowed configuration with a diameter between approximately 6 inches and 21 inches to a streamlined airfoil deployed configuration.
In another embodiment, a method of deploying a streamlined sonobuoy through cylindrical launch tubes is provided. The method comprises aligning a plurality of sections to fit within a cylindrical launch tube, wherein each of the plurality of sections is a cross-sectional piece of a streamline shape, releasing the aligned plurality of sections through the cylindrical launch tube, and rotating each of the plurality of sections about one or more joints, wherein rotation of the plurality of sections aligns the plurality of sections to form a streamlined shape.
DRAWINGS
FIG. 1 is a graph of drag coefficients of common shapes as a function of Reynold's number.
FIG. 2 is an image of an articulating buoy in a stowed configuration according to one embodiment of the present invention.
FIG. 3 is an image of an articulating buoy in a deployed configuration according to one embodiment of the present invention.
DETAILED DESCRIPTION
In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific illustrative embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, mechanical and electrical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense.
FIG. 1 is a graph of drag coefficients of common shapes as a function of Reynold's number. The typical shape of buoys and launch tubes in use is circular. The diameter of these launch tubes ranges from 6 inches to 8 inches. The circular shape presents problems for station-keeping buoys. In order for station-keeping buoys to maintain their station or geographic location for extended periods of time, the buoys need either, more stored energy onboard, a more sufficient power supply system to power a motor and navigation system, a more efficient shape or all of the aforementioned. Embodiments of the present invention address the issue of providing a more efficient shape.
As shown in FIG. 1 , circle 102 -A, the typical shape of buoys, has a high drag coefficient. Due to that high coefficient, a large portion of power is lost through drag. Additionally, as FIG. 1 shows, other shapes have significantly lower drag coefficients and hence would be more efficient and lose less power due to drag. Each shape 102 -A, 104 -A . . . 112 -A is associated with a graph 102 -B, 104 -B . . . 112 -B representative of drag coefficient as a function of Reynold's number, respectively. For example, circle 102 -A is associated with graph line 102 -B while ellipse 104 -A is associated with graph line 104 -B. Additionally, the length and width dimensions for each shape are shown in FIG. 1 as a multiple of length D. For example, circle 102 -A has length D and width D while ellipse 104 -A has length D and width 0.5D or ½ the length of D.
Of the shapes shown in FIG. 1 , circle 102 -A has the highest drag coefficient and shape 110 -A has the lowest drag coefficient. Although shape 112 -A is a flat plate and has a lower coefficient than shape 110 -A, it is included for reference purposes only because its extremely thin shape limits it from being used for most practical purposes. Ellipses 104 -A and 106 -A have lower drag coefficients. As understood by comparing the widths of ellipses 104 -A and 106 -A, the drag coefficient for ellipses 104 -A and 106 -A decreases as the ratio of width-to-length decreases. Shapes 108 -A and 110 -A are streamlined airfoil shapes with even smaller width-to-length ratios. As can be seen, both airfoil 108 -A and airfoil 110 -A have significantly lower drag coefficients than circle 102 -A and ellipses 104 -A and 106 -A. Airfoils 108 -A and 110 -A are representative of National Advisory Committee for Aeronautics (NACA) 0018 and NACA 0009 airfoil shapes. Therefore, it would be advantageous to develop buoys with a streamlined airfoil shape since this would reduce drag and consequently conserve power.
Unfortunately, a streamlined airfoil shape, with similar weight and displacement of a typical cylindrical sonobuoy, will not fit in a launch tube with a diameter of 6 inches to 8 inches. If the length D of the airfoil is reduced to fit within the diameter of the launch tube, the width or thickness of the airfoil will also be significantly reduced to preserve the correct shape. If airfoil 108 -A has a length D equal to 6 inches, the maximum width of airfoil 108 -A would be a mere 1.08 inches. The prohibitively small area in such an airfoil would render the airfoil useless for all practical purposes due to the lack of area for necessary electronic and mechanical components. Additionally, the buoy must be capable of being launched from up to 30,000 feet and such a small size could cause it to be blown far off course.
Embodiments of the present invention, however, enable a buoy with a streamlined airfoil shape to fit into existing launch tubes, which have a diameter between 6 inches to 8 inches, while still being of sufficient size to house necessary electronic and mechanical components. Additionally, it can be launched from aircraft at 30,000 feet or from submarines and surface ships. Therefore, embodiments of the present invention enable station-keeping buoys to station-keep for extended periods of time. In some embodiments, the station-keeping buoys are enabled to station-keep for periods of up to 30 days. Additionally, embodiments of the present invention require few to no adjustments for launch tubes to accommodate buoys made according to embodiments of the present invention which saves both time and money.
FIG. 2 is an image of an articulating buoy 200 in a stowed configuration according to one embodiment of the present invention. The term articulating refers to the fact that buoy 200 is composed of individual sections flexibly connected. Buoy 200 is composed of multiple sections 202 - 1 . . . 202 -N and section 204 . In one embodiment, buoy 200 is composed of 8 sections. Each of sections 202 - 1 . . . 202 -N and section 204 are water-tight sealed preventing water from entering the sections. In one embodiment, section 204 houses a battery compartment. In other embodiments section 204 is used to house other electronic components. In some embodiments, one or more of sections 202 - 1 . . . 202 -N house other components, such as a navigation and control unit, a propulsion system, a radio transmitter, sonar equipment, etc. Additionally, in some embodiments, one or more of sections 202 - 1 . . . 202 -N do not house any components but are used primarily to support floatation and maintain stability of the buoy through means known to one of skill in the art, such as water ballast to support stabilization or air pockets to support floatation. In an embodiment using water ballast each of sections 202 - 1 . . . 202 -N and 204 is individually sealed and any electrical components housed within a section are also water-tight sealed such that only a portion of each section is able to take in water for the water ballast and electronic components are not exposed to water. In all embodiments, buoy 200 is properly weighted to maintain buoy 200 afloat and stable. Sections 202 - 1 . . . 202 -N and section 204 are connected to adjacent sections through joint means (shown in FIG. 3 ). In one embodiment, the joint means comprise pivot hinges. In other embodiments, other appropriate joint means are used.
Buoy 200 is referred to as station-keeping because it can maintain itself in a particular geographic location or station. In some embodiments, one of sections 202 comprises a navigation and control unit 222 that utilizes Global Positioning System (GPS) technology. Additionally, in some embodiments, one of sections 202 comprises a propulsion system 224 which functions in conjunction with a navigation and control 222 unit to maintain buoy 200 in a particular geographic location. In one embodiment, this location is fixed and determined prior to launch. In other embodiments, the location is changeable remotely. For example, in some embodiments, a user operates a remote unit 220 to transmit signals to buoy 200 via wireless link 226 in order to control the location. In yet other embodiments, the geographic location is determined according to the location of impact with the water surface. A propeller based propulsion system is used in one embodiment to maintain the geographic location. In other embodiments, a jet propulsion system is used.
In some embodiments, sleeve 206 is an integral part of buoy 200 used to house buoy 200 . In other embodiments, sleeve 206 is not used and is not a part of buoy 200 . Sleeve 206 facilitates storing, transporting and launching buoy 200 . In one embodiment, buoy 200 is removed from sleeve 206 prior to launch. In other embodiments, buoy 200 is launched while inside sleeve 206 . In such embodiments, sleeve 206 is removed after launch. In one embodiment, sleeve 206 is removed through remote control via remote unit 220 . In other embodiments, sleeve 206 is designed to open and release buoy 200 automatically upon occurrence of a particular event, such as impact with the water surface. Sleeve 206 and buoy 200 are made from any appropriate metal, metal alloy, plastic, foam or other appropriate material.
FIG. 3 is an image of an articulating buoy in a deployed configuration according to one embodiment of the present invention. Once deployed, sections 202 - 1 . . . 202 -N and section 204 fold to form an articulating buoy as depicted in FIG. 3 . Each of sections 202 - 1 . . . 202 -N and 204 folds about one of joints 306 - 1 . . . 306 -N. In one embodiment, sections 202 - 1 . . . 202 -N fold in a fashion similar to the manner in which a Jacob's Ladder is folded together. In one embodiment, section 204 is folded underneath sections 202 - 1 . . . 202 -N maintaining the streamlined shape. As can be seen more clearly in FIG. 3 , sections 202 - 1 . . . 202 -N and section 204 do not all have the same shape. Instead, each of sections 202 - 1 . . . 202 -N and 204 is a cross-sectional piece of a streamlined shape such that when sections 202 - 1 . . . 202 -N and 204 are rotated about joints 306 - 1 . . . 306 -N sections 202 - 1 . . . 202 -N and 204 are aligned to form a streamlined shape. In the embodiment in FIG. 3 , a streamlined airfoil shape is used. The airfoil shape is not limited to a particular National Advisory Committee for Aeronautics (NACA) series airfoil shape. Embodiments of the present invention are compatible with any appropriate NACA series. In some embodiments a NACA 0015 shape is used. NACA 0015 is a symmetrical shape. In other embodiments, other symmetrical airfoil shapes are used. Symmetrical airfoil shapes are typically less subject to drift than asymmetrical or chambered shapes. However, in other embodiments a chambered airfoil shape is used. In other embodiments a NACA 67-015 laminar airfoil shape is used. In other embodiments, a NACA 67-018 laminar airfoil shape is used. In particular, in one embodiment, buoy 200 has a 30 inch chord length, 24 inch span and 5.4 inch maximum thickness. Additionally, in other embodiments, other streamlined shapes not including any NACA series airfoil shape are used.
For illustrative purposes only, gaps between each of sections 202 - 1 . . . 202 -N are displayed in FIG. 3 . In practice, each of sections 202 - 1 . . . 202 -N and 204 will be flush against adjacent sections when in a deployed configuration. Additionally, for illustrative purposes only, joints 306 - 1 . . . 306 -N have been drawn as protruding out from sections 202 - 1 . . . 202 -N and 204 . In practice, joints 306 - 1 . . . 306 -N are integrated into sections 202 - 1 . . . 202 -N and 204 such that joints 306 - 1 . . . 306 -N are flush with the surface of sections 204 and 202 - 1 . . . 202 -N leaving no substantial gap between sections 202 - 1 . . . 202 -N and 204 .
In a folded, deployed configuration, front portion 310 of buoy 200 is maintained facing the direction of current flow. This is achieved through a propulsion system, navigation and control unit and various sensors as known to one of skill in the art. Each of these components is housed in at least one of sections 202 - 1 . . . 202 -N and 204 . In one embodiment, a propulsion system is located in a section in a rear portion 312 of buoy 200 . In one such embodiment, section 202 - 1 houses the propulsion system. In another such embodiment, other rear sections house the propulsion system. In other embodiments, more than one section may house a propulsion system
As depicted in FIG. 3 , in some embodiments, a portion of buoy 200 is maintained above the water surface level. In one embodiment, the draft is 18 inches. Also, in one embodiment, flat surface area 308 of one or more sections 202 - 1 . . . 202 -N is equipped with solar cell paneling used to collect energy and recharge a battery.
Various means are employed in different embodiments to fold buoy 200 such that buoy 200 self-aligns into at least two configurations, a stowed configuration and a deployed configuration. In some embodiments, joints 306 - 1 . . . 306 -N include stored energy hinges biased to a deployed configuration such that once external forces which maintain buoy 200 in a stowed configuration are removed, buoy 200 automatically folds into a deployed configuration. In one such embodiment, an external force used to maintain buoy 200 in a stowed configuration is provided by sleeve 206 . Once buoy 200 is removed from sleeve 206 , in such an embodiment, buoy 200 will automatically fold into a deployed configuration due to the bias in joints 306 - 1 . . . 306 -N. In another embodiment, locking pins are used to maintain buoy 200 in a stowed configuration. Once the locking pins are removed in such an embodiment, buoy 200 folds to a deployed configuration due to the bias in the joints.
In other embodiments, joints 306 - 1 . . . 306 -N are mechanically powered by a motor 314 such that a force acts on joints 306 - 1 . . . 306 -N and sections 202 - 1 . . . 202 -N to cause buoy 200 to fold into a deployed configuration with each of sections 202 - 1 . . . 202 -N and 204 folding about one or more of joints 306 - 1 . . . 306 -N. In one such embodiment, the mechanically powered joints are activated and controlled remotely. In another such embodiment, the mechanically powered joints are activated automatically by occurrence of a particular event, such as impact with the water surface. In yet other embodiments, each of sections 202 - 1 . . . 202 -N and 204 are weighted such that the natural alignment of heavier portions sinking below the water surface and lighter portions rising to the water surface causes buoy 200 to fold into the streamlined deployed configuration. In yet other embodiments, other appropriate means are used for folding buoy 200 into a deployed configuration.
Buoy 200 has various advantages over prior buoys. In a stowed configuration, buoy 200 is capable of being launched from existing launch tubes. In some embodiments, the diameter of buoy 200 in a stowed configuration is 6 inches and the length is 163 inches, enabling buoy 200 to be launched from existing launch tubes in aircraft and submarines which have a diameter of 6 inches to 8 inches. Additionally, in one such embodiment, buoy 200 weighs 100 pounds which gives buoy 200 the capability of being launched by just one person. In other embodiments, buoy 200 is larger with a 21 inch diameter enabling it to be launched from existing torpedo tubes which have a diameter of 21 inches or more.
In a deployed configuration, buoy 200 is optimized for drag reduction by using a streamlined shape. By reducing drag, buoy 200 consumes less power as a station-keeping buoy through a propulsion system. In turn, by consuming less power, buoy 200 has a longer station-keeping duration than typical station-keeping buoys. In one embodiment, buoy 200 can station-keep for 30 days. Thus, through the combination of a streamlined deployed configuration and a cylindrical stowed configuration, embodiments of the present invention provide a much needed solution to the problem of providing a buoy which reduces power consumption through a more efficient shape and yet can still be launched from existing launch tubes which have a diameter ranging from approximately 6 inches to approximately 21 inches.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof. | An articulating sonobuoy is provided. The articulating sonobuoy comprises a plurality of section, and a plurality of joints connecting each of the plurality of section to adjacent sections, wherein each of the plurality of sections self-aligns by rotating about one or more of said plurality of joints changing the shape of the buoy from a stowed configuration to a streamlined deployed configuration. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 09/969,882, filed Oct. 4, 2001.
FIELD OF THE INVENTION
[0002] The present invention relates to a plant cultivation method and apparatus and, more particularly, it relates to a water-efficient and labor-efficient method and apparatus for growing multiple crops of various fruits and vegetables in sequence from a single preparation of the growing medium and plant nutrients.
BACKGROUND
[0003] In the cultivation of various plant species, numerous structures for housing a growing medium have been proposed to enable the grower to control the quantity of water supplied to the roots of the plant as well as to maintain the integrity of the growing medium. In general, these prior art structures have involved a container for the growing medium and other nutrients together with an irrigation system for supplying water.
[0004] In U.S. Pat. No. 5,524,387 to Blake Whisenant, entitled “Plant Cultivation Apparatus and Method,” incorporated herein by reference, there is disclosed a reservoir container assembly for the cultivation of plants. The reservoir container in the Whisenant '387 patent comprises a single reservoir container which may be made of solid materials such as recycled plastic. The reservoir container assembly includes a growing medium volume defined by the reservoir container which is separated from a drain volume along its lower wall by a permeable partition situated in a spaced relationship above the lower wall. In use, the growing medium volume is filled with a growing medium into which the roots of plants are grown. The reservoir container assembly of the Whisenant '387 patent has a top wall made of plastic material such as recycled plastic. The top wall has one or more openings therein for plant growth with the openings being positioned along the side of the top wall adjacent to the lateral wall.
[0005] In the apparatus disclosed in the Whisenant '387 patent, there is at least one drain opening in the lower area of the one of the lateral walls to allow excess water to flow out of the drain volume and thereby prevent the level of water in the drain volume from rising above the drain opening height. This ensures that the top portion of the drain volume will be filled with air and that the growing medium housed above the permeable partition has contact with air, such air being important for proper plant growth.
[0006] The apparatus of the Whisenant '387 patent also utilizes a column or columns of growing medium that extend into the drain volume at the lower portion of the assembly. The column(s) is filled with growth medium to allow the water in the drain volume to reach from the lower portion of the drain volume into the growing medium volume located above the permeable partition. In use, water will move up the growing medium column and into the growing medium volume by the process of capillary action. In addition, in the device disclosed in the Whisenant '387 patent, the column of growing medium is positioned so that it is adjacent to the lateral wall that is near to the plant opening in the top wall. The Whisenant '387 patent discloses that it is preferable that the columns of growing medium be positioned in the corners of the reservoir container but that they can be positioned anywhere along the lateral wall along which the plants are located. In the Whisenant '387 patent, the single reservoir container and its drain volume area is divided into compartments by rectangularly-shaped dividers which may be inter-connected with one another. The purpose of the dividers is to ensure that the permeable partition is positioned in the reservoir container so that the permeable partition lies parallel to the bottom wall and at a given height above the bottom wall thereby forming a drain volume for the water and air.
[0007] The device of the Whisenant '387 patent uses a gradient concept for the growing medium and nutrients. The gradient concept was initiated and evaluated during the 1960s as the nutritional component for a field-oriented, full-bed mulch system of production. The basic components are a soluble source of nitrogen (N) and potassium (K) on the soil bed surface in conjunction with a continuing water table. The N and K move by diffusion to the plant roots and equilibrate concurrently with the less soluble nutrients in the soil to maintain a predictable range of decreasing ionic concentrations with associated decreases in the ratio of N and K to total ions in the soil solution. The full-bed mulch minimizes the effect of evaporation and rainfall as physical forces that can alter the ionic composition of the soil solution. The total concept is designed to synchronize the rates of nutrients/water input with those of crop removal, and thus provide long term nutritional stability.
[0008] Nutrients in the soil move by diffusion, which is synchronized with removal or moved by mass flow with the water which is not synchronized with removal. By eliminating in-bed N—K (conventional procedure) and using on-bed N—K (gradient procedure), it is possible to maintain a continuing nutritional stability in the soil solution.
[0009] When conventional nutritional procedures are exposed to variations in the soil-plant-season combinations, nutritional stability in the soil solution can be weakened or destroyed. In the transition to more intensive production systems, conventional nutritional procedures often cannot maintain the nutritional stability required for continuing advances in productivity, whereas the gradient procedures sustain that stability.
[0010] In the prior art methods and apparatus including the methods and apparatus disclosed in the '387 patent, it is conventional to fill the reservoir container assembly with growing medium and to plant one or more plants in an array at the top location of the assembly. For example, with plants that will produce large vines such as tomatoes, only two plant locations are selected after filling the device with a growing medium. In contrast, with smaller plants, such as green peppers, it is known to plant an array consisting of two lines of three plants aligned along the axis of the reservoir container. In either case, the entire reservoir container assembly is prepared with growing medium and fertilizer for the planting of the selected seedlings and they are grown to maturity and harvested at substantially the same time. Thereafter, after the plants are done with their production, they are removed from the reservoir container assembly and the assembly is again prepared for the planting and growth of a new set of plants.
[0011] In U.S. Pat. No. 5,103,584 to Blake Whisenant, incorporated herein by reference, there is disclosed a plant cultivation apparatus which includes an inverted structure to enclose a plant's roots during growing.
SUMMARY OF THE INVENTION
[0012] While the reservoir container assembly of the Whisenant '387 patent is beneficial for the growing of single crops, in certain instances it has been found advantageous to make multiple seedling plantings from the same previously-prepared growing medium or growing medium and fertilizer combination. More particularly, one object of the present invention is to provide an improved reservoir container assembly which permits multiple cropping from a plant cultivation apparatus of the type disclosed in the Whisenant '387 patent.
[0013] A further object of the present invention is to provide an improved method of plant growth by providing an apparatus and method which permits the sequential planting of seedlings without interference or disturbance of an initially-prepared growing medium and fertilizer.
[0014] A further object of the present invention is to provide an improved apparatus and method of plant growth for use in large commercial scale plant growth operations which are more efficient and less labor intensive than those involved in the prior art. More particularly, it is an object of the present invention to provide an improved method and apparatus for plant growth which permits more than one crop to be grown based upon one series of preparation operations. More specifically, the same growing medium or growing medium and fertilizer combination are used for at least a second crop without the requirement that the growing medium and/or fertilizer need any further significant labor input beyond the initial preparation of the reservoir container assembly. The improved method and apparatus provide greater flexibility because of improved plant size options and improved options for the placement of the plants in either of successive crops.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Numerous other objects and the advantages of the present invention will become apparent from the consideration of the following disclosure taken in conjunction with the drawings, in which:
[0016] FIG. 1 is a side view with portions broken away of one embodiment of a reservoir container assembly prepared according to the present invention;
[0017] FIG. 2 is a cross-sectional view taken along the line 2 - 2 of the reservoir container assembly of FIG. 1 ;
[0018] FIG. 3 is a top plan view of the reservoir container assembly of FIG. 1 with portions broken away;
[0019] FIG. 4 is a side view with portions broken away of another embodiment of a reservoir container assembly according to the present invention;
[0020] FIG. 5 is a cross-sectional view taken along the line 5 - 5 of the reservoir container assembly of FIG. 4 ;
[0021] FIG. 6 is a top plan view of the reservoir container assembly of FIG. 4 with portions broken away;
[0022] FIGS. 7A to 7 D are diagramatic top plan views of several examples of sequential crop plantings according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] As show in FIG. 1 the reservoir container assembly 1 according to one embodiment of the present invention comprises a reservoir container or box 2 , a basket-style growing medium container 3 nested within the reservoir container 2 and resting upon divider 4 . The reservoir container is closed by a top wall 5 having openings 6 and 6 ′ through which one or more plants can grow with their roots embedded in the growing medium 7 contained within the basket-type growing medium container 3 . As best seen in FIGS. 1 and 2 , the roots embedded in growing medium 7 are surrounded by an inverted cup-shaped barrier structure C which will be described in more detail below. As used in this specification and claims, the phrase “means for confining the roots of plants” refers to the inverted cup-shaped barrier structures as well as their equivalents which include, among other things, cylinders and rectangular boxes with or without a planar upper face.
[0024] The reservoir container may be made of solid material such as recycled plastic. The growing medium volume defined within the basket-style growing medium container 3 is separated from drain volume 8 by a permeable bottom wall partition 9 of the basket-style container 3 . The basket-style container 3 may be made of material such as recycled plastic and have side and end walls 14 - 14 ′ and 15 - 15 ′. As an alternative (not shown), the end walls 14 - 14 ′ may be eliminated and the side walls 15 - 15 ′ extended to the length of the reservoir container or box 2 . The growing medium volume contained within the basket-style container 3 is filled with a growing medium such as a potting mixture in which the plants 10 are grown.
[0025] The top wall 5 of the reservoir container 2 may be made of solid material such as recycled plastic. Alternatively, it can be of a flexible plastic sheet with a peripheral edge attached to the upper end of the reservoir container or box 2 . The reservoir container 2 has two end walls 11 , 11 ′ and two lateral walls 12 and 12 ′. Top wall 5 has plant openings 6 and 6 ′ therein for plant growth, said plant opening(s) being positioned at various places depending upon the type and size of plants being grown as discussed in more detail below. As best seen in FIG. 1 , the reservoir container has at least one opening 13 in one of the lateral walls 12 , 12 ′ to allow excess water to flow out of the drain volume 8 and thereby prevent the level of water within the drain volume 8 from accumulating above the opening 13 . This ensures that the top portion of the drain volume 8 will be filled with air and that the growing medium 7 thereabove has contact with air along the bottom 9 and side and/or end walls 14 - 14 ′, 15 - 15 ′ of the basket-style container. Of course, such air is important for proper plant growth.
[0026] Growing medium column(s) 16 in drain volume 8 allows the water in said drain volume to reach from the lower portion in said drain volume into the growing medium 7 . Water will move up the growing medium column(s) 16 , then into the growing medium 7 by the process of capillary action. As best seen in FIGS. 1 and 2 , growing medium column(s) 16 are positioned so that they are adjacent the bottom wall of the basket-style container 3 at locations which are advantageous for the growing of the particular type of plant as described in more detail below.
[0027] FIG. 2 generally shows a layer of fertilizer mixture 17 which is placed on top of the growing medium at the top of the growing medium volume defined by the basket-style container 3 . Using the above gradient-oriented nutritional procedures, the fertilizer 17 is placed in an appropriate location depending upon the type of plant being grown, the numbers of plants being grown and the location of the growing medium column(s) with respect to the plant opening(s) in the top wall 5 .
[0028] The positioning of plant openings 6 and 6 ′, growing medium column 16 , and fertilizer mixture 17 preferably causes the salt deposits to occur remote from the roots of the plant 10 . The positioning of these elements ensures that the water passing next to the plant 10 has not previously passed through fertilizer 17 . Capillary action causes the water in drain volume 8 to flow up the growing medium column(s) 16 and through the growing medium volume to plant openings 6 and 6 ′. There will thus be flow paths leading from the growing medium column(s) 16 , one path to opening 6 and another path to opening 6 ′.
[0029] As best seen in FIG. 3 , the drain volume 8 is divided into rectangular compartments by dividers 4 . These dividers may be rectangularly-shaped and may be positioned so as to be approximately perpendicular to the top wall 5 and the bottom wall 18 of the reservoir container. The dividers ensure that the basket-style container 3 , and its permeable bottom partition 9 , is positioned in the reservoir container 2 so that the permeable partition 9 lies parallel to the bottom wall 18 of the reservoir container and at a given height above the bottom wall 18 , thereby forming a drain volume.
[0030] For further details of the construction of the basket-style growing medium container, reference is made to co-pending application Ser. No. 08/812,572, filed Mar. 6, 1997, which is incorporated herein by reference.
[0031] Further, as best seen diagrammatically in FIGS. 2 and 3 the fertilizer mixture 17 is placed on the growing medium 7 contained within the basket-style growing medium container 3 at locations selected to be appropriate for a given combination of growing medium column(s) 16 and the type, size and number of plants being grown. As seen in FIG. 3 , a water-fill tube 22 may be provided so that water can be passed into the upper end of tube 22 and fed to the lower portion of drain volume 8 .
[0032] FIGS. 4, 5 and 6 relate to a second embodiment of the reservoir container assembly of the present invention. As shown in FIG. 4 , this embodiment is comprised primarily of a single reservoir container or box 100 . The container may be made of a solid material such as recycled plastic. Growing medium volume 101 in reservoir container 100 is separated from drain volume 102 by a permeable partition 103 which may be plastic or rust-proof metal screen. Growing medium volume 101 is filled with a growing medium 104 such as described above in which plants 105 are grown. Top wall 106 of reservoir container 100 may be made of solid or flexible sheet material such as recycled plastic. Reservoir container or box 100 has two end walls 107 - 107 ′ and two lateral walls 108 and 108 ′. Top wall 106 has openings 109 therein for plant growth, said plant openings being positioned over a cup-shaped barrier structure C′. As best seen in FIG. 5 , cup-shaped barrier structure(s) C′ are embedded in the growing medium 104 and are adjacent a layer of fertilizer mixture 109 .
[0033] Further details of this embodiment of the reservoir container assembly are shown in U.S. Pat. No. 5,524,387, which is incorporated herein by reference.
[0034] The following is a description of the apparatus and method of the present invention in use.
[0000] Plant Selection
[0035] Some gardeners prefer starting with seedlings or plant starts in their growing container. Healthy looking plants should be selected. A local nursery or county extension agency can recommend varieties that are best suited to the user's area.
[0000] Location and Assembly
[0036] The user should choose a location for the reservoir container assembly which will receive plenty of sunlight. The growing container assembly can also be indoors if there is enough light. The divider should be in the bottom of the reservoir container with the medium container or the growing medium resting on top of it. Insert the fill tube 22 as seen in FIG. 3 and use a cable or other fastener to fasten it to the upper corner of the reservoir container. The fill tube 22 should be in the front of the reservoir container on the same side as drain hole 13 as seen in FIG. 1 . The user should be sure that the fill tube 22 goes from the top of the reservoir container into the water reservoir drain volume 8 as seen in FIG. 2 .
[0000] Potting Mixture
[0037] 2.3 cubic feet (about 30 pounds or 60 dry quarts) of a light and spongy soil-less potting mixture is suitable for potting and use as a growing medium. Many brands are readily available at any garden center or home store. While the exact composition is not important, most mixes contain about 60% of peat moss plus composted wood products, perlite, vermiculite, and minor elements. Many gardeners mix one cup of dolomite to the potting mix. Soil-based potting soil is too dense and is not recommended for home use. A good potting mix will last for several growing seasons.
[0000] Stakes and Tomato Cages
[0038] Tomatoes, eggplant, pole beans, and other vine plants will need four-foot support stakes. They can be installed at the ends of the growing container and secured to the end walls 11 - 11 ′ by appropriate fasteners (e.g., ties through openings in the walls). Twine can be tied between the stakes to support the plants as they grow. Tomato cages can also be installed after the plants begin to mature. Smaller vegetable and flower plants do not need stakes.
[0000] Filling the Growing Container
[0039] The user should fill the bottom of the growing container with water until it runs out the drain hole 13 . Openings have been cut in the permeable bottom of the basket-style container, exposing the water in the bottom of the reservoir container. Firmly pack these two openings with moist potting mix. Now cover the permeable bottom with potting mix and fill the basket half way up. Pack the soil down and moisten it well with water. Now completely fill the rest of the basket with potting mix and make a slight crown on top similar to a cupcake. Use plenty of potting mix so that a lip is not left between the top of the growing container and the top of the potting mix. Add water on top to make sure the potting mix is moist and refill the reservoir container using the fill tube. In the case of using a growing container assembly without the interior basket-style container, the process is similar only the potting mix is used to completely fill the container above the permeable partition 103 situated above the water drain volume 102 .
[0000] Use of Dry Fertilizer
[0040] The growing container assembly differs from conventional gardens in that fertilizer is added at the beginning. Any general purpose dry granular fertilizer, such as 666, 888, 6-8-10, or organic mixtures can be used. After the growing container has been filled with potting mix, multiple inverted cup-shaped barrier structures C are inserted into the potting mix so that their truncated tops are level with the top of the potting mix. Thereafter, dry fertilizer 17 is added to the top layer of the potting mix, in some cases across the entire top surface of the growing container assembly. Sufficient fertilizer should be provided at this point to fertilize not only the initial crop, but also at least part of the second or later crop(s) to be planted as described below.
[0000] Covering and Planting
[0041] After the potting mix and fertilizer have been applied, completely cover the top of the growing container with one of the plastic top sheets and secure it over the outside edges of the reservoir with clips, clothes pins or the like. Poke the top end of the water fill tube 22 through the cover. Place the white side of the cover up in warmer climates and the black side up in cooler climates. Cut four inch holes or “Xs” in the plastic top sheet, spaced from the outside wall of the growing container. Plant the seedlings through the “Xs” into the potting mix contained within the inverted cup-shaped barrier structures and “water them in” just as in conventional gardening. The plastic top sheet may remain on the growing container assembly for the life of the plants and functions as a mulch, among other things.
[0000] Watering
[0042] Plants are watered by simply adding water through the tube 22 to fill the bottom water drain volume. You cannot over water with the growing container assembly because of the use of a drain hole 13 . The growing container assembly automatically provides the proper amount of moisture. For example, when plants are small one only needs to add water every few days. As the plants grow larger, they will require more water. It may be desirable to add water regularly until it runs out the drain hole 13 indicating that the reservoir is full. Rain will not water the roots of the plants because they are covered by the plastic top sheet and by the upper surface of the truncated, cup-shaped barrier structure as described above.
[0000] Harvesting
[0043] Depending upon the type of plant, the output is harvested and the initial growing crop is terminated. Thereafter, instead of uncovering the growing medium and removing the roots of the plants from the first crop, those are simply left in place and the process of cutting “Xs” into the additional inverted cup-shaped structures is repeated much the same as the above initial planting. Thereafter, watering and growth for those additional plants of the second planting is carried just as above.
[0044] In view of the above, it can be seen that significant economies in a labor-intensive situation can be obtained. Thus, whereas the prior method and structure required a complete replanting and refertilization of the growing medium before planting the second crop in any given container, with the present invention, that additional labor is eliminated because the second crop is planted into the previously-prepared growing medium and fertilizer combination. Thus, significant labor-saving advantages are present, especially in the case where the growing containers are utilized in a commercial setting where many hundreds of growing containers are prepared and used to grow a first crop and then a second crop according to the above-described procedure.
[0045] The following examples are given with reference to the top views of schematic drawings of FIGS. 7A to 7 D.
EXAMPLE 1
[0046] In FIG. 7A , cabbage plants were set in barrier cups B 1 . Fertilizer was applied over the entire top of the growing medium at twice the rate for a single crop. The fertilizer was 6-8-10 and the growing medium, commercially available from Speedling Corp., was Canadian peat moss and vermiculate. The cabbage was harvested and the plants were cut off at the barrier cup. Tomato plants were then set in barrier cups B 2 which had been positioned in the center of the box at the time the growing medium and fertilizer were prepared prior to planting the cabbage plants. No new fertilizer was added; however, a new plastic top was added. The cabbage crop was normal and the tomato harvest was comparable to control boxes.
EXAMPLE 2
[0047] In FIG. 7B , two tomato crops were grown consecutively. The first crop was set in barrier cups B 1 and the second crop was set in barrier cup B 2 . Twice the fertilizer was applied over the entire top prior to setting the first crop. The first crop was in the fall and the second crop in the spring. Both crops were considered normal in both yield and growth. The first growing had a larger growing than the second. This is believed to be more from weather factors than from nutritional factors.
EXAMPLE 3
[0048] In FIG. 7C , two tomato plants PI and P 2 were set in the conventional manner. No barrier cups were used and the fertilizer was placed in a band in the conventional manner. Barrier cups B 2 were set in the center of the box where squash seed will be planted for the second crop. No additional fertilizer is to be applied prior to the second crop and the squash will use the residual fertilizer. The barrier cup provides excellent germination for the squash seed.
EXAMPLE 4
[0049] In FIG. 7D , cabbage P 1 was planted without a barrier cup. Fertilizer was banded along the center axis of the box. Barrier cups B 2 were also placed in the center of the box. Tomatoes were planted in the barrier cups B 2 after the cabbage was harvested. In this configuration, additional fertilizer was added over the entire top of box with a new plastic top being used after the first crop was harvested. The results were considered to be excellent. The tomatoes grew and compared favorably with control boxes. Cabbages were cut after harvesting and all roots were left in place.
[0050] It will be apparent to those skilled in this art that various modifications may be made thereto without departing from the spirit and scope of the invention as defined in the following claims. | An apparatus and method for growing plants with controlled rates of nutrient and water input. The apparatus and method includes the use of a reservoir container and means to contain a growing medium. The apparatus is closed by a top wall having openings through which plants can grow with their roots enclosed in inverted cup-shaped barrier structures imbedded in a growing medium. At the time of the first planting there are multiple inverted cup-shaped barrier structures imbedded in the growing medium, but not all them are provided with seedlings during the first planting. Water and air is provided in a reservoir below the growing medium which has means for assisting the transfer of water from the reservoir into the growing medium. Pre-selected plant nutrients (e.g., N, K) are appropriately placed on the growing medium at the time of the initial planting and are used over the course of time for plant growth during successive plantings. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Filed of the Invention
[0002] This invention is directed toward building elements.
[0003] 2. Description of the Related Art
[0004] Many building elements, such as window sills for example, are presently made from stone or concrete. They are heavy, making handling and installation difficult. Also, they do not always match or complement the finished outer surface of the building on which they are installed. In addition, they can be expensive.
SUMMARY OF THE INVENTION
[0005] It is the purpose of the present invention to provide a building element, such as a window sill, that is light in weight and therefore easy to handle and install. It is another purpose of the present invention to provide a building element, such as a window sill, that can be made to have an appearance that matches or complements the finished outer surface of the building on which it is employed, and that is relatively inexpensive to make.
[0006] The building element can be a window sill; or a decorative header or top for a window or a door; a cornice; an architrave; a corbel; a hood molding; or the like. The building element of the invention is usually an element which has more of a decorative function than a structural function in the building although the elements are useful and could provide some structural function.
[0007] In accordance with the present invention there is provided a building element having an outer visible member, defining the shape and appearance of the building element, and an inner support on which the outer member is mounted. The inner support is adapted to be mounted on the building on which the building element is to be used. The inner support and the outer member have cooperating first and second mounting means for easily and quickly locating the outer member in the correct position on the building when it is mounted on the inner support. When the outer member is mounted on the inner support, the inner support is substantially hidden. Both the inner support and outer member are made from thermoplastic material which is molded, extruded or otherwise formed to provide the required shapes. The outer visible surfaces of the inner support and the outer member have a tough, decorative, protective coating. The color of the coating can match or complement the appearance of the outer finished surface of the building. In addition, the outer visible surfaces can textured to provide various surface apearances and can also be formed to imitate stones, bricks or the like.
[0008] The invention is particularly directed toward a building element comprising an inner support and an outer visible member, separate from the inner support, defining the shape and appearance of the building element. The inner support has first mounting means thereon. The outer member has second mounting means thereon and a support recess at its lower back portion for receiving the inner support. The first and second mounting means cooperate to mount the outer member on the inner support when the inner support is mounted on a building to locate the outer member against the building, the support substantially hidden by the outer member. The outer member and preferably the inner support are made from formable plastic material and the visible surfaces of the outer member and the inner support, when mounted on the building, are covered with a decorative protective coating.
[0009] The invention is also particularly directed toward a building element comprising an outer member defining the shape and appearance of the building element, and an inner support. The inner support is attachable to a building wall and has first mounting means thereon. The inner support has top and bottom surfaces, front and back surfaces and end surfaces. The outer member has a support recess at its bottom, back portion for receiving the inner support, and second mounting means within the recess. The outer member also has top and bottom surfaces, front and back surfaces and end surfaces. The first and second mounting means cooperating to mount the outer member on the inner support when the inner support is mounted on a building wall to locate the inner support within the outer member and the outer member against the building wall, the bottom and back surfaces of the inner support and the outer member aligned.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a front view of a building element on a building;
[0011] FIG. 2 is a cross-section view of the element taken along line 2 - 2 in FIG. 1 ;
[0012] FIG. 3 is an exploded, cross-sectional view of the element;
[0013] FIG. 4 is a cross-sectional view taken along line 4 - 4 in FIG. 2 ;
[0014] FIG. 5 is a detail cross-sectional view taken along line 5 - 5 in FIG. 4 ;
[0015] FIG. 6 is an exploded, cross-section view of a window sill;
[0016] FIG. 7 is an exploded, cross-section view of a window sill adapted for use with siding;
[0017] FIG. 8 is back view of the assembled window sill shown in FIG. 7 ; and
[0018] FIG. 9 is a cross-section view similar to FIG. 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] The building element 1 , as shown in FIGS. 1 to 4 has an inner support 3 and an outer visible member 5 which member defines the shape and appearance of the building element 1 . The building element 1 in this embodiment is shown as forming a decorative facing on the top of a window 7 in a building.
[0020] The inner support 3 of the element is elongate and has top and bottom surfaces 9 , 11 , front and back surfaces 13 , 15 and end surfaces 17 . The top and bottom surfaces 9 , 11 are parallel to each other and the front and back surfaces 13 . 15 are parallel to each other and normally transverse to the top and bottom surfaces 9 , 11 . The front surface 13 can have its top portion cut away to provide a front clearance space 19 if needed. The purpose of the clearance space 19 will be explained later.
[0021] First mounting means 21 are provided on the top surface 9 of the inner support 3 and can comprise a rib 23 extending up from the top surface 9 , the back surface 25 of the rib 23 aligned with the back surface 15 of the inner support 3 . A slot 27 can extend into the inner support 3 from the top surface 9 , the slot adjacent and in front of the rib 23 . The upper surface 29 of the rib 23 can be angled downwardly from its back surface 25 to its front surface 31 . The front surface 31 of the rib 23 is aligned with the back surface 33 of the slot 27 .
[0022] The outer member 5 of the element is an elongated member, slightly longer than the inner support 3 , with top and bottom surfaces 34 , 35 , front and back surfaces 37 , 39 and end surfaces 41 . The top and bottom surfaces 34 , 35 are parallel to each other and the front and back surfaces 37 , 39 can be parallel to each other and normally transverse to the top and bottom surfaces 34 , 35 . A drip channel 43 is preferably provided along the bottom surface 35 near the front surface 37 .
[0023] A support recess 45 is provided at the back, bottom corner of the member 5 to receive the inner support 3 . The support recess 45 is as long as the inner support 3 and slightly shorter than outer member 5 , the ends 47 of the recess 45 spaced slightly inwardly from the ends 41 of the outer member 5 . The support recess 45 is defined by a front wall 49 and a top wall 51 , the front wall 49 spaced outwardly from the back surface 39 and the top wall 51 spaced upwardly from the bottom surface 35 .
[0024] The outer member 5 has second mounting means 53 in the form of a rib 55 extending downwardly from the top wall 51 of the recess 45 and a rib receiving space 57 adjacent the rib 55 and extending upwardly from the top wall 51 . The rib receiving space 57 is adjacent the back surface 39 of the member 5 and is defined by an angled top surface 59 extending forwardly and downwardly from the back surface 39 to a vertical front surface 61 that is aligned with the back surface 63 of the rib 55 .
[0025] Both the inner support 3 and the outer member 5 are molded from a suitable polystyrene or like material. The bottom surface 11 of the inner support 3 can be provided with a thick coating 67 of reinforced stucco-like material providing a hard, protective, decorative, finish to the bottom of the inner support. Similarly, the top, bottom, front and end surfaces of the outer member 5 can be provided with a thick coating 69 of reinforced stucco-like material, the material being the same as the material in the protective coating 67 on the inner support. The coatings 67 , 69 can be made from a settable, cement-plastic material mixture, applied in two layers 71 , 73 with a reinforcing mesh 75 laid over the first layer 71 and then covered with the second layer 73 as shown in FIG. 5 . The stucco-like material is well known. The coatings 67 , 69 , when applied, can be grooved to simulate blocks, bricks, stones or the like if desired and their outer surface can be textured or otherwise treated to provide the required surface finish. The coatings can be coloured as required.
[0026] The building element 1 is mounted in place by first mounting the inner support 3 on the outer surface of the framing wall 79 of a building. The inner support 3 is mounted just above the window 7 , centered with respect to it, with fasteners such as nails 81 driven into the wall 79 through the support 3 from its front surface. The back surface 15 of the support abuts the wall 79 as does the rib 23 . The outer member 5 is then placed above the inner support 3 , with its back surface 39 abutting the wall 79 and with the inner support 3 aligned with the recess 45 , and slide down the wall to locate the inner support 3 within the recess 45 and thus within the outer member 5 . When properly mounted, the inner support 3 is fully within the recess 45 with its bottom surface 11 level with the bottom surface 35 of the outer member 5 and closing the recess 45 .
[0027] Some adhesive can be applied to the slots 27 , 57 and to the ribs 23 , 55 to interlock the outer member 5 with the inner support 3 . The fastener clearance 19 on the front of the inner support 3 provides room for the heads of the fasteners 81 so the heads do not interfere with the assembly of the element. The relatively small, lightweight, inner support 3 is easy to mount in the correct position on the building and once mounted, assembly of the outer member 5 thereon, in the correct position relative to the building, is also easy.
[0028] The building element 1 described above is used to provide a decorative facing over a window or a door in a building. The building element can take other forms. For example, the building element can be in the form of a window sill 101 for windows. In this form, the outer member has the shape of a window sill member 105 as shown in FIG. 6 , and is mounted on the inner support 3 which is mounted just below a window opening 107 in a building wall 109 . The sill member 105 can have a top surface 111 with a horizontal top rear portion 113 and a slightly downwardly extending top front portion 115 . the front surface 117 can be angled inwardly in moving upwardly from the bottom surface. The other elements of the sill member 105 are the same as the outer member 5 . The shape of the sill member 105 , as seen in cross-section, is a squat and wide sill shape as compared to the more narrow, taller facing shown by the outer member 5 . The sill member 105 is mounted on the inner support 3 in the same manner as the outer member 5 was mounted, the inner support 3 being fastened to the outer surface of the building wall 109 just below a window opening 107 to locate the sill member 105 in a proper position relative to a window (not shown) in the window opening 107 .
[0029] If the window sill 101 is used on a building that is to be covered with siding, the window sill 101 can be modified to accommodate the siding. As shown in FIGS. 7 and 8 , the bottom inner corner of both the inner support 3 ′ and the sill member 105 ′ of the window sill 101 ′ can be cut away to form a siding recess 121 . The siding recess 121 extends across the width of sill member 105 ′ and comprises a siding recess section 123 extending right across the bottom inner corner of the inner support 3 ′, and a siding recess section 125 on each side of the support recess 45 ′ in the sill member 105 ′ in its bottom inner corner on each side of the recess. The siding recess sections 125 on each side of the support recess 45 ′ are aligned with the siding recess section 123 on the inner support 3 ′ and form extensions of it to provide the siding recess 121 that extends right across the width of the assembled window sill 101 ′. All three recess sections 123 , 125 are defined by a vertical front wall 127 and a horizontal top wall 129 . The top wall 129 is just slightly wider than the width ‘w’ of a siding member 131 .
[0030] The siding can be installed first on the wall and the siding member 131 adjacent the window opening 107 ′ can be cut to fit in the siding recess 121 on the window sill 101 ′ to present a finished appearance. The window sill 101 ′ can be installed after the siding member 131 adjacent the bottom of the window is installed, the inner support 3 ′ nailed to the wall with a top portion 133 of the siding member 131 within the siding recess section 123 . The window sill member 105 ′ is then mounted on the inner support 3 ′ with its end recess sections 125 also receiving the top portion 133 of the siding member 131 .
[0031] The window sill member 105 ′ can be attached to the siding member 131 with fasteners 137 if desired. In this case, the inner support 3 ′ can be provided with a top clearance space 139 on its top surface 9 ′. The clearance space 139 is provided using a rib 141 on the top front portion of the top surface 9 ′. The rib 141 spaces the top wall 51 ′ of the siding recess 45 ′ from the top surface 9 ′ of the inner support to provide clearance for the fastener heads of the fasteners 137 driven through the siding support 3 ′ into the siding member 131 .
[0032] One form of mounting means 21 , 45 for mounting the outer member on the inner support has been described. The mounting means can take other forms as well. For example, as shown in FIG. 9 the first mounting means 21 ′ on the inner support 3 ″ can be in the form of two spaced-apart bottom ribs 151 , 153 extending upwardly from the rear portion of the top surface 9 ″. The back rib 153 has its back surface 155 aligned with the back surface 15 ″ of the support and has its top surface 157 angled downwardly and forwardly from the back surface 155 . A bottom slot 159 is formed between the ribs 151 , 153 . The second mounting means 45 ′ on the outer member 5 ″ can comprise two spaced apart top slots 161 , 163 extending up from the top wall 51 ″ of the support recess 45 ″ to receive the two bottom ribs 151 , 153 , the outer slot 163 open on its inner side and having an angled top wall 164 to receive the top 157 of the outer rib 153 . The two top slots 161 , 163 define a top rib 165 for extending into the bottom slot 159 . The additional slot and rib provide a more positive connection between the outer member 5 ″ and the inner support 3 ″. Other configurations to mount the outer member on the inner support can be employed. The only criteria is to have the first and second mounting means locate the back surface of both the inner support and the outer member flush against the building wall, and the bottom surface of the outer member aligned with the bottom surface of the inner support.
[0033] The building element has being described above as a facing for the top of a window or door or as a window sill. It can be made into any decorative building element used in building construction such as a cornice, a corbel, door and/or window moldings, and the like. The building element is made in two parts, the outer member, which serves a decorative purpose, and the inner support. The inner support, being attached first to the building, serves to locate and mount the outer member in the correct position on a building.
[0034] It will be seen that the building element is lightweight, making it easily handled and easily mounted; can be easily decorated to match or complement the rest of the finished building; and is relatively inexpensive being primarily made from moldable plastic material.
[0035] It is preferred to manufacture the inner supports 3 , 3 ′ in extended lengths and then cutting sections off to the length needed for the particular application being assembled. It is also preferred to manufacture the outer members 5 , 105 , 105 ′ in extended lengths. The outer members are then cut to the size needed by cutting a central section out of the member to leave the two outer parts, when joined together, forming a member of the required length. Both the inner supports and outer members are made off site.
[0036] The inner support has been described, in the examples shown, as being from moldable plastic material. In some instances, the inner support can be made from suitable metallic material such as aluminum. The inner support can be formed by cutting a section off a long length of extruded metallic material. | A building element for attachment to a building to provide a mainly decorative effect. The building element has an outer member defining the shape and appearance of the building element and a separate inner support. The inner support is attachable to a building wall and has first mounts thereon. The outer member has a support recess at its bottom, back portion for receiving the inner support, and second mounts within the recess. The first and second mounts cooperating to mount the outer member on the inner support when the inner support is mounted on a building wall to locate the outer member against the building wall. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of and claims priority to U.S. Ser. No. 11/434,557 filed on May 15, 2006, which is pending and which is hereby incorporated by reference in its entirety for all purposes.
U.S. Ser. No. 11/434,557 is a non-provisional counterpart to and claims priority to U.S. Ser. No. 60/681,004 filed on May 13, 2005 and is hereby incorporated by reference in its entirety for all purposes.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to pet amusement and exercise equipment and, more particularly, to a treat dispensing toy capable of attracting and generating interaction with a pet animal. The invention furthermore relates to a toy having a unitary, one-piece construction.
2. Discussion of the Related Art
For dogs and other animal companions, toys are not a luxury, but a necessity. Toys help fight boredom in pets left alone, and toys can even help prevent some problem behaviors from developing. Many factors contribute to the “right” toy, and a number of them depend upon the pet's size, activity level, and preferences.
Many pet toys should be interactive. For example, interactive play is very important for pet dogs because dogs need active “people time”—and such play also enhances the bond between the pet owner and pet. By focusing on a specific task—such as repeatedly returning a ball or playing “hide-and-seek” with treats or toys—a pet can expel pent-up mental and physical energy in a limited amount of time and space. This greatly reduces stress due to confinement, isolation, and boredom. For young, high-energy, and untrained dogs, interactive play also offers an opportunity for socialization and helps the dogs to learn about appropriate and inappropriate behavior, such as jumping up or being mouthy.
The goal of animal toy designers is to make the toy attractive to the animal and to the animal caretaker. A toy is attractive to an animal when it presents a challenge that is neither too easy nor too difficult to solve and rewards the animal. The toy is attractive to the caretaker when the toy has good playability, durability, and quality of construction and occupies the interests of the animal.
The term “treatball” generally refers to a class of animal toys, typically dog toys, wherein one or more edible treats may be placed into a ball and the treat and/or treats are dispensed as the animal interacts with the toy. In interacting with the toy, the animal follows its natural instinct to obtain food and performs problem solving tasks that engage the animal's mind. Typically, treat dispensing toys are in the form of solid-covered, non-spheroid toys, such as bone-shaped toys or balls with a series of regular or irregular openings through which is dispensed the treat, which is usually shaped to be insertable along only one axis. Turning to FIG. 6 , an example of a convention spheroid-shaped treatball 600 is depicted. The prior art treatball 600 consists of an outer shell 602 with a number of openings 604 for inserting/accessing treats.
Prior art, ball-shaped treatballs 600 are generally designed and intended to only be rolled by the pet owner or chewed by the pet, but not thrown by the pet owner. Typically the materials used may not bounce and roll well on soft or irregular surfaces such as a grass field. In addition, the insertion/access openings 604 of conventional designs may allow treats to prematurely fall out without animal interaction, particularly if the conventional treatballs are thrown or bounced. Thus, such conventional treatballs 600 do not have bounce or interactivity characteristics that excite and engage an animal. Although non-spheroid toys that dispense treats may retain treats better than conventional ball-shaped treatballs 600 and thus may be more interactive, such toys may not have desirable bounce and roll characteristics. In either case, prior art treat dispensing toys do not provide impact protection to inserted treats and when bounced, treats may crumble and prematurely fall out of the toy.
Accordingly, a need exists for a toy that offers at once the desirable bounce and roll characteristics of a spheroid-shaped treatball and also the engaging aspect of a treat dispensing toy that requires an animal to interact with the treatball in order to cause treats to be dispensed at the appropriate time in response to the animal's efforts.
A further need exists for the toy that permits a person to find enjoyment interacting with a pet.
Still a further need exists for the toy that combines rolling, bouncing and interactivity characteristics that can amuse and attract the pet.
Yet, a further need exists to make the manufacture of the toy as simple as possible.
SUMMARY OF THE INVENTION
In accordance with the invention, an improved treatball is disclosed that has the desirable bounce and roll characteristics of a spheroid-shaped treatball and also the engaging aspect of a treat dispensing toy that requires an animal to interact with the treatball in order to cause treats to be timely dispensed in response to the animal's efforts. Specifically, the toy includes a spherical solid outer cover or exterior wall that has a covered opening for treat insertion and a diametrically disposed opening for treat dispensing. Within the inventive treatball, a series of baffles define a path through the toy from the covered opening to the treat dispensing opening. The path may include a series of interconnected chambers through which treats inserted into the covered opening must be made to traverse in order to reach the dispensing opening.
In use, treats are preferably inserted at the covered end by the pet owner and the toy is thrown or kicked to the pet. As the toy bounces and rolls, the preferably elastic structure of the toy protects the treats (e.g., hard baked and relatively brittle dog biscuits) from crushing impacts. Once the animal begins interacting with the treatball, e.g., via shaking, tossing, compressing, pawing, chasing, scratching, bouncing, etc., the treats are advanced past the baffles, through the toy, and eventually dispensed through the unobstructed opening.
In some embodiments, the treatball of the present invention may be part of a system or kit wherein the treat size and ball size are associated with each other. For example, smaller treats may be used with smaller balls and larger treats may be used with larger balls. Such a system may, for example, allow small dogs, who may be only capable of consuming small treats, to enjoy playtime with a small-sized treatball and prevent such small treats from prematurely dispensing from an inappropriately large treatball.
In accordance with one or more embodiments, the treatball is made using an internal mold that upon formation of the ball is removed through an opening of the treatball.
The above and other features of the invention will become more readily apparent from the following detailed description accompanied by the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a perspective view of a preferred embodiment of the inventive toy according to the present invention;
FIG. 1B is a perspective view of the preferred embodiment of the present toy similar to the one shown in FIG. 1A , but having a smaller size;
FIG. 2 is a perspective cross-sectional view of the inventive toy of FIG. 1 ;
FIG. 2A is a cross-sectional view of the inventive toy of FIG. 1 illustrating a single baffle;
FIG. 3 is a side elevational view of a cross-section of the inventive toy shown in FIG. 1 ;
FIG. 4 is a first diagrammatic planar view of the inventive toy of FIG. 1 ;
FIG. 5 is a second diagrammatic planar view of the inventive toy of FIG. 1 ; and
FIG. 6 is a perspective view of a prior art treatball.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to several embodiments of the invention that are illustrated in the accompanying drawings. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps. The drawings are in simplified form and are not to precise scale. For purposes of convenience and clarity only, directional terms, such as top, bottom, left, right, up, down, over, above, below, beneath, rear, and front may be used with respect to the drawings. These and similar directional terms should not be construed to limit the scope of the invention in any manner. The words “connect,” “couple,” and similar terms with their inflectional morphemes do not necessarily denote direct and immediate connections, but also include connections through mediate elements or devices. Furthermore, such terms as “toy,” “treat toy,” and “treatball” are used interchangeably.
Turning now specifically to FIGS. 1A and 1B , two identically shaped, but differently dimensioned treatballs 100 may be packaged individually to meet the individual needs of dogs classified in accordance with their respective size, which typically includes large, medium and small size dogs. In an alternative embodiment, however, more than one toy 100 can be packaged together so as to constitute a kit. One of the reasons for having the kit is that a pet may like one of the packaged toys 100 and, for some reason, ignore the other one regardless of the size of toys 100 . Treatball 100 is preferably a single unit, which is made from a moldable material selected from a substantially rigid material, such as plastic or foam, or a flexible material, such as rubber or plastic. In some embodiments, the treatball 100 may be molded from a single material in a single pour step.
Focusing on FIG. 1A , a perspective view of an example embodiment of a treatball 100 is depicted. The treatball 100 may include an exterior wall 102 that may be formed in the shape of a spheroid or round ball. The exterior wall 102 may include one or more ports or openings 104 for inserting or dispensing a treat. The exterior wall 102 may also include texturing 106 on the outer surface of the treatball 100 . The opening 104 may include a lip 108 that defines and/or reinforces the edge of the opening 104 .
Turning to FIG. 1B , a different sized embodiment of a treatball 100 is depicted. The same reference numerals are used to identify the corresponding features.
Referring to both FIGS. 1A and 1B , the exterior wall 102 of a treatball 100 may be manufactured of a compressible elastic material such as rubber or plastic. Likewise, the structure (e.g., thickness, density, etc.) of exterior wall 102 may be such that the treatball 100 is compressible and stretchable. The treatball 100 may be manufactured so that it can be distorted by compressive and/or stretching forces and yet, when the distorting forces are removed, return to its original manufactured shape and size. Application of such distorting forces may alter the shape of (e.g., elongate) opening 104 so as to cause a treat within the treatball 100 to be dispensed. The manufacture of exterior wall 102 from a compressible material may further provide improved bounce characteristics when treatball 100 is thrown onto either hard or soft surfaces. Further, the compressible structure and material of exterior wall 102 may absorb impacts resulting from bouncing or other shocks so that treats within the treatball 100 are protected and not broken by the impacts. In some embodiments of the present invention, exterior wall 102 may be constructed to be durable enough to withstand chewing by an animal. Additionally, a material that emits a squeaking sound when chewed by an animal may be selected for constructing exterior wall 102 .
In some embodiments, exterior wall 102 may be manufactured using any of a variety of different colored material, as well as using a clear or multi-color material. Additionally, exterior wall 102 may be manufactured from a material that may include a scent attractive to animals. Some embodiments of treatball 100 may include lighting and/or electronic sound generators within the exterior wall 102 .
The one or more ports or openings 104 may be in any shape including a circular opening. The openings 104 may be of any practicable size to allow insertion or dispensing of different sized or shaped treats. Additionally, the openings 104 may be sized to view treats inside treatball 100 . As indicated above, the treatball 100 may include ports or openings 104 which become temporarily distorted when compressive force is applied. Temporary distortion of openings 104 may allow for treats to be retrieved with either greater ease or greater difficulty. In other embodiments, the treatball 100 may include openings 104 , which do not become distorted (e.g., remain rigid or at least more rigid than exterior wall 102 when compressive force is applied.
Texturing 106 of the outer surface of exterior wall 102 may be embodied to allow for better gripping of treatball 100 , either by pet owners or pets. Some embodiments of treatball 100 may have texturing 106 characteristics including, for example, bumpy, spiky, orange peel, and/or smooth surfaces. The texturing 106 may be such that the visual appearance of the overall treatball 100 is enhanced by intriguing and/or attractive patterns, designs, symbols, and/or the like. Texturing 106 may include words or trademarks in relief. Texturing 106 and/or coloring of the exterior wall 102 may be used to make the treatball 106 appear to be a different object such as, for example, a soccer ball, a basketball, a relief globe/map, a stone, a pumpkin, etc. Texturing 106 may be used to imbalance the treatball 100 by irregularly distributing weight about the surface of the exterior wall 102 to cause the treatball 100 to roll and bounce erratically and/or unpredictably. Texturing 106 may also be used to reinforce or weaken portions of the structure of exterior wall 102 to cause a desired or predefined distortion pattern (e.g., collapse along a predefined meridian) when compressive force is applied to the exterior wall 102 . Such a desired or predefined distortion pattern may cause treats within the treatball 100 to advance through the toy 100 .
Lip 108 may be of any thickness, height or width surrounding openings 104 . Lip 108 may extend out from treatball 100 opening 104 at any length. In some embodiments, lip 108 may provide reinforcement of openings 104 to prevent damage from wear due to extended usage of treatball 100 .
Turning to FIG. 2 , a cross-sectional perspective view of an example embodiment of a treatball 100 is depicted. An embodiment of treatball 100 may include one or more covered ports or openings 202 . Similar to opening 104 , covered opening 202 may include a lip 204 to reinforce the edge of opening 202 . Treatball 100 may include one or more baffles 206 A, 206 B, 206 C extending from the inner surface 208 of the exterior wall 102 .
Covered opening 202 may be of any size or shape including a circle and may include any practicable covering or flap. Covered opening 202 may include characteristics or features such that treats may not be easily removed or dispensed via covered opening 202 allowing for a defined, one-way entry point. Covered opening 202 may function to ensure that treats do not fall out prematurely or without interaction between the treatball 100 and the pet. Covered opening 202 may allow treats to be inserted into treatball 100 at a point farthest away from opening 104 . Maximizing the distance that the treat must travel within the treatball 100 may provide an enhanced challenge to an animal attempting to retrieve a treat. Covered opening 202 may be of any practicable size to allow insertion while preventing dispensing of different sized or shaped treats. As with the one or more openings 104 , in some embodiments, the treatball 100 may include one or more covered openings 202 that do not become distorted (e.g., remain rigid or at least more rigid than exterior wall 102 ) when compressive force is applied to the treatball 100 . In some embodiments, covered opening 202 may be diametrically disposed relative to dispensing opening 104 as pictured in FIG. 2 . In other embodiments, the openings 104 , 204 may be adjacent to each other but still at opposite ends of a predefined path through treatball 100 . In yet other embodiments, the ports or openings 104 , 204 may be disposed at right angles or at any other relative positions that can be practicably used to provide an entrance and exit for treats.
One or more baffles 206 A, 206 B, 206 C may be attached to, or extend from, the interior surface 208 of the exterior wall 102 of treatball 100 . The baffles 206 a , 206 b , 206 c may be embodied so as to prevent treats from passing directly through treatball 100 on a direct or straight path. Thus, baffles 206 A, 206 B, 206 C may provide an enhanced challenge to an animal when attempting to retrieve treats from treatball 100 . In the example embodiment depicted in FIG. 2 , the baffles 206 A, 206 B, 206 C are implemented as semi-circular partitions disposed perpendicular to, and above ( 206 A, 206 C) and below ( 206 B), a center line (not shown) running directly from the covered opening 202 to the dispensing opening 104 . The baffles 206 A, 206 B, 206 C may be of any size, shape, thickness, rigidity, etc. that is practicable to prevent treats from passing straight through the treatball 100 while still allowing treats to pass through if an animal playing with the toy 100 executes or performs an effective or proper sequence of interactions with the toy 100 .
In alternative embodiments, additional or alternative baffles may be included in addition to or in alternative to baffles 206 A, 206 B, 206 C. In some embodiments, treatball 100 may include a spiral tunnel or other limited paths through treatball 100 . Baffles 206 A, 206 B, 206 C may be attached to the interior surface 208 of exterior wall 102 parallel to each other or askew. In some alternative embodiments, the quantity, placement and length of baffles may vary.
In further alternative embodiments shown in FIG. 2A , instead of multiple covered receiving ports or openings 202 and dispensing ports 104 , treatball 100 may have a single port 105 . The baffles, then, are so configured that at least one of them 205 adjoins port 105 along interior surface 107 of the treatball so that one of opposite surfaces of the baffle's wall 209 , 211 defines the upstream of a path “P” of treats through the interior of treatball and the other the downstream of the path. Consequently, port 205 is divided into two adjacent sectors: a receiving sector 213 closable by one or more flaps 215 in the manner discussed above and a dispensing sector 217 . In this embodiment, like in the above discussed embodiments, treats are inserted through the closable port sector and, then are displaced along the treat path which is defined by a single or a plurality of baffles configured so that the treats can be retrieved through the dispensing sector.
Additional embodiments of treatball 100 may include a noise maker (not pictured) or other electronic sound generator for attracting the animal's attention and providing stimulation/feedback to the animal.
Turning to FIG. 3 , a side elevational view of a cross-section of an example embodiment of a treatball 100 is depicted. This view more clearly illustrates the relative size, shape and locations of baffles 206 A, 206 B, 206 C in relation to the overall diameter of the exterior wall 102 and the openings 104 , 202 of the example embodiment. The illustrated proportions may be suitable for particular shaped treats. Alternative proportions may be suitable for different shaped treats. For example, the depicted proportions may allow passage of longer rectangular shaped treats while an embodiment with larger and more numerous baffles may only allow passage of small round treats.
The baffles 206 A, 206 B, 206 C may be thought of as defining a series of adjacent chambers 302 A, 302 B, 302 C within the treatball 100 . An animal playing with the toy 100 may cause the treats to traverse these chambers 302 A, 302 B, 302 C, leading from the covered opening 202 to the dispensing opening 104 , by manipulating and interacting with the treatball 100 . In some embodiments, the chambers 302 A, 302 B, 302 C may be shaped and sized to control the level of difficulty associated with moving treats through the treatball 100 . In some embodiments, a pet owner may be able to add, remove, and/or alter baffles and or chambers within the treatball 100 to adjust the level of challenge to be appropriate for the owner's particular pet. In other embodiments, the pet owner may select different sized and shaped treats to adjust the level of challenge for a given pet.
Turning to FIG. 4 , a diagrammatic planar view showing details of an example embodiment of the covered opening 202 of the treatball 100 is provided. The covering of the opening 202 may be formed by flaps 402 A, 402 B, 402 C, 402 D that together allow treats to be pushed into the treatball 100 but obstruct the treats from exiting via the covered opening 202 . In some embodiments, the flaps 402 A, 402 B, 402 C, 402 D may be formed by cutting a membrane (initially spanning the opening 202 ) along cut lines 404 A and 404 B.
Turning now to FIG. 5 , a diagrammatic planar view depicting the dispensing opening 104 of the treatball 100 is provided. Looking into the unobstructed opening 104 , baffles 206 A and 206 B may be seen. These baffles 206 A, 206 B may prevent an animal that is interacting with the toy 100 , from initially seeing any inserted treats. However, the animal is likely to be able to smell the treats and hear the treats hitting the interior surface 208 ( FIG. 2 ) and the baffles 206 A, 206 B, 206 C as the treatball 100 is moved. This awareness of the treats is likely to stimulate the animal to further interact with the treatball 100 . With further interaction, the animal may be able to view treats as they move into the chamber 302 A closest to the opening 104 . This view may further excite the animal and provide additional motivation to work for the treats.
Returning to FIG. 1 , it is particularly desirable to produce toy 100 in as simple a manner as possible. Thus, it is preferred, but not limited, that toy 100 has a unitary, one-piece construction. Since the toy must have a shape and be made of material that is suited for bouncing and rolling, the toy may be made using an internal mold as further disclosed in U.S. Pat. No. 6,651,590, which is hereby incorporated by reference in its entirety, and using an elastomeric material, which is preferably natural rubber, synthetic natural rubber, or a blend of natural rubber or synthetic natural rubber and one of a plurality of blending polymers including butadiene rubber, styrene-butadiene rubber, nitrile rubber and ethylene-propylene-diene-monomer rubber.
Thus, an inside mold advantageously forms at least one baffle, and preferably baffles 206 A-C, and is disposed between at least one outside mold. The inside mold further advantageously forms at least one cavity defined by inner surface 208 and more preferably forms chambers 302 A-C defined by inner surface 208 and baffles 206 A-C. Therein, the baffles are sized so as to allow the mold to be removed. Additionally, the mold forms a corresponding internal lip of opening 104 and the interior portion of opening 202 . After the inner mold forms toy 100 in cooperation with at least one outer mold, the inner mold is removed from toy 100 . This may be accomplished preferably by removing the inner mold through opening 104 , although opening 202 may also be used after being made more suitable for the task. Therein, it is preferred that the inner mold is removed while the elastomeric material, which has suitable hot tear resistance, is of a suitable temperature.
This document describes the inventive toy for illustration purposes only. Neither the specific embodiments of the invention as a whole, nor those of its features limit the general principles underlying the invention. In particular, the invention is not limited to any specific configuration of openings 104 , 202 , shapes of treatball 100 or treats, texturing 106 , and baffles 206 A, 206 B, 206 C. The specific features described herein may be used in some embodiments, but not in others, without departure from the spirit and scope of the invention as set forth. Many additional modifications are intended in the foregoing disclosure, and it will be appreciated by those of ordinary skill in the art that in some instances some features of the invention will be employed in the absence of a corresponding use of other features. The illustrative examples therefore do not define the metes and bounds of the invention and the legal protection afforded the invention as defined by the appended claims. | A treatball for storing and dispensing pet treats has an elastic body and is restorably compressible in response to an external force applied to the body and has a plurality of spaced-apart internal baffles. A method of making the treatball includes providing an internal mold, introducing an elastomeric material onto the internal mold, molding the elastomeric material into a shape that is representative of the treatball, and extracting the internal mold through an opening in the treatball. Therein, the elastomeric material has sufficient hot tear resistance to allow the internal mold to be extracted through the opening of the treatball without tearing the treatball. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/180,909, filed May 25, 2009.
FIELD OF THE INVENTION
This invention relates to devices in gas turbine engines that contain the combustion of a fuel and air flow as well as devices that manipulate the hot gases' trajectory in such a way to take an ideal path entering the turbine stage. Such devices include but are not limited to fuel-air nozzles, combustor liners and casings, flow transition pieces, and guide vanes that are used in military and commercial aircraft, power generation, and other gas turbine related applications.
BACKGROUND OF THE INVENTION
Gas turbine engines include machinery that extracts work from combustion gases flowing at high temperatures, pressures and velocity. The extracted work can be used to drive a generator for power generation or for providing the required thrust for an aircraft. A typical gas turbine engine consists of a multistage compressor where the atmospheric air is compressed to high pressures. The compressed air is then mixed at a specified fuel-air ratio in a combustor wherein its temperature is increased. The high temperature and pressure combustion gases are then expanded through a turbine to extract work so as to provide the required thrust or drive a generator or a compression device depending on the application. The turbine includes at least a single stage with each stage consisting of a row of blades and a row of vanes. The blades are circumferentially distributed on a rotating hub with the height of each blade covering the hot gas flow path. Each stage of non-rotating vanes is placed circumferentially, which also extends across the hot gas flow path. The included invention involves the combustor and turbine sections of gas turbine engines, each of which will be further discussed.
The combustor portion of a gas turbine engine can be of several different types: silo, can/tubular, annular, and a combination of the last two forming a can-annular combustor. It is in this component that the compressed fuel-air mixture passes through fuel-air nozzles and a combustion reaction of the mixture takes place, creating a hot gas flow causing it to drop in density and accelerate downstream. The can combustor typically comprises of individual, circumferentially spaced cans that contain the flame of each nozzle separately. Flow from each can is then directed through a duct and combined in an annular transition piece before it enters the first stage vane. In the annular combustor type, fuel-air nozzles are typically distributed circumferentially and introduce the mixture into a single annular chamber where combustion takes place. Flow simply exits the downstream end of the annulus into the first stage turbine, without the need for a transition piece. The key difference of the last type, a can-annular combustor, is that it has individual cans encompassed by an annular casing that contains the air being fed into each can. Each variation has its benefits and disadvantages, depending on the application.
In combustors for gas turbines, it is typical to premix the fuel and the air before it enters the combustion chamber through a set of fuel-air nozzles. These nozzles introduce a swirl to the mixture for several reasons. One is to enhance mixing and thus combustion, another reason is that adding swirl stabilizes the flame to prevent flame blow out and it allows for leaner fuel-air mixtures for reduced emissions. A fuel air nozzle can take on different configurations such as single to multiple annular inlets with swirling vanes on each one.
As with other gas turbine components, implementation of cooling methods to prevent melting of the combustor material is needed. A typical method for cooling the combustor is effusion cooling, implemented by surrounding the combustion liner with an additional, offset liner, which between the two, compressor discharge air passes through and enters the hot gas flow path through dilution holes and cooling passages. This technique removes heat from the component as well as forms a thin boundary layer film of cool air between the liner and the combusting gases, preventing heat transfer to the liner. The dilution holes serve two purposes depending on its axial position on the liner: a dilution hole closer to the fuel-air nozzles will cool the liner and aid in the mixing of the gases to enhance combustion as well as provide unburned air for combustion, second, a hole that is placed closer to the turbine will cool the hot gas flow and can be designed to manipulate the combustor outlet temperature profile.
The next portion of a gas turbine engine that the flow travels through is the first stage vane and turbine. At this point in a gas turbine engine, the hot gases are further accelerated as well as turned to a velocity that allows it to strike a row of turbine blades that extract work from the hot gases by producing lift on the turbine blades which results in the rotation of a drive shaft. In such an application, the turbine blades and vanes in the hot gas path operate under conditions of high temperature, pressure, and velocity. These hostile conditions cause thermal oxidation and surface deterioration leading to reduced component life. Inlet turbine gas temperatures typically reach about 200-300° C. above the melting point of turbine components. These high temperatures significantly deteriorate the surface conditions and increase the surface roughness; therefore, it is important that these surfaces be cooled. A variety of designs, materials and configurations are used in gas turbine engines that provide structural robustness as well as effectively cool the turbine vanes and blades in order to enhance its durability against hot combustion gases; however, there has been no attempt at modifying the combustor and turbine in such a way as to eliminate the need for the first row vanes entirely. Currently, this first row of turbine vanes require the development of various technologies in order to cope with the extreme operating environment that include but are not limited to: expensive nickel-alloys, thermal barrier coating, complex casting methods to incorporate internal cooling passages, and filming cooling techniques. In some cases the first row vanes can represent approximately 5% of the complete gas turbine engine cost. In addition, approximately 2% of the total flow losses through a gas turbine can be attributed to pumping cooling air through this single component. This invention will function in a manner consistent with today's gas turbines; however, it will do so without the first stage vane nozzle thus eliminating the associated issues of cost and performance losses.
SUMMARY OF THE INVENTION
With regard to the present invention, there is provided a novel and improved combustor design that is capable of operating in a typical fashion, but displaces the need for a vane nozzle by the combination of having the flue gas exit the combustor with a tangential angle and using the proposed corrugated combustor geometry. The invention consists of a modified combustor liner with corrugations that protrude into and across the entire hot gas stream and also twist about and along the engine centerline. The corrugations turn and accelerate the hot gases to the ideal velocity for the turbine inlet as a typical gas turbine vane nozzle would. To decrease the length of the corrugation section, the fuel/air nozzles are setup in a circumferential mode around the combustor liners in order to establish the tangential angle at the combustor exit. As with other engine components, the corrugations cannot escape the volatile environment in the hot gas path; therefore, impingement, effusion or any other cooling method can be utilized. Cooling air is supplied via the compressor discharge air, which flows between the main combustor liner and another encompassing it and travels through the inside of the corrugations (outside the liner containing the combustion), where it cools the combustor material, and then mixes with the hot gases just upstream from the turbine or the heated air is directed to enter the combustion chamber through the fuel/air nozzles. This invention will result in the removal of the nozzle guide vane (NGV) from the 1 st stage turbine, or at the very least, decrease its required size, which will reduce the cost to manufacture and also minimize inefficiencies that arise from pumping large amounts of cooling air through the components' internal passages to keep the component materials within their operational limits.
The invention also consists of premixed fuel-air nozzles and/or dilution holes that introduce the compressor discharge air and pressurized fuel into the combustor at various locations in the longitudinal and circumferential directions. The fuel and air inlets are placed in such a way as to create an environment with enhanced mixing of combustion reactants and products. Staging the premixed fuel and air nozzles to have more fuel upstream from another set of downstream nozzles enhances the mixing of the combustion reactants and creates a specific oxygen concentration in the combustion region that greatly reduces the production of NOx. In addition, the introduction of compressor discharge air downstream of the combustion region allows for any CO produced during combustion to be burned/consumed before entering the first stage turbine. In effect, the combustor will improve gas turbine emission levels, thus reducing the need for emission control devices as well as minimize the environmental impact of such devices. In addition to this improvement, the tangentially firing fuel and fuel-air nozzles directs its flames to the adjacent burner, greatly enhancing the ignition process of the combustor.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings:
FIG. 1 is a two-dimensional diagram, depicting a generic configuration of a standard combustor, first stage vanes and turbine blades for a gas turbine engine and the flow through same, as seen through a surface of constant radius that intersects with the geometry;
FIG. 2 is a two-dimensional diagram depicting a generic configuration of the invention and first stage turbine blade sections and the flow through same, as seen through a surface of constant radius that intersects with the geometry;
FIG. 3 is a side view of an annular combustor, with said corrugations, oriented such that the direction of flow is from left to right;
FIG. 4 is an isometric, cutaway view of an example invention with the cutaway exposing the profile of the corrugation and giving insight into how the corrugation appears from the inside;
FIG. 5 is an isometric, cutaway view of an example invention that includes the second liner that encompasses the main combustor liner, where the cutaway exposes the generic profile;
FIG. 6A shows a close-up isometric view with the view direction looking slightly downstream of the example invention, which shows outside surfaces of the corrugation;
FIG. 6B shows a close-up isometric view with the view direction looking slightly upstream of the example invention, which shows the start and end of the corrugations;
FIG. 7 is an isometric cutaway view looking in the downstream direction inside the corrugated section of the combustor.
FIG. 8A is a back view of the full combustor with the discharge openings for the hot combustion gases highlighted;
FIG. 8B is a zoomed back view of the combustor highlighting the discharge openings for the hot combustion gases;
FIG. 9 is a two-dimensional sketch showing the nozzles that attach to the outer combustor liner and have a circumferential and radial direction into the combustor (possible longitudinal direction of the nozzle not shown);
FIG. 10 is an isometric side view of an example annular combustor without corrugations with the proposed staged fuel and air injection;
FIG. 11 is an isometric section view with the cutting plane defined by the engine centerline and a radius;
FIG. 12A is an isometric front view of the example combustor without corrugations from a front to aft perspective that shows perforated front wall;
FIG. 12B is a close up view of the image from FIG. 12A ; and
FIG. 13 is a two dimensional diagram showing a generic nozzle cross section layout of the fuel-air nozzles.
DETAILED DESCRIPTION
FIG. 1 shows the general premise of the combustor and first stage turbine of a gas turbine engine. Hot, combusted gases 1 flow in the longitudinal direction through combustor 7 where they exit the combustor threshold 8 . From there, the gases are accelerated and guided by the first stage vane 2 from which the gases now have a resultant velocity 3 with a longitudinal component 4 and a circumferential component 5 and minimal radial component. This accelerated and turned gas flow then flows around the first stage turbine blades 6 , where work is extracted and transferred to the turbine blades and the rotor connected thereto.
FIG. 2 shows the general premise of the invention and consists of the modified combustor 7 and first stage turbine blades, which are to work on a gas turbine engine. Here, hot combusted gases that have a substantial circumferential component of velocity 33 from the tangentially aimed fuel air nozzles, flow through the combustor 7 where it is further turned and accelerated through the corrugations. in circumferential direction 11 These turned hot gases 10 , achieve this condition by first the circumferential arrangement of the fuel/air nozzles and the guidance of the corrugated surfaces 9 that extend through the combustor. The hot gases 10 leave the longitudinal threshold of the combustor 12 with a resultant velocity 3 , which has a longitudinal component 4 and a circumferential component 5 and minimal radial velocity. The flow then passes the 1 st stage turbine blades 6 , where work is then extracted.
FIGS. 3 and 4 show the general design concept of the invention. The annular combustor is made up of essentially two concentric cylinders 14 & 15 forming an annular volume with the upstream end/opening of the two connected/enclosed with an annular face 13 called the front wall. These two cylinders may be of constant radius or have a variable radius that changes in the longitudinal and/or circumferential direction. Fuel-air nozzles are placed in a circumferential arrangement surrounding the outer liner where the flow generated has a strong tangential component in the said invention. For example, they can be arranged in a single row or multiple ones aligned circumferentially on the perimeter of the inner and/or outer liners 14 & 15 where they will inject fuel and air mainly with a tangential component (the injected mixture can exhibit longitudinal and radial components as well). Another placement of the fuel-air nozzles can again be evenly and circumferentially placed, but on the outer shell 14 where the nozzles direct the flow into the combustor volume with mainly a circumferential component of velocity (the injected mixture can also exhibit a longitudinal and/or radial component). The fuel-air nozzles may take on the generic layout as seen in the schematic of FIG. 13 . The FIG. shows a possible embodiment where a circular region 35 in the center of the nozzle may contain an axial swirler where a rich fuel-air mixture passes through and/or a concentric pilot fuel-air nozzle. The key to the tangential fuel-air nozzles is the annular region 34 of the nozzle where air or lean premixed fuel-air mixture may enter with little to no swirl. The purpose of the annular inlet with low swirl is to ensure a substantial tangential inlet velocity into the combustor. This will increase the circumferential velocity component of the flow as it leaves the combustor into the turbine, allowing for a shorter 1 st stage turbine vane or corrugations.
Downstream of the fuel-air nozzles is where the corrugations are located. The corrugations are formed by one or both of the inner 15 and/or outer 14 shell(s) protruding into and across the combustor volume where the shells can either meet or maintain a small gap. If the two shells 14 & 15 were to meet, it would form a line or thin surface contact. This theoretical line represents the path the surfaces take inside the combustor. This path moves longitudinally while rotating about the engine centerline. The amount of rotation depends on the length of the corrugated portion of the combustor, the number of corrugations and the angles of the start and end of the aforementioned line. Two angles are important in the invention, the first is the angle formed between a line tangent to the start of the pathline and the engine centerline that is in a plane which is normal to the radius between the endpoint and engine centerline. The second angle that is important is between a line tangent to the end (downstream point) of the pathline and the engine centerline that is in a plane which is normal to the radius between the endpoint and engine centerline. The second angle must be between 60 and 80 degrees in order for the hot gas flow exiting the combustor to achieve flow conditions suitable for direct introduction to the first stage turbine blades 6 . Each corrugation length must be such that there is a long enough path 20 for which the hot gases can develop and exit the combustor at an angle near the geometry exit angle. The operation of the invention is possible because the surfaces protruding into the combustor 16 & 17 volume create an obstruction in the hot gas flow that the combustor shell contains. The hot gas is therefore forced to follow the path of the corrugations as it would a row of stationary vanes.
As is common with other annular combustors, a second shell/liner 18 & 19 encompasses the main combustor shell that envelops the combustion process. This liner may have constant radii or variable radii in the longitudinal and/or circumferential directions. This liner creates an annular volume inside and outside the annular combustion region. Compressor discharge air is passed through these regions with the intent of removing heat from the combustor shell 14 & 15 . Additionally, the outer cooling region is open to the 1st stage turbine at the downstream end; therefore the flow is pressure driven and exits at this end of the combustor. In this outer, annulus region, the discharge air travels downstream and through the outside of the corrugations 21 , removing heat from that material as well before entering the first stage turbine. This outer liner 18 must attach to the outer combustor shell 14 by establishing a surface contact between 14 and 18 at the end of the combustor. The surface contact will begin at the combustor exit, and end slightly upstream. Establishing this type of mounting/joining of the two liners 14 & 18 creates an enclosed corrugation channel 21 on the cooling flow side. This allows for the cooling flow to become more developed before entering the turbine inlet. In this example, the inner cooling region does not enter the 1st stage turbine. Instead, dilution holes placed in the regions at and around the corrugations allow for the compressor discharge air traveling through this region to transfer to the outer cooling region. Flow through these dilution holes will enhance heat transfer from the combustor shell material, thus aiding in cooling.
Looking at the outlet face for the combustor system, which is normal to the longitudinal direction, there are periodic regions: a large region for the hot gas flow 23 and a region with a smaller circumferential width 22 where the cooling flow exits the combustor and is introduced into the hot gas stream just upstream of the turbine blades.
In another embodiment, the air that cools the corrugation section is directed towards the fuel/air nozzles where this air enters the combustion chamber and help to improve the flame stability.
The corrugations mentioned above to be implemented in an annular combustor with the following features. FIG. 9 shows the general premise of an annular combustor with tangentially directed fuel-air nozzles. The combustor is composed of an outer shell (or liner) 14 , an inner shell (or liner) 15 , both of which can have a constant or varying radius in the longitudinal direction, and a front wall 32 that connects the inner and outer liners 14 , 15 . As seen in the FIG., an example configuration of the invention shows premixed fuel-air nozzles 24 , 25 pointing mainly in a circumferential direction, where the angle 31 is formed between a line 29 tangent to the outer liner and the nozzle 24 , 25 centerlines 30 , but may have a radial or longitudinal component to its direction. These various nozzles 24 , 25 may share a common plane defined by the longitudinal direction and a point along the engine centerline and may be equally spaced circumferentially or have pattern to the spacing in this direction. The nozzles introduce a premixed fuel-air mixture 26 into the combustor volume created by the inner and outer shell 14 , 15 and the front wall 32 . The reactants that are injected by the fuel and air nozzles 24 , 25 combust within this region and create a flow field 27 through the combustor that rotates about the engine centerline.
FIG. 10 shows an example configuration for the invention where fuel/air nozzles 24 , 25 are placed upstream (to the left) of a second set of fuel-air nozzles that share a common plane and are circumferentially spaced. The number of fuel nozzles 24 , 25 may be at least one, and up to an unlimited amount. Compressor discharge air may also be introduced to the combustor volume through a perforated front wall 32 as seen in FIGS. 11 , 12 A and 12 B. The injection of the mixture near the front wall, which may have a higher fuel/air ratio than the second set of nozzles in conjunction with the mixture that is injected downstream of the fuel nozzles 24 , 25 , creates the desired mixing and fuel-air staging effect that will create an optimal combustion environment that reduces NOx and CO emissions from the combustor. The hot combustion products then exit the combustor through an annular opening 23 as seen in FIGS. 8A and 8B where it enters the first stage turbine of the gas turbine.
The present invention is described above with reference to a preferred embodiment. However, those skilled in the art will recognize that changes and modifications may be made in the described embodiment without departing from the nature and scope of the present invention. Various changes and modifications to the embodiment herein chosen for purposes of illustration will readily occur to those skilled in the art. To the extent that such modifications and variations do not depart from the spirit of the invention, they are intended to be included within the scope thereof. | A combustion device used in gas turbine engines includes an annular combustor that contains the combustion process of air and fuel and then guides the hot gas products to a first stage turbine subsection of a gas turbine engine. The annular combustor has an inner/outer shell having corrugated surfaces that extend radially outward and inward across an entire hot gas stream inside the annular combustor. The corrugations twist about the engine centerline in a longitudinal direction of travel of the engine. The resulting flow path accelerates and turns the hot gas stream to conditions suitable for introduction into the first stage turbine blades, which eliminate the need for first stage turbine vanes. The annular combustor is configured with a system of fuel and air inlet passages and nozzles that results in a staged combustion of premixed fuel and air. | 5 |
FIELD OF THE INVENTION
[0001] This invention relates to steel wire rod, steel wire, and a method of manufacturing the steel wire rod and steel wire. More particularly, this invention relates to steel cord used, for example, to reinforce radial tires, various types of industrial belts, and the like, to rolled wire rod suitable for use in applications such as sewing wire, to methods of manufacturing the foregoing, and to steel wire manufactured from the aforesaid rolled wire rod as starting material.
DESCRIPTION OF THE RELATED ART
[0002] In the case of steel wire for steel cord used as a material for reinforcing vehicle radial tires and various types of belts and hoses, or steel wire for sewing wire applications, the general practice is to subject a hot-rolled and controlled-cooling steel wire rod of 5-6 mm diameter to primary drawing for reducing it to a diameter of 3-4 mm, and then to patent the reduced wire rod and conduct secondary drawing for reducing it to a diameter of 1-2 mm. Final patenting is then performed, followed by brass plating and final wet drawing to a diameter of 0.15-0.40 mm. A number of extra fine steel wires obtained by this process are twisted into stranded cable, thereby fabricating steel cord.
[0003] Breakage occurring when wire rod is being processed into steel wire or when steel wire is being stranded usually causes major declines in productivity and yield. It is therefore a strong requirement that wire rod and steel wire falling in the aforesaid technical field does not break during drawing or stranding. While breakage can occur during any of the drawing processes, it occurs most readily during the final wet drawing when the diameter of the processed steel wire is extremely fine.
[0004] Moreover, recent years have seen an increasing move toward lighter weight steel cord and similar products for various purposes. This requires the aforesaid products to offer high strength of a level that cannot be achieved by carbon steel wire rod etc. with a C content of less than 0.7 mass %, so that there is ever greater use of steel wire having a C content of 0.75 mass % or greater. However, increasing C content degrades drawability and thus leads to more frequent breakage. As a result, a very strong need is felt for wire rod that achieves high steel wire strength by dint of abundant C content and that is also excellent in drawability.
[0005] In response to such recent industrial requirements, a number of techniques have been proposed for enhancing the drawability of high-carbon wire rod such as by controlling segregation and/or microstructure or by incorporation of special elements.
[0006] For example, Japanese Patent No. 2609387 teaches “a wire rod for extra fine steel wire of high strength and high toughness, an extra fine steel wire of high strength and high toughness, a stranded product using the extra fine steel wire, and a method of manufacturing the extra fine steel wire,” wherein the steel has a specified chemical composition and the average area ratio of pro-eutectoid cementite content is prescribed. However, the wire rod taught by this patent is costly to manufacture because it requires inclusion of one or both of the expensive elements Ni and Co.
[0007] On the other hand, the reduction of area of patented wire rod is a function of austenite grain size, and since this makes it possible to improve reduction of area by refining the austenite grain size, attempts have been made to achieve austenite grain size refinement by using carbides and/or nitrides of elements such as Nb, Ti and B as pinning particles. Japanese Patent No. 2609387 teaches further improvement of extra fine wire rod toughness/ductility by incorporation of one or more of Nb: 0.01-0.1 mass %, Zr: 0.05-0.1 mass % and Mo: 0.02 to 0.5 mass % as constituent elements. In addition, Japanese Patent Publication (A) No. 2001-131697 teaches austenite grain diameter refinement using NbC. However, the high price of these addition elements increases cost. Moreover, Ni forms coarse carbide and nitride and Ti forms coarse oxide, so that when the wire is drawn to a fine diameter of, for example, 0.40 mm or less, breakage may occur. A study carried out by the inventors found that BN pinning is not readily capable of refining austenite grain diameter to a degree that affects the reduction of area.
[0008] Further, Japanese Patent Publication (A) Nos. 2000-309849, S56-44747 and H01-316420 teach enhancement of high-carbon wire rod drawability by using Ti and B to fix solid-solute N. However, reports published in recent years point out that drawability cannot be easily enhanced by fixing solute N prior to drawing because decomposition of cementite in the wire rod during drawing increases the amount of solid-solute C.
[0009] Moreover, although Japanese Patent Publication (A) Nos. 2000-355736 and 2004-137597 teach use of solid-solute B to inhibit ferrite precipitation, they entail a high risk of wire breakage because they give no consideration to the fact that solid-solute B promotes precipitation of coarse cementite (Fe 23 (CB) 6 ).
SUMMARY OF THE INVENTION
[0010] The present invention was conceived in light of the foregoing circumstances. Its object is to provide wire rod whose excellent cold workability, particularly excellent drawability, make it ideal for steel cord, sewing wire and similar applications, and also to provide steel wire made from the wire rod as starting material with high productivity at good yield and low cost.
[0011] This invention achieves the foregoing object by a method of manufacture constituted to enable production of the steel wire rods set forth in aspects 1) to 3) below, establishment of the method of producing steel wire rod set forth in aspect 4) below, and production of the high-strength steel wire set forth in aspect 5) below.
[0012] 1) A steel wire rod comprising a post-patenting pearlite structure of an area ratio of 97% or greater and a balance of non-pearlite structures including bainite, degenerate-pearlite and pro-eutectoid ferrite, whose fracture reduction of area RA satisfies Expressions (1), (2) and (3) below and whose tensile strength TS satisfies Expression (4) below:
[0000] RA≧Ramin (1), where RAmin=a−b×pearlite block size (μm),
[0000] a=− 0.0001187 ×TS (MPa) 2 +0.31814 ×TS (MPa)−151.32 (2)
[0000] b= 0.0007445 ×TS (MPa)−0.3753 (3)
[0000] TS≧ 1000 ×C (mass %)−10×wire diameter (mm)+320 Mpa (4).
[0014] 2) A steel wire rod according to 1), comprising, in mass %
C: 0.70 to 1.10%, Si: 0.1 to 1.5%, Mn: 0.1 to 1.0% Al: 0.01% or less, Ti: 0.01% or less, N: 10 to 60 mass ppm, B: not less than (0.77×N (mass ppm)-17.4) mass ppm or 3 mass ppm, whichever is greater, and not greater than 52 mass ppm, and the balance of Fe and unavoidable impurities.
[0023] 3) A steel wire rod according to 2), further comprising, in mass %, one or more members selected from the group consisting of:
Cr: 0.03 to 0.5%, Ni: 0.5% or less (not including 0%), Co: 0.5% or less (not including 0%), V: 0.03 to 0.5%, Cu: 0.2% or less (not including 0%), Mo: 0.2% or less (not including 0%), W: 0.2% or less (not including 0%), and Nb: 0.1% or less (not including 0%).
[0032] 4) A method of manufacturing the steel wire rod according to 1), comprising:
[0033] heating a wire rod having the chemical composition of 2) or 3) at a temperature between Tmin shown below and 1100° C.; and
[0034] subjecting the wire rod to patenting in an atmosphere of 500 to 650° C., in which a cooling rate between 800 and 650° C. is 50° C./s or greater,
[0035] said minimum heating temperature Tmin being 850° C. when B (mass ppm)−0.77×N (mass ppm)>0.0, and
[0036] said minimum heating temperature Tmin being Tmin=1000+1450/(B (mass ppm)−0.77×N (mass ppm)−10)° C. when B (mass ppm)−0.77×N (mass ppm)≦0.0.
[0037] 5) A high-strength steel wire excellent in ductility, which is manufactured by subjecting the steel wire rod of 1) to cold drawing and has a tensile strength of 2800 MPa or greater.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a diagram showing how reduction of area varied as a function of non-pearlite area ratio.
[0039] FIG. 2 is a diagram showing how reduction of area varied as a function of pearlite block size.
[0040] FIG. 3 is a diagram showing how actual reduction of area varied as a function of the reduction of area lower limit RAmin calculated according to Expression. (1).
DETAILED DESCRIPTION OF THE INVENTION
[0041] The inventors conducted studies regarding how the chemical composition and mechanical properties of a wire rod affect its drawability. Their findings are set out below.
[0000] a) Although tensile strength can be enhanced by increasing the content of alloying metals such as C, Si, Mn and Cr, a higher content of these alloying metals lowers drawability, namely, increases breakage frequency by causing a reduction in working limit during drawing.
b) Drawability can be estimated from tensile strength and fracture reduction of area before drawing, i.e., after heat treatment. Drawability after final heat treatment exhibits particularly good correlation with tensile strength and reduction of area after final heat treatment, and very good drawability is obtained when reduction of area reaches or exceeds a certain value in correspondence to tensile strength.
c) B forms a compound with N, and the amount of solid-solute B is determined by the total amounts of B and N and the heating temperature before pearlite transformation. Solid-solute B segregates at austenite grain boundaries. During cooling from the austenite temperature at the time of patenting, it inhibits generation of coarse, low-strength microstructures such as bainite, ferrite and degenerate-pearlite that originate from the austenite grain boundaries, and particularly inhibits bainite generation. Among these non-pearlite structures, bainite is the one that has the greatest adverse effect on drawability. Bainite accounts for 60% or greater of the non-pearlite structures. When solid-solute B is deficient, the foregoing effect is minimal, and when it is excessive, pearlite transformation is preceded by precipitation of coarse Fe 23 (CB) 6 that degrades drawability.
[0042] This invention was achieved based on the foregoing findings.
[0043] The requirements of the invention will now be explained in detail.
[0044] Structure and Mechanical Properties of the Wire Rod:
[0045] It is known that the reduction of area of patented wire rod is improved by refining pearlite block size, which is substantially proportional to austenite grain diameter, to 10 μm or less, and that the precipitates TiN, AlN, NbC etc. contribute to austenite grain refinement. However, in a wire rod for steel cord, addition of Ti and/or Al is difficult because the coarse oxides that form cause wire breakage. Use of Nb is also difficult because there is a risk of coarse NbC formation. If pearlite block size refinement is to be achieved without using these precipitates, it is necessary to lower the austenite heating temperature and/or shorten the heating time. But such a method is hard to implement in an actual operation because it makes stable and fine control of austenite grain diameter extremely difficult. In contrast, this invention is characterized in enabling enhancement of wire rod reduction of area, without need for marked block size refinement, by restraining non-pearlite structures constituted of ferrite, degenerate-pearlite and bainite present in the patented wire rod to 3% or less.
[0046] The inventors discovered that the fracture reduction of area RA of conventionally used wire rod is correlated with tensile strength TS and pearlite block size as follows:
[0000] RA≧RAmin (1), where RAmin=a−b×pearlite block size (μm),
[0000] a=− 0.0001187 ×TS (MPa) 2 +0.31814 ×TS (MPa)−151.32 (2)
[0000] b= 0.0007445 ×TS (MPa)−0.3753 (3).
[0048] They further determined that the starting points of cracks occurring during tensile testing are non-pearlite structures that do not exhibit regular lamellar structures, specifically pro-eutectoid ferrite occurring at the former γ grain boundaries, bainite and/or degenerate-pearlite, and discovered that the fracture reduction of area can be dramatically improved by restraining the non-pearlite structure fraction to 3% or less, and that for reducing non-pearlite structures it is effective to add B and to regulate the heating temperature before patenting in accordance with the amount of added B, specifically to conduct heating before patenting at a temperature between the minimum heating temperature Tmin defined by the expression below and 1100° C. and conduct patenting in an atmosphere of 500 to 650° C., in which the cooling rate between 800 and 650° C. is 50° C./s or greater:
[0049] said minimum heating temperature Tmin being 850° C. when B (mass ppm)−0.77×N (mass ppm)>0.0, and
[0050] said minimum heating temperature Tmin being Tmin=1000+1450/(B (mass ppm)−0.77×N (mass ppm)−10)° C. when B (mass ppm)-0.77×N (mass ppm)≦0.0.
[0051] This enables manufacture of a high-strength wire rod having the reduction of area defined by Expression (1).
[0052] Chemical Composition:
[0053] C: C is an element that effectively enhances the strength of the wire rod. However, at a content of less than 0.70 mass %, C cannot easily be made to reliably impart high strength to the final product, while uniform pearlite structure becomes hard to achieve owing to promotion of pro-eutectoid ferrite precipitation at the austenite grain boundaries. When C content is excessive, reticulate pro-eutectoid cementite arising at the austenite grain boundaries causes easy breakage during wire drawing and also markedly degrades the toughness and ductility of the extra fine wire rod after the final drawing. C content is therefore defined as 0.70 to 1.10 mass %
[0054] Si: Si is an element that effectively enhances strength. It is also an element useful as a deoxidizer and, as such, is a required element when the invention is applied to a steel wire rod that does not contain Al. The deoxidizing action of Ti is too low at a content of less than 0.1 mass %. When the Si content is excessive, it promotes pro-eutectoid ferrite precipitation even in a hypereutectoid steel and also causes a reduction in working limit during drawing. In addition, it hampers mechanical descaling (MD) in the drawing process. Si content is therefore defined as 0.1 to 1.5 mass %.
[0055] Mn: Like Si, Mn is also an element useful as a deoxidizer. It is further effective for improving hardenability and thus for enhancing wire rod strength. Mn also acts to prevent hot brittleness by fixing S present in the steel as MnS. At a content of less than 0.1 mass % the aforesaid effects are not readily obtained. On the other hand, Mn is an element that easily precipitates. When present in excess of 1.0 mass %, it segregates particularly at the center region of the wire rod, and since martensite and/or bainite form in the segregation region, drawability is degraded. Mn content is therefore defined as 0.1 to 1.0 mass %.
[0056] Al: 0.01 mass % or less. In order to ensure that the Al does not generate hard, undeformable alumina nonmetallic inclusions that degrade the ductility and drawability of the steel wire, its content is defined as 0.01 mass % or less (including 0 mass %).
[0057] Ti: 0.01 mass % or less. In order to ensure that the Ti does not generate hard, undeformable oxide that degrades the ductility and drawability of the steel wire, its content is defined as 0.01 mass % or less (including 0 mass %).
[0058] N: 10 to 60 mass ppm. N in the steel forms a nitride with B and thus works to prevent austenite grain coarsening during heating. This action is effectively exhibited at an N content of 10 mass ppm or greater. At too high an N content, however, nitrides form excessively to lower the amount of solid-solute B present in the austenite. In addition, solid-solute N is liable to promote aging during wire drawing. The upper limit of N content is therefore defined as 60 mass ppm.
[0059] B: between 3 mass ppm or (0.77×N (mass ppm)−17.4) mass ppm and 52 mass ppm. When B is present in austenite in solid solution, it segregates at the grain boundaries and inhibits precipitation of ferrite, degenerate-pearlite, bainite and the like at the grain boundaries. On the other hand, excessive B addition has an adverse effect on drawability because it promotes precipitation of coarse carbide, namely Fe 23 (CB) 6 , in the austenite. The lower limit of B content is therefore defined as 3 mass ppm or (0.77×N (mass ppm)−17.4) mass ppm, whichever is greater, and the upper limit is defined as 52 mass ppm.
[0060] The contents of the impurities P and S are not particularly defined, but from the viewpoint of achieving good ductility, the content of each is preferably 0.02 mass % or less, similarly to in conventional extra fine steel wires.
[0061] Although the steel wire rod used in the present invention has the aforesaid elements as its basic components, one or more of the following optional additive elements can be positively included in addition for the purpose of improving strength, toughness, ductility and other mechanical properties:
[0062] Cr: 0.03 to 0.5 mass %, Ni: 0.5 mass % or less, Co: 0.5 mass % or less, V: 0.03 to 0.5 mass %, Cu: 0.2 mass % or less, Mo: 0.2 mass % or less, W: 0.2 mass % or less, and Nb: 0.1 mass % or less (where the content ranges of Ni, Co, Cu, Mo, W and Nb do not include 0 mass %). Explanation will now be made regarding these elements.
[0063] Cr: 0.03 to 0.5 mass %. As Cr reduces lamellar spacing, it is an effective element for improving the strength, drawability and other properties of the wire rod. For taking full advantage of these effects, Cr is preferably added to a content of 0.03 mass % or greater. At an excessive content, however, Cr prolongs the time to completion of transformation, thus increasing the likelihood of the occurrence of martensite, bainite and other undercooled structures in the hot-rolled wire rod, and also degrades mechanical descaling ability. The upper limit of Cr content is therefore defined as 0.5 mass %.
[0064] Ni: 0.5 mass % or less. Ni does not substantially contribute to wire rod strength improvement but is an element that enhances toughness of the drawn wire. Addition of 0.1 mass % or greater of Ni is preferable for effectively enabling this action. At an excessive content, however, Ni prolongs the time to completion of transformation. The upper limit of Ni content is therefore defined as 0.5 mass %.
[0065] Co: 1 mass % or less. Co is an element effective for inhibiting precipitation of pro-eutectoid cementite in the rolled product. Addition of 0.1 mass % or greater of Co is preferable for effectively enabling this action. Excessive addition of Co is economically wasteful because the effect saturates. The upper limit of Co content is therefore defined as 0.5 mass %.
[0066] V: 0.03 to 0.5 mass %. V forms fine carbonitrides in austenite, thereby preventing coarsening of austenite grains during heating and improving ductility, and also contributes to post-rolling strength improvement. Addition of 0.03 mass % or greater of V is preferable for effectively enabling this action. However, when the V is added in excess, the amount of carbonitrides formed becomes too large and the grain diameter of the carbonitrides increases. The upper limit of V content is therefore defined as 0.5 mass %.
[0067] Cu: 0.2 mass % or less. Cu enhances the corrosion resistance of the extra fine steel wire. Addition of 0.1 mass % or greater of Cu is preferable for effectively enabling this action. However, when Cu is added in excess, it reacts with S to cause segregation of CuS at the grain boundaries. As a result, flaws occur in the steel ingot, wire rod etc. in the course of wire rod manufacture. To preclude this adverse effect, the upper limit of Cu content is defined as 0.2 mass %.
[0068] Mo: Mo enhances the corrosion resistance of the extra fine steel wire. Addition of 0.1 mass % or greater of Mo is preferable for effectively enabling this action. At an excessive content, however, Mo prolongs the time to completion of transformation. The upper limit of Mo content is therefore defined as 0.2 mass %.
[0069] W: W enhances the corrosion resistance of the extra fine steel wire. Addition of 0.1 mass % or greater of W is preferable for effectively enabling this action. At an excessive content, however, W prolongs the time to completion of transformation. The upper limit of W content is therefore defined as 0.2 mass %.
[0070] Nb: Nb enhances the corrosion resistance of the extra fine steel wire. Addition of 0.05 mass % or greater of Nb is preferable for effectively enabling this action. At an excessive content, however, Nb prolongs the time to completion of transformation. The upper limit of Nb content is therefore defined as 0.1 mass %.
[0071] Drawing Conditions:
[0072] By subjecting the steel wire rod according to aspect 1) of this invention to cold drawing, there can be obtained a high-strength steel wire excellent in ductility that is characterized by having a tensile strength of 2800 MPa or greater. The true strain of the cold-drawn wire is 3 or greater, preferably 3.5 or greater.
EXAMPLES
[0073] The present invention will now be explained more concretely with reference to working examples. However, the present invention is in no way limited to the following examples and it should be understood that appropriate modification can be made without departing from the gist of the present invention and that all such modifications fall within technical scope of the present invention.
[0074] Hard steel wire rods of the compositions shown in Table 1 were prepared to a diameter of 1.2 to 1.6 mm by patenting and drawing and then patented by lead patenting (LP) or fluid bed patenting (FBP).
[0075] Non-pearlite volume fraction measurement was conducted by embedding resin in an L-section of a rolled wire rod, polishing it with alumina, corroding the polished surface with saturated picral, and observing it with a scanning electron microscope (SEM). The region observed by the SEM was divided into Surface, ¼ D and ½D zones (D standing for wire diameter) and 10 photographs, each of an area measuring 50×40 μm, were taken at random locations in each zone at a magnification of ×3000. The area ratio of degenerate-pearlite portions including dispersed granular cementite, bainite portions including plate-like cementite dispersed with spacing of three or more times the lamellar spacing of surrounding pearlite portion, and pro-eutectoid ferrite portions precipitated along austenite were subjected to image processing and the value obtained by the analysis was defined as the non-pearlite volume fraction.
[0076] The pearlite block size of patented wire rod was determined by embedding resin in an L-section of the wire rod, polishing it, using EBSP analysis to identify regions enclosed by boundaries of an orientation difference of 9 degrees as individual blocks, and calculating the average block size from the average volume of the blocks.
[0077] After the patented wire rod had been cleared of scale by pickling, it was imparted with a zinc phosphate coating by Bonde coating and subjected to continuous drawing at an area reduction rate of 16 to 20% per pass using dice each having an approach angle of 10 degrees, thereby obtaining a high-strength drawn wire rod of a diameter of 0.18 to 0.30 mm.
[0000]
TABLE 1
Chemical compositions (Mass % (except for B and N))
No.
C
Si
Mn
P
S
B(ppm)
Al
Ti
N(ppm)
Cr
Mo
Ni
Cu
V
Co
W
Nb
1
Invention
0.70
0.30
0.45
0.019
0.025
24
0.000
0.000
20
—
—
—
—
—
—
—
—
2
Invention
0.82
0.20
0.51
0.015
0.013
15
0.000
0.000
12
0.20
—
—
—
—
—
—
—
3
Invention
0.82
0.20
0.49
0.010
0.007
16
0.000
0.000
50
—
—
—
—
—
—
—
—
4
Invention
0.92
0.25
0.46
0.019
0.025
30
0.000
0.000
60
—
—
0.10
—
—
—
—
—
5
Invention
0.87
1.20
0.5
0.008
0.007
46
0.001
0.000
50
0.20
—
—
—
—
—
—
—
6
Invention
1.09
0.20
0.5
0.010
0.009
25
0.000
0.001
50
0.20
—
—
0.10
—
—
—
—
7
Invention
0.92
0.60
0.5
0.025
0.020
30
0.001
0.000
25
—
—
—
—
—
—
0.10
0.10
8
Invention
0.82
0.20
0.5
0.008
0.008
11
0.000
0.000
34
—
—
—
—
—
—
—
—
9
Invention
0.82
0.20
0.5
0.008
0.008
11
0.000
0.000
20
—
—
—
—
—
—
—
—
10
Invention
0.82
0.20
0.5
0.008
0.008
20
0.001
0.000
25
—
—
—
—
—
—
—
—
11
Invention
0.82
0.20
0.5
0.008
0.008
20
0.000
0.000
35
—
—
—
—
—
—
—
—
12
Invention
0.82
0.20
0.5
0.008
0.008
11
0.000
0.000
35
—
—
—
—
—
—
—
—
13
Invention
0.82
0.20
0.5
0.008
0.008
15
0.000
0.000
25
—
—
—
—
—
—
—
—
14
Invention
0.82
0.20
0.5
0.008
0.008
21
0.000
0.000
16
—
—
—
—
—
—
—
—
15
Invention
0.82
0.22
0.5
0.008
0.008
20
0.001
0.000
35
0.20
—
—
—
0.20
—
—
—
A
Invention
0.92
0.20
0.5
0.008
0.008
15
0.000
0.000
25
0.20
—
—
—
0.03
—
—
—
B
Invention
0.92
0.20
0.5
0.008
0.008
10
0.000
0.000
21
0.20
—
—
—
0.06
—
—
—
C
Invention
1.02
0.20
0.5
0.008
0.008
15
0.000
0.000
25
0.20
—
—
—
0.03
—
—
—
D
Invention
1.02
0.20
0.5
0.008
0.008
10
0.000
0.000
21
0.20
—
—
—
0.06
—
—
—
E
Invention
0.82
0.21
0.48
0.009
0.009
12
0.000
0.000
24
0.03
—
—
—
—
—
—
—
F
Invention
0.82
0.19
0.51
0.009
0.009
11
0.000
0.000
25
0.06
—
—
—
—
—
—
—
G
Invention
0.92
0.20
0.5
0.008
0.008
9
0.000
0.000
23
0.05
—
—
—
0.04
—
—
—
H
Invention
1.01
0.20
0.5
0.008
0.009
10
0.000
0.000
23
0.05
—
—
—
0.03
—
—
—
I
Invention
1.02
0.20
0.5
0.008
0.008
8
0.000
0.000
21
0.04
—
—
—
—
—
—
—
16
Comparative
0.70
0.30
0.6
0.008
0.007
11
0.000
0.000
35
—
0.20
—
—
—
—
—
—
17
Comparative
0.82
0.20
0.5
0.010
0.009
2
0.000
0.010
50
0.20
—
—
—
—
—
—
—
18
Comparative
0.90
0.20
0.8
0.010
0.009
60
0.000
0.005
25
—
—
0.10
—
—
—
—
—
19
Comparative
0.87
1.70
0.4
0.015
0.013
20
0.000
0.010
25
0.20
—
—
—
—
—
—
—
20
Comparative
1.30
1.00
0.3
0.015
0.013
20
0.030
0.000
25
—
—
—
—
—
0.30
—
—
21
Comparative
0.92
0.30
1.5
0.015
0.013
20
0.000
0.000
25
—
—
—
—
0.20
—
—
—
22
Comparative
0.82
1.00
0.5
0.025
0.020
20
0.030
0.000
35
—
—
—
—
0.20
—
—
—
23
Comparative
0.96
0.20
0.5
0.010
0.009
0
0.000
0.010
25
0.20
—
—
—
0.10
—
—
—
24
Comparative
0.82
0.20
0.5
0.010
0.009
0
0.000
0.010
25
—
—
—
—
—
—
—
—
25
Comparative
0.82
0.20
0.5
0.010
0.009
0
0.000
0.010
25
—
—
—
—
—
—
—
—
26
Comparative
0.82
0.20
0.5
0.010
0.009
0
0.000
0.010
25
—
—
—
—
—
—
—
—
27
Comparative
0.82
0.20
0.5
0.010
0.009
0
0.000
0.010
25
—
—
—
—
—
—
—
—
28
Comparative
0.82
0.20
0.45
0.019
0.025
24
0.000
0.000
25
—
—
—
—
—
—
—
—
[0000]
TABLE 2
Non-
Patent-
Patented
pearlite
Final
Final
Diam-
Heat
Patent-
ing
800→650° C.
product
Block
Reduction
RA
area
drawing
drawing
eter
temp
ing
temp
cool rate
strength
size
of area
Tmin
min
ratio
diameter
TS
No.
(mm)
(° C.)
method
(° C.)
(° C./sec)
(MPa)
(μm)
(%)
(° C.)
(%)
(%)
(mm)
(MPa)
Remark
1
1.60
860
LP
575
348
1244
10
59
850
55
2.8
0.20
3776
2
1.40
880
LP
550
480
1310
12
56
850
55
2.4
0.22
3541
3
1.60
1100
LP
575
348
1328
36
56
955
40
1.3
0.22
3846
4
1.50
1000
LP
600
296
1313
21
52
945
49
2.1
0.20
3862
5
1.30
855
LP
570
119
1515
12
49
850
49
2.5
0.22
3930
6
1.40
1000
LP
550
480
1521
27
38
938
38
2.7
0.20
4321
7
1.40
870
LP
575
401
1466
10
56
850
53
2.8
0.20
4165
8
1.45
950
LP
575
386
1329
16
53
942
52
1.3
0.20
3844
9
1.45
950
FBP
575
149
1231
16
56
899
52
2.2
0.20
3560
10
1.30
870
LP
575
433
1329
12
57
850
54
2.6
0.18
3836
11
1.50
940
LP
575
373
1319
15
54
914
53
1.9
0.20
3881
12
1.45
1050
LP
575
386
1328
25
55
944
46
1.9
0.20
3841
13
1.40
920
LP
575
401
1339
16
53
898
52
1.9
0.20
3803
14
1.30
920
FBP
570
173
1231
15
62
839
52
1.2
0.20
3364
15
1.50
1050
LP
575
373
1332
31
51
914
43
2.6
0.20
3918
A
1.40
950
FBP
575
148
1407
21
48
898
47
1.9
0.20
4053
B
1.50
950
FBP
575
146
1407
18
52
910
49
1.8
0.20
4197
C
1.40
950
FBP
575
142
1486
22
46
898
43
1.6
0.20
4394
D
1.50
950
FBP
575
146
1486
16
48
910
48
1.4
0.20
4550
E
1.45
950
FBP
575
143
1289
21
51
912
49
1.8
0.20
3881
F
1.45
950
FBP
575
146
1289
19
52
921
50
2.1
0.20
3883
G
1.45
950
FBP
575
150
1388
24
47
923
46
2.2
0.20
4179
H
1.40
950
FBP
575
150
1458
23
44
918
44
1.9
0.20
4313
I
1.40
950
FBP
575
152
1466
25
43
920
42
1.6
0.20
4337
16
1.40
850
LP
575
401
1261
15
33
944
53
4.1
0.20
3582
17
1.40
870
LP
570
417
1327
10
39
969
56
4.5
0.20
3770
18
1.50
860
LP
600
296
1326
11
56
850
55
2.9
0.20
3902
pro-
eutectoid θ
19
1.40
900
LP
575
401
1577
14
21
850
44
8.6
0.25
3967
pro-
eutectoid α
20
1.20
920
LP
575
470
1799
11
23
850
26
4.7
0.30
3642
pro-
eutectoid θ
21
1.40
920
LP
575
401
1519
14
31
850
47
3.8
0.20
4316
micro-
martensite
22
1.30
820
LP
600
343
1349
10
31
914
56
8.2
0.20
3685
23
1.50
950
FBP
575
144
1341
20
37
950
49
3.6
0.20
3944
No B
24
1.50
870
LP
575
373
1319
13
41
950
54
3.4
0.20
3881
No B
25
1.45
1050
LP
575
386
1339
28
28
950
44
5.2
0.20
3872
No B
26
1.45
950
LP
575
386
1329
21
39
950
49
3.8
0.20
3844
No B
27
1.45
900
LP
575
386
1323
10
44
950
56
4.2
0.20
3827
No B
28
1.80
950
AP
—
30
1020
23
28
850
43
2.7
0.18
3594
TS
deficient
[0078] Table 1 shows the chemical compositions of the evaluated products, and Table 2 shows their test conditions, block size and mechanical properties.
[0079] In Tables 1 and 2, 1 to 15 and A to I are invention steels and 16 to 28 are comparative steels. The minimum reduction of area represented by Expression (1) is designated RAmin. RAmin means the value represented by the equation: RAmin=a−b×pearlite block size (μm).
[0080] 16 and 22 are cases in which the reduction of area was low because a low heating temperature before patenting caused B nitride and carbide to precipitate before patenting and thus make it impossible to obtain adequate solid-solute B. 17 and 23 to 27 are cases in which reduction of area was low because the amount of added B was either low or nil. 18 is a case in which reduction of area was low because excessive B content caused heavy precipitation of B carbide and pro-eutectoid cementite at the austenite grain boundaries. 19 is a case in which pro-eutectoid ferrite precipitation could not be inhibited because Si content was excessive. 20 is a case in which pro-eutectoid cementite precipitation could not be inhibited because C content was excessive. 21 is a case in which micro-martensite formation could not be inhibited because Mn content was excessive. 28 is a case in which the prescribed tensile strength could not be achieved because the cooling rate during patenting was slow.
[0081] The invention steels A, B, C and D among the Examples were used to produce steel wire for 0.2 mm diameter steel cord. The steel wires obtained exhibited tensile strength of 4053 MPa, 4197 MPa, 4394 MPa and 4550 MPa, respectively, and did not experience delamination. On the other hand, a similar product made from the comparative steel 21 had TS of 4316 MPa and experienced delamination.
[0082] FIG. 1 shows how reduction of area varied as a function of non-pearlite area ratio in invention steels and comparative steels. It can be seen that the invention steels, which had a non-pearlite area ratio of 3% or less, tended to have a high reduction of area. However, owing to the fact that, as pointed out earlier, reduction of area is also influenced by tensile strength, some overlapping data are present.
[0083] FIG. 2 shows how reduction of area varied as a function of pearlite block size in invention steels and comparative steels. It can be seen that the invention steels tended to have high reduction of area. However, owing to the fact that, as pointed out earlier, reduction of area is also influenced by tensile strength, some overlapping data are present.
[0084] FIG. 3 shows how actual reduction of area varied as a function of the reduction of area lower limit RAmin represented by Expression. (1). It can be seen that the area reductions of the invention steels were higher than RAmin.
[0085] In FIGS. 1 to 3 , ⋄ indicates an invention steel and □ represents a comparative steel.
[0086] This invention enables manufacture of steel cord usable as a reinforcing material in, for example, radial tires, various types of industrial belts, and the like, and also of rolled wire rod suitable for use in applications such as sewing wire. | The invention provides wire rod excellent in drawability and steel wire made from the wire rod as starting material with high productivity at good yield and low cost. A hard steel wire rod of a specified composition is heated in a specified temperature range to conduct post-reaustenization patenting and thereby obtain a high-carbon steel wire excellent in ductility that has a pearlite structure of an area ratio of 97% or greater and the balance of non-pearlite structures including bainite, degenerate-pearlite and pro-eutectoid ferrite and whose fracture reduction of area RA satisfies Expressions (1), (2) and (3) below:
RA≧Ramin (1), where RAmin=a−b×pearlite block size (μm),
a =−0.0001187× TS (MPa) 2 +0.31814× TS (MPa)−151.32 (2)
b =0.0007445× TS (MPa)−0.3753 (3). | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention concerns structure of a quench chamber for solids and/or liquid gasifiers, in general. More specifically it relates to an improvement of quench chamber structure of the type that employs a dip tube with a down flow high pressure gasification generator.
2. Description of the Related Art
The U.S. Pat. No. 4,218,423 to Robin et al, which issued Aug. 19, 1980, illustrates a typical prior arrangement of the quench chamber structure in a gasifier outlet which employs a dip tube and a quench chamber for receiving the effluent from the gasifier. It has been found that with that arrangement the capacity of the system was limited by excessive carryover of liquid from the quench bath through the exit from the quench chamber. Such significant liquid carryover results from the effluent gas flowing through a single exit port. This invention provides for an improvement of the structure of such a combination, so that quench liquid carry over is minimized.
Thus, it is an object of this invention to provide symmetrical outlet structure from a quench chamber. The combination employs a dip tube for carrying effluent from a high pressure gasifier into a quench chamber and through a liquid quench bath.
SUMMARY OF THE INVENTION
Briefly, invention is in the combination with a down flow high pressure gasifier or the like, having a quench chamber for receiving effluent from said gasifier. The said quench chamber comprises a body of quench liquid, a dip tube for confining said effluent to a flow path into said quench liquid beneath the surface thereof, and means for removing gas from said quench chamber above the surface of said body of quench liquid. In that combination there is gas removing means which comprises outlet means having symmetry relative to the axis of said quench chamber.
Again briefly, the invention is in a down flow high pressure gasifier, wherein effluent from said gasifier is confined to a dip tube for causing it to flow through a body of quench liquid to an outlet above the surface of said quench liquid. The said quench liquid container has coaxial symmetry with said dip tube. In that combination, there is means for minimizing carry over of liquid with said gas to said outlet which comprises symmetrical passage means from said container relative to the axis of said dip tube.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects and benefits of the invention will be more fully set forth below in connection with the best mode contemplated by the inventor of carrying out the invention, and in connection with which there are illustrations provided in the drawings, wherein:
FIGS. 1 and 2 schematically illustrate prior art structures, in general;
FIG. 3 is a longitudinal cross section schematically showing one modification of the structure according to the invention;
FIG. 4 is a horizontal cross section taken along the lines 4--4 on FIG. 3;
FIG. 5 is a longitudinal cross section schematically showing a different modification according to the invention;
FIG. 6 is a horizontal cross section taken along the lines 6--6 on FIG. 5; and
FIG. 7 is an enlarged detail showing yet another modification of a belt type outlet structure similar to that illustrated in FIGS. 5 and 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 schematically illustrate the type of structure which has been employed heretofore. It is a combination in which there is a generator or gasifier 11 that is a down flow type. Effluent from the generator goes via a throat 12 through a dip tube 13 into a bath 15 of quench liquid. The quench liquid 15 is contained in a chamber 16 that is coaxial with the dip tube 13. There is an outlet 19 for the effluent after it has been quenched by contact with, and passage through the quench liquid 15. However, it will be noted that this arrangement has an asymmetric relationship of the outlet relative to the axis of the dip tube and quench chamber. Consequently, heretofore there has been excessive carry over of the quench liquid with the effluent as it leaves the quench chamber.
In order to reduce the amount of liquid carry over of the quench liquid from the bath, this invention provides for making a symmetrical outlet to carry the effluent from the chamber above the quench liquid. One modification of the structure for accomplishing a symmetrical outlet is illustrated in FIGS. 3 and 4. There is a gasifier 23 that has a throat 24 through which the effluent from the gasifier exits. It goes into the inside of a dip tube 25. Then, the effluent which is a high temperature gas with entrained slag particles, must pass down through a quench liquid 28 in order to reach the exit. Quench liquid 28 is in a container 29 which is coaxial with the dip tube 25.
The quenched effluent flows symmetrically relative to the axis of the dip tube 25 to a toroidal conduit 34. That flow is via a plurality of radial conduits 35, and it will be noted that there are an even number of these conduits. Also, they are distributed evenly around the circumference of the container 29 so as to make the path of exit flow of effluent symmetrical relative to the axis of the dip tube 25. After the effluent gases have reached the conduit 34 they exit through an outlet 38.
The conduits 35 slope upward from the container 29 so that any liquid may drain back to the bath 28. In addition, there may be provided a small diameter drain pipe 39 from the bottom of the toroidal conduit 34. It is added in order to drain off any carry over of liquids that might reach the interior of the conduit 34. It will be appreciated that by maintaining the symmetrical outlet structure for the effluent, the flow rate of effluent gases is distributed evenly and consequently a reduction in the velocity of flow is obtained whereby the carry over of liquid from the quench liquid bath 28 is substantially reduced.
FIGS. 5 and 6 illustrate another embodiment according to this invention. The schematic showings of the basic gasifier and quench chamber, are substantially the same as those illustrated in FIGS. 3 and 4. Therefore, the same reference numerals are applied but with primed numbers. In this modification, the outlet structure for the effluent takes the form of a hollow belt 42. This belt 42 is integrally attached to the outside of the walls of the container 29 in any feasible manner, such as by welding. There are a plurality of symmetrically situated passages through the wall of the container 29' in the form of slots 43. Slots 43 permit the effluent gases to flow into the interior of the belt 42 in a symmetrical manner relative to the axis of the dip tube 25' From the belt 42, the effluent gases flow out through an outlet 38'. It will be noted that the slots 43 are located at the bottom of the hollow belt 42. Consequently, any liquid carry over into the belt may drain back into the chamber inside the container 29' and so rejoin the liquid quench bath 28'. It should be noted that the circumferentially located slots 43 may take any feasible form. Thus, they might even comprise an opening or slot (not shown) extending all the way around the periphery of the container 29'. In any event, the symmetry relative to the axis of the dip tube 25' is maintained, and it is effective to provide even distribution of the effluent flow which substantially reduces the amount of carry over of the liquid from the quench liquid bath 28'.
FIG. 7 illustrates a modification of the structure illustrated in FIGS. 5 and 6. This modification takes the form of a hollow belt 46 that is welded onto the outside of a container 47. Container 47 is of course substantially the same type of structure as the containers illustrated in FIGS. 3-6. In the FIG. 7 modification, the passages from the inside of the container 47 take the form of slots or holes 50. These slots 50 are located above the bottom of the belt 46 and are symmetrically located all the way around the circumference of the container 47 in a similar manner as the other modifications. In this modification there is a series of weep holes 51 located at the bottom edge of the belt 46 so that accumulation of any partial carry over of liquid with the effluent may drain back into the inside of container 47. In this case there will be, of course, an outlet 54 to carry the effluent away from the interior of the belt 46.
From the foregoing it will be appreciated that by providing a structure of the outlet path from the quench chamber that is symmetrical relative to the axis of the dip tube, the gases exiting through the quench liquid bath will be evenly distributed. Consequently, it provides an improved chance for the entrained liquid to separate and return to the quench chamber, rather than be carried over with the exit gases from the whole unit. Also, it will be apreciated that the structure of the means for providing such an outlet, might take various forms so long as it is symmetrical relative to the axis of the dip tube in a gasifier according to the type to which this invention applies.
While particular embodiments of the invention have been described above in considerable detail in accordance with the applicable statutes, this is not to be taken as in any way limiting the invention but merely as being descriptive thereof. | With a down flow high pressure gasifier, there is a quench chamber that employs a dip tube for confining the effluent from the gasifier. The quench chamber is coaxial with the dip tube. The dip tube extends beneath the surface of a body of quench liquid, and the exit from the quench chamber is above the surface of the quench liquid. That exit is constructed so that the effluent flow out of the quench chamber is symmetrical relative to the axis of the dip tube in order to minimize the liquid carry over with the effluent. | 8 |
BACKGROUND OF THE INVENTION
1. Field of invention
The invention relates to the field of liquid pumps in medical treatment devices.
2. Description of the Prior Art
Medical treatment devices are in particular blood treatment devices. Blood treatment devices comprise dialysis machines which can be subdivided into hemodialysis machines and machines for performing automated peritoneal dialyses.
Dialysis is a method of purifying the blood of patients with acute or chronic renal insufficiency. Fundamentally, a distinction is made here between methods having an extracorporeal blood circulation such as hemodialysis, hemofiltration or hemodiafiltration (summarized below under the term “hemodialysis”) and peritoneal dialysis, which does not have an extracorporeal blood circulation.
In hemodialysis the blood in an extracorporeal circulation is passed through the blood chamber of a dialyzer, which is separated from a dialysis fluid chamber by a semipermeable membrane. The dialysis fluid chamber has a dialysis fluid containing the blood electrolytes in a certain concentration flowing through it. The substance concentration of the dialysis fluid corresponds to the concentration of the blood of a healthy person. During the treatment, the patient's blood and the dialysis fluid are passed by both sides of the membrane, usually in countercurrent at a predetermined flow rate. Substances that must be eliminated in urine diffuse through the membrane from the blood chamber into the chamber for the dialysis fluid, while at the same time electrolytes present in the blood and in the dialysis fluid are diffusing from the chamber of the higher concentration to the chamber of the lower concentration. If a pressure gradient is built up from the blood side to the dialysate side on the dialysis membrane, for example, due to a pump which withdraws dialysate from the dialysate circulation downstream from the dialysis filter on the dialysate side, water enters the dialysate circulation from the patient's blood through the dialysis membrane. This ultrafiltration process leads to the desired withdrawal of water from the patient's blood.
In hemofiltration, ultrafiltrate is withdrawn from the patient's blood by applying a transmembrane pressure in the dialyzer without passing dialysis fluid by the membrane of the dialyzer on the side opposite the patient's blood. In addition, a sterile and pyrogen-free substitute solution may be added to the patient's blood. We speak of pre-dilution or post-dilution, depending on whether this substitute solution is added upstream or downstream from the dialyzer. The mass exchange takes place by convection in hemofiltration.
Hemodiafiltration combines the methods of hemodialysis and hemofiltration. Thus a diffusive mass exchange takes place between the patient's blood and the dialysis fluid through the semipermeable membrane of the dialyzer, and the plasma water is also filtered through a pressure gradient on the membrane of the dialyzer.
Plasmapheresis is a method blood plasma is separated from corpuscular components of blood (cells). The separated blood plasma is purified or replaced by a substitution solution and return to the patient.
In peritoneal dialysis, the patient's abdominal cavity is filled with a dialysis fluid through the abdominal wall such that the dialysis fluid has a concentration gradient with respect to the endogenous fluids. The toxic substances present in the body enter the abdominal cavity through the peritoneum, which acts as a membrane. After a few hours the dialysis fluid, now spent, which is in the patient's abdominal cavity is replaced. Water can travel from the patient's blood through the peritoneum and into the dialysis fluid by osmotic processes, thereby withdrawing water from the patient.
Dialysis methods are usually performed with the help of automatic dialysis machines such as those already distributed by the applicant under the brand name 5008 or sleep.safe.
To convey fluids in medical treatment devices, pumps of different designs are used. Peristaltic hose roller pumps are often used with machines having an extracorporeal blood circulation, such as hemodialysis machines. These hose roller pumps are often used in medical technology because they permit contactless transport of a fluid. In addition, they theoretically supply a flow which is proportional to the rotational speed over a wide range independently of the flow resistances upstream and downstream from the pump. In the case of a blood pump in extracorporeal treatment methods, the incoming (suction) side is referred to as the arterial side with an adjusted vacuum of typically approx. −100 to −300 mm mercury column in comparison with the outside pressure, and the efferent side is referred to as the venous side with a reduced pressure in comparison with the outside pressure.
DE3326785A1 discloses a typical embodiment of such an occlusive hose roller pump, according to which the delivery medium is moved by means of a periodically occluded hose.
In terms of the basic concept, a roller pump has a stator and a rotor. The stator is designed on the pump housing and has a recess with whose smoothly running vertical wall a pump hose is in contact. The area in which the pump hose is in contact with the wall forms the pump bed, which has the contour of a detail of a circle.
The axis of rotation of a rotor having rotatably mounted rollers on its free ends passes through the midpoint of this section of a circle. In rotation of the rotor in the working direction, the rollers come in contact with the pump hose, which is in contact with the circular contour of the circle of the pump bed and compress it to such an extent as it rotates further that it forms a fluid-tight seal (occlusive).
The delivery medium in the pump hose is conveyed further by further rolling of the rollers on the pump hose. In most cases, such a rotary pump has two rollers, which are mounted on the rotor in such a way that the connecting line passes through the axis of rotation of the rotor.
Other types of pumps which may be used include, for example, centrifugal pumps, diaphragm pumps or gear pumps.
The type of pump is definitive for the stress on the medium to be conveyed. This is important in particular in the case of an extracorporeal blood circulation because the blood can be damaged by pumping, and this may destroy erythrocytes, i.e., the red blood cells in particular (hemolysis). This may occur mechanically in particular, e.g., due to squeezing inside a blood hose or due to excessively high pressures.
A pulsatile non-steady-state flow, which is caused by the continuing engagement of the rollers in the pump hose segment, is characteristic of a hose roller pump. When the rollers mesh with the hose segment, the hose is squeezed together, thereby displacing the fluid. This fluid is displaced both in the direction of flow and opposite the direction of flow. Upstream from the roller, the displaced fluid is superimposed on the flow in the direction of the pump during ongoing operation and thus results in a short-term net reduction inflow, so that the arterial pressure becomes less negative until the hose is completely occluded. Then the fluid in the hose is accelerated again and the arterial pressure drops again. Downstream from the hose roller pump there is a sudden drop in pressure as soon as the roller emerges from the pump segment and a pressure equalization occurs between the reduced pressure in the segment between the rollers, this segment having been enclosed so far, and the excess pressure downstream from the pump.
Pressure peaks (and/or flow peaks) may occur in the area of the puncture site of the needle which returns the extracorporeal blood to a patient, and may cause shearing forces which in the extreme case may lead to thrombosis (coagulation) on the vascular walls and may even lead to hemolysis. Upstream from the pump, high shearing forces may also occur in equalization between high- and low-pressure systems.
In addition, hose roller pumps may also be used in the area of hemodialysis for the addition of blood-thinning substitute fluids. The pressure pulses generated in this way influence the blood to be thinned although to a lesser extent than with the blood pump at least at the location where the substitute and the blood are mixed.
Another type of pump that is used is the impeller pump or centrifugal pump. Centrifugal pumps essentially contain a housing to hold an impeller to which a magnet is fixedly connected. The magnet can be rotated by a second rotating magnet contained in a stationary base so that the impeller is made to rotate and the liquid in the housing is moved from a liquid inlet to a liquid outlet. Due to the operating principle, centrifugal pumps supply a constant volume flow so that the output pressure of the fluid pumped is a function of the input pressure, the viscosity of the fluid and the rotational speed. Pressure pulses in the fluid conveyed as in the case of peristaltic pumps do not occur with centrifugal pumps in normal operation at a constant rate of rotation of the impeller. Therefore, this prevents hemolysis caused by pulsatile conveyance of blood.
When used in the extracorporeal blood circulation, in particular in hemodialysis treatments, it is often necessary to add medication to blood in a controlled manner. A typical example of medication is the addition of anticoagulants such as heparin in hemodialysis treatments to prevent the blood from coagulating in the extracorporeal blood circulation and thereby prevent the fine hollow fibers of the dialysis filter from becoming clogged.
Syringe pumps, which add heparin or another anticoagulant (e.g., citrate) to the blood upstream from a dialysis filter, are often used for this purpose. However, it is also provided that a medication may also be added to the blood by delivering the medication through a special device and into drip chamber.
EP2386324A1 discloses such a device. A medication dosing apparatus which releases doses of a medication into the drip chamber on the basis of pressure pulses in the drip chamber is proposed there. The pressure pulses are generated here by the pulsatile non-steady-state operation of a peristaltic pump which delivers a fluid, preferably blood, into the drip chamber. Thus a pulsating air pressure characteristic develops via the fluid level inside the drip chamber in the cycle of the peristaltic pump, leading to regular dispensing of droplets of medication into the drip chamber.
So far, when using steadily delivering peristaltic pumps, it has not been possible to control the dosing of medication in a variable manner, i.e., to suspend it or have it occasionally occur more often. With centrifugal pumps it has not been possible at all so far to operate the medication dosing apparatus proposed in EP2386324A1 because of the lack of pressure fluctuations.
SUMMARY OF THE INVENTION
The object of the present invention is therefore to create devices and methods which control a pump, so that the occurrence of pressure peaks and/or flow peaks in the delivery medium of the pump is avoided or that they follow a predetermined profile.
This object is achieved by the device and the method described herein. Preferred embodiments of the invention are are also described herein.
It is thus provided that the operating point of a peristaltic pump is to be altered as a function of the angle formed by the rotor with any stationary point. In addition, it is provided that the operating point of a centrifugal pump which drives a medication dosing device is to be altered in accordance with a profile which includes at least one change from a first operating point to a second operating point and a change from the second operating point to the first or a third operating point such that the second operating point comprises at least one operating parameter which is greater or less than this operating parameter of the first and third operating points.
The operating point of a peristaltic pump or a centrifugal pump is understood to refer to at least one of the operating parameters of the pump. Operating parameters include in particular the input and output pressure in the pumped fluid, delivery rates of the pumped fluid at the inlet and outlet of the pump, the angular velocity of the rotor of the peristaltic pump, the angle formed by the rotor of the peristaltic pump with any stationary point, the rotational speed of the impeller of the centrifugal pump and the power supply voltage, power supply current and the power consumption of the electric motor driving the pump.
It is important that the list of operating parameters enumerated cannot be influenced independently of one another. By varying the operating point by varying at least one operating parameter, numerous other operating parameters are also changed automatically. Thus an increase in the rotational speed of a centrifugal pump usually also results in a higher flow rate at the inlet and outlet of the pump, and also causes a higher differential pressure between the inlet and the outlet in the fluid being conveyed. Likewise the power consumption by the pump is also increased.
Embodiments in which certain operating parameters are altered are described below for the peristaltic pump and the centrifugal pump. It is clear to those skilled in the art that the invention can readily be applied to embodiments in which other operating parameters are altered. What is important is the consequences of altering the operating point of the pump by changing one operating parameter or the other.
An embodiment in which the angular velocity of the rotor of the peristaltic pump is modulated periodically to reduce the peaks in the fluid pressure caused by the rollers moving into and out of the pump bed or to completely suppress these peaks in the ideal case is suitable for the device with the peristaltic pump. Due to the design, the pump bed in which the hose is inserted forms approximately a semicircle so that the interaction of the hose rollers with the hose occurs during one half of a revolution.
The angular velocity of the rotor of the peristaltic pump is ideally modulated so that there is a constant fluid pressure. However, if a pressure pulse in the fluid is desired to achieve a controlled delivery of the medication in a device consisting of a drip chamber and a dosing device arranged downstream, as described in EP 2 386 324 A1, then a second modulation of the angular velocity may be superimposed on the first modulation to achieve a controlled pressure pulse in the fluid.
The angular velocity of the rotor of the peristaltic pump is altered as a function of the current position of the rotor in one embodiment, i.e., as a function of the angle formed by the rotor with any stationary point.
In contrast with peristaltic pumps, centrifugal pumps do not produce any pressure pulses in the fluid delivered during operation. Centrifugal pumps are approximately constant pressure sources whose output pressure corresponds to the input pressure plus the pressure generated by the pump. This pressure generated by the pump depends on the viscosity of the fluid being pumped and the rotational speed of the impeller of the centrifugal pump.
If it is desirable to create controlled pressure pulses in an application consisting for example, of a centrifugal pump with a device which is operated downstream and consists of a drip chamber and a dosing device as described in EP2386324A1, then the operating point of the impeller can be modulated accordingly to generate such pressure pulses.
The operating point here changes essentially in a pulse form. In other words, the operating point, which characterized at least by an operating parameter, for example, due to the rotational speed of the impeller, becomes greater at first and then becomes smaller again after a comparatively short time. An alternative embodiment provides that the operating point at first becomes smaller and then becomes greater again. If a peristaltic pump is used instead of a centrifugal pump, then the operating point is characterized by the angle formed by the rotor with any stationary point, for example.
Depending on the pump embodiment and the installed or connected hose, the input pressure and output pressure and/or the pump rates respond differently to changes in operating points. The pump itself and the hose inserted into it or connected to it are thus subject to variances due to production.
In this way, for example, the angles of the rotor of a hose roller pump at which the hose rollers engage in the hose and are lifted up from it again are varied.
In addition, the thickness of the hose and with that the flexibility of the hose also varies from one type of hose to the next but also within the same type of hose due to manufacturing-induced variances.
The flexibility of the hose is important for the restoring force of the hose among other things. The restoring force of the hose is in turn important for the period of time required by hose to restore its original shape after it has been compressed for example, by a hose roller pump. Thus the course of the fluid pressure over time within the hose also depends on the varying restoring force of the hose among other things.
Therefore, a calibration process may be provided for each specific pump and inserted or connected hose. In such a calibration process, a control unit varies the operating point of the pump according to a calibration profile and picks up at least one operating parameter such as the fluid pressure or the pump rate at the inlet or outlet of the pump and assigns the at least one operating parameter to the respective current operating point.
For example, the angular velocity (depending on the rotor angle) or the rotational speed of the rotor and/or the pump may be varied in a targeted manner and the respective angular velocity (depending on the rotor angle) and/or the rotational speed may be assigned to a fluid pressure at the inlet and/or outlet of the pump.
Thus any combination of pump and inserted or connected hose can be measured in a calibration phase to obtain an unambiguous relationship between the operating point and/or the change in the operating point and the parameters that depend on this operating point and/or the change in the operating point and/or the change therein such as the fluid pressure upstream or downstream from the pump or the pump rate.
The relationship thereby obtained can be stored in the form of a table, for example, in a memory. By means of a mathematical operation, a function which maps the table can also be formed from this table. This function may be used in a control circuit to determine the necessary operating point for the respective desired parameter such as the fluid pressure at the pump outlet.
Another embodiment of the invention relates to a system of at least two pumps which convey fluid in the same fluid cycle. Such systems of multiple pumps conveying fluid in the same fluid circulation are known from dialysis. Thus a pump for delivering blood replacement fluid (substitute) is often arranged downstream from a peristaltic blood pump in a hemodialysis machine. This pump may be embodied as a syringe pump, in which the plunger of the syringe can be moved forward and in reverse by a controllable drive (electric, pneumatic or hydraulic).
Other embodiments of substitute pumps comprise for example, gear pumps, diaphragm pumps, hose roller pumps or centrifugal pumps.
The substitute pump can deliver the substitute for example, directly into a venous drip chamber to which a medication dosing device may be connected. Such a system of blood pump and substitute pump delivers a different fluid to each fluid circulation.
However, systems of pumps arranged in succession are also conceivable in which pumps of the same or different types are used and deliver the same fluid. It is thus conceivable that a second pump embodied as a centrifugal pump, for example, is arranged downstream from a peristaltic blood pump.
Regardless of how the pumps are arranged with respect to one another, it is essential for the invention that the operating point of each pump acts on the fluid pressure and/or the delivery rate at least at one single point of a fluid circulation.
For example, it is possible to achieve the effect that the fluid pressure and/or the delivery rate is adjustable by modulation of the operating point of at least one pump at least at this one point.
For example, through appropriate control of the piston of the substitute pump, the pressure in the venous drip chamber may be adjusted to any characteristic regardless of whether or not the blood pump, which is also delivering fluid into the venous drip chamber.
For example, a rise in pressure generated by a blood pump upstream can be counteracted by synchronized retraction of the piston of a substitute pump, which is embodied as a syringe pump, which delivers fluid into the same fluid circulation downstream from the blood pump.
It is also conceivable that, with pumps of the same or different type, which are arranged one after the other fluidically, delivering the same fluid, the operating points of each pump are modulated individually. Thus, for example, with a system consisting of a hose roller pump and a centrifugal pump downstream, the hose roller pump may be modulated in such a way that pressure fluctuations at its pump outlet are minimized and the operating point of the downstream centrifugal pump is modulated, so that pressure pulses for controlling a medication dosing device in the manner described above are generated at the pump outlet thereof.
Combinations of any conceivable type of pump with at least two pumps are conceivable wherein the operating points of each pump used can be modulated like a profile.
The embodiments of the invention are explained further in the detailed description of the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
The following figures are presented to facilitate an understanding of the invention and they show exemplary embodiments of the present invention.
FIG. 1 shows on the basis of three phases the pumping operation when using a traditional peristaltic hose roller pump.
FIG. 2 shows on the basis of two diagrams as an example the change in the operating point of a hose roller pump due to modulation of the angular velocity of the hose roller pump.
FIG. 3 shows a regulating system according to the invention for determining a certain angular velocity of the rotor of a hose roller pump.
FIG. 4 shows a medication dosing device according to the invention in an exemplary embodiment.
FIG. 5 shows the profiles of the output pressure and/or the rotational speed of the centrifugal pump of a device according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
FIG. 1 is subdivided into three phases A, B and C, each having a peristaltic hose roller pump 100 with an inserted hose 104 . The peristaltic pump comprises a rotor 103 with rotatably mounted rollers 102 which engage in the elastic hose 104 and deliver the fluid within the hose 104 due to the rotation of the rotor (counterclockwise in FIG. 1 ).
Phases A, B and C in FIG. 1 differ in the position of the rotor. Each diagram shows the output pressure 112 at the left, next to the hose roller pump, and the input pressure 111 prevailing inside the hose 104 downstream and upstream, respectively, plotted as a function of the adjustment angle α of the rotor.
The broken vertical line characterizes here the current position angle of the rotor 103 . Past pressure curves are shown at the left of this line and future curves are shown as interrupted lines at the right of this line.
Since the pumping operation takes place within one half of a rotation of the rotor due to the geometry of the hose roller pump, the labeling of the abscissa ends at 180 (degrees). The ordinate shows the fluid pressure in mm mercury column with respect to the outside pressure. After half a rotation, the pump operation begins again, and then the previously leading hose roller, i.e., the hose roller closer to the pump outlet in the direction of flow, is then the currently trailing hose roller and vice versa.
The pressure characteristics upstream and downstream from the pump are essential for an understanding of the invention. In phase A the right roller 102 occludes the hose completely and pushes the fluid which is in the hose section 106 counterclockwise toward the pump outlet. The fluid in the hose section 105 is also delivered in the direction of the pump outlet due to the hose moving back into its original shape.
The fluid pressure increases linearly in the hose section 106 whereas the fluid pressure decreases linearly in the hose section 105 .
In phase B, the trailing lower hose roller pump engages with the pump bed for the first time and squeezes the hose at the location 110 . There is thus a displacement of volume there, reflected in the sudden jump in pressure 109 in the hose section 105 . The hose section 106 is not affected by this volume displacement because the leading hose roller completely occludes the hose.
In phase C, the leading roller is lifted up from the pump bed and releases the hose 104 at the location 108 . Then there is an equalization of pressure between the hose sections 105 and 106 . This is reflected in the drop in pressure 110 .
This procedure is repeated with each half revolution so there is a periodic pulsatile fluid transport with the pressure pulses shown in FIG. 1 . The pressure and fluid flow are proportional to one another, so that the fluid flow is higher, the higher the pressure and the lower the flow resistance.
One object of the invention is to reduce these pressure pulses or ideally suppress them completely.
FIG. 2 illustrates on the basis of two diagrams the modulation of the angular velocity of the rotor of a hose roller pump according to the invention, as shown in FIG. 1 to generate a constant fluid pressure and a constant fluid flow.
The diagram 200 shows the curve of the fluid pressure P at the pump outlet and/or the fluid flow Q at a constant angular velocity ω. This shows the typical pulsatile curve of pressure and flow as in the diagrams in FIG. 1 .
In contrast with that the diagram 201 shows the fluid pressure P at the pump inlet or outlet and/or the fluid flow Q when the angular velocity is modulated according to the invention. In principle, the change in the angular velocity in the diagram 201 follows a profile which is in inverse ratio to the change in the fluid pressure P and/or the fluid flow Q in diagram 200 . In other words, if the pressure and/or flow in diagram 200 increase, then the angular velocity in diagram 201 decreases accordingly and vice versa.
Thus the angular velocity according to the invention depends on the angle of rotation of the rotor of the hose roller pump. The angle of the rotor can be made known by any sensors of the control unit which prompt a corresponding angular velocity of the rotor on the basis of the angle, which is then known. Exemplary embodiments of the sensors for detecting the angle of rotation of the rotor include potentiometers whose resistance depends on the angle of rotation or Hall sensors which deliver signals corresponding to the angle of rotation.
However, it is also conceivable that the hose roller pump is driven by a stepping motor, which rotates defined angles with a corresponding electrical control. The angle of rotation can thus be learned by a control unit at any time. Only one starting point of the angle of rotation need be made known to the control unit.
In addition to keeping the fluid pressure or the fluid flow constant, these variables may be regulated at any predetermined profile according to the invention in that a second modulation of the angular velocity of the rotor is superimposed on the first modulation which leads to a constant fluid pressure and/or flow. This may be desired, for example, when a medication dosing device which is driven by the peristaltic pump is present downstream from the pump.
According to another embodiment of the invention, as an alternative to the angle of rotation or in addition to the angle of rotation, additional variables are measured and sent to the control unit. These additional variables may be the fluid pressure and/or the fluid flow at the pump inlet and/or at the pump outlet. It is also conceivable to return of the electrical pump current, i.e., the current which is supplied to the drive motor of the pump. The control unit here regulates the angular velocity of the rotor of the hose roller pump based on the additional variables, so that the pressure and/or the flow assume desired values.
FIG. 3 shows a corresponding control circuit in which the input pressure and the output pressure are compared with corresponding setpoint values and a certain angular velocity is determined from them.
One possible additional or exclusive variable which can be supplied to the control circuit according to FIG. 3 is the engine current of the hose roller pump. It has been found that the engine current and in particular the output pressure of the hose roller pump are proportional to one another.
The control circuits shown in FIG. 3 receive at least one of the additional variables, namely the input pressure Pin, the output pressure Pout and the electrical pump current Ipump with the setpoint values Pin-!, Pout-! and Ipump-! and the control deviation is sent to a control unit 301 . The control unit 301 thus receives at least one operating parameter of the pump. This control unit calculates on the basis of the control deviation a corresponding prevailing angular velocity and sends a corresponding signal to the pump 302 , which causes the pump to rotate at the calculated angular velocity. Optionally and as shown with a dotted line in FIG. 3 , the angle of rotation a of the pump rotor is additionally sent to the control unit 301 . The additional variables here are measured by suitable sensors, for example, pressure sensors, flow rate sensors, electrical sensors (current measurement, voltage measurement).
The control unit 301 can access the data determined in a calibration phase when determining an operating point for the pump. From these calibration data which are representative of the behavior of the pump parameters as a function of the operating point, the control unit then calculates the respective current operating point which leads to maintaining the setpoint values. To do so, the control unit may access a stored table having different operating points and pump parameters assigned to them, for example, an output pressure for a certain angular velocity and a certain rotor angle or an output pressure for a certain rotational speed. Alternatively, however, this assignment may also be made on the basis of a mathematical function which obtained from the data from the calibration phase.
If the feedback of the additional variables replaces the feedback of the angle of rotation of the rotor, then this advantageously eliminates the need for the corresponding sensors for the angle of rotation.
If the feedback of the additional variables supplements the feedback of the angle of rotation of the rotor, then potentially dangerous situations can be inferred from knowledge both the fluid pressure (or flow) and the angle of rotation.
One such potentially dangerous situation is, for example, occlusion of the hose downstream from the hose roller pump. Such an occlusion may occur, for example, when a filter, for example, a dialysis filter becomes clogged downstream from the pump. Due to the design the hose roller pump occludes the hose in normal operation. If the flow resistance increases due to occlusion, the pressure at the pump outlet increases greatly and may cause the hose to rupture or may cause rupturing of hollow fibers in the dialysis filter through which the patient's blood is flowing. In both cases, there is blood loss by the patient.
To prevent this, hose roller pumps are often equipped with rollers in spring mounts in the direction of the access of rotation of the roller. The rollers here are pressed against the hose by springs with a certain spring force (occlusive force). If the fluid pressure in the hose exceeds this spring force, then the rollers move in the direction of the axis of rotation of the rotor. As a result of this they no longer completely occlude the inserted hose, and there is a pressure limitation in the fluid delivered.
The embodiment with fluid pressure or fluid flow feedback at the pump outlet according to the invention, for example, offers an additional security to prevent damage. In addition, however, according to the invention leakage in the hose downstream from the hose roller pump may also be inferred. For example, if leakage occurs downstream from the hose roller pump, for example, due to material defects in the hose or in devices connected to it fluidically, such as dialysis filters, then the pressure and/or the fluid flow will deviate from the expected values. Likewise by monitoring the motor current of the hose roller pump, abnormal situations may be inferred; for example, the motor current may experience an unexpected increase if there is an occlusion at the pump outlet end.
In addition, other potentially dangerous situations can also be inferred. For example, if the connection of the hose to a dialysis filter downstream is completely disconnected from the hose roller pump, the fluid pressure drops suddenly and the flow velocity increases suddenly. The pump current in such a situation drops to unexpected values due to the sudden reduction in flow resistance.
In such a situation the control unit can stop the hose roller pump immediately and initiate further measures such as an alarm message to the attending medical personnel and disconnecting the patient from the extracorporeal blood circulation through appropriate actuators such as hose clamps.
FIG. 4 shows an example of an embodiment of a medication dosing device which is driven by a hose roller pump. This device is described in detail in unexamined European Patent EP 2 386 324 A1, to which reference is made explicitly here. FIG. 4 comprises a drip chamber 410 in which a fluid 408 , for example, patient blood, is kept at a certain fluid level. Above this level there is air 407 . The drip chamber 410 has an inlet 406 through which the fluid 408 enters the drip chamber, driven by a fluid pump. The fluid is removed from the drip chamber through the drain 409 .
In addition, the drip chamber 410 has an additional hose connection 405 which connects the dosing device 401 to the drip chamber in a pressure-proof manner. A medication container 402 containing liquid medication 403 is kept in supply in the dosing device 401 .
The pressure characteristic prevailing in the area 407 of the drip chamber is important for the dosing operation and acts on the dosing device 401 via the hose connection 405 .
The dosing device is equipped with two non-return valves (not shown in detail here) whose through direction is rotated with respect to the other and which connect the hose connection 405 to the interior of the medication container 402 . If the pressure in the drip chamber increases by a certain amount, for example, due to the pressure pulses of a hose roller pump delivering fluid into the drip chamber, then the non-return valve opens, leading from the hose line 405 into the medication container 402 . Accordingly, an air bubble 404 is first forced out of the drip chamber and into the medication container 402 . The pressure inside the medication container 402 then increases.
If the pressure in the drip chamber again drops by a certain amount, which is normal when using hose roller pumps for delivering fluid into the drip chamber, then the formerly open non-return valve closes again and the non-return valve which is rotated 180 degrees in relation to the former is opened. Accordingly, droplets 411 of the medication 403 are conveyed from the medication container 402 into the drip chamber and this is continued until the pressure difference between the medication container and the drip chamber is no longer sufficient to keep the non-return valve open.
Due to the periodic pressure fluctuations produced by a hose roller pump in the manner already described, the fluid is conveyed into the drip chamber via the hose line 406 when the hose roller pump is used as a fluid pump, periodically causing medication to be dispensed from the medication container 402 .
This periodic dispensing of medication is often unwanted. However, causing the medication to be dispensed in a controlled manner is a desired goal. This is achieved by regulating the angular velocity of the rotor in the manner already described according to the invention when using hose roller pumps.
If, however, a centrifugal pump is used for conveying the fluid, then the problem of unwanted pressure fluctuations in the fluid conveyed does not arise because centrifugal pumps do not generate any pressure pulses at a constant rotational speed.
If a centrifugal pump with a medication dosing device like that shown in FIG. 4 is used, however, the problem is how to create pressure pulses in a controlled manner through appropriate control of the centrifugal pump to cause a controlled dispensing of medication.
This is accomplished according to the invention by varying the operating point of the centrifugal pump in accordance with a profile. It has been found that the centrifugal pumps conventionally used for medical purposes react with a change in the rotational speed and associated with this also with the change in the fluid pressure in response to the sudden change in the control signal within a sufficiently short period of time.
FIG. 5 shows two examples of this. The upper diagram in FIG. 5 shows the curve of the output pressure of a centrifugal pump, which is often used for medical purposes, when its rotational speed suddenly changes in a pulsating manner. The amount of the change is different for each of the curves labeled by letters A, B, C, D. It is essential that a change in the output pressure associated with that a change in the delivery rate within fractions of a second are passable.
The output pressure of a centrifugal pump can be varied on the basis of the profile according to the invention, as plotted in the bottom diagram in FIG. 5 . The ordinate is plotted in revolutions per minute. This characteristic variable of a centrifugal pump is proportional to the output pressure and to the delivery rate, if the viscosity of the fluid delivered remains constant. The solid line in the bottom diagram in FIG. 5 indicates the control profile for the centrifugal pump and the interrupted dotted and dashed lines indicate the actual rotational speed of the centrifugal pump acted upon by this profile.
The pulsatile change in the output pressure may occur starting from any basic level as also shown by the lower diagram due to the two basic levels at 6000 revolutions per minute and at 8000 revolutions per minute.
In conjunction with a medication dosing device according to FIG. 4 , control pressure pulses can be generated by this control in the drip chamber 410 , leading to controlled dispensing of medication by the medication-dispensing device 401 .
The regulating mechanisms described further above for the hose roller pump can also be used without restriction for the centrifugal pump. Here again, the input and output pressure as well as the current consumption by the centrifugal pump can be monitored and the results sent to a regulating circuit according to FIG. 3 .
It is thus possible through the invention to simultaneously produce pumping operations that are gentle on the blood and to also generate controlled pressure pulses which in combination with a medication dosing device controlled in this way lead to controlled dispensing of medications.
The invention being thus described, it will be apparent that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be recognized by one skilled in the art are intended to be included within the scope of the following claims. | Fluid pumps and medical treatment devices, in particular dialysis machines, include devices configured such that operating pressures and flow rates of the fluid pumps assume desired characteristics, in particular constant values or controlled profiles. The operating point of a peristaltic hose roller pump is adjusted based on an angle of rotation of a pump rotor, or by adjusting the operating point of a centrifugal pump in accordance with a profile. | 0 |
[0001] This application is a Continuation-in-Part application of U.S. application Ser. No. 10/017,770, filed Oct. 30, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field Of The Invention
[0003] The present invention relates generally to surgical devices and methods, methods for harvesting specimens and accessing remote anatomical sites, more specifically to biopsy devices integrated with access cannulae and methods of use thereof.
[0004] 2. Description Of The Related Art
[0005] Various biopsy devices and access cannulae are known in the art. Typically, these devices are configured to work independently of one another, and are not designed to work in concert so as to allow the precise retrieval of a biopsy specimen relative to placement of an access cannula.
[0006] In certain surgical procedures such as vertebroplasty, endoscopy, laparoscopy, and arthroscopy, an access cannula is used to establish a pathway to a remote operative site in the body. Often the operative site is surrounded by critical neurovascular structures that must be protected from iatragenic compromise. It would therefore be an advantage over the prior art to have an integrated access tool and biopsy device that function in concert with one another to minimize tissue trauma, and more importantly, maintain a tract to the remote operative site. It would be a further advantage over the prior art to have a guided biopsy device for harvesting tissue from a remote internal body site.
[0007] For example, the state of the art provides biopsy tools that work independently of access cannulas. An example of known biopsy tools is shown in U.S. Pat. No. 5,595,186, issued Jan. 21, 1997, to Olah, et al. or U.S. Pat. No. 4,487,209, issued Dec. 11, 1984, to Mehl. In addition, European Patent No. 1074231, granted Feb. 7, 2001, to Al-Assir represents a surgical technique using an access cannula.
[0008] Unfortunately, conventional practices require first establishing a tract to the remote operative site with a biopsy tool. After harvesting a specimen and removing the biopsy tool, the tract to the remote operative site must then be re-established when positioning a cannula, causing additional trauma to intervening tissue (particularly if positioning the cannula creates a different access tract) and risking injury to vital anatomical structures adjacent to or in the cannula access path.
[0009] Additionally, it is often desirable to locate the tract to a remote operative site with a small guide wire under fluoroscopic visualization. After the guide wire tract is established, larger tools can be placed over the guide wire and advanced along the “guided” path to the operative site. It would be an improvement over the prior art to provide a biopsy device that is guided over a wire or rod to reach a remote operative site with minimal disruption or trauma to the adjacent tissue. It would be a further improvement to provide a cannula that is guided into position by a biopsy device to maintain the tract previously established to the remote operative site by the biopsy device and minimize the number of steps required to carry out the surgical procedure.
SUMMARY OF THE INVENTION
[0010] One aspect of the present invention is an integrated biopsy/access tool for harvesting a biopsy specimen and provides access to a remote anatomical site. The inventive biopsy/access tool comprises: i) a biopsy device having distal and proximal ends; ii) a cannula having distal and proximal ends, and a first functional channel extending therebetween; and iii) a handle means, removably coupled to at least one of the biopsy device and cannula.
[0011] In the inventive biopsy/access device, if the handle means is separated from the biopsy device, at least a portion of the first functional channel is capable of telescoping over the biopsy device. Preferred, inventive cannulae may have a distal tip adapted to gently displace tissue outward (thereby avoiding tissue trauma) as a cannula is advanced over a biopsy device. Although alternative embodiments are disclosed herein, generally, when the cannula is completely advanced over the biopsy device, the distal ends of the biopsy device and cannula may be aligned.
[0012] The invention also comprises a method for obtaining a biopsy specimen, accessing a remote anatomical site, or both. In the inventive method one places a biopsy device at an anatomical site; advances a cannula over the biopsy device; secures the biopsy specimen; and withdraws the biopsy device containing the biopsy specimen, thereby providing access to a remote anatomical site without having to re-establish a cannula tract. Although skilled artisans will appreciate various procedural alternatives, in a preferred inventive method, prior to placing the biopsy device, one may position a placement means at the remote anatomical site. The inventive method may employ any of the inventive placement means contemplated herein. In a further exemplary method, one advances a trocar through the skin to a remote anatomical site. The trocar proximal end may preferably be adapted to receive a handle prior to placement of the trocar. The connection between the trocar and the trocar handle is adapted to transmit compression and torque, thus facilitating/advancing the distal end of the trocar to the remote anatomical site. The trocar may be cannulated so as to advance over a guide wire first placed at the remote anatomical site. After final placement of the trocar, the guidewire and handle are removed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] These and other objects and features of the present invention will be more fully disclosed or rendered obvious by the following detailed description of the preferred embodiments of the invention, which is to be considered together with the accompanying drawings wherein like numbers refer to like parts and further wherein:
[0014] [0014]FIG. 1 is an exploded view of a preferred embodiment of an inventive biopsy/access tool;
[0015] [0015]FIG. 2A is a top view showing a vertebra, trocar and trocar handle in a first operative position;
[0016] [0016]FIG. 2B is a top view of the vertebra and trocar in a second operative position;
[0017] [0017]FIG. 2C is a transverse sectional view of the trocar handle shown in 2 A, taken along the line 2 C- 2 C of FIG. 2A;
[0018] [0018]FIG. 2D is a longitudinal sectional view of the trocar handle shown in 2 A, taken along the line 2 D- 2 D of FIG. 2A;
[0019] [0019]FIG. 3A is a top view of a vertebra and guide wire in a first operative position;
[0020] [0020]FIG. 3B is a top view of the vertebra and guide wire in a second operative position;
[0021] [0021]FIG. 3C is a top view of a vertebra, a guide wire, trocar and trocar handle;
[0022] [0022]FIG. 3D is a top view of the vertebra, guide wire, and trocar;
[0023] [0023]FIG. 4A is a top view of a vertebra, biopsy device, removable biopsy handle, and trocar;
[0024] [0024]FIG. 4B is a close-up view of selected portions of a preferred biopsy device, removable biopsy handle, and trocar;
[0025] [0025]FIG. 4C is a sectional view taken along line 4 C- 4 C of FIG. 4B;
[0026] [0026]FIG. 5 is a top view of a vertebra, biopsy device and removable biopsy handle;
[0027] [0027]FIG. 6 is a top view of a vertebra and biopsy device;
[0028] [0028]FIG. 7A is a top view of a vertebra, biopsy device and cannula;
[0029] [0029]FIG. 7B is a close-up view of the elements circled in FIG. 7A;
[0030] [0030]FIG. 8A is a top view of a vertebra, the biopsy device, removable biopsy handle and cannula;
[0031] [0031]FIG. 8B is a close-up view of the elements circled in FIG. 8A;
[0032] [0032]FIG. 9 is a top view of a vertebra and cannula;
[0033] [0033]FIG. 10 is an exploded view of an alternative biopsy/access tool embodiment of the invention;
[0034] [0034]FIG. 11 is a sectional view of the biopsy device, taken along the line 11 - 11 of FIG. 10;
[0035] [0035]FIG. 12 is an end view of the biopsy device shown in FIG. 11;
[0036] [0036]FIG. 13A is a side view of a biopsy device, biopsy handle and trocar;
[0037] [0037]FIG. 13B is a close-up view of selected portions of the trocar and biopsy device shown in FIG. 13A;
[0038] [0038]FIG. 14 is a top view of a vertebra, biopsy device, biopsy handle, and cannula.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] In a preferred embodiment, when the cannula distal end is disposed relative to the biopsy specimen or anatomical site and the biopsy device advanced within said channel such that a handle distal end engages the cannula proximal end, the biopsy device distal end extends a distance beyond said cannula distal end, thereby securing a biopsy specimen.
[0040] Although a wide range of dimensions are within the scope of the invention, preferably, the biopsy device has an outer dimension ranging from 2 to 3 millimeters, and the cannula has an outer dimension between 3 and 4 millimeters. Depending on the intended use for a biopsy/cannula tool according to the invention, components of the tool will typically range in size, such as the, non-limiting, exemplary ranges shown in Table 1, below.
TABLE 1* COMPONENT SMALL LARGE Trocar 1.0 mm ID / 2.0 mm OD 1.5 mm ID / 3.0 mm OD Biopsy Device 2.0 mm ID / 3.0 mm OD 3.0 mm ID / 4.0 mm OD Cannula 3.0 mm ID / 4.0 mm OD 4.0 mm ID / 2.0 mm OD
[0041] In addition, preferred biopsy devices may comprise a means for securing a biopsy. Such securing means operate to sever and retain the biopsy specimen, specifically a cutting tooth, as for example, is disclosed in Australian Patent No. 200033065, granted Oct. 9, 2000, to Cervi, or U.S. Pat. Nos. 5,477,862, and 5,462,062, issued Dec. 26, 1995, and Oct. 31, 1995, to Haaga and Rubinstein, et al., respectively.
[0042] A preferred biopsy/access tool further comprises a placement means for determining proper placement or the biopsy device (e.g., measuring a penetration depth of any one of the biopsy/access tool, biopsy device, cannula or both at the remote anatomical site). The handle means may be removably coupled to the placement means. The placement means may be a trocar, a guide wire, or a linear scale. The trocar may, but not necessarily, be solid, cannulated (for placement over a guide wire), have a tapered distal end, an outer dimension between 2 and 3 millimeters, and a channel extending therethrough. In a preferred embodiment, the placement means (e.g. the trocar) is telescopically received within a second functional channel extending through the biopsy device. In any of the inventive embodiments, tolerance between the placement means, biopsy device and cannula is small enough that tissue does not become wedged therebetween. A representative tolerance between an outer dimension of a placement means or biopsy device and an outer dimension of a biopsy device and cannula, respectively, preferably ranges from 0.02 to 0.3 mm, more preferably from 0.02 to 0.03 mm. Although thickness of a guide wire according to the invention may vary considerably, the guide wire preferably has a thickness of from 1.0 to 3.0 mm, more preferably 1.5 mm.
[0043] A representative, preferred linear scale according to the invention may be one or more axially-spaced demarcations on the biopsy device or cannula. Employing this exemplary linear scale, when the cannula distal end is disposed relative to the biopsy specimen or anatomical site, and the biopsy device is advanced through the first functional channel, aligning a demarcation with the cannula proximal end, then the biopsy device distal end extends a predetermined distance beyond said cannula distal end, thereby positioning the biopsy device for securing the biopsy specimen.
[0044] In an alternative placement means, the biopsy device may have a distally-facing surface distal to its proximal end, and the cannula may have a proximally-facing surface proximate to its proximal end. In operation of this alternative embodiment, when the biopsy device's distally-facing surface engages the cannula's proximally-facing surface, the distal tip of the biopsy device will extend a predetermined distance beyond the distal tip of the cannula, so as secure an adequate length of tissue specimen.
[0045] In an alternative embodiment of the invention, the handle means simultaneously couples distal ends of the biopsy device and cannula. In operating this inventive embodiment, one may place the resulting coupled assembly over the placement means (e.g., the trocar), release the handle means from the cannula, and further advance the biopsy device relative to the cannula to secure the tissue specimen. Or, either the biopsy device, cannula or both may further comprise a leuer-type coupler, the leuer-type coupler being removably coupled to the biopsy device or cannula and capable of removably coupling to the handle means.
[0046] A preferred handle means according to the invention may comprise one or more grip means, the grip means removeably coupled to the biopsy device, cannula, placement means, or all (or any combination of) the foregoing. A preferred grip according to the invention comprises a threaded member having threads that engage proximal threads of the biopsy device, cannula or placement means. In a more preferred embodiment, a first grip removably couples with the biopsy device, and a second grip removably couples to the cannula. In some instances, the inventive biopsy/access tool comprises a trocar, a trocar handle, a biopsy device, a biopsy handle, and a cannula.
[0047] Again, the biopsy device, further adapted to be releasably connected to a biopsy handle, may have a second functional channel for telescopically receiving an outside surface of the trocar. After attaching a handle to the biopsy device, the biopsy device is placed over the trocar and advanced along the trocar so that the biopsy device and trocar distal ends are generally aligned. So as minimize tissue trauma during advancement of the biopsy device, the biopsy device distal tip may be tapered to gently displace tissue outward as the biopsy device is directed over the trocar toward a remote anatomical site. Upon final placement of the biopsy device at a remote anatomical site, the biopsy handle and trocar may be removed, more preferably, one attaches an extension to the biopsy device, thereby preventing its subsequent displacement.
[0048] In the inventive method, one may couple a handle means to a cannula and slide the coupled cannula telescopically over the biopsy device to advance the cannula. In addition, although skilled artisans may appreciate modified method steps, one may secure a biopsy specimen by coupling a handle means to the biopsy device; advancing the coupled biopsy device; and fixing a biopsy specimen in the biopsy device with a securing means, the securing means severing and retaining the biopsy specimen.
[0049] The inventive method most notably provides access to a remote anatomical site for introducing, for example, devices, tools, instruments, medicaments, biomaterials and other matter, such as, without limitation, a delivery cannula, tissue modification devices, catheters, tubes, diagnostic instruments, and pharmaceuticals and therapeutic agents. In preferred, alternative methods according to the invention, one places at the remote anatomical site, through the cannula, one or more delivery cannulae; advances a push rod through the delivery cannula, thereby depositing a pharmaceutical or therapeutic agent contained in the delivery cannula at the remote anatomical site; and removes the delivery cannula. Non-exhaustive and representative: i) tissue modification devices may be mechanical or pressure devices for displacing or modifying tissue; ii) diagnostic instruments may be video-assisted endoscopes and ultrasound probes; and ii) pharmaceuticals and therapeutic agents may be polymethylmethacrylate, bone growth factors, and calcium hydroxy-apatite substances.
[0050] Looking first at FIG. 1, there is shown a biopsy/access tool 3 comprising a trocar handle 6 , a trocar 9 , a biopsy handle 12 , a locking nut 15 , a biopsy device 18 , and a cannula 21 . The trocar handle releasably attaches to the trocar. The trocar handle 6 has a non-circular recess 24 (FIG. 2C) that connects to a corresponding shape on the proximal end 27 (FIGS. 2C and 2D) of the trocar so that torque and compression can be transmitted from the handle 6 to the trocar 9 . The trocar 9 is sized so as to be telescopically received within the biopsy handle 12 and biopsy device 18 . The biopsy handle 12 has a split collet configuration 30 (FIG. 4C) on its distal end and is connected to the biopsy device 18 by means of the locking nut 15 that compresses the split collet 30 against the outside surface of the biopsy device 18 . As will hereinafter be discussed, biopsy device 18 is sized to be telescopically received in the central lumen of cannula 21 .
[0051] [0051]FIGS. 2A and 2B show the approach and placement, respectively, of the trocar 9 into a tissue mass. For purposes of illustration, the tissue mass discussed herein is characterized as a vertebra V, but the methods and devices disclosed herein may be used in connection with any soft or hard tissue mass.
[0052] [0052]FIG. 2C is a sectional view of the trocar handle 6 and trocar 9 shown in FIG. 2A and, in conjunction with FIG. 2D, show how trocar handle 6 may be removably attached to trocar 9 so that torque and compression can be transmitted from handle 6 to trocar 9 , whereby trocar 9 can be advanced into vertebra V (FIGS. 2A and 2B).
[0053] [0053]FIGS. 3A, 3B, 3 C, and 3 D show an alternate technique for the approach and placement of the trocar into vertebra V. More particularly, FIGS. 3A and 3B first show the approach and placement of a guidewire 33 into vertebra V, followed by the placement of the cannulated trocar 9 (with the trocar handle 6 attached) over the guidewire 33 as shown in FIG. 3C. Then the trocar handle 6 is removed (FIG. 3D), and then guidewire 33 is withdrawn leaving just trocar 9 extending into vertebra V.
[0054] [0054]FIG. 4A shows the biopsy device 18 advanced over the trocar 9 , with the distal tip 36 of the biopsy device advanced to the distal tip 39 of the trocar. FIG. 4B shows a close-up veiw of selected portions of FIG. 4A, where the trocar 9 extends proximal to the proximal end of the biopsy removable handle 12 . FIG. 4C is a sectional view taken along line 4 C- 4 C of FIG. 4B, illustrating how an internal taper 42 on the locking nut 15 contacts an external taper 45 on the biopsy removable handle 12 , causing the split collet 30 on the distal end of the biopsy removable handle to compress and secure the biopsy device 18 .
[0055] [0055]FIG. 5 shows the biopsy device 18 (with the biopsy handle 12 attached) after the trocar 9 has been removed.
[0056] [0056]FIG. 6 shows the biopsy handle 12 removed from the biopsy device 18 .
[0057] [0057]FIG. 7A shows the cannula 21 advanced over the biopsy device 18 , with the distal end 48 of the cannula 21 aligned with the distal end 36 of the biopsy device 18 as shown in FIG. 7B.
[0058] [0058]FIG. 8 shows the biopsy handle 12 reattached to the biopsy device 18 , and the distal tip 36 of biopsy device 18 advanced a predetermined distance beyond the distal end 48 of the cannula 21 so as to harvest the desired tissue specimen from vertebra V. At this point the biopsy specimen is secured within the internal cavity of the biopsy device.
[0059] In order to regulate the extent to which the distal tip 36 of biopsy device 18 extends beyond the distal tip 48 of cannula 21 (i.e., in order to regulate the penetration of biopsy device 18 into vertebra V), biopsy device 18 may include axially spaced demarcations 51 (FIG. 8B) on its external surface for referencing against the proximal end 54 of cannula 20 .
[0060] [0060]FIG. 9 shows the cannula 21 with the biopsy device 18 removed. At this point, a subsequent surgical procedure can begin. The cannula 21 can then serve as a working channel for safely advancing operative tools to vertebra V, or for delivering therapeutic agents or biomaterials or diagnostic instruments to vertebra V.
[0061] Considering FIG. 10, there is shown a biopsy/access tool 3 A comprising a trocar handle 6 A, trocar 9 A, biopsy handle 12 A, locking nut 15 A, biopsy device 18 A, and cannula 21 A. The trocar handle 6 A attaches to the trocar 9 A. The trocar handle 6 A has a non-circular recess 24 A (FIG. 10) that connects to a corresponding shape on the proximal end 27 A of the trocar 9 A so that torque and compression can be transmitted from the handle to the trocar. The trocar 9 A is sized so at to to be telescopically received within the biopsy handle 12 A and biopsy device 18 A. The biopsy device 18 A has a distal biopsy securing means 60 A (FIGS. 11 and 12) to aid the retrieval of a biopsy specimen. The biopsy handle 12 A has a split collet configuration (not shown in FIGS. 10 - 14 ) at its distal end and the biopsy handle 12 A is connected to the biopsy device 18 A by means of the locking nut 15 A that compresses the split collet onto the outer surface of the biopsy device. The biopsy device 18 A is sized so as to be telescopically received in the central lumen (functional channel) of cannula 21 A.
[0062] [0062]FIG. 11 shows a cross section of the distal end of the biopsy device 18 A, illustrating a distal biopsy securing means 60 A in cross-section. FIG. 12 is an end view of the distal end of the biopsy device, illustrating an end view of the distal biopsy securing means 60 A.
[0063] [0063]FIG. 13A shows the biopsy device 9 A (with the biopsy handle 12 A attached) assembled to the trocar 9 A, and FIG. 13B is a close-up view of the distal ends of trocar 9 A and biopsy device 18 A.
[0064] [0064]FIG. 14 shows a vertebra V with the biopsy device 18 A and cannula 21 A in place, where the biopsy device 18 A is advanced until the distal surface 63 A of the locking nut contacts the proximal end 54 A of the cannula, thereby precisely determining the depth of penetration of the biopsy device into the tissue mass.
[0065] The biopsy/access tool shown in FIG. 10 is used in a method analogous to the methods illustrated in FIGS. 2 - 9 , with the following two exceptions.
[0066] First, the precision control of the depth of biopsy device penetration beyond the cannula is different, as illustrated in FIG. 14. The locking nut 15 A attached to the biopsy handle 12 A presents a distally-facing surface 54 A that is configured to contact the proximally-facing surface 63 A of the proximal end of the cannula when a predetermined length of the biopsy device extends beyond the distal end of the cannula.
[0067] Second, once the biopsy device has been advanced to the proper depth as shown in FIG. 14, the biopsy device 18 A is rotated 360 degrees so as to score the distal end of the biopsy specimen with the biopsy securing means 60 A. Then the biopsy device 18 A is removed with the tissue specimen. | A biopsy/access tool, comprising an integrated biopsy device and access cannula. The biopsy device is internally guided to a remote anatomical site, and the access cannula is adapted to be guided to the same remote anatomical body site by the biopsy device. | 0 |
GOVERNMENT INTEREST
The invention described herein may be made, used and licensed by or for governmental purposes without paying us any royalty.
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Continuation-in-Part of application U.S. Ser. No. 09/030,519; filed Feb. 23, 1998 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
In one aspect this invention relates to diesel engine controls. In a further aspect this invention relates to diesel engine starting systems.
2. Prior Art
In general, diesel engines require the use of a starting aid particularly when engine starting is attempted in cold weather. The starting aid is used until there is sufficient heat in the cylinder area to sustain knock ignition combustion. At present two different methods are normally used to aid diesel engine starting. One method is ether injection, which provides a source of ether to the combustion chamber, the ether is highly combustible and causes fuel ignition even at low temperatures. This however requires that the ether supply be replenished and adds another fluid to be maintained. Such systems are also very expensive to install making them unsuitable for smaller engines where cost is a important factor.
A second method is to provide a glow plug or similar device which is heated to a temperature that will ignite at least a portion of any fuel injected into the combustion cylinder. The glow plugs continue to assist in igniting fuel until the combustion cylinder has reached a satisfactory operating temperature for knock ignition. The glow plugs can be heated after the engine has started operation to assist fuel combustion thereby minimizing the production of incomplete combustion products. Glow plug starting systems generally have one or more glow plugs associated with each combustion cylinder, a controller circuit to provide electrical current to the glow plug and a power source.
In greater detail, the most traditional prior art system for diesel engine control would include: a glow plug controller which acts through another control box containing a relay connection, the relay in turn activates the glow plugs, starter and related accessories. In such a system upon cold starting, the relay will engage and the glow plugs are activated for a set period of time to attain an operating temperature and then the starter is engaged. The engine is cranked L11 until it starts and assumes normal operation, or the starter is deactivated. During the start cycle, the relay is periodically energized to keep the glow plug temperature near the desired operating temperature of 1800 to 1900 F (about 1000 to 1050 C). The relay cycling provides short, intense pulses of power to all the glow plugs simultaneously. This pulsed after glow sequencing, is maintained during the first few minutes of engine operation which helps reduce pollution and makes for a smoother initial operation. However, this after glow sequencing which activates all plugs simultaneously creates a large electromagnetic impulse, EMI, power surge each time the relay is cycled. Power surges of a magnitude in the 100 amp range for one second are common with the pulses being delivered every 5 to 10 seconds. The cycle time and frequency depend on the starting protocol programmed into the controller. The EMI surges create problems with radio systems on the vehicle and also the other electrically controlled systems on the vehicle.
Prior art systems are generally designed so the duty cycle is dependant on the temperature of a portion of the engine or cooling system at a location removed from the glow plugs. When the engine does not start promptly, the ignition is generally turned off and the starting sequence reinitiated. Since the temperature sensed by the controller has not generally changed markedly, the system will default to its cold start mode and the glow plugs will be reactivated for the full power preglow cycle of the starting protocol. Repeated use of the full power preglow cycle without an adequate cool down period, exposes the glow plugs to premature failure from overheating since the glow plugs are not designed to take the full power preglow energy cycle without a rest period. This type of failure is particularly a problem with many commercial and heavy equipment systems that are powered by 24 volt electrical systems. The higher voltage will over heat the glow plugs faster than 12 volt systems if the plugs preglow cycle is repeated without adequate rest time between cycles since most glow plugs are designed for 12 Volt systems. Failure modes from over heating range from the plugs simply burning out to the heating element breaking inside the engine head. A broken plug failure expands the glow plug element to the point where it can not be removed from the head using normal techniques and requires disassembly of the engine for repair.
It is desirable to create a starting assist system which will both ensure an adequate rest time between repeated pre-glow cycles and is not temperature dependant. Further the system should provide an after glow cycle protocol that maintains an even glow with minimum EMI spikes.
SUMMARY OF THE INVENTION
Briefly the present invention is a starting system for controlling the glow plugs and related starting systems to increase glow plug life and decrease starting emissions pollution. The present system uses a microprocessor to control a number of transistors which in turn allow the glow plugs to achieve the necessary preglow temperature and then are pulsed by the microprocessor to maintain the required operating temperature. In the event of repeated attempts to restart the engine, the controller will ensure that the pre-glow portion of the cycle is repeated only when the plugs have recovered from a previous pre-glow cycle but will allow the after glow cycle to be reinitiated in the event the engine does not begin operating within the initial after glow period.
BRIEF DESCRIPTION OF THE DRAWING
In the accompanying drawing:
FIGS. 1A and 1B show a schematic of one control unit according to this invention for a vehicle.
DETAILED DESCRIPTION
In the accompanying drawing where like numerals refer to like parts, the control system of the current invention is described with respect to a 24 Volt vehicle electrical operating system, common to heavy equipment. To begin the ignition sequence, an on-off switch, such as a toggle switch or key ignition (not shown) is activated. The switch in turn will activate a starting sensor, 12 which transmits a current at 24 Volts to a diode 14 and into a voltage divider formed by a 5.6 K ohm resistor 16 and a 1.0 K Ohm resistor 18. The resulting current at approximately 5 Volts flows through line 18 to an input on a microprocessor 20. This initiates a preprogrammed starting sequence determined by the engine operating characteristics loaded on the microprocessor 20.
Various microprocessors could be used as the processor 20 and are compatible with the present system. One example of a general purpose microprocessor which has been found amenable for use in practicing this invention is the microprocessor designated PIC16C73A manufactured by Microchip. The remainder of this discussion will be based on the inputs-outputs on the Microchip microprocessor. Other microprocessors would have different input-output schemes and designations. However, such microprocessors may also be used in the practice of this invention and their programming altered to fit the operating parameters of the engine being started.
The starting sequence program of this invention is designed for an eight cylinder engine and therefore the starting sequence will activate eight microprocessor outputs 21 on microprocessor 20. As the microprocessor 20 activates the outputs 21, it turns on eight corresponding individual buffers 22 that provide current to activate eight individual transistors 24. There is one buffer and one transistor associated with each glow plug 30 in the engine when using the controller of this invention. Obviously there would be fewer buffers and transistors if there were fewer glow plugs because the engine had fewer cylinders. Each individual transistor 24 delivers current via a line 26 furnished by a battery system (not shown) to the glow plugs 30. The microprocessor 20 will maintain the power to the glow plugs 30 for a calculated length of time to ensure the glow plugs have reached an operating temperature of about 950 C. The preglow time is calculated by the microprocessor 20. Generally, the glow plugs 30 commonly used in diesel engines have about 1.8 Ohm resistance and require about 2000 watt-seconds to reach the required operating temperature. The battery voltage is directly measured by voltage sensor circuit 30 which is connected to the battery system of the vehicle, the battery voltage passing through a voltage divider of the type described above and the output voltage delivered to an input on the microprocessor 20. At the start of the cycle the required pre-glow time is calculated using the formula (2000 watt seconds times 1.8 Ohm divided by the measured voltage squared). After the calculation, the microprocessor 20 will maintain the buffers 22 in an activated state for the calculated time period to maintain a constant current flow to the glow plugs 30 and to elevate the glow plugs to the desired temperature. During this time, the microprocessor 20 will also activate a buffer 32 which will in turn energize a wait to start light 34 located on the vehicle control panel. The wait to start light 34 will warn the operator that the engine is not ready for starting and the starter should not be engaged.
When the calculated preglow time has elapsed, the microprocessor will turn off the current to the wait to start light 34 signaling the operator that the starter can be engaged. At the same time the microprocessor will begin an after glow cycle to maintain the glow plugs temperature.
The after glow cycle should maintain the glow plugs at the approximately 950 C temperature until the engine has achieved a smooth operating temperature. It is estimated that pulses of 40-60 Watts per plug will maintain the glow plugs at their desired operating temperature until the engine starts and reaches operating conditions. Using a predetermined power value, Wattage, and the measured Voltage, the microprocessor can calculate the pulse width and spacing to be applied to each individual glow plug 30 to maintain each individual plug at the desired operating temperature. An acceptable afterglow duty cycle can be calculated using the formula (50 Watts times 1.8 Ohm divided by the measured voltage squared). The microprocessor 20 will sequentially activate the individual buffers 22 to deliver the required power pulse to each glow plug in sequence. As the current to one plug is being turned off the next plug in sequence will be turned on so the sequencing procedure will maintain a nearly constant current flow to the glow plugs throughout the after glow cycle. Sequentially applying current the plugs in a rotating fashion will smooth the current flow by reducing current surges and thereby reduce EMI surges resulting from current flow variations. It will also prevent current surge drains on the battery system which were the result of operating systems utilizing temperature controlled-relay systems. It is expected the afterglow pulses will generally be applied to the glow plugs for 1 to 2 minutes after the pre-glow cycle is complete. This after glow cycle will assist in smoother starting and also lowers emissions during the initial operating cycle until the engine block achieves operating temperature. The after glow cycle will stay on for the predetermined length of time.
After the wait to start light has been turned off by the microprocessor 20 and the after glow cycle initiated, the starter switch can be moved to the engine cranking position to begin engine cranking. The microprocessor 20 will energize buffer 40, which in turn will activate a transistor 42, which acts as a 24 volt switch. The current through transistor 42 activates the starter solenoid 44 causing the starter to crank the engine. The microprocessor 20 can be programmed to lock out the starter solenoid 44 until the pre-glow cycle has been completed to prevent premature starting attempts; however, this is not necessary for most applications.
An alternator tap 46 senses the voltage produced by the engine's alternator. Once the engine begins to operate, the alternator generates a 24 Volt current which passes through a voltage divider and provides a 5 volt current to the microprocessor 20 signaling the microprocessor that the engine is functioning sufficiently that battery power to the starter can be turned off and the starter solenoid 44 disengaged.
A latching circuit 51, powered by the battery contains a switch element 52 with a light emitting diode 54 that is controlled by the microprocessor 20 to remain lit for a predetermined period after run switch starter has been turned off. Generally, the diode will remain lit for about 2 to 3 minutes. The latching circuit 54 will prevent the pre-glow cycle from being reactivated until the delay period has expired and the latching circuit is turned off. If the engine failed to start within the after glow period, the run switch can be turned off and back on. If the restart attempt takes place while the latching circuit 51 is active, the microprocessor 20 will default to the after glow cycle and maintain the glow plugs near their operating temperature.
The latching circuit 51 ensures the glow plugs are not subjected to the higher wattage pre-glow cycle for several minutes after a pre-glow activation. The latching circuit 51 provides the glow plugs 30 with a predetermined minimum rest time to recover before the microprocessor 20 will allow the pre-glow cycle to be reinitiated. The rest time preserves the glow plugs 30 from abuse by an impatient operator thereby preventing the most common operator abuse problem. In general a 2 to 3 minute time out is sufficient to allow the plugs to be recycled. The present controller of this invention allows the run switch to activated more than once to initiate starting without the need to time the rest cycles and will prevent operator abuse to the glow plugs.
The foregoing descriptions and calculations are predicated on a diesel engine using a standard 1.8 Ohm resistance glow plug. If glow plugs with different resistances or operating characteristics were used the microprocessor routine can be modified appropriately to provide the required pre-glow wattage and after glow wattage. The times set forth above are for a normal small truck 4 cycle diesel engine. The controller could also be programmed for larger and 2 cycle diesels which have different requirements and operating characteristics.
The bus designated 80 represents the under-hood bus of the circuit, which connects the various elements that make up integral parts of a normal land vehicle electrical system. The circuit has a connection 70 to the vehicle current source be it battery, external power supply or alternator. The line current from the current source is modified where needed by transistors 72 to provide a lower current for certain lamp and similar devices which require only a minor current to operate while the higher current accessories like the fan, heater and starter are furnished a full current load. The bus 80 has a corresponding attachment area designated generally 90, which represents the dashboard side of the electrical system. The bus 80 receives current and distributes it to the various parts of the electrical system as shown. Undesignated leads on the bus can be used for the various vehicle needs, brake lights, heater, air conditioning for example. These are part of the vehicle's normal equipment but are not part of the present invention and description is omitted in the interest of brevity.
Various alterations and modifications will become apparent to those skilled in the art without departing from the scope and spirit of this invention and it is understood this invention is limited only by the following claims. | A starting controller for a diesel engine. The controller has a microprocor that will provide a current to the glow plugs until they are heated to the desired operating temperature and will then distribute sequential pulses to the individual plugs until the engine reaches the desired operating temperature. The system can have a latching circuit that will prevent the preglow cycle from being reinitiated until the glow plugs have been allowed to cool to a level where reinitiation will not represent a substantial degrading effect on the glow plugs. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International Application No. PCT/EP2006/001741 filed on Feb. 24, 2006, which claims the benefit of German Patent Application No. 10 2005 009 634.4, filed Mar. 3, 2005. The disclosures of the above applications are incorporated herein by reference.
FIELD
[0002] The present disclosure relates to film dressings and in particular application systems for film dressings.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0004] Application aids for adhesive bandages or wound dressings have been known for quite some time. These application aids are particularly used for film dressings. Film dressings are thin, usually transparent, semipermeable films or foils made of polymer materials. The semipermeable nature of the films prevents the penetration of bacteria or moisture and thereby guarantees a sufficient exchange of oxygen and condensation between the skin to be covered and the outside surroundings of the film dressing. These film dressings are used in a variety of ways—for example, as an incision film for sterile covering of surgery wounds, as a water-proof cover of wound dressings that absorb exudates, and for positioning catheters or cannulas. Due to the minimal thickness of these films and their respective instability, these film dressings are equipped with a wide variety of application aids. Most of these application aids use an additional supporting layer which is removed during or after the application of the film dressing.
[0005] The patent literature has also known film wound dressings for quite some time. For example, EP 81 990 B1 describes an adhesive wound dressing that consists of a thin polymer film. This polymer film is coated on one side with an adhesive material that adheres to the skin, which in turn is covered with a removable layer. On the other side, which during application is opposite of the body, the polymer film also has an easily removable support layer to improve the ease of use, which consists of a fibrous material, for example, a non-transparent non-woven material. This support layer is of the same size as the polymer film.
[0006] EP 690 706 B1 describes an adhesive wound dressing, which has a carrying layer to aid the ease of application of a polymer film, which is comprised by a wound dressing. This carrying layer completely covers the polymer film and can be removed from the polymer film in two steps. For this purpose, a center section is removed from the carrying layer, whereas in the next step a frame section is removed. The fact that it is difficult for the user to grasp the carrying layer of this wound dressing is unfavorable.
[0007] In addition, EP 951 263 B1 describes an adhesive film dressing, the adhesive side of which at least one two-part removable protective layer covers the adhesive side and where its non-adhesive second side comprises a one-part support layer. The support layer in this film dressing is hinge-like attached to the protective layer on two opposite sides so that the support layer is removed simultaneously with the support layer.
[0008] EP 473 918 B1 describes a film dressing that comprises a one-sided supporting film, which in turn has one grip strip on each of the two opposite sides. This position of the grip strips has the disadvantage that there is no pre-determined direction for removing the supporting film.
[0009] EP 985 931 A1 describes a film-based dressing material, which comprises a non-adhesive gripper in the peripheral area of the film. The non-adhesive side of the film comprises a one-part support layer, which is equal to the size of the film and comprises at least one grip strip. By pulling the gripper in the direction of the adhesion, the applied film can be removed again painlessly.
[0010] The European patent specification EP 630 628 B1 established a film dressing that comprises for the ease of application a two-part supporting film. This supporting film is larger than the film to be applied and completely covers it. In order to remove the supporting film, the supporting film comprises an additional adhesive removal strip, which is positioned above the intersection line of the supporting film and for handling purposes has two non-adhesive peripheral areas that serve as grip strips. This additional removal strip serves to remove only a portion of the supporting film, whereas the second part of the supporting film remains on the polymer films.
[0011] WO 97/25012 A1 suggests a film dressing which is provided either continuously or only on two opposing peripheral areas of the film with a two-part supporting layer. If the supporting film is continuously attached to the film dressing, then gripper supports may be positioned on the supporting film. The adhesive protective layer opposite of the supporting layer is divided into three sections.
[0012] These industrial property rights present various alternative solutions to film and foil dressings with various application systems. The film dressings which have been suggested as a solution in these industrial property rights are viewed in part as too complicated in their construction and too complicated in their application. Furthermore, the film dressings with application aids suggested in these protective rights all exhibit a rigidity which is considered too high in respect of the very flexible polymer film that is actually to be applied. This flexibility of the film dressings is necessary, however, to apply the polymer films which are actually to be applied, accurate and wrinkle-free.
SUMMARY
[0013] The present disclosure presents a film dressing with application system, which has a simple structure and yet assures wrinkle-free application of the polymer film. At the same time, it is possible to apply the film dressing universally without any limitation to shape or size.
[0014] Accordingly, a film dressing is provided that comprises a polymer film and an application system for permitting an improved ease of use of said film dressing, where the application system is located on the first side of the polymer film and comprises at least one first and one second supporting film, where at least one grip strip is molded, whereby the polymer film comprises at least one first supporting film-free area and the grip strip at least partially overlaps the first supporting film-free area.
[0015] An advantage of such a film dressing with an application system lies in the fact that the supporting film-free area of the polymer film, that is, the area which is not covered by a supporting film, can function as a joint during the application of the film dressing, thanks to the greater flexibility thereof, by comparison to the polymer film with the supporting film. This being the case, even a relatively rigid support material can be used as a supporting film, plus at the same time guaranteeing a snug-fitting application. On the other hand, in the state of the art, whether a supporting film in one part which is of the same size as the polymer film, or a supporting film in several parts which, as a whole, is of the same size as the polymer film, is used, the choice of the support material must be limited to relatively flexible materials, in order to guarantee a snug-fitting application of the polymer film. A further advantage lies in the saving on the material used for the supporting film.
[0016] Furthermore, the fact that at least one section of the supporting film-free area is covered by the grip strip reduces the risk of contamination or damage to the polymer film.
[0017] The “Application system” according to the present disclosure shall include everything that permits the improved ease of use of the polymer film and comprises at least two supporting films and in addition to these supporting films comprises at least two grip strips, which are molded to said supporting films. “Molding” in this context shall mean the combining of two similar or two different materials, which are separable or inseparable from one another by means of adhesives, pressure, thermal energy, ultra-sonic applications or other procedures. The grip strip is therefore presently always an additional material component, whereas the grip strip can always be removed from the polymer film with at least one supporting film. Furthermore, for the ease of understanding in the context of the present disclosure, a film or polymer film shall always refer to the film or polymer film actually to be applied, for example a wound dressing; in contrast, a film or polymer and/or supporting film shall always refer to a part of the application system, that means the difference between film and foil in this case only refers to the function of the components. No distinction shall be made in respect of the material between the terms of film and foil.
[0018] Because of the first supporting film-free area, the surface of the polymer film which is covered by supporting film is accordingly smaller than the surface of the first side of the polymer film. The film dressing comprises in particular one or more supporting films, whereby the total contact surface of said supporting films is less than about 97%, and especially less than about 94%, of the area of the first side of the polymer film to be applied.
[0019] An additional embodiment of the disclosure provides for a grip strip which completely overlaps an area of the polymer film which is not covered by supporting films. In this case, the application system in its entirety can be of the same size as the polymer film. The reference to “the same size” indicates the size of the contact area; that is, the limitation of the perimeter of the application system and that of the polymer film are aligned. The fact that the application system and the polymer film are the same size, and the fact that the grip strip is merely molded to the supporting film and is not connected to the polymer film, guarantee that, in addition to the previously described high level of flexibility in the area which is not covered by the supporting film, the entire film is covered, and is therefore also completely protected before and during the application.
[0020] In a first preferred embodiment of a film dressing according to the present disclosure, the first grip strip comprises a grip area that can be determined by the user when grasping said grip strip, preferably designed as a rear grip device of at least about 2 cm 2 , particularly at least about 5 cm 2 and especially preferred of at least about 7 2 .
[0021] In particular, a first area that is not covered by the supporting films can be positioned at the edge of the polymer film. An edge shall be understood as every section of an area, which extends from the border of an area into the interior of an area, whereas the area extension of the edge is smaller than about 50% of the entire area. This provides a film dressing which favorably comprises an area, which comprises a flexibility that is pre-determined by the polymer film itself and assures an easy first positioning of the film to be applied, where at the same time the supporting films assure secure handling in the additional areas. It has been proven that it is particularly easy and safe to manipulate when one of the supporting films has in at least one point of its outer edge a distance from the outer edge of the polymer film of at least about 2 mm, particularly at least about 3 mm and especially of at least about 5 mm. Particularly preferred is a distance which has in each point of the edge of the supporting film an equal distance of at least about 2 mm, particularly at least about 3 mm and especially at least about 5 mm to the outmost edge of the polymer film.
[0022] In a further embodiment of this disclosure, the application system includes two supporting films which are applied on a plane parallel to the polymer film. In such an embodiment of this disclosure, a first supporting film-free area may be located between the first and the second supporting films. The distance between both supporting films is preferably in each point at least 2 mm, particularly about 3 mm and especially about 5 mm. Particularly preferred is an application system that has two supporting films, which in each point have the same distance to one another.
[0023] The embodiment of the film dressing with two supporting films especially provides for each of the supporting films to include one grip strip. Accordingly, a first grip strip is arranged on the first supporting film and a second grip strip is arranged on the second supporting film.
[0024] A preferred embodiment of this film dressing according to the disclosure with two supporting films provides for the first grip strip to exhibit a gripping surface designed to be gripped by the user, preferably implemented as a means of gripping from behind, and for the first grip strip with this gripping surface to protrude over at least one section, and especially over all, of the second grip strip.
[0025] This positioning of the grip strips provides the user with a particularly simple means to manipulate in each case only the upper-most first grip strip as the first grip strip and therefore remove a first supporting film as the first film from the polymer film. The user is only able to remove a second supporting film in the second step with the aid of a second grip strip. This determines a succession in the removal of the supporting films and provides a particularly safe means of handling the film dressing.
[0026] The size of the gripping surface of the first grip strip is preferably at least about 2 cm 2 , particularly at least about 5 cm 2 and especially preferred of at least about 7 cm 2 . It is particularly intended that the first grip strip completely overlap the second grip strip. It has been proven particularly safe to manipulate when the first grip strip comprises an exposed grip area of at least about 2 cm 2 , particularly at least about 4 cm 2 and especially preferred of at least about 6 cm 2 . This exposed grip area is in this case the section of the grip area that marginally protrudes the second grip strip.
[0027] It has been shown to be especially easy to handle when the first grip strip protrudes completely over both the supporting film-free area of the polymer film and the second grip strip.
[0028] If the film dressing comprises an application system with two supporting films and a first area without supporting film is intended between the supporting films, separate from this first non-covered area a second area can be designed, which is also not covered by a supporting film. This second area can furthermore preferably be covered by a grip strip. Another design is also possible where this second area is covered neither by a supporting film nor by a grip strip. In the preferred version, this second non-covered area of the polymer film is positioned at one edge of the film dressing. The film dressing in this manner comprises a joint within the dressing as well as an area for its initial positioning.
[0029] If an application system is intended that comprises more than two supporting films, then each supporting film can be assigned to a grip strip. In a particularly preferred embodiment, two supporting films may be assigned to one grip strip. In particular, in one film dressing with three supporting films, two supporting films can be assigned to one grip strip. With this arrangement and/or assignment of the grip strips on the supporting films, two separate supporting films can be removed in one-step.
[0030] Transparent or translucent film materials are particularly intended as supporting films. However, opaque or non-transparent film materials can be used alternatively. Used as supporting film are particularly those films that are manufactured from polyester, polyethylene, polypropylene, polyvinylchloride, polystyrene, polyamide, polycarbonate, cellulose ester, ethylene vinyl acetate, polyvinyl acetate, polyvinyl alcohol and/or combinations thereof. Particularly preferred are supporting films from transparent polyester or polyethylene or polypropylene. At the same time, it has been proven to be particularly preferable when the thickness of the supporting films are adjusted to comprise a thickness of about 15 to about 80 μm, particularly of about 20 to about 60 μm and especially of about 20 to about 40 μm.
[0031] In order to manufacture a grip strip, the same materials can be used that are used for the supporting films. In a particularly preferred embodiment, the grip strip is manufactured from a film material that is more flexible than the supporting film. If an application system is intended that comprises two or more supporting films and two or more grip strips, then all grip strips are manufactured from one material that is more flexible than any supporting film. This assures that the grip strips are very easy to grasp. In another particularly preferred embodiment with two grip strips, it is intended that the grip strip of the first supporting film is more flexible than the grip strip of the second supporting film. At the same time, it is also advantageous if the second grip strip completely overlaps the first grip strip.
[0032] An activation device can be provided in addition to a system with two grip strips that is positioned between the first and the second grip strip. This activation device can for example be an additional adhesive strip with an adhesive strength that is different for the contact surface of each side. When using such film dressings, one first grip strip, which is positioned above the second grip strip, can for example be grasped and with this grip strip the activation device and one supporting film can be removed from the polymer film, whereas the second grip strip is hence simultaneously activated and/or lifted up in such manner that it is easier for the user to grasp.
[0033] Alternatively, in a further embodiment of the film dressing, it is also possible for only a perimeter area of the polymer film to be at least partially covered by at least one supporting film, whereby a supporting film-free central area remains within the perimeter area of the polymer film. In this configuration, the supporting film is provided as a kind of frame, which gives the film dressing the necessary stability and safety in order to ensure a full-free application and, irrespective of the material used for the supporting film, simultaneously enables a precise aim at the place where the film dressing is to be applied. Accordingly, in this configuration, it is possible to use not only transparent or translucent supporting films, but also opaque or non-transparent ones as well. The grip strip attached to the supporting film should preferably be made of a transparent or translucent material.
[0034] In a film dressing according to the present disclosure, polymer films can be particularly used that are highly permeable to condensation. For this, those films are particularly practical that are manufactured from polyurethane, polyether urethane, polyester urethane, polyether-polyamide urethane, polyacrylate or polymethacrylate. Particularly preferred as polymer film is a polyurethane film, polyester urethane film or polyether urethane film. Most particularly preferred are also such polymer films that have a thickness of 15 to 50 μm, particularly of 20 to 40 μm and especially of 25 to 30 μm. The condensation permeability of the polymer film in a film dressing according to the present disclosure is preferably at least about 750 g/m 2 /24 hrs., particularly at least about 1000 g/m 2 /24 hrs., and especially at least about 2000 g/m 2 /24 hrs. (measured according to DIN 13726).
[0035] An adhesive can be applied on the second side, which is opposite of the application system, of the polymer film to be applied. This application can be continuously as well as discontinuously or only in certain areas. The applied adhesive can be a common adhesive, particularly an acryl adhesive or a pressure-sensitive adhesive on polyurethane basis. Preferred are gel adhesives, especially on polyurethane basis, particularly water-based polyurethanes. Especially preferred are hydro-gel adhesives, particularly on water-based acrylics.
[0036] In the preferred version, the basic weight of the adhesive is about 20-about 100 g/m 2 , particularly about 35-about 50 g/m 2 , whereas the adhesive can be applied discontinuously, but preferably continuously.
[0037] The condensation permeability of the polymer film which has been prepared with adhesive is preferably at least about 1000 g/m 2 /24 hrs, particularly preferred about 1200 g/m 2 /24 hrs, and especially preferred at least about 2000 g/m 2 /24 hrs. (measured according to DIN EN 13726).
[0038] According to a development of the present disclosure, the film dressing on the second side of the polymer film opposite of the application system can be continuously coated with an adhesive and the adhesive be protected with a cover paper. Any commonly available silicone paper or film as well as a paper or film coated with a fluoride combination can be used as a cover layer.
[0039] If the film dressing is to be produced as a wound dressing, according to a further embodiment a wound pad or wound cushion must be positioned on the second side of the polymer film, which during the application is positioned towards the body. Such film dressing is particularly suited as wound cover when the wound pad or cushion is adhesively attached to the polymer film. This wound cushion can be made of fleece, therefore a non-woven material. This fleece is preferably a hydrophilic fibrous material such as cotton, viscose, cellulose and polyester or their combinations, preferably with hydrophilic polyethylene or polypropylene.
[0040] Instead of the wound cushion or in addition to the wound cushion, the film dressing can on the second side of the polymer film, which during the application is positioned towards the body, particularly be provided with a layer that promotes the healing of the wound. A layer that promotes the healing of the wound means any layer that is used for treatment on moist wounds. Particularly preferred here are hydrogels based on polyurethane, acrylics or water-soluble celluloses or combinations thereof, which comprise water content of at least 20%, preferably at least 50% in relation to the total weight of the hydrogel. These hydrogels can be applied directly to the wound cushion as well as to the second side of the polymer film.
[0041] In order to provide a film dressing that is safe to handle, the used materials must be precisely in coordination with one another. The used materials must be particularly coordinated in respect of their release characteristics. These release characteristics that are adjustable with additional means are based on the forces that exist between the two used materials. A targeted surface treatment of a material can for instance be used to adjust an attracting of rejecting effect in relation to a second material, which is to be joined with the first material. A surface treatment, which causes an attracting effect between two materials, can for instance follow due to an adhesive coating, a static charge or by amalgamating both materials that are to be joined. A rejecting effect can for instance be caused by an additional layer on a material of silicon or fluoride combinations. A release force (pull-off force) is thereby such a force that is necessary to separate two materials from one another (measured according to DIN 53530).
[0042] In another embodiment of the film dressing according to the present disclosure, these release characteristics are adjusted in such manner that the pull-off force which is necessary to release a cover film or paper from the polymer film to be applied is greater than the pull-off force which is necessary to release the supporting film or the supporting foils from the polymer film.
[0043] In a development of the film dressing with two supporting films the release characteristics are adjusted in such manner that the pull-off force which is necessary to release the first supporting film from the polymer film that is to be applied is equal to the pull-off force that is necessary to release the second supporting film.
[0044] In a film dressing with two supporting films and two grip strips the release characteristics are preferably adjusted in such manner that the pull-off force which is necessary to release the first grip strip from the second grip strip or to release the second from the first grip strip is less than the pull-off force that is necessary to release the supporting film from the polymer film that is to be applied.
[0045] In another development of the film dressing with two supporting films the release characteristics are preferably adjusted in such manner that the pull-off force which is necessary to release the first supporting film from the polymer film that is to be applied is greater than the pull-off force which is necessary to release the first grip strip from the second grip strip.
[0046] The adhesion of the supporting film on the polymer film is preferably only about 0.01 to about 0.5 N/25 mm, especially preferred about 0.01 to about 0.1 N/25 mm, measured according to DIN 53530. The supporting material is preferably attached directly here to the polymer film during its manufacturing process, or the polymer film is manufactured directly on the supporting material, respectively. Further, all regular methods for the film manufacturing may be applied, such as melting, spreading, extrusion or other familiar methods for manufacturing of films or foils. If necessary, the supporting material can be roughened on the coated side or be subjected to another treatment that promotes adhesion. A coating that promotes adhesion can also be beneficial.
[0047] In a particular development of the present disclosure, it is intended that a film dressing including a polymer film with an application system is located inside of a package. It is particularly intended that the package is a sterile package.
[0048] It must be emphasized at this point that the here referenced characteristics of the alternative developments of the present disclosure are not to be limited to the individual alternatives. It is rather the case that the combination of the developments and/or the combination of the individual characteristics of the alternative forms must be included in a development according to the present disclosure. The present disclosure shall be understood to be reduced just as little by the subsequent explanations of the illustrations.
[0049] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0050] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0051] The invention is described in greater detail below by means of the drawings, which show:
[0052] FIG. 1 is a top view of a first embodiment of a film dressing constructed in accordance with the principles of the present disclosure;
[0053] FIG. 2 a top view of a second embodiment of a film dressing constructed in accordance with the principles of the present disclosure;
[0054] FIG. 3 is a top view of a third embodiment of a film dressing constructed in accordance with the principles of the present disclosure;
[0055] FIG. 4 is a cross-sectional view, taken along line 4 - 4 of FIG. 1 , of a film dressing in accordance with the principles of the present disclosure;
[0056] FIG. 5 is a cross-sectional view, taken along line 5 - 5 of FIG. 2 , of a film dressing in accordance with the principles of the present disclosure;
[0057] FIG. 6 is a cross-sectional view, taken along line 6 - 6 of FIG. 3 , of a film dressing in accordance with the principles of the present disclosure; and
[0058] FIGS. 7 a - c are cross-sectional views of a film dressing in use in accordance with the principles of the present disclosure.
DETAILED DESCRIPTION
[0059] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
[0060] FIGS. 1 and 4 show a first embodiment of a film dressing according to the disclosure. The film dressing ( 10 ) is shown in a round shape. It consists of a transparent polymer film ( 1 ) which is covered, on the first side thereof, with an application system. Applied on the second side, the side opposite of the application system, is an adhesive ( 2 ) which is covered by a cover layer ( 3 ). The application system consists of a similarly transparent supporting film ( 12 ), which covers one part of the polymer film, a grip strip ( 15 ) and an adhesive ( 14 ). In a margin segment ( 17 ), the polymer film is supporting film-free. The grip strip ( 15 ) is molded to the supporting film ( 12 ) by means of the adhesive ( 14 ). This grip strip fully overhangs the supporting film-free area ( 17 ) of the polymer film. The grip strip is not connected in any way to the polymer film, so that, when the film is in use, the grip strip can be gripped at once without effort. The polymer film is completely covered by the application system, whereby, at the same time, the supporting film-free area ( 17 ) creates a flexible area which, when the film dressing is applied, can primarily be used for initial attachment.
[0061] FIGS. 2 and 5 show a second embodiment of a film dressing according to the disclosure. This film dressing ( 20 ) is basically rectangular in shape and, similarly to the first embodiment, consists of a polymer film ( 1 ), an adhesive layer ( 2 ) which is applied to the entire surface of the polymer film, and a cover layer ( 3 ) which covers the adhesive layer. The polymer film, on the first side thereof, exhibits an application system, which consists of two supporting films ( 22 a , 22 b ), two grip strips ( 25 , 26 ) and two adhesives ( 24 a , 24 b ). The two grip strips are applied to the polymer film in such a way that the polymer film is completely covered by the supporting films, up to a supporting film-free area ( 27 ). The covered area of the polymer film amounts to approximately 96% of the surface of the first side of the polymer film. In this embodiment, the first grip strip ( 25 ), which is glued to the first supporting film ( 22 b ) by means of the first adhesive ( 24 b ), overhangs both the supporting film-free area ( 27 ) and the second grip strip ( 26 ), which is glued to the second supporting film ( 22 a ) by means of the second adhesive ( 24 a ). The first grip strip ( 25 ) exhibits a gripping surface which is meant to be gripped from behind by the user. The outer part of the gripping surface protrudes laterally as a free gripping surface ( 251 ) over the second grip strip ( 26 ). This second grip strip ( 26 ), in the embodiment represented, does not exhibit a gripping surface which is meant to be gripped from behind. This possibility, however, is just as conceivable as the one shown in FIGS. 3 and 6 for a cannula plaster, and is advantageous in order to facilitate the gripping of the second grip strip ( 26 ). The fact that only one grip strip can be gripped and is visible to the user guarantees a sequence of actions in the removal of the two supporting films.
[0062] FIGS. 3 and 6 show a further film dressing ( 30 ). This film dressing can be used as a cannula or catheter plaster. The film dressing exhibits a basically rectangular shape, the short side whereof exhibits a recess parallel to the long side. By means of this recess, the film dressing is given two mutually independent areas, which are connected to each other by means of a third area, and each of which, in the attachment, for example, of a cannula, can be attached to a surface on either side of the cannula. The film dressing exhibits a polymer film ( 1 ), an acrylate adhesive layer ( 2 ) and a cover layer ( 3 ) which covers the adhesive layer. Arranged on the first side of the polymer film, which faces away from the adhesive layer, is an application system. This application system includes two grip strips ( 35 , 36 ), which are attached to three supporting films ( 32 a , 32 b , 32 c ) by means of three adhesives ( 34 a , 34 b , 34 c ). The first grip strip ( 35 ) is provided for both the first supporting film ( 32 c ) and the second supporting film ( 32 b ) and is accordingly molded to both of them. This means that both of these supporting films ( 32 c , 32 b ) can be removed by means of a single grip. The first grip strip ( 35 ) overhangs both the central areas of the polymer film, which are not covered by supporting films ( 37 a , 37 b ) and the second grip strip ( 36 ). The outer part of the gripping surface protrudes laterally as a free gripping surface ( 351 ) over the second grip strip ( 36 ), so that, here too, a series of actions is guaranteed in the removal thereof.
[0063] The supporting films, taken together, cover a surface of the polymer film which accounts for about 92% of the surface of the first side of the polymer film. This is because, in addition to the central areas, which are not covered by supporting films ( 37 a , 37 b ), there is also no supporting film on the two margin segments ( 38 a , 38 b ). These margin segments, after the cover layer has been removed, can be used for initial attachment. To this end, FIG. 6 shows a means of activation ( 39 ) between the two grip strips. This means of activation ( 39 ), similarly to the adhesive used to fasten the grip strip ( 36 ) on to the supporting film ( 32 a ), is not shown in FIG. 3 . This means of activation ( 39 ) is a double-sided adhesive tape, which shows a higher adhesive forced to the first grip strip ( 35 ) had to the second grip strip ( 36 ). Accordingly, when the supporting films ( 32 b , 32 c ) are removed, the first grip strip ( 35 ) causes the second grip strip ( 36 ), which lies beneath it, to stand upright, before the adhesive forced between the first grip strip ( 35 ) and the means of activation ( 39 ) is removed. The second grip strip ( 36 ) thus becomes easier to grip in the second stage, in order to remove the second supporting film ( 32 a ).
[0064] In the use of a film dressing according to the disclosure ( 10 , 20 , 30 , 50 ), the removal of the cover layer ( 3 ) from the adhesive layer ( 2 ) is first provided. As shown in FIGS. 7 a through 7 c , in the case of a film dressing with two supporting film-free areas, in order to apply such a film dressing ( 30 , 50 ), for example, above a wound (W), it is possible to attach a first supporting film-free margin segment ( 38 a , 38 b , 58 ) to an area which adjoins the wound (W). Thanks to the high degree of flexibility of the polymer film in the supporting film-free area, this is quite possible. In the next step, the user, by making use of the arrangement of the grip strips ( 35 , 36 , 55 , 56 ), which are attached to the respective supporting films by means of adhesive gluing means ( 34 a , 34 b , 34 c , 54 a , 54 b ), can place the polymer film to be applied ( 1 ) precisely the wound. By means of the second supporting film-free margin segment ( 37 a , 37 b , 57 ), the film dressing exhibits a kind of joint which guarantees a full-free application. The supporting films ( 32 a , 32 b , 32 c , 52 a , 52 b ) can be removed one after the other during the application, or can be removed one after the other following the successful application, of the polymer film. In so doing, the first grip strip ( 35 , 55 ) is first gripped, by means of its free gripping surface ( 351 , 551 ), in order to be able to remove the first supporting film ( 32 b , 32 c , 52 b ) first.
EMBODIMENT 1
[0065] The film dressing comprises a rectangular basic form with an edge length of about 57×about 80 mm (contact surface about 45.6 cm 2 ). It comprises a transparent polyether urethane film, which on the side that is positioned towards the body is coated with an acrylate-based hydrogel adhesive. The adhesive is affixed continuously in the amount of about 35 g/m 2 onto the about 25 μm thick polymer film (measured with a test pressure of about 0.5 kPa). The polymer film together with the adhesive comprises a condensation permeability of about 2,600 g/m 2 /24 hrs. (measured according to DIN EN 13726, with the difference that after about 4 hrs. the measurement period was terminated and the determined result is extrapolated for about 24 hrs.). Such a polymer film is available under the trade name Inspire 6200 from the company InteliCoat Technologies, Wrexham Industrial Estate, Wrexham LL13 9UF, UK. The adhesive side of this polymer film is available from the company Maria Soell GmbH & Co. KG, Frankenstrasse 45, D-63667 Nidda-Eichelsdorf, with a siliconized cover paper and covered under the trade name Separacon 980-60. The other side of the polymer film, which during the application is positioned away from the body, comprises an application system, which consists of two supporting films that each has one grip strip. The supporting films are as illustrated in FIG. 1 and FIG. 2 positioned on the polymer film. The film dressing at hand additionally realizes a peripheral area, which is not covered by a supporting film or grip strip. This additional peripheral area without a supporting film is positioned on the short side of the rectangle and comprises an equal width of about 5 mm. Both of the supporting films are equal in size and comprise an edge length of about 57×about 36 mm (contact area: 2×20.5 cm 2 =about 41.0 cm 2 ). The distance of both films is about 3 mm in each point of their parallel edges that are of equal length. This results for both supporting films in a combined contact area of about 90% in respect of the surface of the first polymer film. The supporting films are manufactured of a 30 μm thick polyester film (measured at a test pressure of about 0.5 kPa). A grip strip is affixed onto each supporting film with an acrylate adhesive. The grip strips together comprise a configuration, as illustrated in FIG. 4 , whereas the first grip strip, which is sketched with reference mark ( 35 ), has a size of about 57×about 39 mm and is throughout the entire width (about 57 mm) attached to the respective supporting film. The second grip strip, which is illustrated with reference ( 36 ), comprises a size of about 57×about 22 mm. Both grip strips are each attached to the respective supporting film through an about 5 mm wide adhesive connective strip and are manufactured from a 20 μm thick transparent polyester film. The first grip strip thus has a strip surface with an equally formed width of about 34 mm. The size of the grip surface of the first grip strip comprises about 19.4 cm 2 . The equally shaped width of the grip surface of the second grip strip comprises about 17 mm. The size of the grip surface of the second grip strip thus comprises about 9.7 cm 2 . The equally shaped width of that portion, which protrudes beyond the second grip strip, of the first grip surface that is the width of the exposed grip surface of the first grip strip measures about 9 mm. The size of the exposed grip surface thus comprises about 5.1 cm 2 .
EMBODIMENT 2
[0066] The film dressing comprises a rectangular basic form with an edge length of about 57×about 80 mm (contact surface about 45.6 cm 2 ). It comprises a transparent polyether urethane film, which on the side that is positioned towards the body is coated with a pressure sensitive acrylate-based adhesive. The adhesive is affixed continuously in the amount of approx. 25 g/m2 onto the approx. 30 μm thick polymer film (measured with a test pressure of about 0.5 kPa). The polymer film together with the adhesive comprises a condensation permeability of about 1,200 g/m 2 /24 hrs. (measured according to DIN EN 13726). Such a polymer film is available under the trade name Inspire 1305 from the company InteliCoat Technologies, Wrexham Industrial Estate, Wrexham LL13 9UF, UK. The adhesive side of this polymer film is available from the company Maria Soell GmbH & Co. KG, Frankenstrasse 45, D-63667 Nidda-Eichelsdorf, with a siliconized cover paper and covered under the trade name Separacon 980-60. The other side of the polymer film, which during the application is positioned away from the body, comprises an application system, which consists of two supporting films that each has one grip strip. The supporting films are as illustrated in FIG. 1 and FIG. 2 positioned on the polymer film. The film dressing at hand additionally realizes a peripheral area, which is not covered by a supporting film or grip strip. This additional peripheral area without a supporting film is positioned on the short side of the rectangle and comprises an equal width of about 5 mm. Both of the supporting films are equal in size and comprise an edge length of about 57×about 36 mm (contact area: 2×20.5 cm 2 =about 41.0 cm 2 ). The distance of both films is about 3 mm in each point of their parallel edges that are of equal length. This results for both supporting films in a combined contact area of about 90% in respect of the surface of the first polymer film. The supporting films are manufactured of a 30 μm thick polyester film (measured at a test pressure of about 0.5 kPa). A grip strip is affixed onto each supporting film with an acrylate adhesive. The grip strips in a cross-sectional view comprise a configuration, as illustrated in FIG. 4 , whereas the first grip strip, which is sketched with reference mark ( 35 ), has a size of about 57×about 39 mm and is throughout the entire width (about 57 mm) attached to the respective supporting film. The second grip strip, which is illustrated with reference mark ( 36 ), comprises a size of about 57×about 22 mm. Both grip strips are each attached to the respective supporting film through an about 5 mm wide adhesive connective strip and are manufactured from a 20 μm thick transparent polyester film. The first grip strip thus has a strip surface with an equally formed width of about 34 mm. The size of the grip surface of the first grip strip comprises about 19.4 cm 2 . The equally shaped width of the grip surface of the second grip strip comprises about 17 mm. The size of the grip surface of the second grip strip thus comprises about 9.7 cm 2 . The equally shaped width of that portion, which protrudes beyond the second grip strip, of the first grip surface, that is the width of the exposed grip surface of the first grip strip measures about 9 mm. The size of the exposed grip surface thus comprises about 5.1 cm 2 .
[0067] The release characteristics of the materials used in this embodiment 2 were determined on about 60×about 80 mm test sections according to the method described in DIN 53 530. The tests were completed with a pull-off velocity of about 300 mm/min. The silicon paper in respect of the polymer film therefore exhibits a release force of about 0.77 N/25 mm, whereas the supporting film in respect of the polymer film exhibits a release force of about 0.09 N/25 mm. The release characteristics of this film dressing are hence adjusted such that the pull-off force which is necessary to release a cover film from the polymer film that is to be applied is greater than the pull-off force which is necessary to separate the supporting film or the supporting films from the polymer film.
[0068] It should be noted that the disclosure is not limited to the embodiment described and illustrated as examples. A large variety of modifications have been described and more are part of the knowledge of the person skilled in the art. These and further modifications as well as any replacement by technical equivalents may be added to the description and figures, without leaving the scope of the protection of the disclosure and of the present patent. | The present disclosure relates to a film structure having a polymer film and an application system enabling the film structure to be handled in a simple manner. The application system is arranged on a first side of the polymer film and has at least one supporting film to which at least one gripping strip is applied. The polymer film also has at least one first region without a supporting film. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an electric oil pump that can greatly improve the operation, increase the endurance, and extend the service life of an Oldham's coupling connecting a drive shaft that rotates a rotor in a pump housing and a motor output shaft in a motor housing.
[0003] 2. Description of the Related Art
[0004] Electric oil pumps comprising a combination of a pump housing having a drive shaft provided with a rotor of an inner contact gear type and a motor housing having a motor for rotating the drive shaft mounted on the rotor have been used as pumps in lubrication systems of automobiles or the like. A specific example of such electric oil pump is described in Japanese Patent Application Laid-open No. H11-173278. The essence of the invention disclosed in this application is that a hydraulic gear pump and a motor are connected via a bracket. A drive shaft on the side of the hydraulic gear pump and a rotor shaft on the side of the motor are connected via a coupling, and an Oldham's coupling is disclosed as an example of the coupling.
[0005] The construction of the Oldham' coupling disclosed in Japanese Patent Application Laid-open No. H11-173278 enables the rotation transfer even when the input shaft and output shaft are not coaxial. A plate-shaped protrusion is formed on the distal end of the output shaft of the motor, and a groove for inserting the protrusion is formed on the input shaft side of the pump housing. The output shaft of the motor rotates and the rotor shaft rotates in a state where the plate shaped protrusion is inserted into the groove. In this case, the rotation is transferred even though the input shaft and output shaft are not coaxial, but the plate-shaped protrusion and the groove rub against each other and the surfaces thereof wear each other in long-term usage, thereby decreasing the strength of the coupling. It is an object of the present invention to increase the endurance and extend the service life of the Oldham's coupling connecting the output shaft and input shaft.
SUMMARY OF THE INVENTION
[0006] With the foregoing in view, the inventors have conducted a comprehensive study aimed at the resolution of the above-described problems, and the invention of claim 1 resolves the problems by providing an electric oil pump comprising a pump housing comprising a rotor and a drive shaft for rotatably supporting the rotor, and a motor housing connected to the pump housing and having an output shaft connected to the drive shaft via an Oldham's coupling, wherein a coupling chamber for accommodating the Oldham's coupling and a linking channel for transporting the leaked oil from a rotor chamber of the pump housing where a rotor is accommodated to the coupling chamber are provided in the pump housing.
[0007] The invention of claim 2 resolves the problems by providing an electric oil pump comprising a pump housing having a cover section having a bearing hole formed therein, a pump body section having a rotor chamber formed therein, and a base section having a shaft through hole and a coupling chamber connected to the shaft through hole and opened outwardly, a drive shaft rotatably supported by the bearing hole and shaft through hole and protruding into the coupling chamber, a rotor accommodated in the rotor chamber, and a motor housing comprising an output shaft connected by an Oldham's coupling to the drive shaft protruding into the coupling chamber, wherein an annular drain groove is formed between the cover section and the pump body section or between the pump body section and the base section, surrounding the rotor chamber; and a linking channel for linking the annular drain groove and the coupling chamber is formed in the pump body section and the base section.
[0008] Furthermore, the invention of claim 3 resolves the problems by providing the electric oil pump of the above-described configuration, wherein an annular drain groove surrounding the rotor chamber is formed between the cover section and pump body section and between the pump body section and base section.
[0009] The invention of claim 4 resolves the problems by providing the electric oil pump of the above-described configuration, comprising a discharge channel leading from the linking channel to an oil pan, wherein the position of the coupling chamber is below the position of a discharge section provided in the oil pan. The invention of claim 5 resolves the problems by providing the electric oil pump of the above-described configuration, wherein a linking channel is formed between the bearing hole and the annular drain groove in the cover section.
[0010] With the invention of claim 1 , a linking channel for transporting the leaked oil from a rotor chamber of the pump housing where a rotor is accommodated to the coupling chamber is provided in the Oldham's coupling. Therefore, the oil constantly spreads to the rubbing zone in the Oldham's coupling accommodated in the coupling chamber, good and stable rotation transfer is carried out from the output shaft of the motor housing to the drive shaft of the pump housing, and excellent endurance can be attained.
[0011] Furthermore, with the invention of claim 2 , because an annular drain groove surrounding the rotor chamber is formed between the cover section and the pump body section, the leaked oil from the rotor chamber can be reliably removed by the annular drain groove and the leaked oil can be effectively pumped, practically without any waste, to the coupling chamber. Other effects are almost identical to those of the invention of claim 1 . Furthermore, with the invention of claim 3 , forming annular drain grooves on both sides in the axial direction of the pump body section makes it possible to remove the leaked oil from both surfaces of the rotor chamber and to conduct rapid oil supply to the coupling chamber.
[0012] With the invention of claim 4 , providing a discharge channel leading from the linking channel to the oil pan makes it possible to pump the oil from the coupling chamber to the oil pan when the amount of leaked oil increases and pressure rises. Furthermore, because the coupling chamber is positioned below the discharge section provided in the oil pan, the coupling chamber can be maintained in a state where it is filled with oil.
[0013] With the invention of claim 5 , a linking channel is formed between the bearing hole and the annular drain groove. As a result, oil penetrates to the periphery of the shaft and lubrication can be ensured between the shaft and the bearing hole or the bearing, e.g., the shaft through hole. Furthermore, because the bearing holes in both end sections of the shaft and the coupling chamber are linked by the linking channel, they have the same pressure, the shaft is not displaced axially by the difference in pressure between the two end sections of the shaft, and stable rotation operation of the shaft can be ensured.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a side view with partial vertical cut-out illustrating the configuration of the present invention;
[0015] FIG. 2 (A) is a front view of the cover section, (B) is a sectional side view of (A);
[0016] FIG. 3 (A) is a front view of the pump body section, (B) is a sectional side view of (A);
[0017] FIG. 4 (A) is a front view of the base section, (B) is a sectional side view of (A), (C) is a cross-sectional view of the main portion of (A);
[0018] FIG. 5 is an exploded perspective view of an Oldham's coupling;
[0019] FIG. 6 is an exploded side view with a partial vertical section illustrating the present invention;
[0020] FIG. 7 illustrates schematically the operation in which an electric oil pump in accordance with the present invention is mounted on an oil pan and the leaked oil is discharged from the discharge section into the oil pan;
[0021] FIG. 8 is a graph comparing the performance of the pump in accordance with the present invention and the conventional pump.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Embodiments of the present invention will be described below based on the appended drawings. As shown in FIG. 1 and FIG. 6 , the electric oil pump in accordance with the present invention comprises a pump housing A, a motor housing B, a rotor 21 , and a drive shaft 22 . The rotor 21 and drive shaft 22 are mounted inside the pump housing A. The pump housing A comprises a cover section A 1 , a pump body section A 2 , and a base section A 3 , and those cover section A 1 , pump body section A 2 , and base section A 3 are joined via a fastener such as bolts and screws along the axial direction of the drive shaft 22 contained therein.
[0023] As shown in FIG. 1 and FIG. 6 , the cover section A 1 mainly comprises a cover body 1 and a bearing hole 2 . The bearing hole 2 is formed on the side of the surface of the cover body 1 where it is joined to the pump body section A 2 . The bearing hole 2 serves to support the drive shaft 22 inserted therein. Furthermore, as shown in FIG. 2 , port recesses 3 , 4 are formed around the bearing hole 2 . As shown in FIG. 4 (A), the port recesses 3 , 4 correspond to the positions of an intake port 15 and a discharge port 16 formed in the base section A 3 and have almost the same shape in the plane thereof as those intake port 15 and discharge port 16 . Furthermore, the port recesses 3 , 4 are in the form of shallow grooves.
[0024] Furthermore, as shown in FIG. 2 , an annular drain groove 5 is formed so as to surround the port recesses 3 , 4 . Furthermore, a seal groove 6 is formed on the outside of the annular drain groove 5 . A drain hole section 7 is formed between the annular drain groove 5 and seal groove 6 . The annular drain groove 5 is formed to surround from the outside the region of a rotor chamber 10 formed in the pump body section A 2 , and makes it possible to remove the leaked oil. The drain hole section 7 is formed to be located specifically in the lower portion of the cover section A 1 and crosses the annular drain groove 5 on the lower side thereof. The leaked oil flowing in the annular drain groove 5 is collected in the drain hole section 7 (see FIG. 2 (B)). As shown in FIG. 1 and FIG. 2 , this drain hole section 7 comprises a hole opening 7 a and a feed guide recess 7 b . The leaked oil that flowed out from the hole opening 7 a can be transferred in a stable state thereof along the feed guide recess 7 b to the main oil hole section 11 of the below-described pump body section A 2 .
[0025] The drain hole section 7 and bearing hole 2 are linked together via a first linking channel 8 . The first linking channel 8 passes through inside the cover body 1 of the corner section A 1 and serves to pump out the oil that leaked to the bearing hole 2 into the drain hole section 7 . The linking location of the first linking channel 8 and the bearing hole 2 comprises an axial linking passage 8 a with an inner diameter less than the bearing hole 2 and matching the linking location in the axial direction of the bearing hole 2 and a drain-side linking passage 8 b linked to the drain hole section 7 , and the channel is formed by the intersection of the axial linking passage 8 a and drain-side linking passage 8 b (see FIG. 2 (B)).
[0026] Furthermore, the pump body section A 2 is disposed between the cover section A 1 and base section A 3 , as shown in FIG. 6 . The rotor chamber 10 in the form of a through hole accommodating the rotor 21 is formed in a body main unit 9 . The main oil hole section 11 is formed in the position corresponding to the drain hole section 7 on the side of the surface of the pump body section A 2 that is joined to the cover section A 1 , and a second linking channel 12 is formed so as to pass from the main oil hole section 11 toward the surface of the pump body section A 2 that is joined to the base section A 3 .
[0027] The inner diameter of the main oil hole section 11 is formed larger than the inner diameter of the second linking channel 12 . The main oil hole section 11 serves to receive the leaked oil from the drain hole section 7 of the cover section A 1 and feed the leaked oil to the second linking channel 12 . Thus, the second linking channel 12 is linked to the first linking channel 8 and annular drain groove 5 formed in the cover section A 1 via the drain hole section 7 , and this second linking channel 12 transfers the oil that flowed in from the annular drain groove 5 of the cover section A 1 and the first linking channel 8 to a coupling chamber 20 formed in the base section A 3 .
[0028] As shown in FIG. 6 , in the base section A 3 , a shaft through hole 14 is formed in a base main unit 13 . Together with the bearing hole 2 formed in the cover section A 1 , the shaft through hole 14 serves as a bearing rotatably supporting the drive shaft 22 . As shown in FIGS. 4 (A) and (C), the intake port 15 and discharge port 16 are formed around the shaft through hole 14 of the base main unit 13 . Those intake port 15 and discharge port 16 are formed to match the positions of the port recesses 3 , 4 when the pump body section A 2 and base section A 3 are joined together (see FIG. 1 ). The intake port 15 passes through to an oil pan 30 disposed on the outside of the pump housing A (see FIG. 1 and FIG. 7 ).
[0029] A third linking channel 17 is formed in the base main unit 13 . The third linking channel 17 is configured to be linked to the second linking channel 12 when the pump body section A 2 and base body A 3 are joined together. As shown in FIG. 1 (A) and FIG. 4 (B), the third linking channel 17 is linked to the shaft through hole 14 . More specifically, a drain opening section 17 a is formed in the location where the shaft through hole 14 and the third linking channel 17 intersect. The drain opening section 17 a is formed as a zone expanding radially in part of the shaft through hole 14 and makes it possible to pump out the sufficient amount of oil transported from the third linking channel 17 to the shaft through hole 14 in the drain opening section 17 a .
[0030] Furthermore, a discharge channel 18 linked to the oil pan 30 is formed in the third linking channel 17 . As shown in FIG. 7 , the discharge channel 18 is linked to a discharge section 31 provided in the oil pan 30 . Furthermore, the position of the discharge section 31 provided in the oil pan 30 is set to be higher than the coupling chamber 20 . Owing to such a configuration, when the amount of leaked oil increased and pressure rises, the oil can be pumped out to the oil pan 30 via the discharge section 31 and also via the coupling chamber 20 . Furthermore, because the coupling chamber 20 is positioned below the discharge section 31 of the oil pan 30 , the coupling chamber 20 can be almost constantly maintained in a state in which it is filled with oil. A second annular drain groove 19 is formed in the surface of the base section A 3 where the base section is joined to the pump body section A 2 . The second annular drain groove 19 crosses the third linking channel 17 , and the oil present in the second annular drain groove 19 is caused to flow into the third linking channel 17 . Forming the two drain grooves makes it possible to remove the leaked oil from both surfaces of the rotor chamber and supply the rapidly flowing oil to the coupling chamber 20 .
[0031] Furthermore, as shown in FIG. 4 (B), the coupling chamber 20 is formed in the base main unit 13 of the base section A 3 in the joint surface thereof with the motor housing B. The coupling chamber 20 is formed as an almost cylindrical receding zone in the joining outer wall surface of the base main unit 13 . The coupling chamber 20 is linked to the shaft through hole 14 . The coupling chamber 20 comprises a leaked oil pool section 20 a with an inner diameter slightly larger than that of the shaft through hole 14 and a guide section 20 b serving as a guide for joining to the motor housing B. The leaked oil is accumulated in the leaked oil pool section 20 a and part of the guide section 20 b . The drive shaft 22 is disposed inside the coupling chamber 20 of the bump housing A. Furthermore, the drive shaft 22 is connected to an output shaft 26 of the monitor housing B via an Oldham's coupling 23 .
[0032] As shown in FIG. 6 , in the above-described cover section A 1 , pump body section A 2 , and base section A 3 , a rotor 21 constituting a pump with internal contact gears such as torodial gears is contained in the rotor chamber 10 of the pump body section A 2 , and the drive shaft 22 is mounted on the rotor 21 on the drive side thereof via a key or the like. Rotational support is provided by the bearing hole 2 on the side of the cover section A 1 and the shaft through hole 14 on the side of the base section A 3 . More specifically, one end of the drive shaft 22 in the axial direction is the portion fixedly attached to the rotor 21 and supported in the bearing hole 2 . The other end side of the drive shaft 22 in the axial direction thereof becomes an input side and serves for connection to the output shaft 26 of the motor housing B. The end portion 22 a on the input side of the drive shaft 22 is connected to the output shaft of the motor housing B via the Oldham's coupling 23 . A shaft seal 29 is provided on the motor section side in the coupling chamber 20 to seal the oil located inside the coupling chamber 20 .
[0033] In the motor housing B, the motor section is mounted inside a housing main unit 24 , and the output shaft 26 of the motor section. Furthermore, the output shaft 26 of the motor section is disposed inside a flange section 27 . The flange section 27 is connected to the base section A 3 of the pump housing A via a fastener such a screw or a bolt. A second coupling chamber 28 enabling the Oldham's coupling 23 to be inserted and disposed therein is also provided in the flange section 27 .
[0034] As shown in FIG. 5 , the Oldham's coupling 23 comprises insertion groove sections 23 a and insertion plate sections 23 b . The insertion plate sections 23 b are formed in the end portion 22 a on the input side of the drive shaft 22 and the distal end portion of the output shaft 26 , and the insertion groove sections 23 a are formed on both sides in the axial direction of a joint member 23 c . The insertion plate sections 23 b of the drive shaft 22 and output shaft 26 are configured to be inserted into respective insertion groove sections 23 a formed in the joint member 23 c.
[0035] A configuration is also possible in which respective insertion grooves 23 a are formed in the drive shaft 22 and output shaft 26 , and the insertion plate sections 23 b , 23 b are formed in both sides in the axial direction of the joint member 23 c . Furthermore, the joint members 23 c are disposed in the coupling chamber 20 of the pump housing A and the second coupling chamber 28 of the motor housing B, the Oldham's coupling 23 of the drive shaft 22 and output shaft 26 is configured, while inserting the insertion plate sections 23 b into the insertion grooves 23 a , and the pump housing A and motor housing B are joined.
[0036] FIG. 8 is a graph illustrating the amount of wear in the Oldham's coupling 23 with and without lubrication. The figure shows that feeding the leaked oil to the coupling chamber 20 in accordance with the present invention reduced the amount of wear in the rubbing zone of the Oldham's coupling 23 . | An object of the invention is to provide an electric oil pump with greatly improved operation, increased endurance, and extended service life of an Oldham's coupling connecting a drive shaft that rotates a rotor in a pump housing and a motor output shaft in a motor housing. The electric pump comprises a pump housing having a rotor and a drive shaft for rotatably supporting the rotor, and a motor housing connected to the pump housing and having an output shaft connected to the drive shaft via an Oldham's coupling. The pump housing is provided with a coupling chamber for accommodating the Oldham's coupling, and a linking channel for transporting the leaked oil from a rotor chamber accommodating the rotor of the pump housing to the coupling chamber. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/576,202, filed Jun. 1, 2004, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to the hydraulic control of downhole tools and, particularly to methods and devices for determining the state of such hydraulically-actuated tools.
[0004] 2. Description of the Related Art
[0005] Production of hydrocarbons from a downhole well requires subsurface production equipment to control the flow of hydrocarbon fluid into the production tubing. Typical flow control equipment might include a sliding sleeve valve assembly or other valve assembly wherein a sleeve is moved between open and closed positions in order to selectively admit production fluid into the production tubing. The valve assembly is controlled from the surface using hydraulic control lines or other methods.
[0006] In a simple system, a sleeve valve would be moveable between just two positions or states: fully opened and fully closed. More complex systems are provided where a well penetrates multiple hydrocarbon zones, and it is desired to produce from some or all of the zones. In such a case, it is desirable to be able to measure and control the amount of flow from each of the zones. In this instance, it is often desirable to use flow control devices that may be opened in discrete increments, or states, in order to admit varying amounts of flow from a particular zone. Several “intelligent” hydraulic devices are known that retain information about the state of the device. Examples of such devices include those marketed under the brand names HCM-A In-Force™ Variable Choking Valve and the In-Force™ Single Line Switch, both of which are available commercially from Baker Oil Tools of Houston, Tex. These devices incorporate a sliding sleeve that is actuated by a pair of hydraulic lines that move the sleeve within a balanced hydraulic chamber. A “J-slot” ratchet arrangement is used to locate the sleeve at several discrete positions that permit varying degrees of fluid flow through the device.
[0007] Because these devices are capable of being controlled between multiple states, or positions, determination and monitoring of the positions of the devices is important. To date, position determination has been accomplished by measurement of the amount of hydraulic fluid that is displaced within the control lines as the device is moved between one position and the next. Measuring displacement of hydraulic fluid will provide an indication of the particular state that the tool has moved to because differing volumes of fluid are displaced during each movement. In some instances, however, such as with a subsea pod, it may not be possible to measure fluid volume. Also, the fluid volume measurement technique may be inaccurate at times for a variety of reasons, including leaks within the hydraulic control lines and connections or at seals that lead to fluid loss, which leads to an incorrect determination of position. In addition, the hydraulic control lines may expand under pressure (storage effects) or become distorted due to high temperatures within the wellbore. In long lines, the additional storage volume in such expansion/distortion may be larger than the normally small differences in fluid volume between different movements and lead to inaccurate determinations of position.
[0008] The present invention addresses some of the problems of the prior art noted above.
SUMMARY OF THE INVENTION
[0009] In one aspect of the present invention, a flow control device for use in a wellbore to allow flow of formation fluid into the wellbore comprises a valve member adapted to move when disposed in the wellbore. A fluid line supplies a working fluid under pressure to move the valve member to allow the fluid to flow into the wellbore. A sensor in the wellbore, and associated with the fluid line, provides an indication of a position of the valve member.
[0010] In another aspect, a downhole flow control device comprises a hydraulically-actuated sleeve valve that is operable between a first position wherein the valve is in a first fluid flow state and a second position wherein the valve is in a second fluid flow state. A hydraulic control line is operably associated with the sleeve valve for supplying hydraulic fluid to operate the valve between states. A downhole pressure sensor operably associated with the hydraulic control line detects fluid pressure therein to provide an indication of the state of the sleeve valve.
[0011] In another aspect, a method of determining a state of a flow control tool within a wellbore comprises supplying fluid under pressure to the flow control tool to move a flow control member of the tool into the state. Pressure of the supplied fluid is detected downhole. The state of the flow control device is determined from the detected pressure of the supplied fluid.
[0012] In yet another aspect of the present invention, a method of determining the state of a flow control tool within a wellbore comprises detecting a fluid flow downhole within a hydraulic supply conduit in fluid communication with the flow control tool. The state of the flow control tool is determined from the detected fluid flow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For detailed understanding of the present invention, references should be made to the following detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings, in which like elements have been given like numerals, wherein:
[0014] FIG. 1 is a schematic depiction of an exemplary wellbore system wherein multiple hydrocarbon zones and fluid entry points;
[0015] FIG. 2 is a schematic depiction, in side cross-section, of an exemplary sliding sleeve valve assembly incorporating a fluid pressure sensor system in accordance with the present invention;
[0016] FIG. 3A is an illustration of a J-slot ratchet and lug arrangement according to one embodiment of the present invention;
[0017] FIG. 3B is an illustration of an alternative J-slot ratchet and lug arrangement according to one embodiment of the present invention;
[0018] FIG. 4 is a graph of fluid pressure versus time; and
[0019] FIG. 5 is a block diagram of the surface monitoring and control system according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0020] FIG. 1 illustrates an exemplary production well 10 that penetrates the earth 12 into multiple hydrocarbon zones, such as zones 14 , 16 . The well 10 is cased with casing 18 , and perforations 20 are disposed through the casing 18 proximate each of the zones 14 , 16 to provide a flow point for hydrocarbon fluids within the zones 14 , 16 to enter the well 10 . It is noted that, although a single wellbore is shown, there may, in practice, be a plurality of multilateral wellbores, each penetrating one or more zones such as zones 14 , 16 . Additionally, although only two zones are shown, those skilled in the art will recognize that there may be more such zones.
[0021] A production tubing string 22 is disposed within the well 10 from a wellhead 24 and includes flow control devices 26 , 28 located proximate the zones 14 , 16 , respectively. Packers 30 isolate the flow control devices 26 , 28 within the well 10 . In one embodiment, each of the flow control devices 26 , 28 is a sliding sleeve flow control device that is capable of more than two operable positions, also called open/closed states. Examples of suitable flow control devices for this application include those marketed under the brand names HCM-A In-Force™ Variable Choking Valve and the In-Force™ Single Line Switch, both of which are available commercially from Baker Oil Tools of Houston, Tex.
[0022] A monitoring and control station 32 is located at the wellhead 24 for operational control of the flow control devices 26 , 28 . Hydraulic control lines, generally shown at 34 extend from monitoring and control station 32 down to the flow control devices 26 , 28 . The monitoring and control station 32 is of a type known in the art for control of hydraulic downhole flow control devices, and is described in more detail below in reference to FIG. 5 .
[0023] FIG. 2 illustrates an exemplary individual flow control device 26 and illustrates its interconnection with an exemplary pressure sensor position detection system. The flow control device 26 is illustrated in simplified schematic form for ease of description. In practice, the flow control device 26 may be an HCM-A In-Force™ Variable Choking Valve brand flow control device marketed by Baker Oil Tools of Houston, Tex. The device 26 includes a sliding sleeve assembly sub 36 having a tubular outer housing 38 that defines a fluid chamber 40 therewithin. Fluid openings 42 are disposed through the housing 38 below the fluid chamber 40 . A sliding sleeve 44 is retained within the housing 38 and includes a number of fluid ports 46 disposed radially therethrough. Seals 43 a and 43 b are disposed in outer housing 38 above and below fluid openings 42 . When the sliding sleeve 44 is axially displaced such that piston 50 is near the bottom of chamber 40 , the ports 46 are below lower seal 43 b and there is no flow into bore 48 of housing 38 . Depending upon the axial position of the sliding sleeve 44 within the housing 38 and within the seals 43 a,b , the ports 46 of the sleeve 44 can be selectively aligned with the fluid openings 42 in the housing 38 to permit varying degrees of fluid flow into the bore 48 of the housing 38 as the ports 46 overlap the openings 42 in varying amounts. The sliding sleeve 44 also includes an enlarged outer piston portion 50 that resides within the chamber 40 and separates chamber 40 into an upper chamber 52 and a lower chamber 54 . A seal (not shown) on the outer diameter of piston 50 hydraulically isolates upper chamber 52 and lower chamber 54 . Piston 50 exposes substantially equal piston area to each of chambers 52 and 54 such that equal pressures in chambers 52 and 54 result in substantially equal and opposite forces on piston 50 such that piston 50 is considered “balanced”. To move piston 50 , a higher pressure is introduced in one chamber and fluid is allowed to exit from the other chamber at a lower pressure, resulting in an unbalanced force on piston 50 , and thereby moving piston 50 in a desired direction.
[0024] Hydraulic control lines 34 a and 34 b are operably secured to the housing 38 to provide fluid communication into and out of each of the fluid receiving chambers 52 , 54 . As those skilled in the art will recognize, the sliding sleeve 44 may be axially moved within the housing 38 by transmission of hydraulic fluid into and out of the fluid receiving chambers 52 , 54 . For example, if it is desired to move the sleeve 44 downwardly with respect to the housing 38 , hydraulic fluid is pumped through the control line 34 a and into only the upper fluid receiving chamber 52 . This fluid exerts pressure upon the upper face of the piston 50 , urging the sleeve 44 downwardly. As the sleeve 44 moves downwardly, hydraulic fluid is expelled from the lower fluid receiving chamber 54 through control line 34 b toward the surface of the well 10 . Conversely, if it is desired to move the sleeve 44 upwardly with respect to the housing 38 , hydraulic fluid is pumped through control line 34 b into the lower fluid receiving chamber 54 to exert pressure upon the lower side of the piston portion 50 . As the sleeve 44 moves upwardly, hydraulic fluid is expelled from the upper fluid receiving chamber 52 through the control line 34 a.
[0025] In one embodiment, see FIG. 3A , a J-slot ratchet assembly sub 56 is secured to the upper end of the sliding sleeve valve housing 38 . The ratchet assembly sub 56 serves to provide a number of preselected axial positions, or states, for the sliding sleeve 44 within the sleeve assembly sub 36 , thereby providing a preselected amount of flow control due to the amount of axial overlap of fluid ports 46 with fluid openings 42 . The ratchet assembly sub 56 includes a pair of outer housing members 58 , 60 that abut one another and are rotationally moveable with respect to one another. A lug sleeve 62 is retained within the sub 56 and presents upper and lower outwardly extending lugs 64 , 66 . The lugs 64 , 66 engage lug pathways inscribed on the inner surfaces of the housing members 58 , 60 . These pathways are illustrated in FIG. 3A which depicts the inner surfaces of the outer housing members 58 , 60 in an “unrolled” manner. The upper outer housing member 58 has an inscribed tortuous pathway 68 within which upper lug 64 resides. The lower housing member 60 features an inscribed lug movement area 70 having a series of lower lug stop shoulders 72 a - 72 e that are arranged in a stair-step fashion. The stair step shoulders 72 a - 72 e are related to the amount of axial overlap of fluid ports 46 with fluid openings 42 . Lower lug passage 74 is located adjacent the stop shoulder 72 e . Additionally, the lower housing member 60 presents an upper lug stop shoulder 76 . An upper lug passage 78 is defined within the upper housing member 58 and, when the upper and lower housing members 58 , 60 are rotationally aligned properly, the upper lug passage 78 is lined up with lug entry passage 80 so that upper lug 64 may move between the two housing members 58 , 60 .
[0026] Axial movement of the sliding sleeve 44 by movement of piston 50 as described above moves the abutting lug sleeve 62 axially within the ratchet assembly sub 56 . As this occurs, the upper lug 64 is moved consecutively among lug positions 64 a , 64 b , 64 c , 64 d , 64 e , 64 f , 64 g , 64 h , 64 i , and 64 j . Finally, the upper lug 64 moves to its final lug position 64 k , which corresponds to a fully closed position, or state, for the sliding sleeve assembly sub 36 . Additionally, the lower lug 66 is moved consecutively through lug positions 66 a - 66 k . When lug 66 is located adjacent upper shoulder 76 , the fluid ports 46 are aligned with fluid openings 42 to provide a fully open flow condition. It can be seen that abutment of the lower lug 66 upon each of the lower shoulders 72 a , 72 e results in a progressively lower axial position for the lug sleeve 62 with respect to the housing members 58 , 60 . These different axial positions result in different flow control positions or states for the sliding sleeve 44 , by varying the amount of axial overlap of fluid opening 42 with flow ports 46 (see FIG. 2 ). As illustrated in FIG. 3A , the flow opening becomes progressively smaller as lower lug 66 moves from position 66 a to 66 i and is eventually closed at position 66 k . When the lugs 64 and 66 are in the positions 64 k and 66 k , respectively, the sleeve 44 is moved downward such that ports 46 are below seal 43 b and there is no flow. By proper selection of the step change between successive states, a predetermined amount of fluid can be required to move the sliding sleeve between successive states. In one embodiment, the amount of movement, and hence the amount of fluid required, is selected such that the difference in movement between each successive state is uniquely different. By such selection, the amount of fluid required for each movement is unique and the location of the sleeve can then be identified by the amount of fluid required to move the sleeve to a position.
[0027] FIG. 3B shows another embodiment in which the J-slot arrangement is oriented such that the flow opening progressively increases as the system is operated. The J-slot arrangement on the inside of housings 160 and 158 are shown in an “unrolled” view. As shown in FIG. 3B , upper lug 164 moves through positions 164 a - 164 m while lower lug 166 moves through positions 166 a - 166 m , respectively. Lower shoulder 176 acts as a stop for lower lug 166 . Upper shoulders 172 a - g show a stair-step progression that is related to the amount of flow opening caused by the alignment of ports 46 and flow openings 42 in sleeve 44 , however, as contrasted with FIG. 3A , when lug 166 is located against shoulder 176 , there is no direct flow path through opening 42 and ports 46 , but the ports are not below seal 43 b . Therefore, there is some leakage into the bore 48 caused by clearances between sleeve 44 and housing 38 , and is nominally referred to as the diffused position. As indicated with respect to FIG. 3A , the positions of shoulders 172 a - g may be selected to provide unique indications of sleeve 44 position from the amount of fluid required to move sleeve 44 between consecutive positions. To close sleeve 44 using the arrangement of FIG. 3B , lugs 164 and 166 are moved downward through passages 178 and 179 until ports 46 are below seal 43 b (see FIG. 2 ). It is noted that other lug and ratchet arrangements may be used within the scope of the invention.
[0028] FIG. 4 depicts a graph showing fluid pressure, as detected by the pressure sensor 82 , versus time. The curve of the graph is illustrative of the fluid pressure within control line 34 a during the process of moving the sliding sleeve 44 . As hydraulic pressure is applied to the upper fluid receiving chamber 52 , the fluid pressure within the control line 34 a will begin to rise, as illustrated by the first section 90 of the graph. Fluid pressure will continue to rise until forces resisting piston motion, such as internal tool friction, are overcome. Once the friction is overcome piston 50 begins to move and, as a result, expels fluid from that lower chamber 54 . At this point, the sleeve 44 is moving downwardly and the pressure increase in control line 34 a stops and levels off at a substantially constant pressure during sleeve movement. After the sleeve 44 has been moved to its next position or state, as limited by the ratchet sub assembly 56 , the fluid pressure within the line 34 a will again begin to rise, as the sleeve 44 will move no further. The inclined portion 94 of the graph in FIG. 4 illustrates this. Ultimately, the fluid pressure within the line 34 a will level off as the pump pressure reaches a stall pressure of the pump, or alternatively, the pressure reaches a relief value in the supply line.
[0029] By the proper selection of the stair-step shoulders of FIGS. 3 A,B, the length of time (x) for the level pressure associated with sleeve movement (portion 92 of FIG. 4 ) correlates to particular movements between tool states for the flow control device 26 . For example, movement of the device 26 from a position wherein the lower lug 66 is at 66 b to a position wherein the lower lug 66 is at 66 c will take less time than if the device is moved from a position wherein lug 66 is at 66 h and then moved to 66 i . Therefore, measurement of “x” will reveal the state that the tool 26 has been moved to. In one embodiment, the length of “x” is different for each particular movement of the tool 26 .
[0030] Referring to FIGS. 2 and 5 , it is noted that a sensor 82 is operably associated with the fluid control line 34 a to detect the amount of fluid pressure within the line 34 a . In one embodiment, sensor 82 is a pressure sensor that is physically positioned at or near the housing 38 of the flow control device 26 to minimize the fluid storage effects of the control line 34 a . Alternatively, sensor 82 may be a flow sensor that directly measures the amount of fluid passing through control line 34 a and into, or out of, the appropriate chamber in flow control device 26 . A data line 84 extends from the sensor 82 upwardly to the monitoring and control station 32 . In one embodiment, data line 84 comprises an electrical and/or optical conductor. Readings detected by the sensor 82 are transmitted to the station 32 over dataline 84 . Alternatively, readings of sensor 82 might be transmitted wirelessly to the surface, such as for example by acoustic techniques and/or electromagnetic techniques known in the art. Although a sensor is only shown affixed to control line 34 a , it will be understood that sensors may be attached to either, or to both, control lines 34 a , 34 b.
[0031] Monitoring and control station 32 functionally comprises a hydraulic system for powering the flow control system and suitable electronics and computing equipment for powering downhole sensor 82 and detecting, processing, and displaying signals therefrom. In one embodiment, monitoring and control station 32 provides feedback control using signals from sensor 82 to control the hydraulic supply system. Monitoring and control station 32 comprises pump controller 201 controlling the output of pump 202 having fluid supply 203 . Fluid from pump 202 powers downhole tool 26 . In addition, processor 204 , having memory 205 is associated with circuits 206 to provide power and an interface with sensor 82 . Signals from sensor 82 are received by circuits 206 and then transmitted to processor 204 . Processor 204 , acting according to programmed instructions, provides a record and/or storage of the pressure vs. time of from sensor 82 using hard copy 207 , display 208 , and mass storage 209 . In one embodiment, the length of time (x) associated with each sleeve movement, as described previously, may be stored in memory 205 . The measured length of time (x) is compared to the stored signatures and the sleeve position determined based on the comparison. In another embodiment, the pressure profile for each movement is stored in memory 205 and a measured profile is compared to those in memory to determine the sleeve position. Alternatively, manual controls 200 may be operator controlled to operate the hydraulic system.
[0032] While described herein as a system having dual hydraulic control lines and a balanced piston, it will be appreciated by one skilled in the art that the present system is intended to encompass a single hydraulic line system utilizing a piston having a spring return capability.
[0033] Those of skill in the art will recognize that numerous modifications and changes may be made to the exemplary designs and embodiments described herein and that the invention is limited only by the claims that follow and any equivalents thereof. | A flow control device for use in a wellbore to allow flow of formation fluid into the wellbore comprises a valve member adapted to move when disposed in the wellbore. A fluid line supplies a working fluid under pressure to move the valve member to allow the fluid to flow into the wellbore. A sensor in the wellbore, and associated with the fluid line, provides an indication of a position of the valve member. A method of determining a state of a flow control tool within a wellbore comprises supplying fluid under pressure to the flow control tool to move a flow control member of the tool into the state. Pressure of the supplied fluid is detected downhole. The state of the flow control device is determined from the detected pressure of the supplied fluid. | 4 |
TECHNICAL FIELD
[0001] Provided is a semi-continuous fermentation method of a rhamnolipid producing microorganism to produce rhamnolipids. The fermentation may be run as a batch process but at the end of the fermentation, at least about 70% of the fermentation medium comprising one or more rhamnolipids is drawn out and the new culture medium (feedstock) is fed in as a replacement.
BACKGROUND
[0002] Rhamnolipids (RL), an interface-active glycolipid type biosurfactant, having the properties to lower the surface tension between two different liquids are broadly used as emulsifier, detergents and foaming agents [1-3]. Rhamnolipids are shown to be able to efficiently remove crude oil from contaminated soil and facilitate bioremediation of oil spills due to their emulsification properties which so called “enhanced oil recovery (EOR)” [4]. They have also been used in agriculture due to their antimicrobial and antifungal properties. Rhamnolipids are currently available in an agricultural anti-fungal product marketed as ZONIX and in an industrial cleaning product, RECO, for cleaning oil from storage tanks.
[0003] The genus Pseudomonas and E. coli are shown to be capable of producing rhamnolipid (RL) from a variety of carbon and nitrogen sources [5]. Although, the genus Pseudomonas produces higher RL yields and titers than the E. coli [ 5, 6], the RL concentration is not high enough to make the fermentation process commercially viable. A number of approaches have been carried out to increase the RL productivity including different carbon sources, genetic modified strains and fermentation strategy which appears to be the most effective route to achieve.
[0004] Batch and fed batch fermentation are the most common fermentation process with Pseudomonas [ 7-11]. Batch fermentation is the simplest cultivation method [7,8] in which feedstock (carbon source) is added in the fermenter at the beginning with the inoculum. The fermentation takes place until the feedstock is all utilized by the microorganisms, then the fermenter is shut down and the new batch is started [9]. Fed batch, on the other hand, is batch fermentation but with the addition of feedstock (carbon source), after the feedstock is fully utilized, over the course of fermentation [9-11]. The best up-to-date reported RL titer (productivity) is about 0.58-0.72 g/L/h obtained from fed-batch fermentation of P. aeruginosa [ 10]. However, this process requires the shutdown of fermenter after 90-120 hours prior to starting up a new fed batch. Similarly, U.S. Pat. No. 5,658,973 reported a 78 g/L of rhamnolipids produced after 167 hours [8] which is too long to operate.
[0000]
TABLE 1
Summary of various rhamnolipid (RL) fermentation
processes by P. aeruginosa
Fermenta-
RL
Fermenta-
RL
tion time
titer
Refer-
tion type
(g/L)
(h)
(g/L/h)
ence
Batch
70
144
0.49
[7]
Batch
78
167
0.47
[8]
Fed batch
65
90
0.72
[10]
Fed batch
70
120
0.58
[10]
Fed batch
4.1
72
0.06
[11]
Solid state
46
288
0.16
[12]
SUMMARY
[0005] Provided herein is a semi-continuous fermentation method for producing a plurality of fermentations comprising one or more rhamnolipids comprising
[0006] (a) Culturing a rhamnolipid producing microorganism in culture medium comprising at least one carbon source, at least one nitrogen source, at least one phosphorous source, at least one magnesium source, at least one potassium source, at least one sulfur source, at least one chloride source, and at least one sodium source between about 2 to about 5 days to obtain a first fermentation medium comprising one or more rhamnolipids;
[0007] (b) Removing at least about 70% and more particularly between about 70% to about 80%, or alternatively between about 70 to about 90% of the fermentation medium comprising one or more rhamnolipids obtained in (a);
[0008] (c) Replacing said fermentation medium comprising one or more rhamnolipids removed in (b) with culture medium having the composition set forth in step (a);
[0009] (d) Repeating steps (a)-(c) at least one time to obtain a subsequent fermentation comprising rhamnolipids
[0000] Wherein said steps (a)-(c) are capable of being repeated for at least about 30 days.
[0010] In a particular embodiment, said rhamnolipid producing microorganism may be cultured at a temperature of about 25-40 C and more particularly at a temperature of about 30-37 C and/or at a pH of about 5.5 to about 9 and more particularly at a pH of about 6-8.6. The pH at the start of the fermentation after the new culture medium is replaced in step (c) may in a particular embodiment, be around 6-7, preferably 6.2-6.5. The pH of the fermentation does not need to be controlled over the course of fermentation.
[0011] In another particular embodiment, said method further comprises adding a composition comprising one or more micronutrients. In a particular embodiment, said micronutrient is present in no more than about 20 mg/L. In a particular embodiment, said micronutrient is present between about 1 mg/L to about 14 mg/L. Said composition may be added either daily or continuously at 0.1% v/v of total fermentation volume per day.
[0012] The method set forth above may further comprise adding an anti-foaming agent. Said anti-foaming agent may be carbon or silicon based anti-foaming agent.
[0013] The process set forth above allows the fermentation to be run as a batch process but at the end of the fermentation, at least about 70% of the fermentation medium comprising one or more rhamnolipids is drawn out and the new culture medium (feedstock) is fed in as a replacement. This process (step (d)) can be repeated for at least about one month and in another embodiment, up to about 180 days without having to sacrifice RL yield and titer. It allows the fermenter to be utilized at a higher capacity with less downtime for clean-up compared to batch and fed batch fermentation strategies. As noted above, said process step (d) is repeated at least once. In a particular embodiment, said process step (d) is repeated at least 5 times.
[0014] In a particular embodiment, said method produces rhamnolipid concentrations of at least about 45 g/L and more particularly about 60-80 g/L with rhamnolipid productivity (titer) as high as about 1.6 g/L/h. In a particular embodiment, where the carbon source is an oil, there is only a residual oil composition of no more than about 0.8% w/v detected in step (b).
DEFINITIONS
[0015] Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention.
[0016] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, the preferred methods and materials are now described.
[0017] All publications and patents cited in this disclosure are incorporated by reference in their entirety. Nothing herein is to be construed as an admission that the invention is not entitled to antedate such disclosure by virtue of prior invention. To the extent the material incorporated by reference contradicts or is inconsistent with this specification, the specification will supersede any such material.
[0018] It must be noted that as used herein and in the appended claims, the singular forms “a”, “and” and “the” include plural references unless the context clearly dictates otherwise.
[0019] Unless otherwise indicated, the term “at least” preceding a series of elements is to be understood to refer to every element in the series. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed by the present invention. Throughout this specification and the claims which follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” and “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 integer or step. Thus the terms “comprising”, “including,” containing”, “having” etc. shall be read expansively or open-ended and without limitation. When used herein the term “comprising” can be substituted with the term “containing” or sometimes when used herein with the term “having”.
[0020] As defined herein, a “rhamnolipid” refers to a glycolipid that has a lipid portion that includes one or more, typically linear, saturated or unsaturated β-hydroxy-carboxylic acid moieties and a saccharide portion of one or more units of rhamnose.
[0021] The saccharide portion and the lipid portion are linked via a β-glycosidic bond between the 1-OH group of a rhamnose moiety of the saccharide portion and the 3-OH group of a β-hydroxy-carboxylic acid of the lipid portion. Thus the carboxylic group of one carboxylic acid moiety defines the end of the rhamnolipid. Where more than one rhamnose-moiety is included in a rhamnolipid, each of the rhamnose moieties not linked to the lipid portion is linked to another rhamnose moiety via a 1,4 β-glycosidic bond. In embodiments where two or more β-hydroxy-carboxylic acids are present in a rhamnolipid, the β-hydroxy-carboxylic acid moieties are selected independently from each other. β-hydroxy carboxylic acid moieties of a respective plurality of β-hydroxy carboxylic acid moieties may in some embodiments be identical. In some embodiments they are different from each other.
[0022] As defined herein, a “micronutrient composition” is a composition comprising a micronutrient present in an amount no more than about 20 mg/L.
[0023] The terms “culture medium”, “fermentation medium” are synonymous and are used interchangeably.
BRIEF DESCRIPTION OF THE FIGURES
[0024] FIG. 1 is a schematic depiction of the semi-continuous fermentation method for producing rhamnolipids.
[0025] FIG. 2 shows the change in pH over the course of fermentation with steps (a)-(c) being repeated for more than 30 days in Example 4.
[0026] FIG. 3 shows the change in pH over the course of fermentation after post inoculation or after filling with the new culture medium in Example 5.
DETAILED DESCRIPTION
[0027] Provided herein is a semi-continuous fermentation method for producing a plurality of fermentations comprising one or more rhamnolipids. In a particular embodiment, the rhamnolipid may have the structure (I).
[0000]
[0000] Where m=2, 1 or 0, in particular 1 or 0, n=1 or 0, or in particular 1, R 1 and R 2 =independently of one another identical or different organic radical with 2 to 24, preferably 5 to 13, carbon atoms, in particular optionally branched, optionally substituted, in particular hydroxyl-substituted, optionally unsaturated, in particularly optionally mono-, di- or triunsaturated, alkyl radical, preferably one selected from the group consisting of pentenyl, heptenyl, nonenyl, undeceny and tridecenyl and (CH2)o-CH 3 where o=1 to 23, preferably 4 to 12.
[0028] Both the main chain as well as the branches may furthermore contain heteroatoms as for instance N, O, S, Se or Si or a carbon atom may be replaced by one of these heteroatoms. An aliphatic moiety may be substituted or unsubstituted with one or more functional groups. Substituents may be any functional group, as for example, but not limited to, amino, amido, carbonyl, carboxyl, hydroxyl, nitro, thio and sulfonyl.
Rhamnolipid Producing Microorganism
[0029] As noted above, the method comprises culturing a rhamnolipid producing microorganism. A rhamnolipid producing microorganism may be a host cell producing rhamnolipids. A recombinant host cell producing rhamnolipids may be a host cell, such as a bacterial cell that expresses a RhlA gene or ortholog thereof and/or a RhlB gene or ortholog thereof, and/or a RhlC gene or ortholog thereof, and/or RhlR gene or ortholog thereof, and/or RhlI gene or ortholog thereof, and/or RhlG gene or ortholog thereof and others.
[0030] Alternatively, a “rhamnolipid-producing microorganism” may be any microorganism, such as bacteria, which has the capacity to synthesize/produce rhamnolipids under suitable conditions which includes but is not limited to bacterium of the phyla Actinobacteria, Fimicutes and Proteobacteria. In a particular embodiment, the rhamnolipid-producing microorganism is a bacterium of the Gammaproteobacteria class. In a further embodiment, the rhamnolipid-producing microorganism is a bacterium of the Pseudomonadales order. In yet another further embodiment, the rhamnolipid producing microorganism is a bacterium of the Pseudomonadacae family. In an even further embodiment, the rhamnolipid-producing microorganism is a bacterium of the Pseudomonas genus, such as P. alcaligenes, P. aeruginosa, P. chlororaphis, P. clemancea, P. collierea, P. fluorescens, P. luteola, P. putida, P. stutzeri and P. teessidea . In a further embodiment, the rhamnolipid-producing microorganism is P. aeruginosa.
Culture Medium
[0031] The rhamnolipid containing microorganism is cultured in culture medium. Said culture medium comprises at least one carbon source, at least one nitrogen source, at least one phosphorous source, at least one sulfur source, at least one sodium source, at least one magnesium source, at least one potassium source, at least one sulfur source and at least one chloride source.
[0032] The carbon source may be a monosaccharide, e.g. glucose, a disaccharide, e.g. sucrose, a sugar alcohol, e.g. glycerol, a long chain alkane, e.g., n-hexadecane, a fatty acid such as caprylic acid (also termed octanoic acid), vegetable oils (fresh or waste; e.g., soybean oil) or mixtures thereof, organic acids (e.g. lactic acid, acetic acid, citric acid, propionic acid), alcohols (e.g. ethanol), and mixtures of these. In a particular embodiment, the carbon source is a vegetable oil selected from the group consisting of olive oil, rapeseed oil, olive oil, corn oil, sunflower oil, canola oil and soybean oil. The carbon source may be present in the amount of about 6% to about 12% w/w.
[0033] The nitrogen source may be ammonium sulfate, ammonium phosphate, urea, yeast extract, meat extract, peptone, and corn steep liquor. In a particular embodiment, the nitrogen source is NaNO 3 . In yet another embodiment, the nitrogen may be present in the amount of about 1-10 g/L.
[0034] The phosphorous source may in a particular embodiment be H 3 PO 4 or K 2 HPO 4 . In yet another particular embodiment, said phosphorous is present in the amount of about 1-10 g/L.
[0035] The magnesium ion in a particular embodiment may be MgSO 4 *7H2O and/or MgCl 2 . In a particular embodiment, the magnesium is present in the amount of about 0.01-1 g/L.
[0036] The potassium may be KCl and/or KOH. In a particular embodiment, the potassium is present in the amount of about 0.1 to about 2 g/L.
[0037] The sodium may be NaCl, NaNO 3 , and NaOH. In a particular embodiment, said sodium ion is present in the amount of about 1-15 g/L.
[0038] The chloride may be KCl and NaCl. In a particular embodiment, said chloride ion is present in the amount of about 0.1-1 g/L.
[0039] The sulfur may be H 2 SO 4 . In a particular embodiment, said sulfur ion is present in the amount of about 0.1-1 g/L.
[0040] The sulfur, chloride and nitrogen sources may be derived from the aqueous layer, or also referred to as the aqueous liquid phase or aqueous phase of an acid treated and aged microorganism containing fermentation medium obtainable using procedures described in application Ser. No. 14/992,995. In a specific embodiment, the fermentation or culture medium comprising one or more rhamnolipids may be aged by incubating for at least about 1 day and between about 24-72 hrs at between about 0-30 C. In a particular embodiment, the aged aqueous medium may be treated with acid so the culture medium is adjusted to a pH of about 1.5 to 2.5, preferentially, about 2.05 to about 2.15. The acid can be an organic acid such as acetic acid, or a mineral acid. In a preferred embodiment, the acid is a mineral acid, e.g. HCl, H 2 SO 4 , HNO 3 , or H 3 ClO 4 . As a result, an aqueous liquid phase, oily phase and solid phase is generated. The aqueous liquid phase is removed using procedures known in the art and in a specific embodiment using methods set forth above (e.g., filtration, or centrifugation or settling combined with decanting).
[0041] The culture medium may further comprise an emulsifier. In a particular embodiment, the emulsifier is selected from the group consisting of Arabic gum, guar gum and rhamnolipids. In yet another particular embodiment, the ratio of emulsifier to carbon source in said culture medium is between about 0.1% to about 20% w/w. In yet another particular embodiment, wherein said emulsifier may be present in the amount of about 5-10% by weight.
[0042] In a particular embodiment, the culture or fermentation medium is sterilized using methods known in the art. These methods may be filtration based, heat based, chemical based or ultraviolet light radiation based. In a particular embodiment, the heat based treatment may be via moist heat sterilization, particularly autoclaving.
[0043] In one embodiment, the aqueous medium (e.g., fermentation medium) may be sterilized by one of the above procedures. In another embodiment, the fermentation media may be sterilized by more than one of the procedures set forth above and these sterilizations could be in any order. It may be sterilized in the fermentation during the first cycle of fermentation, but should be sterilized in another vessel in subsequent cycles.
Micronutrient Composition
[0044] As noted above, said method may further comprise adding a micronutrient solution or composition. Said micronutrient may be a trace of Fe, Mn, Zn, Cu, Na. In a particular embodiment, said micronutrient is a Fe, Mn, Zn, Na or Cu salt. In a more particular embodiment said micronutrient composition comprises Fe, Mn, Zn, Na and Cu salts. The composition may be sterilized by filtration.
[0045] In particular embodiments, said Cu salt is at least one of CuCl 2 *2H 2 O and CuSO 4 *5H 2 O and may be present in the amount of about 0.5-3 g/L of micronutrient solution; said Mn salt is at least one of MnSO4*H 2 O and MnCl 2 .4H 2 O and may be present in the amount of about 0.1-1.5 g/L of micronutrient solution; said Zn salt is ZnSO 4 *7H 2 O or ZnCl 2 and may be present in the amount of about 0.5-3 g/L of micronutrient solution; said Fe salt is at least one of FeCl 3 *6H 2 O or FeSO 4 and may be present in the amount of about 0.1-1 g/L of micronutrient solution; said sodium salt is Na 3 C 6 H 5 O 7 *2H 2 O and may be present in the amount of about 1-5 g/L of micronutrient solution.
DESCRIPTION OF SPECIFIC EMBODIMENTS
Example 1
Culture Medium Preparation
[0046] A composition of the 8% soybean oil in the culture medium for the fermentation of Pseudomonas aeruginosa for rhamnolipids production is shown in Table 2, infra. Gum Arabic is used at 10% w/w of soybean oil.
[0000]
TABLE 2
Culture Medium Composition
Component
Concentration
Gum Arabic
8.00
g/L
Soybean oil
80.00
g/L
85% H 3 PO 4
9.69
g/L
99% NaOH
5.21
g/L
99% MgSO 4 *7H 2 O
0.50
g/L
99% KCl
1.00
g/L
99% NaNO 3
15.00
g/L
98% H 2 SO 4
0.92
g/L
Deionized water
The rest
[0047] To make the culture medium, gum Arabic is first dissolved in deionized water to obtain 5% w/w gum Arabic solution under agitation at 150-250 rpm and at 40-45 C in a separate container. This step will take at least 30 min to allow all gum Arabic to dissolve in water. Second, mix soybean oil and 5% gum Arabic solution with deionized water using a blender such as kitchen blender. Make sure it is well mixed to obtain an emulsion (i.e. the solution becomes white like milk). After the emulsion of soybean oil is obtained, H 3 PO 4 is added into the emulsion under stirring and the next chemical NaOH is added in after H 3 PO 4 is well dissolved, The next chemical which are MgSO 4 then KCl then NaNO 3 and the last H 2 SO 4 are added into the emulsion under stirring. Before adding the next chemical, make sure that it is well dissolved in the emulsion. The culture medium then can be stream sterilized (autoclave).
Example 2
Micronutrient Composition Preparation
[0048] The composition of micronutrient is shown in Table 3. Please note that the concentration of each salt is in g/L of micronutrient solution.
[0000]
TABLE 3
Composition of Micronutrient
Component
Concentration
Na 3 C 6 H 5 O 7 * 2H 2 O
2.0
g/L
FeCl 3 * 6H 2 O
0.3
g/L
ZnSO 4 * 7H 2 O
1.4
g/L
CuCl 2 * 2H 2 O
1.2
g/L
CuSO 4 * 5H 2 O
1.2
g/L
MnSO 4 * H 2 O
0.8
g/L
[0049] All chemicals are ACS grades (highest purity available). Na 3 C 6 H 5 O 7 *2H 2 O is first added into deionized water using stirring. After it is all dissolved, the next chemical which is FeCl 3 *6H 2 O can be added in. This step is repeated until all the chemicals listed in the table are added into the solution in the order of FeCl 3 *6H 2 O then ZnSO 4 *7H 2 O then CuCl 2 *2H 2 O then CuSO 4 *5H 2 O and MnSO 4 *H 2 O the last. The micronutrient can be sterilized using a 0.2 micron sterilized filtration. Do not steam autoclave the micronutrient.
Example 3
Seed Culture of P. aeruginosa (Schroeter) Migula (R4 Strain)
[0050] R4 strain obtained from ATCC #55734 is first inoculated in agar plates containing 40 g/L Tryptic Soy Agar at 32 C for 18-24 hours. After R4 colonies are formed, a single colony is then cultured in 5 ml of 20 g/L LB Broth (Lennox) in a shake tube at 37 C for 20-24 hours. The final OD 600 is about 3-5 and the LB Broth (Lennox) solution in the shake tube will change from yellow to green. Then, the R4 culture obtained from a shake tube is inoculated in a shake flask containing 20 g/L LB Broth (Lennox) at 1% inoculation and incubated at 37 C for 20-24 hours. This process is repeated as necessary in order to generate sufficient inoculum of R4 required for the fermentation. The LB Broth (Lennox) is obtained from Sigma Aldrich #3022 which contains 10 g/L Tryptone, 5 g/L yeast extract and 5 g/L NaCl.
Example 4
Semi-Continuous Fermentation of Rhamnolipids with Deionized Water and 10% w/w Gum Arabic (as Emulsifier) to Soybean Oil
[0051] The fermentation of P. aeruginosa (Schroeter) Migula obtained from ATCC #55734 (R4) is performed in 10 L bioreactor and is schematically set forth in FIG. 1 . It is initiated with the preparation of 8 L of the culture medium of 8% soybean oil and 10% w/w gum Arabic to soybean oil in the fermenter 10. The chemicals used in the culture medium in Example 1 are ACS grades (highest purity available). After sterilization of the culture medium, the temperature is cooled down to 37 C using a water heating jacket and the agitation starts (250 rpm). Once the temperature is stable at 37 C, 0.2 micron filtered air is supplied to the fermenter thru aeration line (#4) at 1.5 L/min and the fermenter is inoculated with 2.5% (200 ml) inoculum of R4 obtained from Example 3 thru line #1. Filter sterilized 8 ml micronutrient prepared in Example 2 is then added to the fermenter thru line #2 once a day. In the case when the micronutrient cannot be added daily, 8 ml micronutrient is diluted in 32 ml of deionized water (per day) in order to be added continuously in the fermenter at 40 ml/day using a peristatic pump. Silicon based antifoam (Sigma Aldrich #85390) is automatically added to knock down the foam during fermentation thru line #3.
[0052] The fermentation is run at a temperature of 37 C with the initial pH of the culture medium of 6.2 with no pH control over the course of fermentation. The stirring rate automatically increases as necessary in order to keep % dissolved oxygen (% DO) at 15%-20%. The stirring rate goes up 500 rpm before the air flow rate increases from 1.5 to 3.5 L/min at 40-48 hours post inoculation in order to keep up with the oxygen demand of the microbes during growth rate. After 60 hours post inoculation, the pH is increasing after it slightly dips down (or remains stable). Additionally, the % DO increases while the agitation and air flow are at the lowest values (250 rpm and 1.5 L/min, respectively) indicating that the fermentation is completed at 72 hours. This can be confirmed with a residual soybean oil in fermentation medium comprising one or more rhamnolipids to be less than 0.8%.
[0053] The peristatic pump is then started to remove 6 L (75% of the total) of the fermentation medium comprising one or more rhamnolipids thru line #5. Once 6 L of broth is removed which so called “Draw#1”, the recently sterilized 6 L of 8% soybean oil culture medium prepared in sterilized tank 20 is fed into the fermenter 10 using a gravity feed. The initial fermentation pH is 6.5. The fermentation parameters described in the above paragraph are used. In this case, after 48 hours, the fermentation is completed and 75% of the fermentation medium comprising one or more rhamnolipids is being ready to be drawn out (Draw#2). Subsequently, the next batch of sterilized soybean oil culture medium is fed in from the sterilized tank 20. The process repeats for 6 weeks with no sign of loss in rhamnolipids yields and titers before the fermenter is shut down for cleaning. A change in pH over the course of fermentation between the drawing and for each drawing is shown in the FIG. 2 . The rhamnolipid (RL) concentration and titer are shown in Table 4 infra. The rhamnolipid (RL) concentration of all of the 12 draws is at least 62 g/L up to 79 g/L. The RL productivity (titer) is 0.92-1.61 g/L/h.
[0000]
TABLE 4
Rhamnolipid Conc and Titer During Semi-
Continuous Fermentation With Soybean Oil
Fermenta-
% Initial
tion time
Total
RL
Soybean
(between draw)
RL
titer
Micro-
Draw#
oil
(h)
(g/L)
(g/L/h)
nutrient
1
8.0%
72
66
0.92
Continuously
2
6.0%
48
62
1.29
added
3
6.0%
46
71
1.54
4
7.5%
69
77
1.12
5
6.0%
46
74
1.61
Added
6
6.0%
48
74
1.54
daily
7
7.5%
71
79
1.11
8
6.0%
47
70
1.49
9
6.0%
46
66
1.43
10
7.5%
69
65
0.94
Continuously
11
6.0%
48
68
1.42
added
12
6.0%
48
69
1.44
Example 5
Semi-Continuous Fermentation of Rhamnolipids with Deionized Water, 5% w/w Gum Arabic to Soybean Oil with Continuously Added Micronutrient
[0054] The composition of the culture medium used in Table 5. 7.3 L of 8% soybean oil with 5% w/w gum Arabic to soybean oil is prepared as described in Example 1. All chemicals used in this example are industry grade containing impurities.
[0000]
TABLE 5
Composition of Culture Medium w/5% Gum Arabic,
8% Soybean Oil and 5% R4 Inoculum
Component
Concentration
Gum Arabic
4.00
g/L
Soybean oil
80.00
g/L
85% H 3 PO 4
9.69
g/L
99% NaOH
5.21
g/L
99% MgSO 4 *7H 2 O
0.50
g/L
99% KCl
1.00
g/L
99% NaNO 3
15.00
g/L
98% H 2 SO 4
0.92
g/L
Deionized water
The rest
[0055] The fermentation is run as in Example 4 except that 5% (360 ml) R4 inoculum is used to inoculate the fermenter and 77% of the fermentation medium comprising one or more rhamnolipids (5.6 L) is drawn out and the new culture medium contains 5% w/w gum Arabic to soybean oil. Micronutrient is prepared as described in Example 2. By diluting 7.3 ml of micronutrient in 32.7 ml deionized water (per day), it is added continuously at the flow rate of 40 ml/day using a peristatic pump. Silicon based antifoam (DOW AFE-1510) is automatically added to knock down the foam during fermentation. The stirring rate automatically increases as necessary in order to keep % dissolved oxygen (% DO) at 15%-20% with air flow rate of 1.5 L/min. Pure oxygen is additionally added to the fermenter at 0.005-0.1 L/min in order to keep the agitation down and thus, less foaming issue. A typical change in pH over the course of fermentation post inoculation or after filling with the new culture medium is shown in FIG. 3 . The rhamnolipid (RL) concentration and titer are shown in Table 6 infra.
[0000]
TABLE 6
Rhamnolipid Conc and Titer Using Semi-
Continuous Method Using 5% R4 Inoculum
Fermenta-
% Initial
tion time
Total
RL
Soybean
(between draw)
RL
titer
Draw#
oil
(h)
(g/L)
(g/L/h)
1
8.0%
59
56
0.90
2
7.7%
70
79
1.13
3
6.1%
65
76
1.17
4
8.0%
96
70
0.73
5
7.7%
91
76
0.84
6
8.0%
82
70
0.85
7
7.7%
70
78
1.11
Example 6
Semi-Continuous Fermentation of Rhamnolipids with Deionized Water, 5% w/w Gum Arabic to Soybean Oil with Continuously Added 2× of Micronutrient
[0056] In this example, the culture medium and fermentation parameters are the same as shown in Example 5 except that the amount of micronutrient used is double. By diluting 14.6 ml of micronutrient (prepared in Example 2) in 26.4 ml deionized water (per day), it is added continuously at the flow rate of 40 ml/day using a peristatic pump. The stirring rate automatically increases as necessary in order to keep % dissolved oxygen (% DO) at 15%-20% with air flow rate of 1.5 L/min. Pure oxygen is additionally added to the fermenter at 10-30% of air flow to keep the total flow rate constant at 1.5 L/min in order to keep the agitation down and thus, less foaming issue. The rhamnolipid (RL) concentration and titer are shown in Table 7 infra.
[0000]
TABLE 7
RL Conc and Titer During Semi-Continuous
Fermentation With 2X Micronutrient
Fermenta-
% Initial
tion time
Total
RL
Soybean
(between draw)
RL
titer
Draw#
oil
(h)
(g/L)
(g/L/h)
1
7.7%
73
75
1.03
2
6.1%
48
64
1.33
3
7.7%
68
69
1.01
4
6.1%
69
66
0.96
Example 7
Semi-Continuous Fermentation of Rhamnolipids with 8% Soybean Oil and 85% Cold Tap Water/15% Aqueous Top Layer Waste Stream from Fermentation Medium Comprising One or More Rhamnolipids
[0057] The composition of the culture medium used in this Example is shown in Table 8.
[0000]
TABLE 8
Culture Medium with Aqueous Layer
Component
Concentration
Soybean oil
80.00
g/L
85% H 3 PO 4
9.69
g/L
99% NaOH
5.21
g/L
99% MgSO 4 *7H 2 O
0.50
g/L
99% KCl
1.00
g/L
99% NaNO 3
15.00
g/L
Aqueous layer waste water
150.00
g/L
Cold tap water
The rest
[0058] The aqueous top layer waste stream may be obtained using the procedures described in U.S. application Ser. No. 14/992,995, filed Jan. 11, 2016 (See Example 3 of said application). Briefly, aqueous top layer waste stream is obtained from clarified fermentation broth. Clarified broth is made by allowing fermentation medium containing P. aeroginosa that ends at a pH of 6.0 to 6.5 to age under ambient conditions for about 2 days. The biomass settles to the bottom of the vessel used for this aging process and the clear supernatant, after removal, is clarified broth. The next step in the process is to add acid, such as concentrated sulfuric acid, until the pH is about 2.1. The rhamnolipids precipitate out of solution and form a solid phase and an oily liquid phase at the bottom of the vessel used for this step. The separation of the solid and oily liquid phases can be sped up by centrifugation. The solid and oily liquid phases are separated from the aqueous top phase or layer, which can be discarded or recycled. The above-referenced aqueous layer is a source of H 2 SO 4 and micronutrients of which 15% w/w is used in the culture medium with 8% soybean oil in the balance of cold tap water. The waste stream aqueous top layer is first filtered at 1 micron to remove large particles prior to its use.
[0059] 7.3 L of the culture medium containing 8% soybean oil with 15% waste stream aqueous top layer and cold tap water is prepared by first mixing soybean oil, aqueous top layer and cold tap water using a kitchen blender. After they all are well mixed, H 3 PO 4 , NaOH, MgSO 4 , KCl and NaNO 3 are added into the solution in that order under stirring. The culture medium then can be stream sterilized (autoclave). All chemicals used in this example are industry grade containing impurities.
[0060] The fermentation is carried out at the same parameters as Example 5. Micronutrient composition is added continuously. Pure oxygen is additionally added to the fermenter at 10-30% of air flow to keep the total flow rate constant at 1.5 L/min in order to keep the agitation down and thus, less foaming issue. The rhamnolipid (RL) concentration and titer are shown in Table 9 infra.
[0000]
TABLE 9
RL Conc and Titer During Semi-Continuous
Fermentation (Aqueous Layer)
Fermenta-
% Initial
tion time
Total
RL
Soybean
(between draw)
RL
titer
Draw#
oil
(h)
(g/L)
(g/L/h)
1
8.0%
95
74
0.78
2
6.1%
75
64
0.85
3
7.7%
92
73
0.79
4
6.1%
60
62
1.03
5
7.7%
83
71
0.85
6
6.1%
71
68
0.96
7
7.7%
89
77
0.86
Example 9
Semi-Continuous Fermentation of Rhamnolipids in 100 L Scale
[0061] 100 L of the culture medium (composition as in Example 5) is prepared as in Example 1 and sterilized in 120 L bioreactor. Its composition is shown in Table 10. Seed culture of R4 strain is prepared according to Example 2. The 100 L fermenter is inoculated with 2.9 L R4 strain incubated in a shake flask at 37 C for 24 hours in 20 g/L LB Broth Lennox.
[0062] The fermentation is run at a temperature of 37 C with the initial pH of the culture medium of 6.2 with no pH control over the course of fermentation. Silicon based antifoam (DOW AFE-1510) is diluted with 50% deionized water which is then autoclaved prior to use. The antifoam is automatically added to knock down the foam during fermentation. The agitation is at 150 rpm with 17 L/min of air. The stirring rate automatically increases as necessary in order to keep % dissolved oxygen (% DO) at 15%-20%. 800 ml of micronutrient prepared and composition as Example 2 is diluted with 2.2 L deionized water and thus, it is being fed in continuously at 375 ml/day for 8 days.
[0063] 70 L of culture medium containing 9% soybean oil (composition in Table 10 infra) is prepared as in Example 1 and is sterilized in a different 100 L bioreactor a day prior to the draw. After 105 hours post inoculation, the pH starts to increase after it remains constant around 7. The fermentation is completed at 115 hours with a pH at 7.3.
[0000]
TABLE 10
Composition of 9% Soybean Oil Culture Medium (70 L)
Component
Concentration
Gum Arabic
4.50
g/L
Soybean oil
90.00
g/L
85% H 3 PO 4
9.69
g/L
99% NaOH
5.21
g/L
99% MgSO 4 *7H 2 O
0.50
g/L
99% KCl
1.00
g/L
99% NaNO 3
15.00
g/L
98% H 2 SO 4
0.92
g/L
Deionized water
The rest
[0064] After 115 hours post inoculation, the peristatic pump is then started to remove 70 L (70% of the total) of the fermentation medium comprising one or more rhamnolipids. Once 70 L of broth is removed which so called “Draw#1”, the recently sterilized 70 L of 9% soybean oil culture medium is fed into the fermenter using a peristatic pump. The initial fermentation pH is 6.5. The fermentation parameters described in the above paragraph are used. In this case, after 70 hours, the fermentation is completed with a pH at 7.14. The rhamnolipid (RL) concentration and titer are shown in Table 11 infra.
[0000]
TABLE 11
RL Concentration and Tier (100 L Scale)
Fermenta-
% Initial
tion time
Total
RL
Soybean
(between draw)
RL
titer
Draw#
oil
(h)
(g/L)
(g/L/h)
1
8%
115
70
0.61
2
6.3%
70
75
1.07
Example 9
Shake Flask Experiment without Micronutrient
[0065] 50 ml of culture medium (composition as below) is prepared as Example 1 in a 250 ml shake flask. Its composition is shown in Table 12. After being autoclaved and cooled down to room temperature, the shake flasks are inoculated with 5% frozen stock of R4 strain. The frozen stock is obtained from mixing 70% R4 tube culture having OD 600 of 3-4 with 30% glycerol and stored at −80 C. The incubation is carried out at 37 C in a shaker for 92 hours without the addition of micronutrient. After 92 hours post inoculation, the rhamnolipid concentrations are average 47±3 g/L for 5 shake flasks.
[0000]
TABLE 12
Culture Medium Concentration For Use
In Fermentation Without Micronutrient
Component
Concentration
Gum Arabic
6.00
g/L
Soybean oil
60.00
g/L
85% H 3 PO 4
9.69
g/L
99% NaOH
5.21
g/L
99% MgSO 4 *7H 2 O
0.50
g/L
99% KCl
1.00
g/L
99% NaNO 3
15.00
g/L
98% H 2 SO 4
0.92
g/L
Deionized water
The rest
REFERENCES
[0000]
[1] Randhawa et al. (2014) “Rhamnolipid biosurfactants—past, present, and future scenario of global market”, Frontiers in Microbiology 5:1-7.
[2] Muller et al. (2012) “Rhamnolipids—Next generation surfactants?”, J Biotechnol 162(4):366-80.
[3] Banat et al. (2010) “Microbial biosurfactants production, applications and future potential” Appl. Microbiol. Biotechnol. 87:427-444.
[4] Wang et al (2007) “Engineering Bacteria for Production of Rhamnolipid as an Agent for Enhanced Oil Recovery” Biotech. and Bioeng. 98: 842-853.
[5] Wittgens et al. (2011) “Growth independent rhamnolipid production from glucose using the non-pathogenic Pseudomonas putida KT2440” Microbial Cell Factories 10: 80-98.
[6] Nitschke et al (2011) “Rhamnolipids and PHAs: Recent reports on Pseudomonas -derived molecules of increasing industrial interest” Proc Biochem 46: 621-630.
[7] Gong et al (2015) “Rhamnolipid production, characterization and fermentation scale-up by Pseudomonas aeruginosa with plant oils” Biotechnol Lett 37: 2033-2038.
[8] Giani et al (1997) “ Pseudomonas Aeruginosa and its use in a process for the biotechnological preparation of L-rhamnose” U.S. Pat. No. 5,658,973.
[9] Mcneil and Harvey (2008) “Practical fermentation technology” John Wiley & Sons Ltd, England.
[10] Zhu et al (2012) “Enhanced rhamnolipids production by Pseudomonas aeruginosa based on a pH stage-controlled fed-batch fermentation process, Bioresource Technology 117: 208-213.
[11] Ghomi et al (2012) “Comparison between batch and fed-batch production of rhamnolipid by Pseudomonas aeruginosa ” Iranian J Biotech 10: 263-269.
[12] Camilios et al (2009) “Production of rhamnolipids in solid-state cultivation: characterization downstream processing and application in the cleaning of contaminated soil” Biotechnol J 4: 748-755. | Provided is a semi-continuous fermentation method of a rhamnolipid producing microorganism to produce rhamnolipids. The fermentation may be run as a batch process but at the end of the fermentation, at least about 70% of the fermentation medium comprising one or more rhamnolipids is drawn out and the new culture medium (feedstock) is fed in as a replacement. This process may be repeated for at least about one month without having to sacrifice RL yield and titer. It allows the fermenter to be utilized at a higher capacity with less downtime for clean-up compared to batch and fed batch fermentation strategies. | 2 |
FIELD OF THE INVENTION
[0001] The present invention is related to the field of printers and copiers and more particularly to fusers, intermediate transfer members, and/or elements that function as both fusers and intermediate transfer members and to printers or copiers that utilize the same.
BACKGROUND OF THE INVENTION
[0002] Printers and copiers are well known. Modern copiers that utilize powder or liquid toners comprising toner particles to form visible images generally form a latent electrostatic image on an image forming surface (such as a photoreceptor), develop the image utilizing a toner (such as the aforementioned powder or liquid toners) to form a developed image and transfer the developed image to a final substrate. The transfer may be direct, i.e., the image is transferred directly to the final substrate from the image forming surface, or indirect, i.e., the image is transferred to the final substrate via one or more intermediate transfer members.
[0003] In general, the image on the final substrate must be fused and fixed to the substrate. This step is achieved in most copiers and printers by heating the toner image on the substrate. In some copiers and printers the fusing and fixing of the image is performed simultaneously with the transfer of the image to the substrate. This is achieved by utilizing a heated intermediate transfer member to perform the transfer and by pressing the intermediate transfer member against the final substrate. This combination of heat and pressure softens the toner particles and fixes them to the substrate. In other copiers and printers, the image is first transferred to the final substrate, and then fused by a separate fuser. Once the transferred image has been fused, it is desirable for the surface of the intermediate transfer member or fuser to cool below a certain temperature while it is still in contact with the final substrate, so that none of the toner sticks to it.
[0004] In several prior art devices, a drum used as an intermediate transfer member or fuser contains water or another liquid in its interior. These include devices described in PCT Publication WO 00/31593, EP 0 772 100 A2, JP Publication 08320625, U.S. Pat. No. 4,172,976, PCT Application PCT/IL00/00652 filed Oct. 13, 2000, and a PCT Application titled “Fusers and Intermediate Transfer Members” filed Oct. 30, 2001 at the Israel Patent Office by Ilan Romem of Indigo N. V., the disclosures of all of which are incorporated herein by reference. There are two reasons for including liquid inside the drum. The first reason is that the liquid can keep the outer surface of the drum at a uniform temperature. This is important for obtaining good image quality, and especially for avoiding “short-term memory” effects, in which an image can be affected by the previous image. Such short-term memory effects are believed to be caused by lower surface temperatures in regions where the drum previously had liquid toner, which cools the surface locally when it evaporates. Having liquid inside the drum has been found to practically eliminate short-term memory. The second reason for using liquid, described in WO 00/31593, is that when the liquid gets hot, the vapor pressure of the liquid inside the drum can support a thin membrane, allowing it to conform slightly to the surface of the substrate that it is in contact with, when transferring images or fixing images. That could also be accomplished by maintaining air under pressure inside the drum, or by including a layer of compliant spongy material underlying the outer surface of a drum whose interior is rigid. But maintaining air under pressure inside the drum would require a pumping system, and a spongy layer can easily become damaged, and thermally insulates the surface from the source of heat inside the drum. Another advantage of using a thin membrane supported by gas pressure is that the heat capacity on transfer is low, so the image cools and hardens during transfer.
[0005] There are some disadvantages to using a drum with liquid in it, particularly a drum whose outer surface is a thin membrane supported by gas pressure. The liquid can have a high heat capacity, and hence take a long time to heat up. This means there may be a long waiting time when the copier or printer is first turned on, until it is ready to print. To avoid waiting, the drum may be kept hot all the time, but this can be dangerous, because someone inadvertently touching the drum could be burned, and because the drum could explode if the gas pressure inside gets too high. Also, toner particles on the drum could be burnt onto the drum. If the surface of the drum is a thin somewhat flexible membrane, then it cannot be built to withstand very high pressure. Using liquid with high heat capacity also means that, if the gas pressure does get too high, it will take a long time to bring the pressure down by cooling off the liquid. The heating problem is especially acute if a large amount of liquid is used.
SUMMARY OF INVENTION
[0006] An aspect of some embodiments of the invention is concerned with rapidly changing the temperature of a drum containing a liquid used as an intermediate transfer member or fuser, in a printer or copier.
[0007] An aspect of some embodiments of the invention is concerned with rapidly heating such a drum, in order to bring it up to the temperature required for printing, and rapidly cooling the drum once the printing is completed.
[0008] An aspect of some embodiments of the invention is concerned with rapidly cooling such a drum, in order to reduce the gas pressure, if it gets too high.
[0009] An embodiment of the invention comprises a reservoir of hot liquid and a reservoir of colder liquid, and pipes connecting the reservoirs to the interior of the drum. The embodiment also comprises valves which can be opened and closed, to control the flow of liquid between the interior of the drum and the reservoirs. When the printer or copier is idle, the drum contains colder liquid, so that it is safe to touch, and there is no danger of explosion or fusing toner to the drum. Before the printer or copier begins to print, the colder liquid is pumped out of the drum back to the colder liquid reservoir, and hot liquid is pumped from the hot liquid reservoir to the drum, which transfer heats up the drum very quickly, especially if the drum has a cylindrical surface formed of a thin membrane.
[0010] Once printing is done, hot liquid is pumped out of the drum back to the hot liquid reservoir, and colder liquid is pumped into the drum from the cold liquid reservoir. If the drum becomes too hot and the gas pressure gets too high in the middle of printing, and/or if there is a paper jam, the gas pressure and temperature can be quickly reduced to a safe level by pumping at least some of the hot liquid out of the drum, and/or pumping some colder liquid into the drum. This is particularly true when the cylindrical surface is thin so that the heat capacity of the liquid is much higher than that of the cylinder, but it is not necessary for the surface to be thin. The valves can be arranged so that this transfer of liquid is done automatically, and in a fail-safe way, whenever the gas pressure gets too high. The colder liquid need not be colder than room temperature, it could be room temperature or even hotter than room temperature.
[0011] In an embodiment of the invention, a heater within the drum is used to replace heat transferred to the final substrate and other rollers of the system. Alternatively or additionally, this heat is provided by the heater in the reservoir, for example, in response to a temperature measurement of the drum surface and/or the temperature of the liquid in the drum.
[0012] The volatile liquid used to produce gas pressure in the drum in some embodiments need not be the liquid that is being pumped into and out of the drum to heat and cool the drum. The liquid transfer system which is used to pump the liquid into and out of the drum will work best if it uses a non-volatile liquid, free of gas. The volatile liquid used to produce gas pressure could be in a thin outer region just beneath the outer surface of the drum. The liquid being pumped into and out of the drum could fill a separate, more central portion of the drum, below the outer region, sealed off from the outer space but in good thermal contact with it.
[0013] In some embodiments, the hot liquid reservoir has a heating element and thermostat, and/or the cold liquid reservoir has a refrigeration element and a thermostat, to maintain the hot liquid and the cold liquid at the desired temperature. The hot liquid reservoir, unlike a drum with a thin membrane, can be kept well insulated thermally, and it can be kept some distance away from the parts of the printer or copier that require frequent handing (for example, to remove paper jams), so there will be little danger that someone will be burned by touching it. The hot liquid reservoir can also be designed to withstand much higher gas pressure than a drum using a thin membrane, since it can have thick walls, so there will be little danger of it exploding. It can also be kept at a higher temperature than the desired final temperature of the liquid, so that the final temperature, after the change of liquid in the drum, will be the desired final temperature. For both these reasons, it will be safe to keep the liquid in the hot liquid reservoir heated all the time. Having good thermal insulation around the hot liquid reservoir and the cold liquid reservoir also means that it will not require much power to maintain the hot liquid and the cold liquid at their desired temperatures.
[0014] There is thus provided, in accordance with an embodiment of the invention, a drum intermediate transfer member or fuser apparatus, for use in a printer or copier, comprising:
[0015] a drum having a drum surface and including a liquid-containing region in the interior of the drum thermally connected to the drum surface, such that the liquid is capable of heating and cooling the drum surface; and
[0016] a liquid transfer system including a hot liquid reservoir, a cold liquid reservoir, at least one pump, pipes and optionally at least one valve arranged to selectively pump liquid between the liquid-containing region and the hot liquid reservoir, and between the liquid-containing region and the cold liquid reservoir.
[0017] In an embodiment of the invention, the liquid-containing region and the liquid transfer system are sealed from the outside, and are substantially free of gas.
[0018] In an embodiment of the invention, the liquid-containing region does not rotate when the drum rotates.
[0019] In an embodiment of the invention, there is at least one rotating seal used to transfer liquid into and out of the liquid-containing region.
[0020] In an embodiment of the invention, the optional at least one valve comprises a three-way valve and including an outlet pipe connecting the liquid-containing region directly or indirectly to the three-way valve, controllable to direct liquid leaving the liquid-containing region into either the hot liquid reservoir or the cold liquid reservoir.
[0021] In an embodiment of the invention, the optional valve comprises a three-way valve and including an input pipe connecting the liquid-containing region directly or indirectly to a three-way valve, controllable to direct liquid from either the hot liquid reservoir or the cold liquid reservoir into the liquid-containing region.
[0022] In an embodiment of the invention, there is a heating element in the hot liquid reservoir.
[0023] In an embodiment of the invention, there is a temperature sensor in the hot liquid reservoir.
[0024] Optionally, the temperature in the hot liquid reservoir is maintained in a certain range by using feedback from the temperature sensor to control the heating element.
[0025] In an embodiment of the invention, there is a refrigerating element in the cold liquid reservoir.
[0026] In an embodiment of the invention, there is a temperature sensor in the cold liquid reservoir.
[0027] Optionally, the temperature in the cold liquid reservoir is maintained in a given range by using feedback from the temperature sensor to control the refrigerating element.
[0028] In an embodiment of the invention, there is an accumulator in the hot liquid reservoir which allows the volume of liquid in the hot liquid reservoir to change substantially without a commensurate change in liquid pressure.
[0029] In an embodiment of the invention, there is an accumulator in the cold liquid reservoir which allows the volume of liquid in the cold liquid reservoir to change substantially without a commensurate change in liquid pressure.
[0030] Optionally, the accumulator in the hot liquid reservoir is linked to the accumulator in the cold liquid reservoir, so that when one reservoir increases in volume, the other reservoir decreases in volume by the same amount.
[0031] Optionally, the accumulators comprise a movable sealed barrier between the hot liquid reservoir and the cold liquid reservoir.
[0032] In an embodiment of the invention, there is an accumulator in the liquid-containing region which allows the volume of liquid in the liquid-containing region to change substantially without a commensurate change in liquid pressure.
[0033] Optionally, the liquid-filled region is largely drained of liquid of one temperature, before it is filled with liquid of a different temperature.
[0034] In an embodiment of the invention, the liquid-containing region heats and cools the surface of the drum indirectly through a separate thin region which also contains liquid.
[0035] In an embodiment of the invention, the liquid in the thin region is volatile and increases the gas pressure in the thin region when the liquid therein is heated.
[0036] In an embodiment of the invention, different liquids are used in the liquid-containing region and in the thin region.
[0037] In an embodiment of the invention, the liquid in the liquid-containing region has low volatility in the operating range of temperature.
[0038] In an embodiment of the invention, there is a pressure sensor in the thin region.
[0039] In an embodiment of the invention, at least part of the boundary between the liquid-containing region and the thin region is flexible, so that an increase in pressure in the thin region will lead to an increase in pressure in the liquid-containing region.
[0040] In an embodiment of the invention, there is a pressure sensor in the liquid-containing region or in the liquid transfer system, and a controller that controls one or more of said at least one pump and at least one valve, wherein the controller causes hot liquid to flow out of the liquid-containing region and/or causes cold liquid to flow into the liquid-containing region, if the pressure in the liquid-containing region or in the liquid transfer system rises higher than a given value.
[0041] In an embodiment of the invention, there is an overflow valve in the liquid-containing region or in the liquid transfer system, wherein the valve opens and relieves the pressure in the liquid-containing region and in the thin region, if the pressure rises higher than a given value.
[0042] In an embodiment of the invention, there is an overflow valve in the liquid transfer system or the liquid-containing region that allows excess liquid to leave the liquid transfer system or the liquid-containing region.
[0043] Optionally, the overflow valve is forced open mechanically when the liquid pressure rises higher than a given value.
[0044] In an embodiment of the invention, there is a pressure sensor in the liquid-containing region or in the liquid transfer system.
[0045] In an embodiment of the invention, there is an overflow reservoir, wherein excess liquid that flows through the overflow valve enters the overflow reservoir, and liquid can flow from the overflow reservoir into the liquid transfer system or the liquid-containing region when the pressure falls below a given value.
[0046] In an embodiment of the invention, there is a controller that controls one or more of said at least one pump and at least one valve, wherein the controller causes hot liquid to flow out of the liquid-containing region and/or causes cold liquid to flow into the liquid-containing region, if the pressure in the thin region rises higher than a given value.
[0047] In an embodiment of the invention, the controller receives data from the pressure sensor and opens the overflow valve when the pressure rises higher than a given value.
[0048] In an embodiment of the invention, there is a controller that controls one or more of said at least one pump and said at least one valve, thereby to control selective pumping.
[0049] In an embodiment of the invention, there is a bleed valve for removing unwanted gas from the apparatus.
[0050] In an embodiment of the invention, there is a shut-off valve closable to prevent liquid from flowing into the liquid-containing region.
BRIEF DESCRIPTION OF THE DRAWING
[0051] Exemplary embodiments of the invention are described in the following section with reference to the drawing. The drawing is generally not to scale.
[0052] [0052]FIG. 1 is a schematic diagram showing the elements of an embodiment of the invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0053] The embodiment shown in FIG. 1 has a drum 10 , with a region 12 filled with a liquid. Optionally, there is a thin outer region 11 , between region 12 and the outer surface of drum 10 , which contains its own liquid, optionally a different liquid more volatile than the liquid in region 12 , which maintains gas pressure supporting the outer surface when the drum is hot. Generally, the liquid in region 12 need not be replaced when the temperature of the drum is to be changed. Region 12 is connected to a liquid transfer system 13 , consisting of pipes, connectors, valves, and reservoirs. An outlet 14 of region 12 connects region 12 to a return pipe 16 . In those embodiments where there is an outer region 11 between region 12 and the outer surface of drum 10 , region 12 optionally remains fixed in place while drum 10 is rotating. In this case, outlet 14 is optionally an ordinary pipe connector. If region 12 rotates with the outer surface of drum 10 , then outlet 14 optionally comprises a rotating seal. Return pipe 16 is optionally connected to a three-way valve 18 , with connections to both a hot liquid reservoir 20 and a cold liquid reservoir 22 . The three-way valve 18 can be electrically controlled by a controller 19 , to allow liquid from the return pipe 16 to flow into either the hot liquid reservoir 20 or the cold liquid reservoir 22 . The hot liquid reservoir has a heating element 24 and a thermostat 26 . The cold liquid reservoir has a refrigeration element 28 , and optionally also has a thermostat. Controller 19 optionally maintains the hot liquid reservoir and/or the cold liquid reservoir at desired temperatures by using feedback from the thermostats to control the heating element and refrigeration element. Hot liquid reservoir 20 has an outlet 30 , and cold liquid reservoir 22 has an outlet 32 , which both connect to a three-way valve 34 , which also connects to a pump 36 . Three-way valve 34 can be electrically controlled by controller 19 , to selectively control the pump to pump liquid out of either the hot reservoir 20 or the cold reservoir 22 . Controller 19 can also turn the pump on and off. The outflow of pump 36 connects to a pipe 38 , which connects to an inlet 40 to drum 10 . Pipe 38 has a bleed valve 42 somewhere along its length, which allows trapped air or other gas to be removed from liquid transfer system 13 . Trapped gas in the liquid transfer system may make it operate less efficiently, or, in an extreme situation, not operate at all. Pipe 38 also has a shut-off valve 43 somewhere along its length, which can be used to prevent liquid from flowing into region 12 . Pipe 38 also has an overflow valve 44 somewhere along its length, which allows liquid from the liquid transfer system to flow into an overflow reservoir 46 and relieve the pressure, if the liquid pressure gets too high. Overflow valve 44 can also allow liquid transfer system 13 to draw liquid from overflow reservoir 46 , if the liquid pressure gets too low. The overflow valve can allow liquid to flow in each direction automatically, when the pressure difference exceeds some value. Alternatively, a pressure sensor 47 in pipe 38 , or elsewhere in liquid transfer system 13 , triggers controller 19 to open overflow valve 44 . In some embodiments, pressure data is not used by the controller for this purpose; it may still be used to notify an operator of a problem. Too high a pressure could lead to leaking or even catastrophic failure of the liquid transfer system. Too low a pressure could lead to cavitation, which would adversely affect the performance of the pump. Even before those extreme conditions are reached, the shape of the drum can be distorted, or the compliance of the drum can be less than or greater than optimal, if the pressure is too high or too low.
[0054] Because, in a desired operating range of pressures, the liquid is essentially incompressible, and it is generally desirable not to have any trapped gas in the liquid transfer system, hot reservoir 20 and cold reservoir 22 optionally change their volumes as liquid is pumped into and out of them. One way to do this, illustrated in FIG. 1, is to have a movable barrier 48 between hot reservoir 20 and cold reservoir 22 . In response to a small difference in pressure between hot reservoir 20 and cold reservoir 22 , barrier 48 moves to increase the volume of one reservoir and decrease the volume of the other reservoir by the same amount. With this configuration, cold liquid preferably flows into region 12 at the same rate as hot liquid is being pumped out, and vice versa. This can lead to some mixing of hot and cold liquid in region 12 , when both hot and cold liquid are present there.
[0055] An alternative scheme is to have separate accumulators in region 12 , hot reservoir 20 , and cold reservoir 22 . Each accumulator independently changes the volume of its region or reservoir in response to a small change in pressure. Each accumulator may consist of a gas-filled balloon or bellows, or any other kind of accumulator known to the art. In this scheme, it is possible to largely or completely empty the hot liquid from region 12 before starting to pump in the cold liquid, and vice versa. Also, because barrier 48 between hot reservoir 20 and cold reservoir 22 is not necessarily movable, it might be easier to make the barrier a better thermal insulator, and to avoid having liquid leak past it. In this embodiment, hot reservoir 20 and cold reservoir 22 do not have to be adjacent to each other, which makes it even easier to thermally insulate them, and to prevent liquid leaking from one reservoir into the other.
[0056] Another alternative scheme is to have separate accumulators in hot reservoir 20 and cold reservoir 22 , but not in region 12 . Like the first scheme, this scheme may require that when liquid is pumped from region 12 to one reservoir, an equal volume of liquid is pumped from the other reservoir into region 12 . However, in this scheme the hot and cold reservoirs could be some distance apart, and better insulated from each other. A disadvantage of this scheme, compared to the first scheme, is that there will be larger transient increases in pressure if the pumping starts suddenly, which can lead to noise and vibrations that could damage the liquid transfer system.
[0057] In some embodiments, drum 10 has a thin outer region 11 between region 12 and the outer surface of the drum, containing a volatile liquid which produces gas pressure to support the outer surface when the drum is hot. The boundary between outer region 11 and region 12 could either be rigid or flexible. If the boundary is flexible, then raising the gas pressure in outer region 11 will also cause the liquid pressure to rise in region 12 . This relationship is optionally used to prevent the gas pressure from getting too high or too low. For example, raising the liquid pressure in region 12 above a given level could force open a valve at outlet 14 , allowing liquid from region 12 to flow through pipe 16 , past the 3-way valves, reservoirs and pump, and through overflow valve 44 , even without the pump running. The resulting increase in volume of outer region 11 , as the flexible boundary expands at the expense of region 12 , would immediately decrease the gas pressure. (Having a flexible boundary between region 12 and outer region 11 might not work, however, if region 12 had its own accumulator, since this would tend to prevent the gas pressure in the outer blanket from changing.) Alternatively or additionally, a pressure sensor in outer blanket 11 or region 12 optionally triggers the pump to draw hot liquid out of region 12 and to pump cold liquid into region 12 , if the pressure exceeds a given value, or the pressure sensor triggers the pump to pump more hot liquid into region 12 if the pressure falls below a given value. Pressure sensor 47 , even it is located in pipe 38 or elsewhere in liquid transfer system 13 , optionally is used for this purpose.
[0058] The invention has been described in the context of the best mode for carrying it out. It should be understand that not all features shown in the drawing may be present in an actual device, in accordance with some embodiments of the invention. Furthermore, variations on the method and apparatus shown are included within the scope of the invention, which is limited only by the claims. As used herein, the terms “have”, “include” and “comprise” or their conjugates mean “including but not limited to.” | Drum intermediate transfer member or fuser apparatus, for use in a printer or copier, comprising: a drum having a drum surface and including a liquid-containing region in the interior of the drum thermally connected to the drum surface, such that the liquid is capable of heating and cooling the drum surface; and a liquid transfer system including a hot liquid reservoir, a cold liquid reservoir, at least one pump, pipes and optionally at least one valve arranged to selectively pump liquid between the liquid-containing region and the hot liquid reservoir, and between the liquid-containing region and the cold liquid reservoir. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] None
TECHNICAL FIELD
[0002] This disclosure relates to radio frequency (RF) switches, and in particular to RF-PCM switches using phase change material (PCM).
BACKGROUND
[0003] RF switches are key elements used in RF systems including communications and radars. RF switches enable low-loss, low-noise, fast, linear signal routing. They may also be used for impedance tuning and phase shifting. Due to varying system RF power handling requirements, it is important that an RF switch have linear performance from approximately a milli-watt (mW) to a watt level. While micro-electromechanical (MEMS) switches have been demonstrated in the prior art for RF systems with the desired low-loss, low-noise, isolation, linearity, and adequate power handling properties, these prior art RF switches have high switching voltage (30-70 V) requirements, low reliability and packaging issues. Thus, even after the decades of research, RF-MEMS switches are not commonly found in RF systems.
[0004] Monolithic microwave integrated circuit (MMIC) integration has in general been limited due to the size and high voltage requirements of prior art RF-MEMS switches, and mobile platform applications are very difficult to realize due to the high switching voltage requirements.
[0005] In the prior art Chua et al., “Low resistance, high dynamic range reconfigurable phase change switch for RF applications”, Applied Physics Letters vol. 97, 183506, (2010) mentions using PCM material for RF switches; however, Chua does not describe an RF switch design using PCM materials. Lo et al., “Three-terminal probe reconfigurable phase-change material switches”, IEEE Transactions on Electron Devices., vol. 57, p. 312, (2010) describes a switch with a three-terminal layout, consisting of an array of sub-vias; however, in Lo the switching is performed using external probes. Wen et al., “A phase-change via-reconfigurable on-chip inductor”, IEDM Tech digest, (2010) describes via structures with GeTe material, with an R on of 1.1 ohm and an Ron/Roff of 3×10 4 ; however, in Wen the switching is also performed using external probes.
[0006] The principal of PCM has been known since the 1960s. Rewritable optical DVDs have been developed using Ge2Sb2Te5, and also using (Ag or In)Sb2Te. Lately, phase change materials have been being developed for non-volatile memory, as a future replacement of flash memory. Companies involved in these developments include Micron, Samsung, IBM, STMicroelectronics, and Intel. Following are recent publications on use of PCMs for digital applications: EE Times, November, 2011, “Samsung preps 8-Gbit phase-change memory”, Perniola et al”, “Electrical behavior of phase change memory cells based on GeTe”, IEEE EDL., vol. 31, p. 488, (2010).
[0007] What is needed are RF switches using phase-change materials that are compatible with conventional semiconductor RF integrated circuit (RFIC) and MMIC processes. The embodiments of the present disclosure answer these and other needs.
SUMMARY
[0008] In a first embodiment disclosed herein, a radio frequency switch comprises a first transmission line, a second transmission line, a first electrode electrically coupled to the first transmission line, a second electrode electrically coupled to the second transmission line, and a phase change material, the first transmission line coupled to a first area of the phase change material and the second transmission line coupled to a second area of the phase change material, wherein when a direct current is sent from the first electrode to the second electrode through the phase change material, the phase change material changes state from a high resistance state to a low resistance state allowing transmission from the first transmission line to the second transmission line, and wherein the radio frequency switch is integrated on a substrate.
[0009] In another embodiment disclosed herein, a radio frequency switch comprises a first transmission line, a second transmission line, a first electrode, a second electrode, and a phase change material, the first transmission line coupled to a first area of the phase change material, the second transmission line coupled to a second area of the phase change material, the first electrode coupled to a third area of the phase change material, and the second electrode coupled to a fourth area of the phase change material, wherein when a direct current is sent from the first electrode to the second electrode through the phase change material, the phase change material changes state from a high resistance state to a low resistance state allowing transmission from the first transmission line to the second transmission line, and wherein the radio frequency switch is integrated on a substrate.
[0010] In yet another embodiment disclosed herein, a method of making a radio frequency switch comprises forming an insulator on a substrate, forming a first transmission line on the insulator and coupled to a first area of a phase change material, forming a second transmission line on the insulator and coupled to a second area of the phase change material, forming a first conductor connected to a third area of the phase change material, forming a first electrode connected to the first conductor, forming a second conductor connected to a fourth area of the phase change material, and forming a second electrode connected to the second conductor.
[0011] In still another embodiment disclosed herein, a reconfigurable circuit comprises a first circuit comprising at least a first radio frequency switch integrated with circuitry comprising GaN based transistors or III-IV bipolar transistors, the first radio frequency switch comprising a first transmission line, a second transmission line, a first electrode, a second electrode, and a phase change material, wherein the first transmission line coupled to a first area of the phase change material, the second transmission line coupled to a second area of the phase change material, the first electrode coupled to a third area of the phase change material, and the second electrode coupled to a fourth area of the phase change material, and wherein when a direct current is sent from the first electrode to the second electrode through the phase change material, the phase change material changes state from a high resistance state to a low resistance state allowing transmission from the first transmission line to the second transmission line.
[0012] These and other features and advantages will become further apparent from the detailed description and accompanying figures that follow. In the figures and description, numerals indicate the various features, like numerals referring to like features throughout both the drawings and the description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1A shows a four-terminal RF-PCM switch with a vertical arrangement of RF transmission lines in accordance with the present disclosure;
[0014] FIG. 1B shows a four-terminal RF-PCM switch with a parallel arrangement of RF transmission lines in accordance with the present disclosure;
[0015] FIG. 2A shows an equivalent circuit model for a RF-PCM switch and simulation results for R-SET, when the PCM is at a low resistance, and for R-RESET, when the PCM is at a high resistance, in accordance with the present disclosure;
[0016] FIG. 2B shows the simulated R-SET of an RF-PCM switch for different PCM configurations in accordance with the present disclosure;
[0017] FIG. 3A shows a three dimensional (3D) arrangement of RF-PCM switches integrated with inductors (Ls) and capacitors (Cs) in accordance with the present disclosure;
[0018] FIG. 3B shows a reconfigurable filter with six RF-PCM switches in accordance with the present disclosure;
[0019] FIG. 3D shows a filter transfer function of the reconfigurable filter of FIG. 3B having pass band center frequencies of 1 GHz and 2.4 GHz, respectively, depending on the RF-PCM switch settings as shown in FIG. 3C , in accordance with the present disclosure;
[0020] FIG. 4A shows an example MMIC layout consisting of RF-PCM switches and GaN LNAs in accordance with the present disclosure; and
[0021] FIG. 4B shows an example layout of a GaN MMIC amplifier with a reconfigurable output matching network using RF-PCM switches in accordance with the present disclosure.
DETAILED DESCRIPTION
[0022] In the following description, numerous specific details are set forth to clearly describe various specific embodiments disclosed herein. One skilled in the art, however, will understand that the presently claimed invention may be practiced without all of the specific details discussed below. In other instances, well known features have not been described so as not to obscure the invention.
[0023] In the following RF switches with phase change materials are referred to as RF-PCM switches. Referring now to FIGS. 1A and 1B , two different four-terminal RF-PCM switches are shown. The RF-PCM switch shown in FIG. 1A is designed with a vertical geometry between the RF transmission lines. The RF-PCM switch shown in FIG. 1B is designed with a parallel geometry between the RF transmission lines.
[0024] The RF-PCM switch shown in FIG. 1A has a first RF transmission line 12 , which is electrically connected to a first conductor 22 . The first conductor 22 is also electrically connected to a top electrode 16 , which functions as a switch control, and is electrically connected to the PCM 20 . The PCM is formed on an insulator 26 . A second conductor 24 is connected to the PCM 20 , and separated from the first conductor 22 by the PCM 20 . The second conductor 24 is electrically connected to a bottom electrode 18 , which along with the top electrode 16 functions as the switch control. The second conductor 24 is also electrically connected to a second RF transmission line 14 . The RF-PCM switch may be built on a substrate 34 . The RF transmission lines may be also used to transmit signals other than RF signals.
[0025] To switch the RF-PCM switch of FIG. 1A , a current pulse may be applied from the top 16 electrode to the bottom 18 electrode, thereby passing through the PCM 20 . The current pulse may have a pulse width of less than a microsecond. The current pulse changes the PCM 20 from an amorphous high resistance material to a crystalline low resistance state. When in a crystalline low resistance state, the PCM 20 allows an RF signal to be transmitted from the first RF transmission line 12 to conductor 22 , then through the PCM 20 and through the conductor 24 to the second RF transmission line 14 .
[0026] To prevent the RF signals from transmitting through the top electrode 16 or the bottom electrode 18 , the top electrode 16 is connected to RF blocking inductor 17 , and the bottom electrode 18 is connected to RF blocking inductor 19 to block RF signals. Also, because the first RF transmission line 12 and the top electrode 16 are electrically connected, to block any direct current (DC) on the top electrode 16 from transmission on the first RF transmission line 12 , the first RF transmission line 12 is connected to DC blocking capacitor 30 . Similarly, because the second RF transmission line 14 and the bottom electrode 18 are electrically connected, to block any DC on the bottom electrode 18 from transmission on the second RF transmission line 14 , the second RF transmission line 14 is connected to DC blocking capacitor 32 .
[0027] The RF-PCM switch may be fabricated on a substrate 34 , which may be silicon (Si), silicon germanium (SiGe), silicon carbide (SiC), sapphire, pyrex, gallium arsenide (GaAs), or III-V compounds such as GaN, InAs, InSb, and InP. The first and second RF transmission lines 12 and 14 , and the top and bottom electrodes 16 and 18 may be formed from any metal such as aluminum (Al), cooper (Cu), or gold (Au). The insulator 26 is preferably a low-k dielectric insulator, such as silicon dioxide (SiO 2 ), silicon nitride (Si 3 N 4 ), or benzo-cyclo-butene (BCB), to reduce any parasitic capacitive coupling between the first and second RF transmission lines 12 and 14 . Other appropriate materials for insulator 26 are polyimide, and polymethylglutarimide (PMGI). The first and second conductors 22 and 24 can be titanium nitride (TiN), tungsten (W) or any other metal that doesn't deform at high temperature and that doesn't form an alloy with the phase-change material (PCM).
[0028] The RF-PCM switch shown in FIG. 1B is similar to the RF-PCM switch of FIG. 1A ; however, the RF-PCM switch shown in FIG. 1A is designed with a vertical geometry between the RF transmission lines, while the RF-PCM switch shown in FIG. 1B is designed with a parallel geometry between the RF transmission lines.
[0029] The RF-PCM switch of FIG. 1B has a first RF transmission line 42 , which is electrically connected to PCM 50 . A second RF transmission line 44 is electrically connected to PCM 50 , but is not electrically connected to the first RF transmission line 42 . A top electrode 46 is connected to conductor 52 , and the conductor 52 is connected to the PCM 50 . The PCM 50 is also electrically connected to conductor 54 to electrically connect the PCM 50 to the bottom electrode 48 . The RF transmission lines 42 and 44 and the PCM 50 may be formed on insulator 56 , which along with bottom electrode 48 may be formed on substrate 64 .
[0030] To switch the RF-PCM switch of FIG. 1B , a current pulse may be sent from the top electrode 46 to the bottom electrode 48 electrode thereby passing through the PCM 50 . The current pulse may have a pulse width of less than a microsecond. The current pulse changes the PCM 50 from an amorphous high resistance material to a crystalline low resistance state. When in a crystalline low resistance state, the PCM 50 allows an RF signal to be transmitted from the first RF transmission line 42 to the second RF transmission line 44 .
[0031] To prevent the RF signals from transmitting via the top electrode 46 or the bottom electrode 48 , the top electrode 46 is connected to an RF blocking inductor 17 . The bottom electrode 48 is also connected to an RF blocking inductor similar, such as RF-blocking inductor 19 shown in FIG. 1A to block RF signals. To block any DC on the top electrode 46 from being transmitted on the first RF transmission line 42 , the first RF transmission line 42 is connected to DC blocking capacitor 60 . Similarly, to block any DC on the bottom electrode 48 from being transmitted on the second RF transmission line 44 , the second RF transmission line 44 is connected to DC blocking capacitor 62 .
[0032] The RF-PCM switch may be fabricated on a substrate 64 , which may be silicon (Si), silicon germanium (SiGe), silicon carbide (SiC), sapphire, pyrex, gallium arsenide (GaAs), or III-V compounds such as GaN, InAs, InSb, and InP. The first and second RF transmission lines 42 and 44 , and the top and bottom electrodes 46 and 48 may be formed from any metal such as aluminum (Al), cooper (Cu), or gold (Au). The insulator 56 is preferably a low-k dielectric insulator, such as silicon dioxide (SiO 2 ), silicon nitride (Si 3 N 4 ), or benzo-cyclo-butene (BCB), to reduce any parasitic capacitive coupling between the first and second RF transmission lines 42 and 44 . Other appropriate materials for insulator 56 are polyimide, and polymethylglutarimide (PMGI). The first and second conductors 52 and 54 can be titanium nitride (TiN), tungsten (W) or any other metal that doesn't deform at high temperature and that doesn't form an alloy with the phase-change material (PCM).
[0033] The phase-change materials (PCMs) 20 and 50 may be Ge x Te 1-x , Ge x Sb y Te z , or their derivatives. Measurements of sheet resistance of Ge 0.16 Sb 0.24 Te 0.6 and Ge 0.4 Te 0.6 PCM materials have shown a phase change from an amorphous high resistance state to a crystalline low resistance state with a 106:1 resistance ratio between the high resistance and the low resistance.
[0034] The sheet resistance of the crystalline state of PCM may be 100 Ω/sq for 100 nm thick GeTe and 82 Ω/sq for 200 nm thick GeSbTe. Important for switch applications, it has been shown that GeSbTe digital-PCM cells fabricated with a 190 nm diameter can successfully have 10 million read/write cycles, and be switched with a current pulse 0.5 mA.
[0035] A RF-PCM switch with PCM cells of approximately 40 μm 2 may be designed to deliver a resistance in the R-SET state of approximately 1Ω. GeTe-based digital PCM cells with PCM cells having approximately a 0.3 μm diameter may have a resistance in the R-SET state of 20Ω. In this configuration the ratio of the resistance in the R-RESET state to the resistance in the R-SET state is approximately 105, which allows RF-PCM switches to be designed with a low on resistance (Ron), a high off resistance (Roff), and a high Ron/Roff ratio.
[0036] For example, a RF-PCM switch with 2 μm 2 PCM switch may have a resistance in the R-SET state of <1Ω and a RESET/SET resistance ratio of 105:1.
[0037] The maximum needed voltage and current for switching the PCM from R-SET to R-RESET may be 3 volts and ˜500 mA, respectively.
[0038] FIG. 2A shows a schematic of an equivalent circuit 70 for an RF-PCM switch and its simulated RF insertion loss at the SET state and RF isolation at the RESET state. An RF-PCM switch may be simulated with a resistor 72 and a capacitor 74 to model parasitic capacitance.
[0039] The RF insertion loss and isolation was simulated for an RF-PCM switch with a R-SET resistance of 10 Ω/sq and a contact resistance of 15 Ω·μm between the conductors 22 , 24 , or 52 , 54 and the PCM 20 or 50 . An RF insertion loss S21 SET of 0.1-0.2 dB and an RF isolation S21 RESET of 25 dB or better can be achieved up to 100 GHz. The RF isolation result is mainly due to the parasitic capacitive coupling though the substrate. The RF insertion loss and isolation may also be traded off, one for the other, in RF-PCM switch designs. FIG. 2A shows the R-RESET for a PCM configuration with 5×10 4 Ω/sq and for a PCM configuration with 10 5 Ω/sq.
[0040] FIG. 2B shows the simulated RF S21_SET insertion loss of an RF-PCM switch for different configurations of the PCM and a contact resistance of 15 Ω·μm. The contact resistance is the resistance between a conductor, such as conductor 22 , 24 , 52 , or 54 , and the PCM. The PCM configurations shown in FIG. 2B include curves for R-SET equal to 1 Ω/sq, 5 Ω/sq, 10 Ω/sq, and 20 Ω/sq from 0 to 100 GHz.
[0041] RF-PCM switches can be integrated with conventional semiconductor RFIC and MMIC processes, enabling reconfigurable RFICs and MMICs. The semiconductor materials used for the substrate 34 and 64 for integration into RFICs and MMICs may include Si, SiGe, and III-V compounds such as GaN, InAs, InSb, and InP. The device technologies that may be integrated include FETs and bipolar transistors. The RF-PCM switches may also be integrated with resistors (R), inductors (L), and capacitors (C). Integrating the RF-PCM switches with other circuit elements allows the circuits of passive elements, such as L, R, C elements, and active circuits, such as FETs or bipolar transistors or other such elements, to be reconfigurable.
[0042] For example, FIGS. 3A and 3B show filter schematics with LC lumped elements and RF-PCM switches integrated together. The reconfigurable filter shown in FIG. 3C may have its passband reconfigured to be 1 GHz or 2.4 GHz, as shown in FIG. 3D , depending on the R-SET and the R-RESET status, as shown in FIG. 3C , of the RF-PCM switches 88 .
[0043] Another aspect of the use of RF-PCM switches is shown in FIG. 3A . The ability to integrate RF-PCM switches with other circuit elements in a RFIC or MMIC allows very compact structures and even three dimensional (3D) circuitry. As shown in FIG. 3A , RF-PCM switches 80 and other circuitry, such as capacitors, inductors, resistors, and transistors may be integrated on one circuit plane 82 . The circuit plane 80 may be a substrate, a RFIC, a MMIC, or a circuit board with the integrated RF-PCM switches 80 and other circuitry. Other RF-PCM switches 84 and other circuitry, such as capacitors, inductors, resistors, and transistors may be integrated on another circuit plane 86 , which also may be a substrate, a RFIC, a MMIC, or a circuit board. The RF-PCM switches allow the circuitry to be reconfigurable. By stacking circuit planes on one another and connecting the circuitry on circuit plane 82 to the circuitry on circuit plane 86 with conductors 85 between the circuit planes, a very compact three dimensional reconfigurable circuit may be realized, as shown in FIG. 3A . The conductors 85 between the circuit planes 82 and 86 may be metal vias.
[0044] FIG. 4A shows a reconfigurable low-noise amplifier consisting of RF-PCM switches 90 , 92 , 94 and 96 and GaN field effect transistors (FETs) in a MMIC layout. The two GaN LNAs, shown in FIG. 4A may be configured to improve the third order intercept point (OIP3) to 51 dBm and the spurious signal performance to less than 98 dBc at a Pin of −10 dBm up to 18 GHz, which enables high dynamic range signal detection immune to jamming signals.
[0045] FIG. 4B shows an example layout of a GaN MMIC amplifier with a reconfigurable output matching network 100 using RF-PCM switches 102 .
[0046] The fabrication process flow for an RF-PCM switch may be made to be similar to a tantalum nitride (TaN) MMIC resistor process with some modifications. The process for fabricating a RF-PCM switch is the following.
[0047] 1. Lift-off metal-1 to form a bottom DC electrode and an RF transmission line,
[0048] 2. Deposit a low-loss dielectric layer #1 such as SiO2,
[0049] 3. Pattern an opening #1 in the dielectric layer around to be formed RF-PCM switches,
[0050] 4. Lift-off an adhesion metal pillar (Tungsten (W) or TiW) on phase change material (PCM),
[0051] 5. Deposit a low-loss dielectric layer #2 such as SiO2,
[0052] 6. Pattern an opening #2 in the dielectric layer #2 to the PCM,
[0053] 7. Lift-off an adhesion metal (TiN),
[0054] 8. Lift-off metal-2 for the top DC electrode and RF transmission line.
[0055] In summary, the disclosed RF-PCM switches based on PCM materials such as Ge x Te 1-x , Ge x Sb y Te z , or their derivatives enable reconfigurable RF functions in RFICs, MMICs, and passive devices such as single-pole-double-throw (SPDT) switches, phase shifters, and filters. The disclosed RF-PCM switches are binary (on or off). If necessary, the RF-PCM switches can be designed with multi-bit switches, especially for phase-shifter, phase-shift-key (PSK), and quadrature-amplitude-modulation (QAM) applications.
[0056] Having now described the invention in accordance with the requirements of the patent statutes, those skilled in this art will understand how to make changes and modifications to the present invention to meet their specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention as disclosed herein.
[0057] The foregoing Detailed Description of exemplary and preferred embodiments is presented for purposes of illustration and disclosure in accordance with the requirements of the law. It is not intended to be exhaustive nor to limit the invention to the precise form(s) described, but only to enable others skilled in the art to understand how the invention may be suited for a particular use or implementation. The possibility of modifications and variations will be apparent to practitioners skilled in the art. No limitation is intended by the description of exemplary embodiments which may have included tolerances, feature dimensions, specific operating conditions, engineering specifications, or the like, and which may vary between implementations or with changes to the state of the art, and no limitation should be implied therefrom. Applicant has made this disclosure with respect to the current state of the art, but also contemplates advancements and that adaptations in the future may take into consideration of those advancements, namely in accordance with the then current state of the art. It is intended that the scope of the invention be defined by the Claims as written and equivalents as applicable. Reference to a claim element in the singular is not intended to mean “one and only one” unless explicitly so stated. Moreover, no element, component, nor method or process step in this disclosure is intended to be dedicated to the public regardless of whether the element, component, or step is explicitly recited in the Claims. No claim element herein is to be construed under the provisions of 35 U.S.C. Sec. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for . . . ” and no method or process step herein is to be construed under those provisions unless the step, or steps, are expressly recited using the phrase “comprising the step(s) of . . . .” | A radio frequency switch includes a first transmission line, a second transmission line, a first electrode electrically coupled to the first transmission line, a second electrode electrically coupled to the second transmission line, and a phase change material, the first transmission line coupled to a first area of the phase change material and the second transmission line coupled to a second area of the phase change material. When a direct current is sent from the first electrode to the second electrode through the phase change material, the phase change material changes state from a high resistance state to a low resistance state allowing transmission from the first transmission line to the second transmission line. The radio frequency switch is integrated on a substrate. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to a passive membrane system which may be used to recover carbon dioxide from a carbon dioxide plant vent gas stream.
2. Description of the Background
Depending upon whether a gas mixture contains carbon dioxide (CO 2 ) in a high or low amount, a variety of techniques have been used to separate CO 2 from the mixture. For example, when the amount of CO 2 present in the gas mixture is low, and purification cannot be achieved directly by cooling and partial condensation, it is possibly to scrub the gas mixture with a suitable solvent to dissolve the CO 2 , and then to strip the CO 2 from the solution so obtained. The carbon dioxide obtained can then be compressed, dried, cooled and further purified by partial condensation or distillation.
When the gas mixture contains a high amount of CO 2 , however, the gas mixture may be compressed and then dried by absorption or other means. Finally, after removing undesirable impurities such as sulfur containing compounds, the mixture is cooled and after distillation CO 2 is obtained as a bottoms product. Unfortunately, the overhead product of the distillation column will always contain a significant amount of CO 2 which is inevitably wasted. This problem is particularly acute in conventional CO 2 liquifaction plants.
In a typical CO 2 liquifaction plant, a significant percentage of the CO 2 feed is lost as stripper vent gas. For example, in a 200 ton/day CO 2 liquifaction plant, about 10 to 15% of the CO 2 feed is lost. The composition of this dry waste gas steam is usually 75% or more of CO 2 with the remainder being N 2 , O 2 , H 2 , and CH 4 with trace amounts of NH 3 , CO and sulfur containing compounds.
In order to address this problem, at present, carbon dioxide is recovered from gas mixtures by subjecting the gas mixture to membrane separation, recovering from the membrane separation a permeate having a carbon dioxide concentration between the equilibrium concentration and about 98% by volume and then distilling the permeate at subambient temperature above the freezing temperature of the permeate and recovering carbon dioxide as a liquid bottoms product of the distillation.
The above conventional process is described in U.S. Pat. No. 4,639,257. In this process, a distillation step is required and the only energy savings available is attained by recycling the overhead stream from the distillation step to the membrane separation step.
The process of U.S. Pat. No. 4,639,257 accomplishes the recovery of carbon dioxide by first directing a gas mixture through a membrane and thereafter distilling the permeate in a cryogenic unit. The process is modified depending upon whether the carbon dioxide is present in the gas mixture in a high concentration or in a concentration which is not greater than the equilibrium concentration at the freezing temperature of the mixture.
When carbon dioxide is present in the lesser amount, the gas mixture is subjected to membrane separation and is then distilled at sub-ambient temperature to recover substantially pure carbon dioxide as a liquid bottoms product of the distillation. In some cases, the overhead stream from the distillation is recycled to the membrane as noted above.
When carbon dioxide is present in a high concentration, however, the gas mixture is distilled at sub-ambient temperature in a distillation column, and substantially pure carbon dioxide is recovered as a liquid bottoms product of the distillation. The overhead stream from the distillation is warmed to approximately ambient temperature, and is then directed over a membrane, and the resulting carbon-dioxide rich permeate is recycled to the distillation column.
Notably, in the above process, the warming step is an essential step in the process as this patent teaches that the tail gas from the distillation must be warmed before contact with the membrane separation unit.
Thus, such a separation technique requires an external energy source for operation. This renders the process economics very unfavorable.
U.S. Pat. No. 4,595,405 discloses a process for the production of nitrogen using a cryogenic separation unit and one or more membranes, however, cryogenic separation units in combination with membranes were known prior to U.S. Pat. No. 4,595,405. See, for example, U.S. Pat. No. 4,180,553 and 4,181,675.
U.S. Pat. No. 4,595,405 discloses a process wherein air is fed to a cryogenic separation unit, and a portion of the output from the unit is then fed to a membrane unit to form a nitrogen-rich gas stream. Thereafter, the nitrogen-rich stream is returned to the cryogenic unit, and a purified nitrogen-rich stream is recovered therefrom.
This patent discloses that the use of the membrane provides "an additional degree of freedom" to adjust the process parameters for further optimization. This only appears to mean, however, that the pressure of the various streams no longer must be determined by ambient pressure but may be set at substantially any desired level. However, this patent is clearly not specifically addressed to the separation of carbon dioxide from vent gas mixtures. Further, the disclosed process does not use the existing temperatures and pressures of a carbon dioxide plant in separating carbon dioxide from vent gas mixtures.
Thus, it would be extremely desirable if a method for separating CO 2 from a gas mixture could be effected without the use of an external energy source for a warming step and in an economically advantageous manner using the temperature and pressure of the CO 2 plant It would also be extremely desirable if vent gas which is lost from conventional CO 2 liquifaction plants could be treated to recover CO 2 in a completely passive manner using the pressure of the waste gas stream.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a method for recovering CO 2 from the waste gas stream of a CO 2 liquifaction plant without the use of an external energy source.
It is also an object of the present invention to provide a method for recovering CO 2 from the waste gas stream of a CO 2 liquifaction plant which can allow the recovered CO 2 to be recycled back to the feed side of the liquifaction plant at a purity compatible with the feed gas stream to the plant.
Moreover, it is also an object of the present invention to provide a CO 2 recovery process which is completely passive using the pressure of the waste gas stream from a CO 2 liquifaction plant.
These objects and others which will become apparent are provided by a process for recovering CO 2 from a CO 2 liquifaction plant vent gas, which entails feeding vent gas from a CO 2 liquifaction plant to a semi-permeable gas membrane through which and at a pressure at which CO 2 is capable of diffusing therethrough, to form a CO 2 -enriched permeate, and then returning the CO 2 -enriched permeate to a feed side of said CO 2 liquifaction plant at a pressure capable of effecting the same.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the effect of temperature on gaseous separation factors for mixtures of CO 2 /N 2 , CO 2 /O 2 and CO 2 /H 2 .
FIG. 2 illustrates a single-stage membrane CO 2 recovery unit in accordance with the present invention.
FIG. 3 illustrates a dual-stage membrane CO 2 recovery unit in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The process of the present invention utilizes a semi-permeable gas membrane to recover carbon dioxide from a waste gas stream of a CO 2 liquifaction plant Notably, the recovery systems of the present invention are completely passive in that they contain no moving parts and use only the pressure energy of the waste gas stream to effect separation of CO 2 from the gas mixture. Further, the recovery systems of the present invention are advantageously operated at about the CO 2 plant temperature in order to enhance the CO 2 /impurity separation and to improve process economics. Notably, an excellent degree of separation is achieved by the present invention inasmuch as the membrane is operated at the cold temperature of the off-gas stream. The enriched CO 2 strain that is produced by the membrane is then recycled back to the feed side of the liquifaction plant at a purity compatible with the feed gas stream to the plant.
In accordance with the present invention, it has been found to be quite advantageous to use a membrane to achieve separation of the CO 2 from the gas mixture since the waste gas stream is already pressurized. Hence, no external energy source is required in order operate the CO 2 recovery systems of the present invention. Further, as noted above, it is surprisingly observed that at low temperature the separation factors between CO 2 and other gases present are quite high, resulting in a higher product purity than if the gas mixture were at room temperature.
FIG. 1 illustrates the effect of temperature on various separation factors for gaseous mixtures of CO 2 /N 2 , CO 2 /O 2 and CO 2 /H 2 . With decreasing temperature, an improved separation factor is obtained. Thus, no external cooling of the gas is required in the present invention to achieve these high separation factors inasmuch as the vent gas temperature is already at low temperature, i e., about -2° F. Hence, the present CO 2 recovery units enjoy very favorable process economics.
A single-stage membrane recovery unit of the present invention is illustrated in FIG. 2. This recovery system and the operation thereof will now be described.
The carbon dioxide-containing feed gas mixture is provided through a feed header pipeline to a compressor 1 and then the compressed mixture is fed via pipeline 2 to condenser 3 which contains refrigeration unit 6, an exit 4 at the bottom of the condenser for removal of liquid CO 2 , and pipeline 5 through which the overhead stream or vent gas stream passes at elevated pressure through pressure regulator 7 to separation membrane 8.
Generally, the term "elevated pressure" means that the pressure of the vent gas is sufficient to facilitate permeation of CO 2 through the separation membrane. Typically, however, pressures in the range of about 260-315 psia are used. This will be explained in more detail below.
The non-permeating waste gas is exhausted through a vent or pressure regulator 9 to the atmosphere.
The CO 2 -enriched permeating gas passes out of the membrane shell and is then recycled via conduit 11 to the feed side of the liquifaction plant for reprocessing at a purity compatible to the feed concentration to the plant.
Additionally, the purity of the CO 2 obtained may be further increased by the addition of a catalytic burn-out system 10 in the permeate return line. Quite advantageously, it has been found that the passive catalytic unit reacts the remaining combustibles with oxygen in the product gas to raise the purity to above 99%. For this purpose, any commercially available catalytic unit will suffice.
In the above single-stage recovery process, the vent gas is typically fed from the condenser at an elevated pressure in the range of about 260-315 psia and at a low temperature in the range of about -10° F. to about 5° F. However, it is most desirable if a pressure of about 300-310 psia is used, and a temperature of about -5° F. to 0° C. is used. Most often, however, is used a pressure of about 305 psia, and a temperature of about -2° F.
Additionally, prior to membrane separation, if desired, the gas mixture can be filtered to remove impurities.
Further, a pressure regulator is advantageously used to provide a constant feed pressure on the membrane unit. Also, a back pressure regulator in the membrane vent line will maintain adequate pressure on the module feed side. Usually, a pressure of about 305 psia is maintained at the pressure regulator 7 input, and a pressure of about 123 psia is maintained at the module feed side. Typically, a pressure in the range of about 15 to 40 psia is maintained on the permeate side and in the feed line returning to the CO 2 liquifaction plant. It is essential only that the pressure of the gas at this stage have sufficient pressure to be returned to the feed side of the CO 2 -liquifaction plant. Non-permeating gas exits the membrane unit and is exhausted to the atmosphere.
Although FIG. 2 illustrates the presence of pressure regulator 10 and catalytic unit 10a, these features are optional.
In FIG. 3, a dual-stage membrane CO 2 recovery unit is illustrated From FIG. 3, it is seen that membranes 8 and 9a are positioned in series such that the permeate from the first stage becomes the feed to the second stage. In this recovery system, a pressure regulator and two back pressure regulators maintain gas pressures at the desired levels within the system. Pressures in this system are in accordance with the pressures used in the single-stage system. For example, the permeate pressures in the single-stage and dual-stage recovery systems are maintained in a range of about 15 to 40 psia. It is more preferred, however, to maintain these pressures within the range of about 15 to 30 psia. Most often, however, the permeate pressure in the single-stage and dual-stage recovery systems is maintained at about 23 psia. In any event, in accordance with both single- and dual-stage recovery systems, it is sufficient if the permeate pressure is merely adequate to push the CO 2 product back to the feed side of the liquifaction plant.
In the dual-stage recovery system, the non-permeate streams from stage 1 and stage 2 are vented to the atmosphere.
In more detail, in FIG. 3, it is seen that the carbon dioxide-containing feed gas mixture is provided through a feed header pipeline to a compressor 1 and then the compressed mixture is fed via pipeline 2 to condenser 3 which contains refrigeration unit 6, an exit 4 at the bottom of the condenser for removal of liquid CO 2 , and pipeline 5 through which the overhead stream or vent gas stream passes at elevated pressure through pressure regulator 7 to separation membrane 8. The non-permeating gas is vented to the atmosphere through pressure regulator 8a. The term "elevated pressure" is defined hereinabove.
The permeating gas from the first membrane 8, which is enriched in CO 2 , is then passed through pipeline 9 to the second separation membrane 9a. The non-permeating gas from this membrane is vented to the atmosphere via pressure regulator 9b.
Although FIG. 3 illustrates the presence of pressure regulator 9b and catalytic unit 9d, these features are optional.
The permeating gas from the second membrane, which is further enriched in CO 2 , is then passed through pipeline 10 at a pressure sufficient to push the highly CO 2 enriched gas back to the feed side of the CO 2 liquifaction plant. Typically, pressures on the permeate side of the second membrane are in the range of about 15 to 40 psia, preferably 15 to 30 psia. Most often, however, a pressure of about 23 psia is used.
In accordance with the present invention, any semi-permeable gas membrane may be used as the separation membrane or membranes provided that it exhibits sufficient permeability to CO 2 and has a sufficient separation factor with respect to impurity gases. Although any such membrane may be used, a membrane having a bundle of hollow fibers is advantageously used as it has an excellent surface area/volume ratio. This allows for more membrane to be fit into the geometry of the hollow fibers.
In order to illustrate the present invention, reference will now be made to the following Examples which are provided solely for purposes of illustration and are not intended to be limitative.
EXAMPLE 1
A test membrane consisting of a bundle of hollow fibers, with a bore side diameter of approximately 0.13 mm, was inserted into a pressure shell. A gas mixture containing CO 2 at high pressure was fed to the feed side of the membrane module which allowed fast permeating CO 2 to diffuse through the membrane into the lower pressure permeate side where it was recovered. The remainder of the slow permeating gas exited the module at high pressure from the end opposite the feed side and was vented. The operating limits of the membrane were a 200 psi maximum pressure differential with a -20 to 120° F. temperature range.
EXAMPLE 2
Using a pilot plant evaluation for a feed gas rate of 25,000 SCFH and a concentration of 75% CO 2 , CO 2 recovery as a function of product gas recovery was determined using industrially sized membrane modules.
Using a single-stage recovery unit, a maximum CO 2 purity of greater than 99.5% at a low CO 2 recovery was obtained. The recovery increases rapidly as the product purity requirement decreases, however. At a CO 2 recovery of 75%, a 98% pure CO 2 product stream is produced in a single membrane stage.
EXAMPLE 3
Further to Example 2, it is observed that when using a passive catalytic burn-out system with either the single- or dual-stage recovery system of the present invention to react the remaining combustibles and oxygen in the product gas, the purity of the resulting final product gas is raised to greater than 99%.
The above Examples illustrate several processes in accordance with the present invention. However, it is understood that many variations and modifications would be apparent to one skilled in the art which would be within the ambit of the present invention. For example, more than two separation units might be used instead of a catalytic burn-out unit, or a filtration system might be used to remove gaseous impurities prior to membrane separation.
Additionally, the present invention provides not only the processes described above but the various described apparati for practicing these processes.
The present invention provides an apparatus and a process for efficiently recovering CO 2 from a CO 2 plant vent gas using membranes, and without using moving parts, and without the input of energy. It is a passive system.
Generally, the membranes most advantageously used in accordance with the present invention are those made by DuPont which exhibit a surprisingly increased selectivity for CO 2 with decreasing temperature. This feature is, in itself, surprising inasmuch as for most membranes permeability for all gases increases with increasing temperature.
The preferred membranes of the present invention are those disclosed, for example, in U.S. Pat. Nos. 3,567,632; 3,822,202; 3,899,309 (and Reissue 30,351); 4,113,628; 4,705,540; 4,717,393; 4,717,394; and 3,775,361, which are each and all incorporated herein by reference in their entirety. However, the most preferred membranes are polyimide, polyaramid, polyester and polyamide membranes. | A process for recovering CO 2 from a CO 2 liquifaction plant vent gas, which comprises feeding vent gas from a CO 2 liquifaction plant to a first semi-permeable gas separation membrane through which and at a pressure at which CO 2 is capable of diffusing therethrough, to form a CO 2 -enriched permeate, and then returning the CO 2 -enriched permeate to a feed side of said CO 2 liquifaction plant at a pressure capable of effecting the same. | 5 |
BACKGROUND OF INVENTION
This invention relates to a process for the preparation of fibers of stereoregular polystyrene, in particular isotactic and syndiotactic polystyrene.
In many industries there is a drive to replace the metals used as structural materials with plastic materials. Plastic materials offer several advantages in that they are frequently lighter, do not interfere with magnetic or electrical signals, and often are cheaper than metals. One major disadvantage of plastic materials is that they are significantly weaker than many metals. To provide plastic structural articles and parts which have sufficient strength for the intended use, it is common to use composite materials which comprise a polymer or plastic matrix with high strength fibers in the plastic or polymer matrix to provide enhanced strength. Examples of composites made using such high strength fibers can be found in Harpell et al. U.S. Pat. No. 4,457,985 and Harpell et al. U.S. Pat. No. 4,403,012.
A series of patents have recently issued which relate to high strength fibers of polyethylene, polypropylene or co-polymers of polyethylene and polypropylene. Such fibers are demonstrated as being useful in high strength composites. See Harpell et al. U.S. Pat. No. 4,563,392; Kavesh et al. U.S. Pat. No. 4,551,296; Harpell et al. U.S. Pat. No. 4,543,286: Kavesh et al. U.S. Pat. No. 4,536,536: Kavesh et al. U.S. Pat. No. 4,413,110: Harpell et al. U.S. Pat. No. 4,455,273; and Kavesh et al. U.S. Pat. No. 4,356,138. Other polymers which have been used to prepare fibers for composites include polyphenylene sulfide, polyetheretherketone and poly(para-phenylene benzobisthiazole).
The polyethylene and polypropylene fibers although exhibiting excellent modulus and tensile properties, have a relatively low heat distortion temperature and poor solvent resistance. The polyphenylene sulfide, polyetheretherketone, and poly(p-phenylene benzobisthiazole) polymers exhibit excellent heat distortion temperatures and solvent resistance, but are difficult to process and quite expensive.
What are needed are fibers useful in composites which exhibit good solvent resistance and heat distortion properties, are processible, and prepared from materials which have reasonable costs. What are further needed are such fibers with high strength. What is further needed is a process for the preparation of such fibers.
SUMMARY OF INVENTION
The invention is a process for the preparation of fibers of syndiotactic polystyrene, or a mixture of isotactic polystyrene and syndiotactic polystyrene which comprises:
A. heating syndiotactic polystyrene, or a mixture of syndiotactic polystyrene and isotactic polystyrene, to a temperature between its crystal melting point and the temperature at which the polystyrene undergoes degradation, wherein the polystyrene has sufficient viscosity to be extruded;
B. extruding the polystyrene through an orifice to form a fiber at elevated temperatures;
C. quenching the fiber by passing the fiber through one or more zones under conditions such that the fiber solidifies; and
D. cooling the fiber to ambient temperature.
Preferably the fibers prepared are high strength fibers of syndiotactic polystyrene, or a mixture of isotactic polystyrene and syndiotactic polystyrene, wherein the fibers are monoaxially oriented, have a tensile strength of about 10,000 psi or greater, and a modulus of about 1,000,000 psi or greater.
To prepare high strength fibers, the fibers are further exposed to the following process steps:
E. heating the fiber to a temperature above the glass transition temperature of the polystyrene: and
F. redrawing the fiber to elongate the fiber, maximize crystallinity, and induce monoaxial orientation of the polystyrene in the fiber.
The fibers prepared by the process of this invention exhibit excellent solvent resistance and heat distortion properties. The starting materials used to prepare these fibers can be prepared at a relatively low cost.
DETAILED DESCRIPTION OF THE INVENTION
The fibers of this invention may be prepared from syndiotactic polystyrene or a mixture of syndiotactic and isotactic polystyrene. Syndiotactic polystyrene is polystyrene in which the phenyl groups pendent from the chain alternate with respect to which side of the chain the phenyl groups are pendent. In other words, every other phenyl group is on the opposite side of the chain. Isotactic polystyrene has all of the phenyl rings on the same side of the chain. Note that standard polystyrene is referred to as atactic, meaning it has no stereoregularity, and the placement of the phenyl groups from the styrene with respect to each side of the chain is random, irregular, and follows no pattern.
Preferably, the fibers prepared by this invention are monoaxially oriented to improve the tensile strength and modulus of the fibers. Preferably the fibers have a tensile strength of 10,000 psi or greater, more preferably 20,000 psi or greater and most preferably 30,000 psi or greater. The fibers of this invention preferably have a modulus of 1,000,000 psi or greater, more preferably 2,500,000 psi or greater, and most preferably 5,000,000 psi or greater. The fibers may be extruded into any size, shape or length desired. Preferably the fibers have a heat distortion temperature of 150° C. or greater, more preferably 170° C. or greater and most preferably 190° C. or greater. Preferably the fibers have a crystalline melting temperature of 200° C. or greater, more preferably 220° C. or greater, and most preferably 240° C. or greater.
Isotactic and syndiotactic polystyrene may be prepared by methods well known in the art. For procedures for the preparation of isotactic polystyrene, see Natta et al., Makromol. Chem., Vol. 28, p. 253 (1958) (relevant portions incorporated herein) by reference. For procedures for the preparation of syndiotactic polystyrene, see Japanese Patent 104818 (1987) and Ishihara, Makromolecules, 19 (9), 2464 (1986) relevant portions incorporated herein by reference.
If the viscosity of the heated polystyrene fed to the extruder is too low the fibers coming out of the extruder will have no physical integrity, and if the viscosity is too high the mixture is not extrudable. Preferably the polystyrene has an upper limit on viscosity at the extrusion sheer rate of 1,000,000 poise, more preferably 500,000 poise and most preferably 100,000 poise. Preferably the polystyrene has a lower limit on viscosity at the extrusion sheer rate of 100 poise, more preferably 1,000 poise and most preferably 10,000 poise.
The polystyrene molecular weight should be sufficient such that fibers with reasonable integrity may be formed. The preferred upper limit on molecular weight (Mn) is 4,000,000, with 3,000,000 being more preferred, and 1,000,000 being most preferred. The preferred lower limit on molecular weight (Mn) is 200,000, with 300,000 being more preferred and 400,000 most preferred.
Where a fiber is to be prepared from both syndiotactic polystyrene and isotactic polystyrene the ratio of syndiotactic polystyrene to isotactic polystyrene in the blend is any ratio which gives fiber with structural integrity and is preferably between about 0.1 and 20, more preferably between about 0.75 and 3, most preferably between about 1 and 1.25.
In the process of this invention, the neat polymer is heated to a temperature between its crystal melting point and the temperature at which the polymer undergoes degradation. The particular temperature depends upon whether syndiotactic polystyrene or a mixture of isotactic and syndiotactic polystyrene is used. Generally the crystal melting temperature of isotactic polystyrene is somewhat lower than that of syndiotactic polystyrene. The neat polymer is first melted to a temperature at which the material has sufficient viscosity to extrude. The viscosity should be high enough such that the fiber extruded has integrity, yet not so high that the polymer is too viscous to be extruded. Preferably the polymer is melted to a temperature of between about 260 and 320, and most preferably between about 270° and about 300° C. Thereafter the fiber is extruded at such temperatures.
Once the polystyrene has been heated it is extruded through a die of a desired shape, usually a circular die, into the form of a fiber. The extrusion is performed at elevated temperatures, the upper limit on the temperature is the degradation temperature of the polystyrene. The lower limit on temperature is the lowest temperature at which the polystyrene has low enough viscosity to be extruded. Preferred extrusion temperatures are between about 260 and 320 with between about 270° and 300° C. most preferred. Thereafter the fiber is passed through a quench zone. The quench zone may be either a gaseous quench zone or a liquid quench zone.
From the extruder the fiber is passed through one or more quench zones. Such quench zones may be gaseous quench zones, liquid quench zones or a combination thereof. In the quench zones the fiber is cooled, solidified and drawn down. In a quench zone the fiber is passed through a gaseous zone, such zone may be at a temperature of between 0° and 100° C., preferably the temperature is ambient temperature. The preferred gas is air. For a melt extrusion generally an air quench zone is preferred. The air quench zone is generally long enough to quench and solidify the fiber. Such zone is preferably between about 1 and 6 feet. The temperature of the quench zone can be any temperature at which the fiber undergoes a reasonable rate of cooling and solidification. The preferred lower temperature is about 0°, most preferably about 20°. The preferred upper temperature is about 100° C., most preferably about 50° C.
The liquid which may be used for the liquid quench is a liquid which does not dissolve the polystyrene. Preferred quench zone materials include water, lower alcohols, halogenated hydrocarbons, and perhalogenated carbon compounds. Perhalogenated carbon compounds are materials with a carbon backbone wherein all of the hydrogen atoms have been replaced with halogen atoms. The most preferred liquid quench material is water. The lower limit on the temperature of a liquid quench zone is that temperature at which the quench material freezes. The upper limit on the temperature of a liquid quench zone is that temperature above which the fiber does not undergo solidification when in contact with the quench material or the quench material boils. Preferably the upper limit on temperature is 80° and more preferably 30° C. Preferably the lower limit on temperature is 0° C. The residence time of the fiber in a quench zone is preferably greater or equal to 0.5 seconds, more preferably between about 0.5 and 10 seconds.
During the quench period the fiber is also drawn down. Preferably the lower limit on the draw down is from about 10:1, more preferably about 50:1. Preferably the upper limit on the draw down is about 100:1. Drawing down means the fibers are stretched such that the cross sectional area of the fiber is smaller at the end of the process and the draw down ratio is the ratio of the beginning cross sectional area to the final cross sectional area. During the quench period the fiber is drawn down from between about 10:1 to 100:1. After the quench period, the fiber is allowed to cool to ambient temperatures.
When it is desired to improve the strength of the fiber, the fiber is reheated to a temperature at which the fiber can be redrawn. It is in the redraw process that the fiber is oriented such that the fiber has monoaxial orientation. The fiber is heated to a temperature between its glass transition temperature and its melting point. Preferable upper temperatures are 280° C. or below and more preferably 270° C. or below. Preferable lower temperatures are 150° C. or above and more preferably 250° C. or above. Thereafter the fiber is redrawn by stretching the fiber with tension: this is usually performed by running the fibers over a set of godets wherein the latter godets are going at a much faster rate than the earlier godets. The fiber is elongated at a ratio of between about 1.5:1 and about 10:1. Preferably the rate of elongation is 1 foot per minute or less. The redraw occurs while the fiber is at or near the temperature to which it was preheated. The fiber may be drawn in one or more stages with the options of using different temperatures, draw rates, and draw ratios in each stage. The slower the rate the better the orientation and stronger the fiber will be. Generally the elongation will be up to a ratio of 4 to 1.
The fibers can be incorporated into composites. The methods for such incorporation and the composites in which the fibers can be used in are well known to those skilled in the art.
SPECIFIC EMBODIMENTS
The following examples are included for illustrative purposes only and are not intended to limit the scope of the invention or the claims. Unless otherwise stated all parts and percentages are by weight.
EXAMPLE 1
Syndiotactic polystyrene, with a molecular weight of 300,000 M w , is placed in the heating zone of an extruder and heated to 250° C. The polystyrene is extruded at 250° C. through a 1.0 mm diameter spinnerette into an air quench zone, the zone having a length of 5 feet. The residence time in the quench zone is 3 seconds. The fiber after quenching is taken up and allowed to cool to ambient temperature. The fiber exhibits a tensile strength of 15,000 psi, and a modulus of 1,200,000 psi with a final elongation of 5.6%.
EXAMPLE 2
Syndiotactic polystyrene, with a molecular weight of 700,000 M w , is placed in the heating zone of an extruder and heated to 260° C. The polystyrene is extruded at 260° C. through a 1.0 mm diameter spinnerette into an air quench zone, the zone having a length of 5 feet. The residence time in the quench zone is 3 seconds. The fiber after quenching is taken up and allowed to cool to ambient temperature. The fiber is redrawn 100% at 180° C. The fiber exhibits a tensile strength of 19,000 psi, and a modulus of 830,000 psi with a final elongation of 4.1%.
EXAMPLE 3
Syndiotactic polystyrene, with a molecular weight of 700,000 M w , is placed in the heating zone of an extruder and heated to 260° C. The polystyrene is extruded at 260° C. through a 1.0 mm diameter spinnerette into an air quench zone, the zone having a length of 5 feet. The residence time in the quench zone is 3 seconds. The fiber after quenching is taken up and allowed to cool to ambient temperature. The fiber is redrawn 160% at 280° C. The fiber exhibits a tensile strength of 15,000 psi, and a modulus of 950,000 psi with a final elongation of 3.9%.
EXAMPLE 4
Syndiotactic polystyrene, with a molecular weight of 800,000 M w , is placed in the heating zone of an extruder and heated to 275° C. The polystyrene is extruded at 275° C. through a 1.0 mm diameter spinnerette into an air quench zone, the zone having a length of 5 feet. The residence time in the quench zone is 3 seconds. The fiber after quenching is taken up and allowed to cool to ambient temperature. The fiber exhibits a tensile strength of 10,000 psi, and a modulus of 410,000 psi with a final elongation of 3.7%.
EXAMPLE 5
Syndiotactic polystyrene, with a molecular weight of 800,000 M w , is placed in the heating zone of an extruder and heated to 275° C. The polystyrene is extruded at 275° C. through a 1.0 mm diameter spinnerette into an air quench zone, the zone having a length of 5 feet. The residence time in the quench zone is 3 seconds. The fiber after quenching is taken up and allowed to cool to ambient temperature. The fiber is redrawn 50% at 280° C. The fiber exhibits a tensile strength of 8,000 psi, and a modulus of 470,000 psi with a final elongation of 2.1%.
EXAMPLE 6
Syndiotactic polystyrene, with a molecular weight of 3,000,000 M w , is placed in the heating zone of an extruder and heated to 300° C. The polystyrene is extruded at 300° C. through a 1.0 mm diameter spinnerette into an air quench zone, the zone having a length of 5 feet. The residence time in the quench zone is 3 seconds. The fiber after quenching is taken up and allowed to cool to ambient temperature. The fiber exhibits a tensile strength of 12,000 psi, and a modulus of 450,000 psi with a final elongation of 6.3%.
EXAMPLE 7
Syndiotactic polystyrene, with a molecular weight of 3,000,000 M w , is placed in the heating zone of an extruder and heated to 300° C. The polystyrene is extruded at 300° C. through a 1.0 mm diameter spinnerette into an air quench zone, the zone having a length of 5 feet. The residence time in the quench zone is 3 seconds. The fiber after quenching is taken up and allowed to cool to ambient temperature. The fiber is redrawn 50% at 280° C. The fiber exhibits a tensile strength of 14,000 psi, and a modulus of 700,000 psi with a final elongation of 3.8%. | A process for the preparation of fibers of syndiotatic polystyrene, or a mixture of isotactic polystyrene and syndiotactic polystyrene which comprises:
A. heating syndiotactic polystyrene, or a mixture of syndiotactic polystyrene and isotactic polystyrene, to a temperature between its crystal melting point and the temperature at which the polystyrene undergoes degradation, wherein the polystyrene has sufficient viscosity to be extruded:
B. extruding the polystyrene through an orifice to form a fiber at elevated temperature;
C. quenching the fiber by passing the fiber through one or more zones under conditions such that the fiber solidifies; and
D. cooling the fiber to ambient temperature. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional application of U.S. Ser. No. 11/671,181, filed Feb. 5, 2007, the contents of which are incorporated by reference herein in their entirety.
BACKGROUND OF THE INVENTION
[0002] For a variety of reasons there are occasions when tubular structures such as casings and production tubing, for example, positioned downhole in wellbores need to be cut. Some examples are for removal of a damaged section of tubing or to provide a window for diagonal drilling.
[0003] Cutters have been developed that have rotating portions with knives that are pivoted radially outwardly to engage the inner surface of the tubular structure to perform a cut. Such cutters have a multitude of pivoting joints, cams and actuators that interact to rotate the knives between the noncutting and cutting configurations. The complexity of such cutters increases fabrication costs and potential failure modes.
[0004] Accordingly, the art is in need of less complex cutting tools.
BRIEF DESCRIPTION OF THE INVENTION
[0005] Disclosed herein relates to a single piece tubular member. The tubular member having a non-radially displaceable portion and a radially displaceable portion, the radially displaceable portion being movable to a position of similar radial displacement as that of the non-radially displaceable portion and a position of relatively large radial displacement in comparison to the non-radially displaceable portion. The tubular member also having at least one cutting arrangement disposed at the radially displaceable portion.
[0006] Further disclosed herein relates to a cutting tool. The cutting tool having a deformable tubular member having an inside surface and an outside surface and a plurality of lines of weakness thereat. At least one of the lines of weakness being positioned closer to one of the outside surface and the inside surface and at least one other of the plurality of lines of weakness being positioned closer to the other of the outside surface and the inside surface. The cutting tool also having at least one cutting element disposed at a portion of the tubular member most radially displaceable from an undeformed position of the tubular member.
[0007] Further disclosed herein relates to a method of cutting a downhole tubular. The method includes delivering a tubular cutting tool, with a plurality of lines of weakness thereon, to a downhole position within a downhole tubular that is to be cut, rotating the tubular cutting tool, and actuating the tubular cutting tool. The actuating causing a radially deformable portion of the tubular cutting tool to radially deform compared to an unactuated position of the tubular cutting tool. The actuating also causing a cutting element attached to the radially deformable portion to contact a downhole tubular to be cut.
[0008] Further disclosed herein relates to a method for making a cutting tool. The method includes configuring a deformable tubular member with a plurality of lines of weakness, with at least one of the plurality of lines of weakness disposed at each of an inside dimension and an outside dimension of the tubular member. The method also includes locating the plurality of lines of weakness relative to each other to facilitate deforming a portion of the tubular member to a greater radial dimension than the undeformed tubular member, and locating a cutting arrangement on the portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
[0010] FIG. 1 depicts a partial cross sectional view of a cutting tool disclosed herein in an unactuated configuration;
[0011] FIG. 2 depicts a partial cross sectional view of the cutting tool of FIG. 1 in an actuated configuration;
[0012] FIG. 3 depicts a partial cross sectional view of the cutting tool of FIG. 2 taken at arrows 3 - 3 ;
[0013] FIG. 4 depicts a partial cross sectional view of another embodiment of a cutting tool disclosed herein in an unactuated configuration;
[0014] FIG. 5 depicts a partial cross sectional view of the cutting tool of FIG. 4 in an actuated configuration; and
[0015] FIG. 6 depicts a partial cross sectional view of the cutting tool of FIG. 5 taken at arrows 6 - 6 .
DETAILED DESCRIPTION OF THE INVENTION
[0016] A detailed description of several embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
[0017] Referring to FIGS. 1 and 2 , a partial cross sectional view of an embodiment of the cutting tool 10 is illustrated. The cutting tool 10 includes a tubular member 14 that has a radially displaceable portion 18 and a non-radially displaceable portion 20 . As illustrated in FIG. 1 the radially displaceable portion 18 is in an unactuated configuration and as illustrated in FIG. 2 the radially displaceable portion 18 is in an actuated configuration. In the actuated configuration the radially displaceable portion 18 forms two frustoconical sections 22 and 26 . The greatest radial deformation 30 of the tubular member 14 occurs where the two frustoconical sections 22 and 26 meet. Thus, an annular flow area 34 is defined by the greatest radial deformation 30 and an outside surface 38 of the non-radially displaceable portion 20 . At least one axial groove 42 in the outside surface 38 forms a first fluid passage through which fluid can flow between an uphole annular area 44 and a downhole annular area 46 when the radially displaceable portion 18 is in the actuated configuration. A second fluid passage 50 is formed through the center of the tubular member 14 defined by an inside surface 52 of the tubular member 14 .
[0018] The greatest radial deformation 30 contacts an inner surface 60 of a tubular structure 62 that is to be cut by the cutting tool 10 . A cutting arrangement positioned at the greatest radial deformation 30 engages with and cuts through the tubular structure 62 . The cutting arrangement can include a hardened portion of the metal of which the tubular member 14 is made, which can include sharpened portions of the metal, for example. Alternately the cutting arrangement can include an insert 16 of another material into the tubular member 14 . A cutting arrangement insert 16 can be made of such materials as tungsten carbide or diamonds, for example, which can be used separately or in combination.
[0019] The radially displaceable portion 18 is reconfigurable between the unactuated configuration and the actuated configuration. In the unactuated configuration the frustoconical sections 22 and 26 are configured as cylindrical components having roughly the same inside dimension as the tubular member 14 in the uphole annular area 44 and a downhole annular area 46 . Reconfiguration from the unactuated to the actuated configuration is effected, in one embodiment, by the application of an axial compressive load on the tubular member 14 . Conversely, reconfiguration from the actuated to the unactuated configuration is effected by the application of an axial tensile load on the tubular member 14 .
[0020] Reconfigurability of the radially displaceable portion 18 between the actuated configuration and the unactuated configuration is due to the construction thereof. The radially displaceable portion 18 is formed from a section of the tubular member 14 that has three lines of weakness, specifically located both axially of the tubular member 14 and with respect to the inside surface 52 and the outside surface 38 of the tubular member 14 . In one embodiment, a first line of weakness 66 and a second line of weakness 70 are defined in this embodiment by diametrical grooves formed in the outside surface 38 of the tubular member 14 . A third line of weakness 74 is defined in this embodiment by a diametrical groove formed in the inside surface 52 of the tubular member 14 . The three lines of weakness 66 , 70 and 74 each encourage local deformation of the tubular member 14 in a radial direction that tends to cause the groove to close. It will be appreciated that in embodiments where the line of weakness is defined by other than a groove, the radial direction of movement will be the same but since there is no groove, there is no “close of the groove”. Rather, in such an embodiment, the material that defines a line of weakness will flow or otherwise allow radial movement in the direction indicated. The three lines of weakness 66 , 70 and 74 together encourage deformation of the tubular member 14 in a manner that creates a feature such as the radially displaceable portion 18 . The feature is created, then, upon the application of an axially directed mechanical compression of the tubular member 14 such that the radially displaceable portion 18 is actuated as the tubular member 14 is compressed to a shorter overall length. Other mechanisms can alternatively be employed to actuate the tubular member 14 between the unactuated relatively cylindrical configuration and the actuated configuration presenting the frustoconical sections 22 and 26 . For example, the tubular member 14 may be reconfigured to the actuated configuration by diametrically pressurizing the tubular member 14 about the inside surface 52 in the radially displaceable portion 18 .
[0021] Referring to FIG. 3 , a cross sectional view of the cutting tool 10 of FIG. 2 is shown taken at arrows 3 - 3 . The fluid passages between the cutting tool 10 and the inside surface 52 , of the tubular structure 60 , created by the axial grooves 42 , is illustrated. Although the axial grooves 42 are illustrated herein as V-shaped, it should be appreciated that alternate embodiments can have grooves of any shape. It should also be noted that in alternate embodiments the cutting tool 10 could be used to cut through any downhole tubular structure such as a casing 78 for example.
[0022] Referring to FIGS. 4 and 5 , an alternate exemplary embodiment of the cutting tool 110 is illustrated. The cutting tool 110 includes a tubular member 114 and a radially displaceable portion 118 . The radially displaceable portion 118 includes a plurality of extension members 120 attached thereto. As illustrated in FIG. 4 the radially displaceable portion 118 is in an unactuated configuration and as illustrated in FIG. 5 the radially displaceable portion 118 is in an actuated configuration. In the actuated configuration the radially displaceable portion 118 forms two frustoconical sections 122 and 126 . The extension members 120 are fixedly attached to the first frustoconical section 122 at a first portion 128 . A second portion 129 of the extension members 120 is positioned radially outwardly of the second frustoconical section 126 but is not attached to the second frustoconical section 126 . As such when the radially displaceable portion 118 is actuated the extension members 120 remain substantially parallel to the first frustoconical section 122 causing the second portion 129 of the extension members 120 to extend radially outwardly of the outermost portion of the frustoconical members 122 , 126 . As such the greatest radial deformation 130 of the cutting tool 110 occurs at an end 132 of each of the extension members 120 . Control of the relationship of the greatest radial deformation 130 to the radial dimension of the end 132 in the unactuated configuration is completely controllable by setting the lengths of the second portions 129 . An annular flow area 134 is defined by the greatest radial deformation 130 and an outside surface 138 of a non-radially displaceable portion 140 . At least one axial space 142 between adjacent extension members 120 forms a first fluid passage through which fluid can flow between an uphole annular area 144 and a downhole annular area 146 when the centralizer 110 is in the actuated configuration. A second fluid passage 150 is formed through the center of the tubular member 114 defined by the inside surface 162 in the outside surface 138 forms a first fluid passage through which fluid can flow between an uphole annular area 144 and a downhole annular area 146 when the radially displaceable portion 118 is in the actuated configuration. A second fluid passage 150 is formed through the center of the tubular member 114 defined by an inside surface 152 of the tubular member 114 .
[0023] The greatest radial deformation 130 contacts an inner surface 60 of a tubular structure 62 that is to be cut by the cutting tool 110 . A cutting arrangement positioned at the greatest radial deformation 130 of the extension members 120 engages with and cuts through the tubular structure 62 . The cutting arrangement can include a hardened portion of the metal from which the extension members 120 are made. Alternately the cutting arrangement can include an insert of another material into the extension members 120 . A cutting arrangement insert can be made of such materials as tungsten carbide or diamonds, for example, which can be used separately or in combination.
[0024] The radially displaceable portion 118 is reconfigurable between the unactuated configuration and the actuated configuration. In the unactuated configuration the frustoconical sections 122 and 126 are configured as cylindrical components having roughly the same inside dimension as the tubular member 114 in the uphole annular area 144 and a downhole annular area 146 . Reconfiguration from the unactuated to the actuated configuration is effected, in one embodiment, by the application of an axial compressive load on the tubular member 114 . Conversely, reconfiguration from the actuated to the unactuated configuration is effected by the application of an axial tensile load on the tubular member 114 .
[0025] Reconfigurability of the radially displaceable portion 118 between the actuated configuration and the unactuated configuration is due to the construction thereof. The radially displaceable portion 118 is formed from a section of the tubular member 114 that has three lines of weakness, specifically located both axially of the tubular member 114 and with respect to the inside surface 152 and the outside surface 138 of the tubular member 114 . In one embodiment, a first line of weakness 166 and a second line of weakness 170 are defined in this embodiment by diametrical grooves formed in the outside surface 138 of the tubular member 114 . A third line of weakness 174 is defined in this embodiment by a diametrical groove formed in the inside surface 152 of the tubular member 114 . The three lines of weakness 166 , 170 and 174 each encourage local deformation of the tubular member 114 in a radial direction that tends to cause the groove to close. It will be appreciated that in embodiments where the line of weakness is defined by other than a groove, the radial direction of movement will be the same but since there is no groove, there is no “close of the groove”. Rather, in such an embodiment, the material that defines a line of weakness will flow or otherwise allow radial movement in the direction indicated. The three lines of weakness 166 , 170 and 174 together encourage deformation of the tubular member 114 in a manner that creates a feature such as the radially displaceable portion 118 . The feature is created, then, upon the application of an axially directed mechanical compression of the tubular member 114 such that the radially displaceable portion 118 is actuated as the tubular member 114 is compressed to a shorter overall length. Other mechanisms can alternatively be employed to actuate the tubular member 114 between the unactuated relatively cylindrical configuration and the actuated configuration presenting the frustoconical sections 122 and 126 . For example, the tubular member may be reconfigured to the actuated configuration by diametrically pressurizing the tubular member 114 about the inside surface 152 in the radially displaceable portion 118 .
[0026] Referring to FIG. 6 , a cross sectional view of the cutting tool 110 of FIG. 5 is shown taken at arrows 6 - 6 . The fluid passages between the cutting tool 110 and the inside surface 60 , of the tubular structure 62 , created by the axial spaces 142 between the extension members 120 , is illustrated. Although the extension members 120 depicted herein are rectangular prisms, it should be noted that alternate embodiments could have extension members of any shape. It should also be noted that in alternate embodiments the cutting tool 110 could be used to cut through any downhole tubular structure such as a casing 78 for example.
[0027] While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. | Disclosed herein relates to a single piece tubular member. The tubular member having a non-radially displaceable portion and a radially displaceable portion, the radially displaceable portion being movable to a position of similar radial displacement as that of the non-radially displaceable portion and a position of relatively large radial displacement in comparison to the non-radially displaceable portion. The tubular member also having at least one cutting arrangement disposed at the radially displaceable portion. | 4 |
FIELD OF THE INVENTION
The present invention generally relates to a machine readable code and method using the same. More particularly, the invention relates to a method and apparatus for using a circular bar code to measure a variable quantity.
BACKGROUND OF THE INVENTION
Kirby-Bauer plates are used in clinical laboratories to determine the type(s) and concentration(s) of antibiotics most effective in killing infectious bacteria. A Kirby-Bauer plate is a Petri dish, typically 100-150 mm diameter, containing a thin (typically 1-5 mm) layer of agar or growth medium on which a uniform lawn of the bacteria in question, usually isolated from a clinical specimen, is grown.
Disks or pellets containing antibiotics at various concentrations are placed on top of the growing bacteria and the plate is incubated, for example in an oven, for an appropriate period of time (hours to days). Typically, each disk is constructed of filter paper and uniformly loaded with an antibiotic of a desired concentration. At the end of the incubation period, the plate is examined. If the antibiotic in a particular disk or pellet is effective against the bacteria, there will be a clear zone around the disk/pellet in which all of the bacteria have been killed. If the antibiotic is not effective, an opaque zone, e.g., a fuzzy whitish brown layer on the agar, will remain around the disk/pellet in which the bacteria have not been killed. The size of the clear zone is an indicator of antibiotic effectiveness.
Traditionally, measurement of the clear zone size has been performed by the naked eye or using a ruler or caliper. More recently, a number of automated readers based upon machine vision technology (such as, for example, Bioscan™ or Videobac™ made by Biokit of Barcelona, Spain), have become available for carrying out clear zone size measuring. However, a problem exists in ensuring that the measurement of the appropriate disk/pellet is carried out. The disk/pellets are placed at different locations in the Petri dish on top of the bacteria manually by a technician such that the disks/pellets are in relatively uncontrolled positions. Moreover, most plates are circular which makes it very difficult to determine or control plate orientation. Both known manual and automated systems require a technician to manually assign identification/concentration information to each disk/pellet. This is both a time consuming and error prone process.
Currently, most disks and some pellets are supplied with some form of a printed textual identification code. However, attempts to read these codes have proven unsuccessful due to small character size (many disks/pellets are 6 mm in diameter), poor print quality (disk/pellet surfaces are usually rough), and random orientation resulting from manual placement. Efforts directed to bar coding have proven to be even more troublesome for substantially the same reasons. Further, linear bar codes inefficiently utilize space, so much so that the amount of information that can be applied to a disk/pellet is even less than can be applied with traditional alphanumeric codes.
Accordingly, there is a need in the art to provide a method and apparatus for automatically correlating disks/pellets of various concentrations with their clear zones to reduce the time, increase the accuracy of disk identification, and enhance the assessment of antibiotic effectiveness.
SUMMARY OF THE INVENTION
The present invention solves the aforementioned problems by providing a machine readable code for measuring a variable quantity. Several advantages are provided by the coding scheme of the present invention. For example, the code can be easily read by a machine vision system on disks having a diameter of 6 mm or less. Moreover, the coding scheme can encode a substantial amount of information and is relatively insensitive to print quality. Further, the code can be read in different orientations including face down under certain circumstances.
An illustrative circular bar code according to the present invention includes an outer ring, a plurality of first teeth, each first tooth directed radially inward from the outer ring and defining a radial position at which information is encoded, an inner ring, and a plurality of second teeth, each second tooth directed radially outward from the inner ring and opposing a corresponding one of the first teeth, wherein the information is encoded based on subdivisions of a gap between opposing first and second teeth. In an illustrative embodiment of the present invention, the circular bar code is printed on a disk coated with an antibiotic. The disk is used for determining the effectiveness of the antibiotic in killing bacteria, wherein the code provides identity and concentration information for the antibiotic. Another exemplary circular bar code according to the present invention includes a ring, and a plurality of teeth, each tooth directed radially inward from the ring and defining a radial position at which information is encoded, wherein the information is encoded based on subdivisions between the teeth and a center point of the ring.
A system for measuring a variable quantity according to the instant invention includes a vessel containing a first solution, a circular bar coded medium coated with a second solution and placed in the first solution in the vessel for a predetermined time, and a bar code reader for scanning the circular bar coded medium and radially reading the circular bar code after the expiration of the predetermined time, the circular bar code read providing information identifying the second solution. Information representative of the effect of the second solution on the first solution may be obtained simultaneously with the information contained in the circular bar code. According to a preferred embodiment, the first solution includes bacteria and the second solution is an antibiotic solution. The information obtained during reading of the code may include the identity and concentration of the antibiotic and an indication of how effective the antibiotic is in killing the bacteria.
A method for measuring a variable quantity according to the present invention includes the steps of placing a circular bar coded medium coated with a first solution in a vessel containing a second solution for a predetermined time, scanning the circular bar coded medium and radially reading the circular bar code after the expiration of the predetermined time, and comparing the circular bar code read with a plurality of predefined codes to identify the first solution and to determine the effect of the first solution on the second solution.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the present invention and many of the attendant advantages thereof will be readily obtained as the invention becomes better understood by reference to the following detailed description when considered in connection wcte accompanying drawing.
FIG. 1 shows an illustrative embodiment of a circular bar code pattern according to the present invention;
FIG. 2 shows an illustrative embodiment of another circular bar code pattern according to the present invention; and
FIG. 3 shows a system in which coded disks are employed according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
For the sake of convenience, the present invention will be described in terms of a machine code reader used to measure the effectiveness of an antibiotic in killing a bacteria culture in a Petri dish. However, it should be understood that the present invention may be used in numerous applications for which a code reader may be adapted.
According to the present invention, a coding system has been developed for determining the effectiveness of a particular concentration of a particular antibiotic in killing a bacteria culture in a Petri dish. Specifically, the present invention provides a circular bar code with bars configured in a radial direction where information can be coded in the length or the presence/absence of a bar rather than in its width. This differs from many conventional bar codes, such as orientation-independent target codes, in which the bars are in the form of concentric circles which are read circumferentially (rather than radially, as with the present device).
Illustrative embodiments of a disk 10 having a circular bar code according to the present invention are shown in FIGS. 1 and 2. The illustrative codes in FIGS. 1 and 2 are particularly useful for use with 12.5 mm disks. However, each of these codes can be scaled to work with all commercially available disk diameters. In a preferred, but not restrictive embodiment, a 0.5 mm line width has been found to be particularly suitable for both disk manufacture and reading. The codes of FIGS. 1 and 2 each include two concentric rings 20, 30. An inner concentric ring 20 is located at the center of the disk 10 and an outer concentric ring 30 is located at the outer periphery of the disk 10.
For ease in manufacture, the disks 10 may be printed as sheets and then punched to size. However, to ensure that each disk is punched properly so that the inner edge of the outer ring 30 and both edges of the inner ring 20 remain intact, the punching should be aligned to the printing to within less than one line width. The appropriate alignment will also provide a high contrast between the edge of the disk 10 and the surrounding bacterial lawn which simplifies zone measurement. Since identifying and locating the center of a circular object is a standard and relatively straight forward image processing operation, having three or more concentric circles in the code makes location of the center and edge of a disk 10 very accurate.
The inner edge of the outer ring 30 has a series of at least two teeth. Each tooth 40 defines a radial position at which information is encoded. Teeth are also shown around the outer edge of the inner ring 20, although not necessary for interpreting the coded pattern. The exemplary patterns in FIGS. 1 and 2 respectively contain twelve and eight teeth on both the inner ring 20 and outer ring 30, but other numbers of teeth can be used.
In the illustrative patterns of FIGS. 1 and 2, one tooth position on the outer ring 30 creates a solid bar that extends to the inner ring 20. This tooth position serves as an index mark, as identified in FIGS. 1 and 2, and denotes the position where code reading starts. The other teeth are of various lengths depending upon the information encoded. For example, the smallest teeth have lengths equal to the line width although this is not critical. The amount of information that can be encoded at any tooth position depends upon how the gap between a pair of opposing teeth 40 is subdivided. FIGS. 1 and 2 show five subdivisions, three which encode information (e.g., the dark subdivisions) and two which serve as separators (e.g., the light subdivisions). The separators are not really necessary, but help to improve decoding reliability.
When there is no inner ring, and accordingly no pairs of inner teeth, the amount of information that can be encoded is determined by the distance from the teeth to the center, i.e., the distance to the center from the outer circles, which is calculated by standard methods. The outer teeth are then projected to the center point.
The illustrative arrangements in FIGS. 1 and 2 provide a total of seven possible tooth designs: no tooth extension; outer tooth extension by one or two units; inner tooth extension by one or two units; both teeth extended by one unit; and an isolated segment 45 floating between two teeth 40. The eighth possible tooth design is the solid bar joining two opposed teeth which is reserved for the previously described index mark. Accordingly, one radial position in the patterns of FIGS. 1 and 2 can encode seven states. The pattern in FIG. 1 can encode 7 11 (1.98 * 10 9 ) different coded states plus the index mark and the pattern in FIG. 2 can encode 7 7 or 823,500 different coded states plus the index mark. By changing the number of radial positions and subdivisions, other numbers of possible states can be obtained.
Code reading is performed radially in circular zones concentric with the previously determined center of the pattern. According to an illustrative embodiment shown in FIG. 3, a light source 50 generates light which impinges on the disks 10 in the Petri dish 60. A linear diode array 70 responsive to light emanating from light source 50 detects the light which has been refracted or reflected by the code on the disks 10. The light source 50 scans the code on the disk radially. Other types of scan readers known in the art including, but not limited to, spin readers, image processors, and other contact type readers, may be utilized to read the encoded disks. Also, different types of colors and lights based on different types of reflectances or refractances can be utilized including those outside the visible spectrum.
For the code patterns in FIGS. 1 and 2, four zones of scanning are required. One scanning zone is located within each of a one unit extension of either an inner or outer tooth, a two unit extension/isolated center mark; and the outer teeth. The outer tooth scanning zone defines the radial positions at which valid information can be obtained while the remaining scanning zones carry the information. A mark appearing in all four zones denotes the index position at the start of the code. By convention, the codes are read in a clockwise direction from the index. Reducing the code density to six states per radial position generates a self clocking code that eliminates the need to read the outer teeth since there will be at least one mark at each radial position.
According to an illustrative scanning operation according to the present invention, the following steps are carried out: 1) acquire an image of the dish and its contents (e.g., bacterial lawn, inhibition zones, antibiotic disks with radial bar codes) as a rectilinear array of pixels; 2) optionally enhance the image by, for example, creating a binary (two intensity level) representation of the initial image, edge enhancement, etc. which can facilitate subsequent analysis using well known methods; 3) determine the locations of the circular image features corresponding to the interior boundary of the dish, the inhibition zones, and the inner and outer rings of the antibiotic disks by standard methods such as correlation of the image with matched filters; 4) compute the locations of each circular feature found in step 3 using basic trigonometry or another known method; 5) convert, for convenience and improved computational efficiency, the circular features corresponding to antibiotic disks and inhibition zones from rectangular to polar coordinates; 6) determine code segment locations by examining each circular feature from step 5 (or 4) along multiple radii for antibiotic disks, the number of radial positions being larger than the number of radial positions used in the code; and 7) decode the code segment locations determined in step 6 by a lookup table or another known method to identify the particular antibiotic and antibiotic concentration associated with the disk being examined.
Thus, the resulting code number can be decoded into antibiotic identification and concentration information and other information by automatically comparing the detected code with a set of defined code patterns in a lookup table. Therefore, each disk 10 can use the radial bar code to combine information relating to identity and concentration of the antibiotic as well as to determine the effectiveness of the antibiotic in breaking down the bacteria. By providing numerous codes for encoding different types of information, many disks (e.g., six to twelve) may be placed in the Petri dish 60 to determine the effectiveness of each antibiotic solution on each disk 10 without any difficulty in identifying which disk corresponds to which antibiotic solution. The number of disks used depends, of course, on the plate and disk size as well as the acceptable overlap between inhibition times.
Several factors determine the code segment locations in step 6. Intensity changes along each radial line correspond to the edges of the code features traversed. The radial line along which no transitions occur between the inner and outer code rings identifies the index mark. The locations of the other coding locations can be estimated from this information and confirmed by radial scans. The locations of transitions along these subsequent scans identify whether the position is occupied by a tooth spined to the inner or outer ring, a code segment joined by the inner or outer ring, or an isolated code segment. For inhibition zones, radii are extended beyond the boundary of the antibiotic disk until a transition indicating the edge of the inhibition zone is observed. If no zone edge is observed at any radial position, no inhibition is assumed to have occurred and the antibiotic is determined to be ineffective against the bacteria.
Since the number of code states available can be far larger than the number of possible antibiotic type/concentration combinations used in a typical laboratory, disks not containing an antibiotic, but coded with otherwise unused code states, can be used to unambiguously identify the particular specimen in a machine readable manner. In current practice, the identification of the specimen is written on the outside of the dish or a label, e.g., written, bar code, is applied to the outside of the dish. This information must be acquired and correlated with the test results in a separate step. The well documented potential for error when the specimen identification and test results are separately determined and manually correlated can be eliminated by applying a radially encoded identification disk to the surface of the growth medium in the manner described above.
Although illustrative embodiments of the present invention have been described in detail with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments and that changes and modifications may be effected therein by those in the art without departing from the scope and spirit of the invention. | A circular bar code includes first teeth directed radially inward from an outer ring and defining a radial position at which information is encoded and second teeth, tooth directed radially outward from an inner ring and opposing a corresponding one of the first teeth, wherein the information is encoded based on subdivisions of a gap between opposing first and second teeth. In one implementation, the circular bar code is printed on a disk coated with an antibiotic. The disk is used for determining the effectiveness of the antibiotic in killing bacteria, wherein the circular bar code provides identity and concentration information for the antibiotic. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to pending PCT/BG2010/000005 filed May 14, 2010 which, in turn, claims priority to BG 110389 filed May 19, 2009.
FIELD OF THE INVENTION
The invention relates to biodegradable halogen-free flame retardants composition, used for fire-safety and prevention, limiting and extinguishing fires by means of increased resistance to ignition, slowing down burning rates and the rate of heat, smoke and toxic gas release from polymers with different physical and chemical properties and structure, especially textiles, wooden materials, paper, cardboard, corrugated board, leather, cellular polystyrene, foamed polyurethane and items made of them.
BACKGROUND OF THE INVENTION
Fire causes death, serious injury and significant material damages. The risk of fire can be reduced by using flame retardants effective in both, the solid and gas phase of the burning process.
Literature and practice show the availability of halogen containing flame retardants, which contain bromine or chlorine. They have proven effective for achieving the desired fire-protection effect in low application concentrations. The mechanism of their action is in the gas phase of the burning process, where H + and OH − radicals are released from the burning gas in the flame burning phase, as a result of which the system is cooled-down and the formation of combustible gases and the release of heat are suppressed. During burning however, a major part of the halogen-containing flame retardants release halogen gases, harmful to human health and the environment.
In consideration of the protection of human health, as well as the environmental safety, now the phosphorus- and nitrogen-containing flame retardants are becoming widely used.
The phosphorus containing flame retardants, such as red phosphorus, phosphates, polyphosphates, organic phosphorus esters etc., are efficient in the solid phase of the burning process, where a charred layer is formed on material's surface, protecting it from the access of oxygen and heat that suppresses the formation and release of combustible gases, required for maintaining of the flame burning.
The nitrogen-containing flame retardants act, based on different mechanisms. Some of them form nitrogen netted structures in the treated material, which are relatively stable at high temperatures and prevent its decomposition and release of combustible gases. Other nitrogen-containing flame retardants release nitrogen as a gas, which dilutes the combustible gases, thus limiting the flame burning. The nitrogen-containing compounds display synergism with the phosphorus containing flame retardants by enhancing their effect.
There are many compositions of flame retardants, based on ammonium phosphates and methods for their production, described in the patent literature.
U.S. Pat. No. 3,900,327 illustrates a composition, which is a reaction product of the orthophosphoric acid or ammonium phosphate with ethylene oxide. It is known that the alkylene oxides, such as the ethylene oxide are toxic and carcinogenic, which makes the flame retardant practically unusable, although efficient as a flame retardant.
U.S. Pat. No. 6,989,113 describes a composition of a flame retardant, containing predominantly ammonium phosphate, urea, non-ionic surfactant, sugar and anti-foaming agent, which is used solely for fire protection of wooden surfaces.
As disclosed in RU2204582, the composition represents a dry-mixed composition of mono-, diammonium phosphate with urea and a surfactant. This fire-protection composition is used for treatment of cellulose-containing materials—wood, woven and non-woven fabrics, made of natural and mixed-type fibers, and paper.
Patent RU 2233296, as described in recent developments, is based on phosphorus- and nitrogen-containing components, as it does not only contain any halogen-containing compounds, but it also does not contain any surfactants either.
U.S. Pat. No. 5,064,710 outlines a composition that contains water solution of ammonium phosphate, an alkyl acid phosphate and a glycol, containing from 2 to 4 carbon atoms, which ensures reduced fume formation, during combustion of cardboard, when treated with the composition. However, this is only efficient for treatment of cellulosic materials, such as paper, plywood, fiber boards.
Patent BG 66022 (Patent application US 2008/138534 A1) describes a method of plasma chemical surface modification of porous materials and workpieces, where the treated materials are impregnated with the solution containing fire retardants according to BG 33508.
BG 33508 refers to a composition that ensures reduced combustibility of cotton textile materials. This formulation contains mainly orthophosphoric acid, urea, triethanolamine, ammonia water and optional surfactant-diisooctylsulphosuccinate, which is used solely for textile materials.
The main specific for the aforesaid compositions and the level of technique in this area, is that the efficiency of the known flame retardants is manifested selectively, with respect to certain types of polymers with various chemical structure.
In some fire-protection treatments, in case of swiftly changing humidity and high drying temperature of the impregnated materials there is an increased migration of the flame retardant towards the surface and unwanted depositions, which results in decreased fire-protection effect and deterioration of product's appearance.
A serious disadvantage for the fire protection of polymer materials by means of flame retardants is the trend for deterioration of their physical properties, such as loss of strength, which is a significant defect for certain materials such as fabrics, wooden materials, cardboard, leather and items, made of them.
Another shortcoming is the environmental safety of the ingredients of the flame retardants and the respective fire-protected polymers. The halogen-containing flame retardants are not safe, when being used, and in case of fire, they release toxic gases and smoke, which are very hazardous for human health, that could even cause death and serious injuries.
It is known that the toxic smoke is much more dangerous to people than the fire occurring as a result of ignition of polymer materials untreated with flame retardants. The U.S. Pat. No. 5,064,710 mentioned above, is the only example that provides data on smoke development tests of fire-protected cardboard.
There are not any compositions of flame retardants based on phosphorus- and nitrogen-compounds, known in the art, that could be applied to a wide range of porous hydrophilic and hydrophoblic polymers.
SUMMARY OF THE INVENTION
Fire protection effect depends on the uniformity, firmness and thickness of the insulating charred surface, and therefore, the flame retardants must enhance the result of the impregnation, i.e. higher quantity of flame retardant penetrates to a greater depth in the material, after a single application. The treated polymers must have a low smoke developed index when exposed to fire.
The principal object of the present invention is to create a general composition of biodegradable halogen-free flame retardants, efficient for hydrophilic and hydrophobic polymers, such as fabrics, wooden materials, leather, paper, cardboard, corrugated board, extruded and expanded cellular polystyrene, foamed polymers and items, made of them, irrespective of their physical and chemical properties and structure. The flame retardants of the composition provide a wide range of application methods, such as impregnation in an autoclave under pressure, plasma-assisted impregnation, continuous methods—soaking, draining and drying at high temperature, as well as energy-saving methods for “in situ” application, such as impregnation by dipping, pouring, brush application, roller application or by spraying at air pressure and room temperature.
The subject matter of the invention is the formulation of a composition of flame retardants, with percentages (%) by mass, as follows: orthophosphoric acid from 15 to 30, urea from 3 to 7, triethanolamine from 3 to 10, ammonia water from 15 to 30, polydimethylsiloxane from 0.1 to 4; surfactants (anionic, cationic, amphoteric or non-ionic or mixtures thereof) from 3.1 to 15 and water to 100.
The orthophosphoric acid is preferably 75-85% orthophosphoric acid. The polydimethylsiloxane is pure (100%) polydimethylsiloxane, with preferred viscosity determined at 25° C., from 20·10 −6 to 350·10 −6 m 2 /s.
The following compounds are used in the invention as anionic surfactants:
Alkylsulphates with the following formula ROSO 3 − ;
Alkylethersulphates with the following formula: R(CH 2 CH 2 O) n OSO 3 − ;
Alkylsulphonates with the following formula: RSO 3 − ;
Salts of fatty acids with the following formula: RCOO − ; and
Sulphosuccinates with the following formula: R(CH 2 CH 2 O) n OCOCHSO 3 CH 2 COO − , where the R radical may be alkyl, alkene, alkyne or alkylaryl, and the value of n is 2 or 3.
The preferred anionic surfactants in the invention are the alkylethersulphates with length of the alkyl chain C 6 -C 18 and/or the alkylsulphonates.
The cationic surfactants used in the invention are as follows:
Quaternary esters with the following formula: (R 1 OCH 2 CH 2 )(R 2 OCH 2 CH 2 )CH 3 (CH 2 CH 2 OH)N + CH 3 OSO 3 − ; or
Quaternary ammonium chlorides with the following formula: R 1 R 2 (CH 3 ) 2 N + Cl − . where R 1 and R 2 may be alkyl radicals with chain length of C 7 -C 22 .
The preferred cationic surfactants in the invention are the alkylbenzyldimethylammonium chloride with alkyl chain length of C 8 -C 14 or dialkylammoniumsulphate or triethanolaminestearatemethosulphate.
The following amphoteric surfactants or so called zwitterions are used in the invention:
Alkylbetaines with the following formula: R(CH 3 ) 2 N + CH 2 COO − ; or
Alkylamidopropylbetaines with the following formula: RCONH(CH 2 ) 3 (CH 3 ) 2 N + CH 2 COO − , where R may be alkyl, alkene, alkyne, alkylaryl with chain length of C 8 -C 18 .
The preferred amphoteric surfactants in the invention are the alkylamidopropylbetaines.
The following non-ionic surfactants are used in the invention:
Ethoxylated alcohols with the following formula: R 1 (CH 2 CH 2 O) n OH; or
Ethoxylated alkylphenols with the following formula: R 2 Ar(CH 2 CH 2 O) n OH where
R 1 is an alkyl radical with chain length of C 6 to C 22 ;
R 2 is an octyl or nonyl radical;
Ar is an aryl radical.
The preferred non-ionic surfactants in the invention are ethoxylated alcohols.
In flaming conditions, the surfactants included in the compositions of the flame retardants, according to the invention, enhance the formation of an uniform, firm, thick and dense surface charred layer, which effectively slows down the burning rate and the amount of the released heat and toxic smoke.
The composition according to the invention is formed by mixing orthophosphoric acid and urea, heating the resulting reaction mixture from 40° C. to 50° C. under stirring continuously. At the end of their interaction, the mixture is cooled down to 20-25° C., diluted with water and homogenized. Following, the triethanolamine, ammonia water, polydimethylsiloxane and the surfactants are added, stirring until the mixture is homogenized. Due to the strong exothermic process that takes place in the reactor, an intensive cooling is needed.
The composition of the invention may be applied to the treated materials utilizing various methods:
1) Impregnation by Spraying
The materials are impregnated at atmospheric pressure and room temperature using a pulverized device, e.g. by means of an air pistol from a distance of at least 40 cm, strictly observing the relevant consumption rate for the respective material. The treated materials are dried at room temperature.
In this way, the composition of the flame retardant, according to the invention, may be used to treat various materials and items made of them, such as:
hydrophilic textile materials, such as cotton, silk, hemp, linen, wool, viscose;
hydrophobic textile materials, such as polyester, polyacrylnitrile, polyamide, polypropylene, polyethylene and their blends;
wooden materials, such as wood and wooden products, beams, boards, plywood and plywood based products, wooden particle boards, wooden fiber boards, MDF, HDF;
cellulosic materials, such as paper, cardboard, pressed cardboard, corrugated board;
natural and artificial leather;
foamed polymers, such as foamed polyurethane;
expanded and extruded cellular polystyrene.
2) By Continuous Methods—Soaking, Draining and Drying at High Temperature.
This is a continuous treatment method, where the non-treated material passes through a bath with a small module, containing the flame retardant, i.e. dipping in a bath, full of the respective composition of the flame retardant according to the invention. After soaking in the bath, the material passes between rollers, where applying controlled pressure, it is drained so that only the specified quantity of the flame retardant remains in the material, and after that it passes at an appropriate speed and at temperature, appropriate for drying the respective material through a drying machine.
This treatment method is appropriate for hydrophilic and hydrophobic textile materials; cellulosic materials, such as paper, foamed polymers, such as foamed polyurethane on rolls.
3) By Impregnation in a Pressurized Autoclave
The impregnation under pressure in an autoclave ensures partial filling of the free volume of the wooden materials with flame retardants and greater penetration depth. The drying takes place in a drier at atmospheric pressure.
The introduction of the vacuum technologies in the drying and wood impregnation creates a significant diversity of technological impregnation options. Various technological cycles, such as “vacuum-atmospheric pressure-vacuum”, “vacuum-high pressure-vacuum”, pulse impregnation by means of brief alternation of vacuum and high pressure, cyclic impregnation with alteration of “vacuum-pressure” cycles, combining vacuum drying and vacuum impregnation in a single autoclave.
This treatment method is appropriate for wooden materials, such as solid wood and wooden items, beams and boards.
4) By Means of Plasma-Assisted Impregnation
The materials are treated at atmospheric pressure, using a plasma device with cold plasma obtained from a barrier electric discharge. After the primary plasma-chemical surface modification, the materials are impregnated, with the composition of the respective flame retardant according to the invention.
This treatment method is appropriate for hydrophilic and hydrophobic textile materials; wooden materials, such as solid wood and wooden products, beams, boards, plywood and plywood-based products, wood particles boards, wood fibres boards, MDF, HDF; cellulosic materials, such as paper, cardboard, pressed cardboard, corrugated board; natural and artificial leather; foamed polymers, such as foamed polyurethane; expanded and extruded cellular polystyrene.
5) Energy-Saving Impregnation by Means of Simple Dipping, Pouring, Brush Application, Roller Application
This treatment method is appropriate for wooden materials, such as solid wood and wooden products, beams, boards, plywood and plywood-based products, wood particles boards, wood fibres boards, MDF, HDF; foamed polymers, such as foamed polyurethane; expanded and extruded cellular polystyrene.
The compositions of the flame retardants may be used in combination with softeners, wetting agents and other textile auxiliaries, after preliminary tests are carried out with respect to the stability of the solutions and their possible negative effect on material's flammability.
Wooden materials, impregnated with the compositions of the flame retardants according to the invention, may be treated with paints and polishes, after tests for compatibility with the used solutions of the flame retardants and the impregnation technology are performed.
The compositions of the flame retardants according to the invention, applied to wooden materials may be combined also with any suitable insecticide and any suitable mold inhibitor.
The composition of the flame retardant according to the invention may also serve as fire-extinguishing media, if used in fire-extinguishers and sprinkler systems. It is used in pressurized liquid fire-extinguishers, approved for class A fires, which includes ignition of paper, wooden materials and textiles. The fire-extinguishing compositions are easy to use and environmentally friendlier than those working with water and powder.
They can be used in sprinkler systems for extinguishing fires in hotels, hospitals, schools, public and residential buildings, as well as for extinguishing forest fires.
The tests, performed regarding the corrosive effect of the flame retardants according to the invention on steel plates X18H10T, show that the composition of the invention does not have any corrosive effect on the metal parts of the equipment for production, transport and the machines used for the industrial application.
When working with the composition of the flame retardant according to the invention, there were not any skin rashes or erythema in people, while working with the product, which serves as an evidence of the absence of toxic properties.
Tests with enzymes with phosphatase activity were performed to determine the biodegradability of the composition of the flame retardant according to the invention.
Tests were performed for the biodegradation of hydrophobic and hydrophilic polymers, fire-protected with flame retardant according to the invention.
The hydrophobic polymers, based on polypropylene, polyester, polyacrylnitrile, polyamide, polyethylene, cellular polystyrene and foamed polyurethane were treated with the enzymes lipase and esterase of various microbe strains. The hydrophilic polymers, such as cellulosic and woolen textile materials, wooden materials, paper, natural leather, were treated with proteolytic enzymes, laccase and cellulase complexes. Microbe stain, such as Phanaerochete chrysosporium with high lignin decomposition activity was also used.
It was determined that all the polymers, fire-protected with the composition of the flame retardant according to the invention are biodegradable.
Tests were performed for determining the smoke developing of the polymers, fire-protected with the composition of the flame retardant according to the invention, applying the methods, described in Tzenov, Tz. “Construction materials—burning behaviour”, Sofia, “Albatros” 1996, as follows:
At least three samples of the polymer material are measured, each with a weight of 0.001 kg. The test sample is placed in a smoke chamber at a temperature of 100° C., 150° C., 300° C., 450° C. and 600° C.
The smoke developed index is calculated, based on the following formula:
D m =( V/L·m 0 ) (lg I 0 /I min)
where D m —smoke developed index, [m 3 ·m −1 ·kg −1 ]
V—volume of the smoke chamber (0.9×0.9×0.6 m)=0.486 [m 3 ]
L—beam length (as generated by a He—Ne laser with wave length λ=632.8 nm), 2.5 mW, passing through the smoke chamber
m 0 —mass of the tested polymer sample, [kg]
I 0 —initial value of the He—Ne laser beam power in the chamber without smoke, [mA]
Imin—minimum value of the He—Ne laser beam power in the smoke-filled chamber, [mA].
The I 0 and I min values are calculated by a special detector. The polymer materials, depending on the smoke developed index D m are classified as:
materials with low smoke development capability—D m =0-50 [m 3 ·m −1 ·kg −1 ]
materials with medium smoke development capability—D m =50-500 [m 3 ·m −1 ·kg −1 ]
materials with high smoke development capability—D m ≧500 [m 3 ·m −1 ·kg −1 ].
It was determined that the smoke development of polymers, fire-protected by the flame retardant according to the invention is with a low index, which indicated that in case of fire less toxic smoke will be released.
The efficiency of the flame retardants according to the invention was proven by means of tests for determining the burning behaviour of treated test specimens of various materials, according to the following standards:
for textile materials—BDS EN ISO 6941; JAR(FAR)§25.853 and Fiche UIC 564-2;
for wooden materials—CAN/ULC-S102, ASTM E 84, DIN 4102/1998 and EN ISO 11 925-2, BDS 16359/86;
the polystyrene, impregnated with the composition of the flame retardant according to the invention, meets the requirements of BDS ISO 9772:2004;
the foamed polyurethane, impregnated with a composition of the flame retardant according to the invention meets the requirements of JAR(FAR) §25.853 and BDS ISO 9772:2004.
The test methods, according to the aforesaid standards are, as follows:
A) BDS EN ISO 6941 Textile fabrics—Burning behaviour, measurement of flame spread properties of vertically oriented specimens.
This European standard, details the method of measurement of flame spread time of vertically oriented textile materials. The dimensions of each specimen are 560 mm×170 mm. The number of the specimens for testing is 24, as 12 are cut in a longitudinal, and the other 12 in transverse direction of the textile material.
Marking threads are placed at certain positions, horizontally on the test specimen.
The test specimen is placed on carrying pins on a rectangular frame. The frame is fixed onto an appropriate stand, placed in a chamber.
The specimens are subjected to the effects of a gas burner (propane-butane) with flame height of 40±1 mm, for 15 seconds.
The textile material is classified as Class 1 (difficult to ignite material) if the sustained flame (duration of flaming) is 5 seconds and if the first marking thread is not burnt.
B) JAR (FAR) 25.853. This method is applicable to interior polymer materials, which are used in civil and cargo airplanes.
A minimum of 3 specimens must be tested. The materials must be tested either as section, cut from fabricated part as installed in the airplane, or as specimen simulating a cut section. The specimen may be cut from any location in a fabricated part. The specimen must be fixed firmly in a specimen frame, placed in a fireplace or combustion chamber.
In case of the vertical method, the lower edge of the specimen must be 19 mm above the top edge of a gas burner (propane/butane) with flame temperature of 843° C.
The flame must be applied for 60 seconds and then removed. The main criteria for the assessment of the burning behavior are the flame time, in seconds and the burnt length, in millimeters.
The polymer material is classified as difficult to ignite material (self-extinguishing), if the test specimen extinguishes after the removal of the flame, and the front of the burnt length does not reach the marking and no flaming droplets are recorded.
C) Fiche UIC 564-2. Test method for determining the fire resistance of coated and uncoated textiles
The subject matter of this method is the exposure of a textile material to the flame of a gas burner (propane-butane) for a certain period of time. Six test specimens with dimensions 190×320 mm are measured—three in warp direction and three in weft direction. The burner is inclined at an angle of 45° and is placed close to the test specimen in such a way, that the blue cone of the flame touches the lower edge of the test specimen. After that, the specimen has cooled and the charred area is measured. The “charred section” is defined as the area destroyed and actually charred. Areas where deformation, color change, etc. have occurred are not part of the fire damaged area.
Progress of the test shall be observed and the following points noted:
length of time of continued burning or glowing and the burning or glowing of the burning particles or drops after extinction of burner;
the charred area in cm 2 ;
possible release of burning particles or drops;
the degree to which the upper edge of the test specimen is fire damaged.
D) Methods, based on DIN 4102 Part 1, B2 (analogous test method EN ISO 11925-2). Determining the combustibility of building products and structural elements. Determining the difficult to ignite materials.
This method is used for classification of building products and structural elements, according to the European System for class B, B fl , C, C fl , D, D fl , E and E fl . The method is used for testing all types of building and structural products, for which class B2 is required.
18 test samples with dimensions 900 mm×230 mm are required for the test. The specimens are installed vertically in a combustion chamber. The fire is induced on the lower edge and/or the surface of the specimens by means of the flame of a gas burner.
The ignition time is recorded, as well as the possible release of burning particles and whether the front of the burnt area reaches the upper marking for a certain period of time of inducing fire from the flame source.
E) CAN/ULC-S102 (similar method ASTM E 84). Standard method of test for “Surface Burning Characteristics of Building Materials and Assemblies”
This method is designed to determine the relative surface burning characteristics of the material by evaluating the flame spread over its surface and measuring the density of the smoke developed, compared to a selected type of red oak and noncombustible material, under specific test conditions. The Classification of the materials concerns the flame spread (FSC) and smoke developed (SD).
The test specimens are 7315 mm long and 508 mm wide. Prior to testing, they are conditioned at 23±3° C. and relative humidity of 50±5%.
The specimens are placed in a tunnel furnace with controlled airflow and flame sources (gas burners). The spreading of the flame on the surface of the specimens is recorded at every 15 seconds. During the test, the ignition of the material and the spreading of the flame within a certain time are recorded, as well as the smoke development of the test samples.
F) BDS 16359/86. Protective agents for wood. Method for determining the flame retardant properties.
The subject matter of this method is the exposure of pine wood to the flame of a gas burner. At least ten test specimens are measured. The test specimens are prepared as a rectangular prism with the following dimensions: height 30 mm, width 60 mm and length 150 mm. The test specimens are mounted vertically in a ceramic tube at 200° C. and tested for a period of 2 minutes. The mass loss of the test specimen, Δm, in percents, is determined with a precision of 0.1% applying the following formula:
Δ m =(( m 1 −m 2 )/ m 1 )100,
where
m 1 —the mass of the test specimen prior to testing, g;
m 2 —the mass of the test specimen after testing, g;
The average of the 10 values, round to 1%, is considered as a test result.
The mass loss, varying from the average by more than 5%, is not taken into consideration for the calculations. New test specimens are prepared, instead of those ones.
According to the information appendix to BDS 16359/86, the value and allowance of the method indicator is to amount to 9% mass loss. In case of weight loss of up to 9% the protected specimens are difficult to ignite (self-extinguishing), and therefore the flame retardant is designated as difficult to ignite (self-extinguishing).
G) BDS ISO 9772:2004. Cellular plastics. Determination of horizontal burning characteristics of small specimens subjected to a small flame.
This method is designed for laboratory testing, allowing comparison to the relative burning characteristics of test-specimens of foamed plastics, in horizontal position, with density of at least 250 kg/m 3 . At least 20 test specimens with length 150±10 mm and width 50±10 mm are prepared. The test specimens must be placed on a support of metal mesh, positioned in a certain way in the fireplace. The test specimens are subjected to the flame of a gas burner for 60 seconds.
For the classification of the materials in classes HF-1, HF-2, HF-3, the linear burning rate, the after flaming are recorded, as well as the duration of the flameless ignition of a cotton pad, from ignited drops and particles and damaged length of each similar object.
The efficiency of the flame retardants according to the invention, is proven by applying the methods of thermogravimetric analysis (TGA), the differential thermal analysis (DTA) and the differential scanning calorimetry (DSC), as shown in FIG. 1 .
The results of the thermogravimetric analysis of the developed flame retardants (based on a dry ingredient), show its thermal stability at temperatures up to 125° C. The first stage of the TG-curve is determined from the release of the volatile components and mostly of water (4.60%). Significant thermal decomposition, where substances, blocking the release of the combustible gases, e.g. phosphoric acid, are formed, is represented by the maximum of the DTG-curve at 185° C.—in the interval from 125° C. to 250° C., where the dry substance loses about 27.7% of its mass. This process is characterized by a heat absorption up to 356° C., as the total endothermic effect is 439.6 J/g. The exothermic effect of the decomposition above that temperature is approximately 5 times lower −81.3 J/g, FIG. 2 .
Therefore the invented flame retardants have behaviour, specific for the phosphorus containing flame retardants—the temperature interval for activation of the flame retardant is from 125° C. to 250° C. The activation takes places in endothermic regime with mass loss of more than 20% from the initial weight of the flame retardant.
The specialists in this area are aware that most effective are the flame retardants, which form a protective charred layer below 300° C. The invented flame retardants, as evidenced by the DTA-TGA thermal tests, form a firm, dense and thick charred layer below 250° C., which does not allow any heat or oxygen to penetrate beyond the area of thermal decomposition of the polymer, and the combustible gases, released in the process of thermal decomposition—to reach the area of flaming and feed it.
The thickness and morphology of the charred layer formed determines also the quality of the flame retardants.
DESCRIPTION OF THE DRAWINGS
FIG. 1 —Thermogravimetric analysis (TGA) of flame retardants, based on phosphorus and nitrogen compounds;
FIG. 2 —Differential scanning calorimetry (DSC) of a flame retardant solution, based on phosphorus and nitrogen compounds.
FIGS. 3A and 3B are Integral (a) and differential (b) curves of alteration of the relative mass loss ΔM.
FIG. 4 —Comparison of the thermal effects of the tested samples, beyond the ignition point (IP, T>229° C.) of the protected wood sample (PhFR—wood).
DESCRIPTION
The advantages of the flame retardants, based on the composition according to this invention, are detailed below:
they are applicable for a wide range of hydrophilic and hydrophobic polymers and provide a high fire protection level of the treated materials;
increase the fire resistance of the treated materials;
slow down the burning rate, the amount of released heat, toxic gases and the smoke development during the exposure to fire;
may be used as fire-extinguishing media as well;
enhance the impregnation result—larger quantities of flame retardant, penetrating to a greater depth in the material with single application;
do not deteriorate the physical and mechanical indexes and the appearance of the materials, treated with the flame retardant;
non-toxic;
the flame retardants, as well as the polymers, treated with them are biodegradable, which ensures a positive environmental effect;
have low price;
appropriate for application both by industrial scale-up treatment and “in situ” energy-saving technologies (at normal atmospheric pressure and room temperature), such as dipping, pouring, brush application, roller application or by spraying.
EXAMPLES FOR IMPLEMENTATION OF THE INVENTION
This invention is illustrated, but in no way limited, by the following examples.
Textile Materials
The compositions of the flame retardants, according to the invention are applicable to fire protection and slowing down the smoke development of both hydrophilic textile materials, such as cotton, silk, hemp, linen, wool, viscose, and hydrophobic textile materials, such as polyester, polyacrylnitrile, polyamide, polypropylene, polyethylene and their blends.
Example 1
In one preferred embodiment the flame retardant for cellulosic textile materials is prepared by a composition, which contains, with percentages (%) by mass: 85% orthophosphoric acid—15.0; urea—3.0; triethanolamine—4.0; ammonia water—15.0; polydimethylsiloxane with kinematic viscosity, 20·10 −6 m 2 /s—1.5, dialkyldimethylammonium sulphate—3.1 and water—58.4.
The orthophosphoric acid and the urea are mixed and the obtained reaction mixture is heated up from 40° C. to 50° C. with continuous stirring. After the finalization of the interaction, the mixture is cooled down to 20-25° C., diluted with water and homogenized. Then the triethanolamine, ammonia water, polydimethylsiloxane and dialkyldimethylammonium sulphate (surfactant) are added, while continuously stirring until the finished mixture is homogenized.
The phosphates content in the cellulosic materials, such as P 2 O 5 % is within the scope 3.20 to 9.64, depending on the type of fibers, the structure of the fabric, its preliminary treatment and the desired self-extinguishing level.
Example 2
In another embodiment the flame retardant for hydrophobic textile materials (such as polyester, polyamide, polypropylene) and their blends with hydrophilic materials, is prepared from a composition which contains with percentages (%) by mass: 85% orthophosphoric acid—25.0; urea—6.0; triethanolamine—5.0; ammonia water—25.0; polydimethylsiloxane with viscosity 100·10 −6 m 2 /s—2.5, mixture of alkyl (C 6 -C 18 ) sulphates and sulphonates—7.5 and water—29.0.
The composition is prepared based on the methods, detailed in Example 1. The phosphates content in the polymer materials, such as P 2 O 5 % is within the range from 3.70 to 7.50.
Example 3
In a different embodiment the flame retardant for hydrophobic textile materials (such as polyacrylnitrile, polyacrylnitrile/polyester blends) is prepared from a composition, which contains with percentages (%) by mass: 85% orthophosphoric acid—16.0; urea—3.0; triethanolamine—4.0; ammonia water—20.0; polydimethylsiloxane with viscosity 100·10 −6 m 2 /s—2.0, mixture of alkyl (C 6 -C 18 ) sulphates and sulphonates—7.5, alkylamydopropylbetaine—2.5 and water—45.0.
The composition is prepared, based on the method, detailed in Example 1.
The phosphates content in the hydrophobic materials, such as P 2 O 5 % is within the range from 4.80 to 12.80.
Example 4
In other embodiment the flame retardant for polyethylene fabrics is prepared from a composition, which contains with percentages (%) by mass: 85% orthophosphoric acid—30.0; urea—7.0; triethanolamine—9.0; ammonia water—29.0; polydimethylsiloxane with viscosity 350·10 −6 m 2 /s—0.5, alkylethersulphate with alkyl chain length (C 6 -C 18 ) and alkyl sulphonates—10.0 and water—14.5.
The composition is prepared, based on the method, detailed in Example 1. The phosphates content in the polymer materials, such as P 2 O 5 % is within the range from 3.21 to 4.60.
The flame retarded textile materials, treated with the compositions according to the invention satisfy the test requirements of the following standards: BDS EN ISO 13934-1:2002 Textile—Tensile properties of fabrics—Part 1: Determination of maximum force and elongation at maximum force using the strip method; BDS EN ISO 13937-1:2002 Textile—Tear properties of fabrics—Part 1: Determination of tear force using ballistic pendulum method (Elmendorf); BDS 9586:1992 Textiles. Fabrics. Methods for determination of drapery characteristics; BDS EN ISO 12947—:2002 Textiles—Determination of the abrasion resistance of fabrics by the Martindale method—Part 2: Determination of specimen breakdown; Color difference determined according to BDS EN ISO 105-J03L:2001.
The test results for abrasion resistance of the treated fabrics indicate that the fabric quality has been improved. The waste of all the tested impregnated fabrics is less than the waste of the untreated materials.
The burning behaviour of the flame retarded, textile materials is in accordance with BDS EN ISO 6941, JAR(FAR)§25.853 and Fiche UIC 564-2. The treated textiles are classified as difficult to ignite materials which extinguish after the removal of the flame of the burner and no flaming droplets are released. The flame retarded textile materials are with low smoke developed indexes.
Examples for the smoke developed indexes of some of the tested materials are shown in Tables 1-4.
TABLE 1
Smoke developed by fire-protected cotton textile material
test
Type of
I min
D max av.
No.
T ° C.
material
I o μA
μA
I min av.
(m 3 /m · kg)
Note
Conclusions
1-1
300
Cotton
25
18.10
18.16
46.93
no self-
low smoke
1-2
300
Cotton
25
18.00
ignition
developed index
1-3
300
Cotton
25
18.40
2-1
450
Cotton
25
17.30
17.06
86.71
no self-
medium smoke
2-2
450
Cotton
25
17.00
ignition
developed index
2-3
450
Cotton
25
16.90
3-1
600
Cotton
25
20.20
20.03
50.31
no self-
medium smoke
3-2
600
Cotton
25
20.10
ignition
developed index
3-3
600
Cotton
25
19.80
TABLE 2
Smoke developed by fire-protected polyester textile material
test
Type of
I min
D max av.
No.
T ° C.
material
I o μA
μA
I min av.
(m 3 /m · kg)
Note
Conclusions
1-1
300
Polyester
25
20.60
20.70
42.87
no self-
low smoke
1-2
300
Polyester
25
20.80
ignition
developed index
1-3
300
Polyester
25
20.70
2-1
450
Polyester
25
19.60
19.56
54.66
no self-
medium smoke
2-2
450
Polyester
25
19.70
ignition
developed index
2-3
450
Polyester
25
19.40
3-1
600
Polyester
25
6.10
6.13
319.20
no self-
medium smoke
3-2
600
Polyester
25
6.00
ignition
developed index
3-3
600
Polyester
25
6.30
TABLE 3
Smoke developed by fire-protected textile material, polyacrylnitrile/polyester blend
test
T
Type of
I min
D max av.
No.
° C.
material
I o μA
μA
I min av.
(m 3 /m · kg)
Note
Conclusions
1-1
300
74% Polyacryl
25
19.90
20.06
49.93
no self-
low smoke
26% Polyester
ignition
developed index
1-2
300
74% Polyacryl
25
20.20
26% Polyester
1-3
300
74% Polyacryl
25
20.10
26% Polyester
2-1
450
74% Polyacryl
25
6.20
6.16
317.96
no self-
medium smoke
26% Polyester
ignition
developed index
2-2
450
74% Polyacryl
25
6.00
26% Polyester
2-3
450
74% Polyacryl
25
6.30
26% Polyester
3-1
600
74% Polyacryl
25
8.20
8.43
246.86
no self-
medium smoke
26% Polyester
ignition
developed index
3-2
600
74% Polyacryl
25
8.50
26% Polyester
3-3
600
74% Polyacryl
25
8.60
26% Polyester
TABLE 4 Smoke developed by polyethylene fabrics test T Type of I min D max av. No. ° C. material I o μA μA I min av. (m 3 /m · kg) Note Conclusions 1-1 300 Non-treated 25 17.90 17.93 75.46 no self- medium smoke Polyethylene ignition developed 1-2 300 Non-treated 25 17.70 index Polyethylene 1-3 300 Non-treated 25 18.20 Polyethylene 2-1 450 Non-treated 25 3.60 3.63 438.46 no self- medium smoke Polyethylene ignition developed 2-2 450 Non-treated 25 3.40 index Polyethylene 2-3 450 Non-treated 25 3.90 Polyethylene 3-1 600 Non-treated 25 13.40 13.60 143.90 self-ignition medium smoke Polyethylene at 600° C. after developed 3-2 600 Non-treated 25 13.10 7-9 s and the index Polyethylene smoke is 3-3 600 Non-treated 25 13.30 grayish-white Polyethylene 1-1 300 Treated 25 19.20 19.36 58.00 no self- medium smoke Polyethylene ignition developed 1-2 300 Treated 25 19.60 index Polyethylene 1-3 300 Treated 25 19.30 Polyethylene 2-1 450 Treated 25 14.00 14.16 129.36 no self- medium smoke Polyethylene ignition developed 2-2 450 Treated 25 14.40 index Polyethylene 2-3 450 Treated 25 14.10 Polyethylene 3-1 600 Treated 25 13.40 13.40 141.60 self-ignition medium smoke Polyethylene at 600° C. after developed 3-2 600 Treated 25 13.70 17-22 s and index Polyethylene the smoke is 3-3 600 Treated 25 13.10 grayish-white Polyethylene
Wooden Materials
The compositions of the flame retardants are applicable to fire protection and slowing down smoke development for wide range of wooden materials, such as: solid wood and wooden products, beams, boards, plywood and plywood-based products, wood particles boards, wood fibres boards, MDF, HDF.
Example 5
In the fifth embodiment the flame retardant for Douglas Fir is prepared from a composition, which contains with percentages (%) by mass: 85% orthophosphoric acid—22.0, urea—5.0, triethanolamine—8.0, ammonia water—25.0, polydimethylsiloxane with viscosity 20·10 −6 m 2 /s—1.5, mixture of alkylbenzyldimethylammonium chloride with alkyl chain length (C 8 -C 14 ) and alkylamydopropylbetaine—14.0 and water—24.5.
The composition is prepared, based on the method, detailed in Example 1.
The Douglas Fir impregnated with the flame retardant was tested in accordance with CAN/ULC-S 102 (similar standard ASTM E 84) and showed flame spreading rate FSC-35, smoke developed index SDI-170 according to CAN/ULC-S 102 and FSC-32, SDI-170 according to ASTM E 84.
The performed TGA, DTA and DSC thermal analyses on non-treated Douglas Fir and Douglas Fir treated with the flame retardant according to the invention, indicate that the impregnated Douglas Fir slows down the burning process by more than 50% and burns for approximately 30 minutes, unlike the non-treated Douglas Fir which burns for 10 minutes.
Example 6
In another embodiment the flame retardant for pine wood is prepared from a composition, which contains with percentages (%) by mass: 85% orthophosphoric acid—22.0, urea—5.0, triethanolamine—10.0, ammonia water—18.0, polydimethylsiloxane with viscosity 20·10 −6 m 2 /s—0.2, mixture of alkyl (C 6 -C 18 ) sulphates and sulphonates—3.5 and water 41.3.
The composition is prepared, based on the method, detailed in Example 1.
The wooden building product made of pine wood was treated by means of a plasma device with cold plasma, at atmospheric pressure, obtained from a barrier electric discharge at frequency 30 kHz for a period of 10 s. After the preliminary plasma-chemical surface modification, the wooden product was impregnated by means of a brush with the composition indicated in this example. The phosphates content in the material as P 2 O 5 % is 5.98%.
The pine wood product was tested in order to determine its combustibility according to DIN 4102/1998 and was classified as self-extinguishing (Class B1).
The mode of delaying the burning process is studied by means of thermal analysis of two samples—control sample and sample, protected with flame retardant for pine wood which is introduced by means of a plasma-assisted impregnation, as the preliminary plasma-chemical activation is realized for 1 min at voltage of 15 kV (50 Hz) and at atmospheric pressure. The experimental conditions for all thermal tests—DTG, DTG and DSC, performed in air environment on Perkin-Elmer equipment, are as follows: heating rate 10 K/min with heating range from room temperature to 600° C.
The relative loss of mass ΔM of the fire-protected sample remains significantly lower (by approximately 30%) above 300° C., FIG. 3 a . The released heat also corresponds to the suppressed flaming, FIG. 4 .
The maximum loss of mass is registered at approximately 280° C. ΔM(max)=14% (i.e. below 300° C.), while in the control sample, this takes place at 315° C., ΔM(max)=30% (i.e. above 300° C.), FIG. 3 b.
At a temperature of 650° C., the natural wood burnt completely (100%), while the fire-protected one lost only about 65% of its initial mass, FIG. 3 a.
The composition from the Example 6 can be combined with any suitable insecticide and any suitable mold inhibitor. The protected wood is in conformity with standard BDS 16359/86 and is classified as self-extinguishing material.
The flame retarded pine and beech wood have low smoke developed indexes values, Table 5-6.
TABLE 5
Smoke developed by fire-protected pine wood
test
Type of
D max av.
No.
T ° C.
material
I o μA
I min μA
I min av.
(m 3 /m · kg)
Note
Conclusions
1-1
300
Pine wood
20
17.60
17.26
33.46
Only
low smoke
1-2
300
Pine wood
20
17.10
smoldering of
developed
1-3
300
Pine wood
20
17.10
the sample is
index
observed,
with minor
flaming
2-1
400
Pine wood
20
14.50
14.73
69.46
The flame
medium
2-2
400
Pine wood
20
14.90
does not have
smoke
2-3
400
Pine wood
20
14.80
a gray layer
developed
smoke
index
3-1
600
Pine wood
20
17.80
17.96
24.43
Full charring
low smoke
3-2
600
Pine wood
20
18.20
of the sample
developed
3-3
600
Pine wood
20
17.90
with
index
slowing down
smoke
TABLE 6 Smoke developed by fire-protected Beech test Type of D max av. No. T ° C. material I o μA I min μA I min av. (m 3 /m · kg) Note Conclusions 1-1 300 Beech 20 18.50 18.33 19.80 No flame is low smoke 1-2 300 Beech 20 18.40 observed, only developed 1-3 300 Beech 20 18.10 smoldering index 2-1 400 Beech 20 13.40 14.63 71.01 More time is medium smoke 2-2 400 Beech 20 14.80 required for developed 2-3 400 Beech 20 15.70 smoke index development to start 3-1 600 Beech 20 18.90 19.43 6.56 Almost no smoke low smoke 3-2 600 Beech 20 19.60 developed 3-3 600 Beech 20 19.80 index
Paper, Cardboard, Pressed Cardboard, Corrugated Board
Example 7
In this embodiment the flame retardant for paper contains, with percentages (%) by mass: 85% orthophosphoric acid—25.0, urea—5.0, triethanolamine—9.0, ammonia water—30.0, polydimethylsiloxane with viscosity 100·10 −6 m 2 /s—3.1, mixture of triethanolaminestearatemethosulphate and ethoxylated alcohol—8.0 and water—19.9.
The composition is prepared, based on the method, detailed in Example 1.
The flame retardant is applicable to fire protection and slowing down smoke development of paper products. The impregnation may be performed by industrial scale-up treatment or “in situ”, by spraying under pressure, brush or roller application and by means of plasma-assisted impregnation. The industrial impregnation of the paper is carried out by the continuous process. The phosphates content in the material as P 2 O 5 % is within the range 2.44-4.88%.
The combustibility of the impregnated and non-impregnated paper by spraying was determined in accordance with BDS 16359/86 in a “ceramic tube”.
The non-treated paper with dimensions 150×30×1 mm and weight 0.001 kg upon applying gas burner (propane-butane) flame with height of 200 mm, ignites immediately and burns for 7-9 seconds. There is a mass loss ΔM=80-82%.
The impregnated paper with the flame retardant, prepared by the composition from Example 7, with dimensions 150×30×1 mm and weight 0.001 kg upon applying gas burner (propane-butane) flame with height of 200 mm for 60 seconds does not ignite, but just chars, without smoldering. There is a mass loss ΔM=47-52%. The smoke developed index of the impregnated paper, compared to the non-treated one, is with very low value, Table 7.
TABLE 7 Smoke developed by paper test Type of I min D max av. No. T ° C. material I o μA μA I min av. (m 3 /m · kg) Note Conclusions 1-1 300 Non-treated 25 18.10 18.30 70.90 no self- medium smoke Paper ignition developed index 1-2 300 Non-treated 25 18.50 Paper 1-3 300 Non-treated 25 18.30 Paper 2-1 450 Non-treated 25 2.10 2.17 556.20 no self- high smoke Paper ignition developed index 2-2 450 Non-treated 25 2.40 Paper 2-3 450 Non-treated 25 2.00 Paper 3-1 600 Non-treated 25 23.10 23.17 17.30 self-ignition low smoke Paper at 600° C. developed index 3-2 600 Non-treated 25 23.00 after 5-6 s Paper and burns 3-3 600 Non-treated 25 23.40 fast 8-10 s Paper light smoke 1-1 300 Treated 25 19.00 19.16 60.33 no self- medium smoke Paper ignition developed index 1-2 300 Treated 25 19.40 Paper 1-3 300 Treated 25 19.10 Paper 2-1 450 Treated 25 15.00 15.20 113.03 no self- medium smoke Paper ignition developed index 2-2 450 Treated 25 15.40 Paper 2-3 450 Treated 25 15.20 Paper 3-1 600 Treated 25 12.20 12.43 158.43 self-ignition medium smoke Paper at 600° C. developed index 3-2 600 Treated 25 12.70 after Paper 8-11 s and 3-3 600 Treated 25 12.40 the smoke is Paper light
Foamed Polyurethane
Example 8
In this embodiment the flame retardant for foamed polymers, such as foamed polyurethane contains, with percentages (%) by mass: 85% orthophosphoric acid—28.0, urea—4.0, triethanolamine—7.0, ammonia water—27.0, polydimethylsiloxane with viscosity 350·10 −6 m 2 /s—0.5, mixture of triethanolaminestearatemethosulphate with polyethyleneglycol 20 and polyoxyethylether of the lauryl alcohol n=7-10 and water—23.5.
The composition is prepared, based on the method, detailed in Example 1.
The phosphates content in the material as P 2 O 5 % is within the range 14.30-17.90%.
The impregnation of foamed polyurethane products may be performed by dipping, by continuous process in industrial environment, and by spraying under low or high pressure. The burning behaviour of the impregnated soft and hard foamed polyurethane was determined in accordance with BDS ISO 9772/2004, JAR(FAR)§25.853 and Fiche UIC 564-2. The impregnated materials are classified as self-extinguishing materials.
Cellular Polystyrene
Example 9
In other embodiment the flame retardant for impregnation of expanded and extruded cellular polystyrene contains with percentages (%) by mass: 85% orthophosphoric acid—15.0, urea—3.0, triethanolamine—3.0, ammonia water—15.0, polydimethylsiloxane with viscosity 100·10 −6 m 2 /s—2.0, mixture of alkylethersulphates with alkyl chain length (C 6 -C 18 ), alkylamidopropylenebetaine and etoxylated alcohol—15 and water—47.0.
The composition is prepared, based on the method, detailed in Example 1.
The fire protection of polymer materials for thermal insulation from expanded (EPS) or extruded (XPS) cellular polystyrene is performed in industrial environment or “in situ” by means of brush application, roller application, spraying under pressure or plasma-assisted impregnation. The phosphates content in the material as P 2 O 5 % is 5.51%.
The burning characteristics of the extruded and expanded cellular polystyrene, impregnated with the flame retardant was determined in accordance with BDS ISO 9772/2004 “Cellular plastics. Determination of horizontal burning characteristics of small specimens, subjected to a small flame”.
The impregnated cellular polystyrene materials are classified in Class HF-1/self-extinguishing materials.
The smoke developed index of the cellular polystyrene, impregnated with the flame retardant is lower than that of the non-impregnated, Table 8.
TABLE 8 Smoke developed by cellular polystyrene test T Type of I o I min D max av. No. ° C. material μA μA I min av. (m 3 /m · kg) Note Conclusions 1-1 300 Non-treated 25 7.40 7.60 270.56 no self- medium smoke Polystyrene ignition developed index 1-2 300 Non-treated 25 7.90 Polystyrene 1-3 300 Non-treated 25 7.50 Polystyrene 2-1 450 Non-treated 25 5.20 5.23 355.43 no self- medium smoke Polystyrene ignition developed index 2-2 450 Non-treated 25 5.00 Polystyrene 2-3 450 Non-treated 25 5.50 Polystyrene 3-1 600 Non-treated 25 8.10 8.40 247.76 self-ignition medium smoke Polystyrene at 600° C. developed index 3-2 600 Non-treated 25 8.50 after 3-4 s, Polystyrene burns 26-31 s 3-3 600 Non-treated 25 8.60 with black Polystyrene smoke 1-1 300 Treated 25 8.40 8.70 239.86 no self- medium smoke Polystyrene ignition developed index 1-2 300 Treated 25 8.70 Polystyrene 1-3 300 Treated 25 9.00 Polystyrene 2-1 450 Treated 25 6.30 6.20 316.86 no self- medium smoke Polystyrene ignition developed index 2-2 450 Treated 25 5.90 Polystyrene 2-3 450 Treated 25 6.40 Polystyrene 3-1 600 Treated 25 11.10 11.10 184.46 self-ignition medium smoke Polystyrene at 600° C. developed index 3-2 600 Treated 25 10.80 after 4-9 s, Polystyrene burns with 3-3 600 Treated 25 11.40 white smoke Polystyrene
Natural Leather
Example 10
In this embodiment the flame retardant for leather contains with percentages (%) by mass: 85% orthophosphoric acid—20.0, urea—5.0, triethanolamine—5.0, ammonia water—18, polydimethylsiloxane with viscosity 20·10 −6 m 2 /s—0.5, alkylamidopropylbetaine—10.0 and water—41.5.
The phosphates content in the material as P 2 O 5 % is within the range 2.44-4.88%. The fire protection of leather is performed in industrial environment or “in situ” by spraying with pulverized device.
The combustibility of the leather impregnated by spraying was determined according to BDS 16359/86 in a “ceramic tube” and is classified as self-extinguishing material.
Comparative Examples
The main methods for fire protection of flammable materials are:
1. Flame retardants used as additives to materials such as plastics, textiles, foams, timber;
2. Flame retardant impregnation of porous polymer materials—textiles, wooden materials, paper, corrugated board, cellular polystyrene, foamed polyurethane;
3. Flame retardants used during the production process for chemical modification of some plastic materials;
4. Fire protective coating method.
The flame retardant compositions of the present invention are applied by the impregnation method.
It is known in the prior art, that the fire protection efficiency and reliability depends on the insulating char depth during exposure to heat (fire). Therefore, the mode of action of the flame retardant compositions is determined by their amount and penetration depth into the polymer matrix.
The fire protection efficiency of the biodegradable halogen-free flame retardants' composition according to the present invention (indicated as D) is illustrated by comparison with BG 33508 (indicated as D1) and PCT US 2008/138534 (indicated as D2) for wooden materials in the examples given hereunder.
Example 11
The flame retardant compositions are prepared according to D, D1 and D2. For all the specimens, treated with the above cited compositions, the amount of the flame retardants per one square meter is equal −490 g/m2.
The method for fire protection of the wooden materials is the energy saving method—impregnation by roller.
Then the specimens are left to dry at room temperature and normal atmospheric pressure. The results are given in Table 9.
Example 12
The flame retardant compositions according to the present invention (D) are compared with the compositions according to D1 and D2.
The specimens of the textile materials are impregnated by spraying. Then they are left to dry at room temperature and normal atmospheric pressure.
The amount of the flame retardant compositions according to D is determined experimentally for each textile material depending on the fiber types, the structure and the weight of the fabrics, their preliminary treatment and the desired self-extinguishing level. The impregnation carried out is two-side. The amount of the composition per one square meter of the textile material is divided into 2—the first part for the face side and the second part for the back side of the fabric.
The compositions according to D, D1 and D2 are applied in equal amounts for each textile material.
The results are given in Table 10.
Example 13
The composition according to the present invention (D) is compared with the compositions according to D1 and D2.
The compositions are applied for fire protection of testliner and corrugated board. The amount of the flame retardants per one square meter is the same for all the compositions.
The impregnation of the specimens is carried out by brush.
The specimens are left to dry at room temperature and normal atmospheric pressure.
The results are given in Table 11.
Example 14
The composition for fire protection of foamed polyurethane according to D is compared with the composition according to D1 and the composition according to D2.
The amount of the flame retardant compositions per one square meter is one and the same for all the used flame retardants.
The impregnation of the specimens is by brush.
The specimens are left to dry at room temperature and normal atmospheric pressure.
The results are given in Table 12.
Example 15
The composition for expanded polystyrene according to the present invention (D) is compared with the compositions according to (D1) and (D2).
The amount of the flame retardant compositions per one square meter is one and the same for all the used flame retardants.
The impregnation is by brush.
The tested specimens are left to dry at room temperature and normal atmospheric pressure.
The results are given in Table 13.
TABLE 9
Flame retarded
Test results
Test results
Test results
No
Test methods
materials
for D
for D1
for D2
1
2
3
4
5
6
1.
Penetration depth
PINE WOOD
5 mm.
3 mm.
3.5 mm.
BEECH WOOD
10 mm.
6 mm.
4 mm.
2.
BDS 16359/86
Average mass loss
Average mass loss
Average mass loss
Protective agents
PINE WOOD
2.23%
7.30%
6.80%
for wood.
BEECH WOOD
1.56%
5.15%
4.45%
OAK WOOD
3.96%
5.00%
4.25%
MDF
2.10%
5.78%
5.26%
DOUGLAS FIR
3.26%
6.20%
5.38%
3.
Methods, based on
PINE WOOD
Class B1
Class B2
Class B1
DIN 4102 Part 1.
MDF
Self-extinguishing
Ignitable
Ignitable
4.
BDS EN ISO 11925-2
PINE WOOD
Self-extinguishing
Self-extinguishing
Self-extinguishing
Reaction to fire tests -
Ignitability of products
subjected to direct
impingement of flame -
Part 2
5.
BDS EN ISO 9239-1.
PINE WOOD
Self-extinguishing
Ignitable
Ignitable
Reaction to fire tests for
(class B fl sl)
floorings - Part 1:
according to
Determination of the
BDS EN 13501-1
burning behaviour using a
radiant heat source
6.
CAN/ULC-S102 (similar
DOUGLAS FIR
Flame spread
Ignitable
Ignitable
method ASTM E 84).
FSC - 32
Standard Method of Test
for Surface Burning
Characteristics of Building
Materials and Assemblies
7.
Smoke development
PINE WOOD
Low smoke
Medium smoke
Medium smoke
according to a method,
developed index
developed index
developed index
described in
D m < 50[m 3 · m −1 · kg −1 ]
D m > 50[m 3 · m −1 · kg −1 ]
D m > 50[m 3 · m −1 · kg −1 ]
PCT BG 2010/000005
8.
Smoke development
PINE WOOD
Determination
Determination
Determination
according to BDS EN ISO
of smoke
of smoke
of smoke
9239-1
development
development >750% · min
development >750% · min
152.7% · min
Limit: ≦750% · min
9.
Smoke development
DOUGLAS FIR
Smoke developed
SDI > 450
SDI > 450
according to CAN/ULC-
index
S102 (similar method
SDI −170
ASTM E 84)
Limit SDI < 450
10.
Biodegradable flame
PINE WOOD
Biodegradable to a
Biodegradable to a
Biodegradable to a
retarded corrugated board
BEECH WOOD
greater degree than the
less degree than the
less degree than the
DOUGLAS FIR
untreated material
untreated material
untreated material
TABLE 10
Flame retarded
Test results
Test results
Test results
No
Test methods
materials
for D
for D1
for D2
1
2
3
4
5
6
1.
BDS EN ISO
“Nia” fabric
Self-
Ignitable
Ignitable
6941 Textile
Composition:
extinguishing
fabrics -
100% cotton.
(Class 1)
Burning
,,Clam” fabric
Self-
Ignitable
Ignitable
behaviour.
Composition:
extinguishing
Measurement of
70% cotton;
(Class 1)
flame spread
30% polyester.
properties of
,,Mini Mat” fabric
Self-
Ignitable
Ignitable
vertically
Composition:
extinguishing
oriented
100% polyester.
(Class 1)
specimens.
Plush fabric
Self-
Ignitable
Ignitable
Composition:
extinguishing
40% polyacrylnitrile;
(Class 1)
40% polyester/viscose;
20% cotton/polyester.
2.
JAR (FAR)
Polyamide carpet
Self-
Ignitable
Ignitable
25.853 This
Composition:
extinguishing
method is
100% polyamide.
applicable to
Polypropylene carpet
Self-
Ignitable
Ignitable
interior polymer
Composition:
extinguishing
materials, which
100% polypropylene
are used in civil
and cargo
airplanes
3.
Fiche UIC 564-2.
,,Liliana” fabric
Class A
Class C
Class C
Appendix 5. Test
composition:
method for
100% polyacrylnitrile
determining the
fire resistance of
coated and
uncoated textiles
in passenger
carrying railway
vehicles
4.
Biodegradable
,,Nia” fabric
Biodegradable to a
Biodegradable to
Biodegradable to
flame retarded
,,Clam” fabric
greater degree than
a less degree than
a less degree than
corrugated
,,Mini Mat” fabric
the untreated
the untreated
the untreated
board
Plush fabric
material
material
material
Polyamide carpet
Polypropylene carpet
TABLE 11
Flame retarded
Test results
Test results
Test results
No
Test methods
materials
For D
For D1
For D2
1.
Capillary activity of
Single wall
4.8 s
297.0 s
61.3 s
solutions of flame
corrugated board
retardants, s
2.
Paper and board.
Testliner
Self-extinguishing
Ignitable
Ignitable
Method based on BDS
16359/86 for
determination of
ignitability group
3.
Paper and board.
Single faced
Self-extinguishing
Ignitable
Ignitable
Method based on JAR
corrugated board
(FAR) 25.853 for
determination of
ignitability group
4.
Paper and board.
Single wall
Self-extinguishing
Ignitable
Ignitable
Method based on JAR
corrugated board
(FAR) 25.853 for
determination of
ignitability group
5.
Smoke development
Testliner
Low smoke
High smoke
High smoke
according to a method,
developed index
developed index
developed index
described in D
D m < 50[m 3 · m −1 · kg −1 ]
D m ≧ 500[m 3 · m −1 · kg −1 ]
Dm ≧ 500[m 3 · m −1 · kg −1 ]
6.
Smoke development
Single faced
Low smoke
High smoke
High smoke
according to a method,
corrugated board
developed index
developed index
developed index
described in D
D m < 50[m 3 · m −1 · kg −1 ]
D m ≧ 500[m 3 · m −1 · kg −1 ]
D m ≧ 500[m 3 · m −1 · kg −1 ]
7.
Smoke development
Single wall
Low smoke
High smoke
High smoke
according to a method,
corrugated board
developed index
developed index
developed index
described in D
D m < 50[m 3 · m −1 · kg −1 ]
D m ≧ 500[m 3 · m −1 · kg −1 ]
D m ≧ 500[m 3 · m −1 · kg −1 ]
8.
Biodegradable flame
Single wall
Biodegradable to a
Biodegradable to a
Biodegradable to a
retarded corrugated
corrugated board
greater degree than
less degree than the
less degree than the
board
the untreated
untreated material
untreated material
material
TABLE 12
Flame retarded
Test results
Test results
Test results
No
Test methods
materials
for D
for D1
for D2
1.
BDS ISO 9772: 2004
Polyurethane
Class HF-1
Class HF-2
Class HF-2
Cellular plastics.
Determination of horizontal
burning characteristics of
small specimens subjected
to a small flame
2.
Smoke development
Polyurethane
Low smoke
High smoke
High smoke
according to a method,
developed index
developed index
developed index
described in
D m < 50[m 3 · m −1 · kg −1 ]
D m ≧ 500[m 3 · m −1 · kg −1 ]
D m ≧ 500[m 3 · m −1 · kg −1 ]
Present invention
3.
Biodegradable flame
Polyurethane
Biodegradable to a
Biodegradable to a
Biodegradable to a
retarded corrugated board
greater degree than the
less degree than the
less degree than the
untreated material
untreated material
untreated material
TABLE 13
Flame
retarded
Test results
Test results
Test results
No
Test methods
materials
for D
for D1
for D2
1.
BDS ISO 9772: 2004
Expanded
Class HF-1
Class HF-2
Class HF-2
Cellular plastics.
polystyrene
Determination of horizontal
burning characteristics of
small specimens subjected
to a small flame
2.
Smoke development
Expanded
Low smoke
High smoke
High smoke
according to a method,
polystyrene
developed index
developed index
developed index
described in
D m < 50[m 3 · m −1 · kg −1 ]
D m ≧ 500[m 3 · m −1 · kg −1 ]
D m ≧ 500[m 3 · m −1 · kg −1 ]
Present invention
3.
Biodegradable flame
Expanded
Biodegradable to a
Biodegradable to a
Biodegradable to a
retarded corrugated board
polystyrene
greater degree than
less degree than the
less degree than the
the untreated material
untreated material
untreated material | The invention relates to a biodegradable halogen-free flame retardants composition used for fire-safety and prevention, that limits and extinguishes fires by means of increased resistance to ignition, slowing down burning rates and the rate of heat, smoke and toxic gas release from polymers with different physical and chemical properties and structure, such as textiles, wooden materials, paper, cardboard, corrugated board, leather, cellular polystyrene, foamed polyurethane, and items made of them. The composition according to the invention contains orthophosphoric acid, urea, triethanolamine, ammonia water, polydimethylsiloxane, surfactant, which may be anionic, cationic, amphoteric, non-ionic or mixtures thereof and water. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to brushless motors for driving storage disks, such as CD-ROM, CD-R, CD-RW, DVD-ROM, DVD-RAM, and DVD-RW. More particularly, the present invention relates to brushless motors in which magnetic field variations, generated by a rotor magnet, are detected by a rotational position detecting means that is disposed in a particular position on the stator side, such that the stator current can be switched using the detected result.
[0003] 2. Background Art
[0004] As shown in FIG. 6, by way of example, a brushless motor used to drive a disk comprises a stationary frame 100 , a shaft 104 rotatably supported by the stationary frame 100 through a bearing 102 , a rotor 106 mounted to the shaft 104 and rotating in union with the shaft 104 , a rotor magnet 108 attached to the rotor 106 , and a stator 110 supported by the stationary frame 100 in a position facing the rotor magnet 108 .
[0005] The stator 110 comprises a stator core 112 and statorwindings 114 having, for example, 3 phases, which are wound over the stator core 112 . Also, the rotor magnet 108 is magnetized with multipolar magnetization, in which the rotor magnet is magnetized into different magnetic poles alternating in the circumferential direction. The direction of current supplied to the stator winding 114 of each phase is changed in correspondence with the rotation of the rotor magnet 108 . The torque of the motor is obtained through repeated attraction and repulsion between the magnetic poles of the stator 110 and the magnetic poles of the rotor magnet 108 .
[0006] In order to make the brushless motor rotate, the current supplied to the stator winding 114 of each phase must be switched in sync with the rotation of the rotor magnet 108 . The timing for switching the current is generated by detecting variations of a magnetic field generated by the rotation of the rotor magnet 108 . The field detecting means 116 is disposed in a particular position on the stationary side. A Hall device 116 is used as one known example of field detecting means for that purpose.
[0007] The Hall device 116 generates a voltage depending on the amount of magnetic flux penetrating the Hall device. Accordingly, the greater a change in the magnitude of the terminal voltage, more precisely a change in the amount of magnetic flux penetrating the Hall device can be measured with higher sensitivity. In the brushless motor, variations of magnetic flux caused by the rotation of the rotor magnet 108 are detected by the Hall device 116 that is disposed in a particular position on the stationary side. Detection sensitivity in the rotor rotation can be increased by arranging the Hall device 116 at a position where the magnetic flux penetrating the Hall device is maximally changed with the rotor rotation.
[0008] Further, the rotor magnet 108 is multipolar-magnetized such that different magnetic poles are alternating in the circumferential direction and in the radial direction. In a cross-section of the rotor magnet 108 shown in FIG. 6, the radially inner side of the rotor magnet is magnetized into an N (or S) pole and the radially outer side thereof is magnetized into an S (or N) pole. Then, lines of magnetic force generated by the rotor magnet 108 are radially extended from both poles and are deflected, to a large extent, depending on the arrangement of magnetic bodies disposed in the surroundings of the rotor magnet. It is usually thought that the sensitivity in detecting the rotor rotation is increased by arranging the Hall device in a position directly below, and closer to, the rotor magnet. In positions away from the position directly below the rotor magnet, the rotation detection sensitivity is reduced, while it is relatively increased by arranging the Hall device in a position where the lines of magnetic force are concentrated (and hence the density of magnetic flux is relatively high).
[0009] Recently, notebook personal computers capable of handling CDROMs or the like have been commercialized. The size and thickness of these disk drives for driving CD-ROMs or the likes have been reduced. Correspondingly, there is a demand for a reduction in the size and thickness of the brushless motors that are to be incorporated in these disk drives.
[0010] However, because the Hall device 116 is disposed directly below the rotor magnet 108 , as shown in FIG. 6, the presence of the Hall device 116 impedes an attempt at reducing the motor thickness in the axial direction.
[0011] On the other hand, when attempting to move the position of the Hall device 116 radially inward of the rotor magnet 108 to avoid such a drawback, there is not sufficient space to accommodate the Hall device, because the stator windings 114 are disposed radially inward of the rotor magnet as shown in FIG. 7. Also, even if there is sufficient space, it would be difficult to precisely detect the rotor rotation because, in a position away from the rotor magnet, the density of magnetic flux is reduced and, therefore, the sensitivity in detecting the rotor rotation is reduced.
SUMMARY OF THE INVENTION
[0012] It is an object of the present invention to provide a brushless motor, in which a rotor position detecting device is able to detect changes in the density of magnetic flux that are caused by rotation of a rotor magnet, while reducing the size and thickness of the motor.
[0013] According to the present invention, a brushless motor includes a rotor position detecting device disposed between stator teeth, rather than directly below a rotor magnet, so that the distance between a lower end of a rotor magnet and a stationary frame is minimized. This results in a thinner brushless motor than conventional designs. In the preferred embodiment of the present invention, the rotor position detecting device is a Hall device.
[0014] Further, according to the present invention, the windings are wound over a stator in larger number on the inner peripheral side than they are on the outer peripheral side thereof. However, the total number of stator windings remains substantially equal to that in a conventional motor, so that sufficient space to accommodate the Hall device is defined between the adjacent teeth of a stator core.
[0015] In addition, the Hall device that is disposed in such a space is fixed in a position where the lines of magnetic force generated from the rotor magnet are concentrated (and hence the density of magnetic flux is relatively high), and the magnetically sensitive surface of the Hall device is inclined with respect to the axial direction of a shaft of the motor. This arrangement enables the Hall device to receive the most possible magnetic flux generated during the rotation of the rotor magnet. As a result, the Hall device can detect, with satisfactory accuracy, the timing of switching in a stator current supplied to the brushless motor.
[0016] With the arrangements described above, the present invention has succeeded in reducing the size and thickness of the brushless motor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a sectional view of a brushless motor, according to the present invention;
[0018] [0018]FIG. 2 is a sectional view of a stator of the brushless motor of FIG. 1;
[0019] [0019]FIG. 3 is a perspective view of a Hall device of the brushless motor of FIG. 1;
[0020] [0020]FIG. 4 is a side view of the Hall device of FIG. 3;
[0021] [0021]FIG. 5 is a sectional view of a disk drive with the brushless motor of FIG. 1 disposed therein;
[0022] [0022]FIG. 6 is a sectional view of a portion of a conventional brushless motor; and
[0023] [0023]FIG. 7 is a plan view of a portion of the conventional brushless motor of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] [0024]FIG. 1 is a sectional view of a brushless motor for driving a disk according to one embodiment of the present invention, and FIG. 2 is a sectional view of a stator used in the brushless motor.
[0025] It is to be noted that the “vertical direction” used in the following description of one embodiment of the present invention implies the vertical direction as defined on each of the drawings for the sake of convenience, but that the direction of the brushless motor as actually mounted is not limited to the illustrated direction.
[0026] The brushless motor for driving a disk according to the described embodiment illustrates a motor used in a disk drive for a CD-ROM or the like. The brushless motor comprises a frame 1 , a bushing 5 fixed to the frame 1 to stand in the vertical direction, a sleeve bearing 9 fitted to the bushing 5 , a shaft 7 rotatably supported by thesleeve bearing 9 , and a substantially cup-shaped rotor 17 .
[0027] The frame 1 , serving as a stationary member, has a central hole 3 formed therein, and the bushing 5 is fitted to the central hole 3 . The bushing 5 is fabricated from a magnetic material, such as iron or stainless steel, and has a substantially cylindrical shape. The bushing 5 is fixed to the frame 1 by plastically deforming a caulked portion 51 a , which is formed at a lower end of the bushing 5 , toward the outer peripheral side. The sleeve bearing 9 is fitted to an inner periphery of the bushing 5 on the upper side, and a closing plate 11 is attached to a lower end of the bushing 5 to enclose a bottom opening of the bushing 5 . A disk-shaped thrust bearing plate 13 is attached to an upper surface of the closing plate 11 , and the thrust bearing plate 13 and the closing plate 11 are both fixed to the bushing 5 by plastically deforming a caulked portion 51 b , which is formed at the lower end of the bushing 5 , toward the inner peripheral side.
[0028] A projection 52 is formed at the upper end of the bushing 5 and extends outwardly from its outer periphery. A hook 14 is attached to an inner portion of a rotor 17 so that it is capable of engaging the projection 52 , whereby the amount of axial movement of both the shaft 7 and the rotor 17 is restricted.
[0029] The rotor 17 , serving as a rotating member, is formed of a magnetic material, such as iron, by pressing. The rotor 17 comprises an upper wall portion 17 a , a peripheral wall portion 17 b extending downward from an outer periphery of the upper wall portion 17 a , and a boss portion 17 c erected at the center of the upper wall portion 17 a and having a circular bore formed through the boss portion 17 c . Then, the boss portion 17 c is fitted over an upper portion of the shaft 7 so that the shaft 7 and the rotor 17 are rotated in union with each other.
[0030] An upper surface of the upper wall portion 17 a of the rotor 17 serves as a loading portion on which a disk, such as a CD-ROM, is loaded. A buffer member 21 is attached to an upper surface of an outer peripheral portion of the upper wall portion 17 a , and a disk (not shown) is placed on the upper wall portion 17 a with the buffer member 21 interposed therebetween.
[0031] Further, a center boss 23 formed of a nonmagnetic material and fitted to a center hole of the disk is mounted to the boss portion 17 c of the rotor 17 . The center boss 23 is provided with a plurality of chucks 25 which are movable in the radial direction and are arranged at equal angular intervals. Each of the chucks 25 is urged radially outward by a spring 26 disposed inside the chuck 25 . Accordingly, when the center hole of the disk is fitted to the center boss 23 , an inner peripheral edge of the disk pushes the chucks 25 radially inward against the biasing forces of the springs 26 acting radially outward. Then, when the disk is loaded in a position where it contacts the buffer member 21 , a distal end of each chuck 25 is positioned over an upper surface of an inner peripheral portion of the disk around the center hole, whereupon the chuck 25 now presses the disk against the upper wall portion 17 a of the rotor 17 by the biasing force of the spring 26 acting radially outward. As a result, the disk is properly placed on the upper wall portion 17 a of the rotor 17 . In addition, the center boss 23 is provided with a plurality of center aligning fingers 27 positioned between the chucks 25 in the circumferential direction. Upon loading of the disk, the center aligning fingers 27 contact the inner peripheral edge of the disk for center alignment of the disk.
[0032] The structure constituting the features of the present invention will now be described in detail with reference to FIGS. 1, 2, 3 and 4 .
[0033] As shown in FIG. 1, a cylindrical rotor magnet 19 is attached to an inner surface of the peripheral wall portion 17 b of the rotor 17 and is positioned to face the stator 15 with a very small gap left between them in the radial direction. The stator 15 comprises a stator core 15 a and windings 15 b wound over teeth (not shown) projecting from a base portion of the stator core 15 a in a radial pattern. The stator 15 is fitted to a stepped portion 53 formed in an upper outer peripheral portion of the bushing 5 . Further, an annular magnet 18 is attached to an upper surface of the base portion of the stator core 15 a . The annular magnet 18 is positioned to face the upper wall portion 17 a of the rotor 17 in the axial direction for applying a magnetic bias to the rotor 17 .
[0034] As shown in FIG. 2, by way of example, the windings 15 b are wound such that the number of windings is larger on the inner peripheral side than on the outer peripheral side. With this arrangement, a space sufficient to accommodate a Hall device 31 is ensured between the adjacent teeth of the stator core 15 a.
[0035] Corresponding to those spaces, a plurality of Hall devices 31 are attached to a circuit board 29 that is disposed on the frame 1 . In this embodiment, since the number of teeth of the stator core 15 a is 12 and the windings 15 b are wound in 3 phases, three Hall devices 31 are disposed between three pairs of the adjacent teeth of the stator core 15 a.
[0036] Further, as shown in FIGS. 3 and 4, the Hall devices 31 are each fixed in the above-mentioned space at a position where magnetic flux is maximally changed with the rotor rotation, and the magnetically sensitive surface 31 a of each Hall device 31 is inclined at a predetermined angle with respect to the axial direction of the shaft 7 . The predetermined angle is selected to a value at which magnetic flux is maximally changed with the rotor rotation. With this arrangement, in spite of the Hall device being fixed to a location away from the position directly below the rotor magnet 19 , the Hall device can detect, with satisfactory accuracy, changes in the density of magnetic flux caused by the rotation of the rotor magnet 19 . Consequently, not only the stator current can be switched using the detected result to make the rotor rotate accurately, but also the rotor magnet 19 can be positioned closer to the upper surface of the frame 1 , with the circuit board 29 interposed between them. The resulting brushless motor has a smaller thickness than a conventional one.
[0037] As described above, by winding the windings 15 b over the stator core 15 a in a larger number on the inner peripheral side than on the outer peripheral side thereof, while keeping the total number of the stator windings 15 b wound over each tooth of the stator core 15 a substantially equal to that in the conventional motor, a space sufficient to accommodate the Hall device 31 is defined between the adjacent teeth of the stator core. Such unevenness in the number of windings can be realized by estimating a position where the sensitivity in detecting the rotor rotation is maximized by arranging the Hall device 31 in that position, and determining a manner of winding the windings, with which the space is created in that position. By thus ensuring the space, it is possible to adjust the position where the Hall device 31 is to be fixed.
[0038] The inner construction of a general disk drive 40 will now be described with reference to FIG. 5. The disk drive 40 comprises a housing 42 , a brushless motor 44 fixedly disposed within the housing 42 , a removable disk 46 having the shape of a circular plate and held on the brushless motor 44 , and a pickup device 48 for writing and/or reading information in and/or from a predetermined position on the disk 46 during the motor rotation.
[0039] While one embodiment of the present invention has been described above, the present invention is not limited to the above-mentioned embodiment, but can be modified in various ways.
[0040] For example, the above-mentioned embodiment uses the Hall device 31 having the magnetically sensitive surface 31 a inclined with respect to the axial direction of the shaft 7 . However, a Hall device having a magnetically sensitive surface parallel to the axial direction of the shaft may also be used.
[0041] Further, while a Hall device is used as a rotational position detecting means in the above description, the rotational position detecting means is not limited to the Hall device.
[0042] Moreover, the embodiment has been described in connection with the disk driving motor of the so-called outer rotor type in which the rotor magnet 19 is disposed on the side radially outward of the stator 15 . However, the present invention is also applicable to a disk driving motor of the so-called inner rotor type in which a rotor magnet is disposed on the radially inward side of a stator. In such a case, similar advantages in operation to those in the above-mentioned embodiment can also be obtained.
[0043] Additionally, while the embodiment of the present invention has been described in connection with the disk driving motor, the applicable range of the present invention is not limited to the field related to driving of disks. The present invention can also be employed in other various fields of applications, and similar advantages in operation to those in the above-mentioned embodiment can be obtained. | A brushless motor includes a rotor position detecting device disposed between stator teeth, rather than directly below a rotor magnet, so that the distance between a lower end of a rotor magnet and a stationary frame is minimized. This results in a thinner brushless motor than conventional designs. In the preferred embodiment of the present invention, the rotor position detecting device is a Hall device. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to insulating and leaktight coverings, and in particular coverings for industrial buildings.
These coverings fixed to a framework comprise a thermal insulation between a loadbearing element and a cladding. This insulation is principally realized by plates or panels laid touching one another. These plates are fastened firmly to the loadbearing element by a mechanical fixing means when a support consists of profiled steel sheets.
The mechanical fixing means consists of a screw, or a rivet or a bolt fastened firmly to the profiled steel sheet by drilling or by welding. At its upper part, a head of the screw, rivet or bolt has a washer of small dimensions, of a diameter of the order of 50 to 70 mm.
The cladding is fastened firmly to the insulating plates by adhesive bonding or by welding using a heat source, usually with a flame or air torch, over the entire surface of the insulating panels and/or at the level of the washers of the mechanical fixing means. The latter can be improved for welding by an appropriate surface coating or by a washer made from the same material as the cladding, and of larger dimensions, placed in between the metal washer and the underlying insulating panel.
A more recent technique provides for a first bed of foils constituting the lower part of the cladding to be unwound dry over the insulating panels. The mechanical fixing means then traverse the foil bed and the insulating panels. In the case of panels sensitive to the flame of a torch, a prior heat screen can be employed on the insulator. The upper part of the cladding is then adhesively bonded or welded to the lower part comprising its visible washers.
Another technique provides mechanical fixing means at the level of lap joints of the widths of the cladding. A lapped part is adhesively bonded or welded, on the one hand, to the edge of the adjacent width and, on the other hand, to the small washers of the fixing means.
The wind creates considerable localized compression and suction forces on the covering (vortices, shielding effect behind a wall or a salient part of the roofing). The forces are exerted on the outer surface and hence on the cladding, which ultimately stresses the loadbearing element and the structure of the building.
In the area lying between the cladding and the loadbearing element, these forces create, at the level of one or more fixing means, tear-away forces perpendicular and parallel to the covering surface. These latter forces are more substantial the greater the spacing between the fixing devices. They can result in the cladding ripping at the head of the fixing means and/or the fixing means being torn away at the level of their connection to the framework or the loadbearing element under a torque or traction effect.
For these two latter techniques, at least one sheet of the cladding is pierced by the mechanical fixing means.
In all cases, in order to resist the suction forces created by the wind, the French standards defined within the D.T.U. 43.3 and common practice provide for a minimum of five fixing means per m 2 of roofing, based on the fact that a fixing means resists a tear-away force of approximately 900N.
A rupture occurs at the level of the plane of the adhesive bonding of the cladding to the washer, or as a result of the head of the fixing means becoming dislodged and passing through the washer, or as a result of the fixing means being torn away through the profiled steel sheet. The values of the rupture are relatively homogeneous, of the order of 900 to 1300N.
The large number of fixing means makes implementation lengthy and expensive. Furthermore, the performance of the cladding is considerably diminished at the level of the fixing means because the cladding is partially pierced, or because it can be punched by the head of the fixing means passing through the washer, or alternatively torn at the periphery of the washer when the latter is locked, redundantly, on the rod of the, fixing means, as described in French Patent 1,522,378. Such phenomenon favors the breaking of the weld between the bolt and the profiled steel sheet. These disadvantages are considerably amplified when the insulating panels are compressible but elastic.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a covering which is simpler and quicker to implement than the conventional openings covering and, moreover, which has an improved resistance to wind.
To this end, the invention provides a leaktight covering, in particular for an industrial building, comprising a loadbearing element adapted to be fixed to a framework element of the building, a layer of an insulating material arranged on the loadbearing element, and a cladding covering the layer of insulating material, connection means being provided in order to maintain such three components assembled together. The connection means comprise a first fixing member fixing the loadbearing element to the framework and comprising, above the loadbearing element, an extension piece of a length substantially equal to the thickness of the insulating layer and a flexible plate and a second fixing member bearing on such flexible plate via a widened head and/or a rigid washer and fixed to the extension piece. The dimension of the widened head or of the rigid washer is between the maximum dimension of the first or the second member in the vicinity of the outer surface of the layer of insulating material and the dimension of the flexible plate. The cladding is fixed only to the flexible plates.
In this manner, the cladding which will be fixed to a number of flexible plates will be fastened firmly to the framework moreover, the invention also makes it possible to fasten the loadbearing element firmly to the framework in such a way that all the suction forces to which the covering is subjected will be transmitted to the framework element, purlin or beam.
This high-performance device permits the use of at most one fixing means per m 2 of covering (or even one per 2 m 2 ), thus dividing the total number of fixing means by more than five as compared with the conventional techniques described above.
In the case of a steel framework, the above-mentioned screw can be a self-tapping screw. In the case of a concrete framework, the abovementioned screw is engaged in a metal insert of the framework element.
BRIEF DESCRIPTION OF THE INVENTION
Other features and advantages of the invention will become apparent from the description which follows of illustrative embodiments of the invention, made with reference to the attached drawings, in which:
FIG. 1 is a diagrammatic sectional representation of a first embodiment of the invention;
FIG. 2 is a diagrammatic sectional representation of a second embodiment of the invention;
FIG. 3 is a view in section along a framework element and corresponds to the embodiment in FIG. 2; and
FIGS. 4 and 5 are sectional views illustrating a particular embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
A framework element can be seen in FIGS. 1 and 2 would consists of a steel joist 1 constituting a purlin of a framework. A loadbearing element 2 consisting of a profiled steel sheet is arranged transversely on purlins 1.
An insulating layer 3 consisting, for example, of plates of insulating material is placed on the load-bearing element 2. The covering or roofing is completed by a cladding 10 which is placed on the outer face of the insulating layer 3.
A fixing device according to the invention comprises a first fixed member comprising a screw 4 which is fixed to the purlin 1 with interposition of the support element 2 which is therefore in this way firmly fastened to the framework.
This first member serves firstly to fix the loadbearing element 2 to the framework purlin 1, and also constitutes an element forming part of a connection means for the three components of the covering, namely the loadbearing element 2, the insulating layer 3 and the cladding 10.
The screw 4 is advantageously a self-tapping screw. In the case of a concrete framework, screw 4 engages in a metal insert of the framework element.
A head 5 of the screw 4 has an extension piece aligned with the shaft of the screw and arranged on the opposite side of the head 5. In the first embodiment of FIG. 1, this extension piece consists of an internally threaded, hollow, cylindrical intermediate piece 6 which is open at its free end and a bottom 20 of which is fixed to the loadbearing element via the screw 4. In the embodiment in FIG. 2, the extension piece consists of a threaded rod 7. The length of the cylinder 6 or of the rod 7 is substantially equal to the sum of the thicknesses of the insulating layer 3 and of the loadbearing element 2.
A second member comprising a part including a rigid washer is fastened firmly to the abovementioned first member. In the case of FIG. 1, this second member is a screw 8 which engages in the cylinder 6, which has a milled flat head and on which is engaged a rigid washer 9 of diameter and forming a rigid distribution element.
In the embodiment in FIG. 2, the second member consists of a sort of plug 11 which has an internally threaded tubular part 12 which interacts with the rod 7 and which is surmounted by a rigid flat head 13 constituting a bearing washer or rigid distribution element similar to the rigid washer 9.
Lastly, the fixing device comprises a flexible plate 21 which is placed between the rigid washer 9 or the rigid flat head 13 and the insulating panels 3. Plate 21 is preferably circular, of diameter D and of large dimensions.
Flexible plate 21 is, for example, made from a metal of small thickness and can comprise a surface coating compatible with the material constituting the cladding. It is also possible to use a material comprising a reinforcement which is woven or nonwoven, made from glass, polyester, organic material or from a mixture of these components, in which case the plate is coated with a material identical to or compatible with that of the cladding.
The abovementioned plate 21 can advantageously be fastened beforehand firmly to the washer 9 or to the rigid head 13 by adhesive bonding or welding.
In the embodiment in FIG. 1 comprising a first member consisting of a screw, it is also possible to provide for the flexible plate to be crimped between two rigid washers corresponding to the washer 9.
The rigid washer 9 or the flat head 13 can have a diameter a of the order of 80 mm.
The flexible plate 21 must have a mechanical strength under tension which conforms with the equation R t πa>5000N and preferably of the order of 8000N, the mechanical strength under tension R t being expressed in Newtons per cm width and measured in accordance with the standard NF G07--001. Plate 21 must also have a tear strength Rd (measured in accordance with the UEATC method 5.4.1., July 1982) which is at least equal to 200N and preferably of the order of 400N. To this end, the diameter d of the cylindrical piece 6 in the embodiment in FIG. 1, or of the second member 11 in the embodiment in FIG. 2, in the vicinity of the outer surface of the layer 3 of insulating material, must be not less than 6 mm and preferably of the order of 10 mm.
Moreover, the difference between the diameter D of the plate 21 and the diameter a of the rigid washer 9 or of the flat head 13 must be at least equal to 100 mm and preferably of the order of 170 mm. As a result, it is possible to use, for example, a flexible plate whose diameter D is of the order of 250 mm.
The diameter of the washer or rigid head a and the diameter d of the fixing element are advantageously selected in such a way that the difference (a-d) is approximately equal to 90 mm and in any case greater than 70 mm. This makes it possible to prevent the flexible plate 21 from allowing the rigid piece 9 or 13 to "escape" by slipping, tearing or becoming dislodged.
FIG. 3 is a view in section perpendicular to FIG. 2 and shows the method of fixing the loadbearing element 2 to the purlin 1. It can be seen that the rod 7 is integrally connected to the head of the self-tapping screw 4 which is fixed in a recess of the profiled sheet 2 on the purlin 1 with the interposition of a washer 14.
The fixing device according to the invention advantageously comprises at least one thermally insulating element in order to prevent the formation of thermal bridges.
FIGS. 4 and 5 show an alternative embodiment of the invention. This is intended in particular for edge purlins 41 which are directly adjacent to an acroterium or ornamental summit 42.
In this case, the axis of the fixing point of the cladding is offset relative to the axis of fixing of the loadbearing element to the purlin. To this end, the first member consists of two screws 51 and 52 arranged symmetrically relative to the axis of a purlin 41 which constitutes the axis of fixing of a profiled sheet 44 to the purlin 41.
Screws 51, 52 serve to fix one end of a base 43 to the purlin 41. Base 43 preferably has, in cross-section (FIG. 5), the shape of a U and carries, at one of its ends, a hollow cylindrical member 45 similar to the cylindrical piece 6 in FIG. 1.
It can be seen that the axis of the hollow member 45 is offset relative to the axis of the purlin 41. It is, of course, possible to provide a similar arrangement in which the base 43 supports a rod similar to the rod 7 in FIG. 2.
A covering in accordance with the present invention can be realized as follows. Firstly, the loadbearing element 2, 44 (profiled sheet) is fixed to the beams or purlins 1, 41 of the framework by means of the fixed members 4 or 51, 52. The panels of the insulating layer 3, 46 are positioned by "impaling" them on the extension pieces 6 and 7 respectively of the first members. The flexible plates are positioned where they are not firmly fastened to the rigid washers, and then the fixing of the second members 8, 11 to the first members is carried out so as to fasten the second members firmly to the loadbearing element and the purlin or beam. Then the cladding is positioned and is fixed by welding or adhesive bonding to the flexible plate and the rigid washer of the devices according to the invention.
The various mechanical elements (self-tapping screw, first member, second member) are dimensioned so as to have a tear strength of the order of 5000N. In this way a homogeneous assembly is obtained which has a tear strength of 5000N, and all of the forces resulting from a suction exerted on the cladding are transmitted directly to the framework by the fixing members.
Since the number of fixing means per m 2 is very considerably reduced, the cost and the time taken to install a covering are considerably reduced, which makes it possible to construct coverings with large surface areas, in particular coverings for industrial buildings.
Furthermore, in the event of people moving about on the covering or of compressive loads, the cladding follows the movements of the flexible plate and cannot therefore be torn at the level of the periphery of the rigid washer. Highly compressible insulators can be used for the insulating layer, which makes it possible to reduce further the cost and this is particularly so in the case where the flexible plate is crimped between two rigid washers.
It is possible, for example, to use mineral wool having a density of less than 120 kg/m 3 and preferably equal to 100 kg/m 3 instead of mineral wool of a density of 150 kg/m 3 which is currently used.
It is also possible to use glass wool with a density of less than 90 kg/m 3 instead and in place of a glass wool of a density of 110 kg/m 3 . | A leaktight covering, in particular for an industrial building, includes a loadbearing element adapted to be fixed to a framework element of the building, a layer of an insulating material arranged on the loadbearing element, and a cladding covering the layer of insulating material, with connection structure holding such three components assembled together. A first member is used, on the one hand, to ensure fixing of the loadbearing element to the framework element and, on the other hand, forms part of the connection structure. A second member is linked to the first member and to the cladding. In a first embodiment, the first member is a screw screwed into the framework element, and the connection structure includes a hollow, cylindrical intermediate piece, a bottom of which is fixed to the loadbearing element via the screw. | 4 |
RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 61/760,045, filed on Feb. 2, 2013.
BACKGROUND OF THE INVENTION
The present disclosure describes an apparatus and process for sterilization of items, most notably surgical instruments, used in medical, dental, veterinary, or other patient-care markets. The invention relates, more particularly to an improved high velocity dry heat sterilization device to prohibit the introduction of microbial contaminants to the sterilization chamber during the entire sterilization cycle and to ensure such items once sterilized, remain sterile when removed from the high velocity dry heat sterilization device.
There are three distinct types of dry heat sterilizers: (1) Static hot air sterilizers in which air convection is generated solely by gravity as hot air rises and cooler air descends; (2) Mechanical convection sterilizers in which air is moved by blowers to uniformly distribute the heated air and equally transfer heat throughout the load; and (3) High velocity hot air sterilizers in which air is moved at a high rate, such as at 2500 feet per minute, with the flowing air serving as the heat transfer medium. Both static air and mechanical convection sterilizers require minimally one hour (at 340° F.) or two hours (at 320° F.) to achieve sterilization whereas the high velocity hot air sterilizer can sterilize in six to twelve minutes (at 375° F.), depending on instrument type or packaging.
A high velocity hot air sterilization device has been disclosed by Cox et al. in U.S. Pat. Nos. 4,824,644; 4,894,207; 4,923,681; and 4,975,245. This device was designed and marketed for use in the dental and orthodontic markets to rapidly sterilize small instruments without instrument corrosion. The Cox High Velocity Hot Air Sterilization Device accommodates wrapped or unwrapped instruments which are placed into a wire mesh, open basket and held for pre-designated times at 375° F. as prescribed under the U.S. Food and Drug Administration 510(k) notification (K8726643A and K881371). Upon completion of the sterilization cycle, the basket containing the instruments is removed from the sterilizer. In this system described by Cox et al., unwrapped instruments are subjected to potential microbial contamination from environmental sources during the sterilization process and upon removal from the sterilizer since the sterilizer allows outside air to circulate within the sterilization chamber during the sterilization cycle and because the trays are subjected to outside air following removal from the sterilizer. For dental procedures this practice is acceptable since sterilization of dental instruments has placed emphasis on obtaining complete kill of microorganisms originating from previous patients with no concern regarding contamination from microbial contaminants having environmental origin. Other high velocity hot air sterilization devices by Allen and Sildve (U.S. Pat. No. 4,935,604) and Goldman (U.S. Pat. No. 6,039,926) also operate in a similar fashion that allows unwrapped instruments to be subjected to environmental microbial contaminants.
Existing high velocity hot air sterilization devices do not address the introduction of environmental microbial contaminants during the sterilization process or afterward as detrimental to dental patient care. Most orthodontic and dental procedures are topical and are performed in an oral environment already containing high microbial concentrations and contaminants of environmental origin play no role in disease transmission from instruments. All high velocity hot air sterilization devices directly allow outside air into the air handling system by means of fans, louvered vents, or unclosed or unsealed plenums before, during, and after the sterilization cycle. In these systems any instrument or device that is not wrapped, packaged, or pouched is subjected to microbial contamination from continually introduced outside air during the sterilization cycle that has not received the prescribed time and temperature requirements necessary to ensure microbial inactivation. Upon completion of the sterilization cycle, unwrapped instruments are directly subjected to potential environmental microbial contaminants upon the opening of the sterilization chamber and their removal. No unwrapped instrument protection is afforded with existing high velocity, hot air sterilization devices.
For use in critical-care environments including dental surgical, hospital surgical, ambulatory or outpatient surgical, and veterinary surgical procedures, patient contact items must be devoid of all viable microbial contaminants to avoid infection or disease transmission. No microbial contaminants can be introduced during the sterilization process, nor can they be introduced after the sterilization process. For unwrapped or directly exposed instruments, any air introduced to the sterilization chamber after the initiation of the sterilization cycle must be subjected to the identical sterilization parameters of designated time and temperature as the instruments being sterilized. This requirement precludes the introduction of any outside air to the air handling system and hence the sterilization chamber, once the sterilization cycle has been initiated; this requirement is not followed by the prior art high velocity hot air sterilizers.
High velocity, hot air sterilization technology has the potential to meet the sterilization requirements of the critical-care medical environment as a standard sterilization technology for heat-resistant instruments or devices. However, the original design of high velocity hot air sterilizers has also limited its usefulness due to the sterilizer's inability to accommodate closed instrument containers that could assure internal sterilization parameters are achieved within an instrument container for instrument sterilization and yet maintain the sterility of those instruments from environmental microbial contamination once the instrument container was removed from the sterilizer chamber.
Although wrapping instruments had been a primary mechanism of maintaining instrument sterilization using wet steam heat, static dry heat, high velocity hot air, radiation, and chemical agents in the past, emphasis has shifted to the use of closed containers for sterilizing larger quantities of instruments and providing subsequent protection from environmental microbial contaminants. With the increased use of closed container systems in critical-care medical environments, the use of closed containers in dental practices has also become the preferred way to protect and store sterilized dental instruments.
Closed containers allowing migration of the sterilizing agent into the container for instrument sterilization have been developed to accommodate specific sterilizing agents. The design of the container and/or its portal design must be congruent with the attributes of the sterilizing agent and must not interfere with the influx of the sterilizing agent. Accordingly the container design must assure the protection of the sterilized instruments from microbial agent contamination from the point of the container's removal from the sterilizer until the container is opened for instrument use within the sterile field.
Closed containers have been designed to incorporate top and bottom perforations protected by a microbial filtering material permeable to gas or vapor sterilants, but impermeable to microorganisms. These perforations may be static, remaining continuously open and filtered. An example of such a container is described in U.S. Pat. No. 4,551,311 issued Nov. 5, 1985 to Lorenz and entitled “Sterilizer Container.”
Another design incorporates open side vents (U.S. Patent Application Publication No.: US 2003/0211023 A1; Su-Syin Wu and Charles Howlett; “Instrument Sterilization Container Having Improved Diffusion”) to allow gas or vapor sterilants into the container. Protection from microbial contaminants is accomplished through the incorporation of internal or external microbial filters by wrapping the instruments or wrapping the entire container.
The container may also be of a non-static design, providing an automatic opening and shutting mechanism. For steam sterilization the pressure differential between the inside and outside of the container triggers an automatic opening and closing of a pressure-sensitive valve (U.S. Pat. No. 5,352,416 issued Oct. 4, 1994 to Wagner and entitled “Valve Arrangement for a Sterilization Container”).
High velocity hot air sterilizers employ rapidly flowing hot air over the surface of an article to affect microbial kill Hot air influx into the container at a sufficient rate is therefore necessitated to achieve sterilization in the prescribed time-temperature profile. Any barrier to that necessitated rate of airflow will significantly impact sterilization conditions. Research has demonstrated that container perforation coupled with fabric filtration will disturb the high velocity influx of hot air into the instrument container and have significant impact on the conditions necessary to achieve reliable instrument sterilization. Sterilization conditions cannot be achieved within an instrument container employing high velocity hot air as the sterilant when using air filtration devices designed to prevent the influx of microbial contaminants. Existing instrument containers that employ perforations in the top, sides, and/or bottom of the container also require fabric filtration to mitigate microbial contaminants and thus, prohibit the necessary conditions required for instrument sterilization by high velocity hot air. Existing instrument containers that utilize pressure valves were specifically designed for pressurized wet steam sterilizers and do not function under the non-pressurized treatment conditions employed in high velocity dry heat sterilization. Static, open vent designs still require instrument or container wrapping.
A need exists in the art for a high velocity hot air sterilizer that provides and maintains sterile conditions within the high velocity hot air sterilizer's air handling system and sterilization chamber during the complete sterilization cycle. A need also exists in the art for a high velocity hot air sterilizer that provides the capability to sterilize medical instruments within an instrument container that allows re-distribution of sterile air during the sterilization cycle, yet can be closed and sealed before removal from the high velocity hot air sterilizer upon the completion of the sterilization cycle to assure instrument sterility to point of use.
U.S. patent application Ser. No. 14/073,536 (Slavik, 2013) provides a mechanism that allows rapidly flowing hot air to enter an instrument container. This mechanism incorporates a sliding door into the instrument container to be opened during the sterilization cycle and closed upon its completion. The mechanism to open and close the container's sliding door is incorporated within the sterilizer with both components being integral to one another in their operation.
The present invention provides a novel alternative to the one described by Slavik, 2013 by supplying high velocity hot air from the high velocity hot air sterilizer to the instrument container by means of an air supply portal and directing that air flow over the instruments by means of an inserted and removable plenum and directed air vents housed in the container, thus providing the airflow and temperature required of high velocity hot air sterilization. Instrument container air is continuously re-circulated from the container to the high velocity hot air sterilizer by means of a second portal, re-directing it to the base unit for re-heating for re-introduction at the designated velocity and temperature back into the instrument container. This process continues through the completion of the sterilization cycle at which time the container is removed from the high velocity hot air sterilizer. Upon the container's removal, the instrument container's air supply and exhaust ports are automatically closed, sealed, and latched to ensure that the sterilized instruments remain sterile within the instrument container.
SUMMARY OF THE INVENTION
The present disclosure describes a high velocity hot air sterilization device for sterilizing medical, dental, or veterinary instruments or other objects used in critical-care environments. The sterilization device described herein is an improvement over prior devices because the sterilization device described herein (1) incorporates a closed and sealed recirculating air handling system and sterilization chamber during the course of the sterilization cycle and (2) provides the capacity within the high velocity hot air sterilization device to sterilize instruments within an instrument container that allows the parameters necessary of high velocity hot air sterilization, yet can be closed and sealed to prevent instrument contamination once the container is removed from the sterilization device.
More specifically, the disclosure describes a sterilization device having: (1) the ability to sterilize trays or racks of instruments and objects within an instrument container or in an open basket configuration, wrapped or unwrapped and ensure such are not subject to any outside air entering the sterilization chamber and all aspects of the sterilizer's air handling system during the course of the sterilization cycle; (2) the ability to generate and supply high velocity hot air to instruments, objects, or instrument containers therein said high velocity hot air sterilizer device being configured to deliver to the sterilization chamber only high velocity hot air that undergoes the identical sterilization parameters of time and temperature prescribed by the U.S. Food and Drug Administration (FDA) for the sterilization of instruments; (3) the ability to maintain the sterilization chamber's sterilized environment by ensuring all sterilizer doors, air handling plenums, vents, and other potential air infiltration areas are sealed to prevent the flow of external air into the air handling system or sterilization chamber during the sterilization cycle; and (4) the ability to accommodate instrument containers which allow the sterilization parameters of high velocity hot air sterilization be fulfilled and yet not allow the infiltration of environmental microbial contaminants once removed from the sterilizer.
The present disclosure describes the instrument container as either being positionable within the high velocity hot air sterilization device or external to the sterilization device and mateable therewith to receive high velocity hot air from the high velocity hot air sterilization device. As described herein, the container is configured to uniformly distribute the air within the container, and exhaust the air back to the closed air handling system of the high velocity hot air sterilization device for subsequent, continuous recharging of heat and air velocity and re-distribution to the instrument container during the course of the sterilization cycle. The instrument container is configured to accept and exhaust sterilizing air during the sterilization cycle. The container is also configured to close to the influx of environmental microbial agents prior to its removal from the high velocity hot air sterilizer upon completion of the sterilization cycle to assure instrument sterility until time and place of use.
Thus, the present invention relates to a high velocity hot air sterilization device for sterilizing medical, dental, veterinary instruments, or other objects requiring total sterility of such instruments or objects by providing during the course of the sterilization cycle a closed and sealed, recirculating air handling system and sterilization chamber which disallows the influx, intrusion, or infiltration of outside contaminated air to come into contact with aforementioned instruments or objects.
The high velocity hot air sterilization device consists of an air handling system comprised of (1) a recirculating fan with associated plenum, (2) an electric heating coil or similar device (3) a hot air supply plenum, (4) a sterilization chamber, and (5) a return air plenum. The air handling system is completely sealed and closed to the infiltration of outside air once the sterilization cycle is initiated. Air contained in the air handling system is brought to the prescribed air velocity by means of the recirculating fan. The high velocity air is subsequently directed over the electric heating coil to bring that air to the prescribed temperature. The heated, high velocity air is then directed to the sterilization chamber via the hot air supply plenum where it is uniformly distributed throughout the sterilization chamber; the sterilization chamber is a space suitable for holding the instruments to be sterilized. In the preferred embodiment, the instrument container is the sterilization chamber. In another instance the sterilization chamber, containing a basket or tray which holds instruments, is integral to the sterilizer.
Air from the sterilization chamber is subsequently directed into the return air plenum which then directs the air to the recirculating fan which recycles the air through the aforementioned system. Hot, high velocity air is continuously recirculated through the air handling system during the complete sterilization cycle to maintain the air temperature and air velocity conditions required to sterilize instruments and objects. At no time during the sterilization cycle is outside air allowed to enter or infiltrate any subset of the air handling system or sterilization chamber.
Preferably, the high velocity hot air sterilizer, sterilization chamber, and all its subparts are comprised of materials able to withstand the rigors presented by the temperatures utilized in high velocity hot air sterilization (375 degrees F. or higher). Preferably, these materials include stainless steel, aluminum, high temperature resistant thermoplastic and thermosetting polymers, ceramics, silicone, and nylon fabric plastics.
Preferably, the high velocity hot air sterilizer contains the mechanism to heat the air to its required temperature, to give the heated air its required velocity, to deliver the high velocity hot air to the sterilization chamber, and to continuously re-circulate the air to maintain the prescribed air velocity and temperature required throughout the complete sterilization cycle.
Preferably, the high velocity hot air sterilizer and associated air handling system are sealed, closed and retains positive pressure relative to the outside environment to preclude the infiltration of external, non-sterile air into the sterilizer's air handling system during the sterilization cycle.
Preferably, the high velocity hot air sterilizer contains thermocouples, an air flow velocity meter, and a timer integrated with a controller to properly monitor, maintain, and record desired temperatures, airflow velocity, and sterilization cycle times, respectively, to ensure proper sterilization conditions.
Preferably, the high velocity hot air sterilizer contains pressure gauges and transmitters integrated with a controller to properly monitor and maintain positive air pressure in the air handling system to preclude the infiltration of external air in the event of inadequate positive air pressure.
The aforementioned monitoring devices are integrated with a controller. The fans and heaters described herein are also integrated with the controller. The controller is a microcontroller based system with high-resolution ADCs (analog-to-digital converter) to read the monitoring devices input data such as temperature, pressure and air flow and provide control of the output devices such as the blowers, heaters and alarms. The controller is also integrated with an input system, such as a touch screen, keyboard, or other suitable input system, to allow a user to change settings, run a sterilization cycle, or otherwise control the hot air sterilization system. In addition, the controller will also provide operating instructions and system status information for the user through a display system such as a LCD or LED display.
Preferably, the high velocity hot air sterilizer contains a cooling cavity surrounding the sterilization chamber in which its contained air remains separated and segregated from the sterilizer chamber and its associated air handling system.
Preferably, the high velocity, hot air sterilizer has a locking mechanism on the sterilizer door to maintain an airtight door seal during the sterilization process.
Preferably, the instrument container is positioned into the high velocity, hot air sterilizer by its placement onto a sliding tray, which guides the instrument container into and out of the high velocity hot air sterilizer and assures the proper alignment and positioning of the high velocity hot air sterilizer's hot air supply and exhaust portals with corresponding air supply and exhaust portals of the instrument container.
The instrument container includes moveable covers which cover the hot air supply and exhaust portals of the container prior to the container being removed from the high velocity hot air sterilizer. The moveable covers are structured such that the high velocity hot air sterilizer cannot be opened unless the movable covers are in the closed position. The high velocity hot air sterilizer has a locking mechanism to ensure the moveable covers over the instrument container are covered, sealed and latched. The moveable covers may consist of both internal covers and external covers.
The instrument container internal covers can be sealed over the instrument container's internal hot supply air and spent exhaust air portals prior to the container's removal from the high velocity, hot air sterilizer.
The instrument container external covers can be sealed over the instrument container's external hot supply air and spent exhaust air portals subsequent to the container's removal from the high velocity hot air sterilizer.
Preferably, the instrument container has internal plenums that circulate the hot air within the container and direct it for uniform distribution throughout the instrument container.
Preferably, the internal plenum within the instrument container also creates an air exhaust flow where captured spent air is pulled to the exhaust portal for return to the high velocity hot air sterilizer for re-heating and re-circulation back to the instrument container via strategically placed, spaced, and oriented vents.
Preferably, the instrument container has a plenum insert that creates a plenum that circulates the hot air supply and directs it to uniformly distribute the hot air at a high velocity over the instruments to be sterilized via strategically placed, spaced, and oriented vents in the supply plenum walls.
Preferably, the plenum insert also creates an air exhaust plenum where captured spent air is pulled to the exhaust portal for return to the base unit via strategically placed, spaced, and oriented vents in the exhaust plenum walls for re-heating and re-circulation back to the instrument container.
Preferably, the air plenum insert is removable and cleanable and is sealed in place by latching the instrument container's lid, which contains heat resistant gaskets to ensure the integrity of the created plenums.
Preferably, the instrument container's design is configured to accept multiple layers of instruments and to accept instruments that are uncovered on perforated trays or in baskets or are wrapped or pouched.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of this invention has been chosen wherein:
FIG. 1 is a perspective view of the recirculating high velocity hot air sterilizer with enclosed instrument container;
FIG. 2 is a cross-sectional side view of the recirculating high velocity hot air sterilizer, with the door in the closed position, and holding the instrument container;
FIG. 3 is a cross-sectional top view of the recirculating high velocity hot air sterilizer, with the door in the closed position with the enclosed instrument container depicting the air handling plenum, the circulating fan, the circulating fan motor, and the cooling fan;
FIG. 4A is a cross-sectional side view depicting the instrument container partially inserted into the heating chamber;
FIG. 4B is a cross-sectional side view depicting the instrument container fully inserted into the heating chamber;
FIGS. 5A and 5B are perspective views of the butterfly valve depicting the valve in the closed and open positions, respectively;
FIG. 6 is a perspective view of an instrument container with the lid removed with plenum insert and depicting the air supply and air exhaust valves in the open position;
FIG. 7 is a cross-sectional side view depicting the instrument container partially inserted into the heating chamber showing closed air supply valve only;
FIG. 8 is a cross-sectional side view depicting the instrument container fully inserted into the heating chamber showing open air supply valve only;
FIG. 9 is a cross-sectional side view of an instrument container's air supply valve plate in the open configuration;
FIG. 10 is a perspective view of the instrument container's plenum insert;
FIG. 11A is a side elevation view of the instrument container's plenum insert;
FIG. 11B is a front elevation view of the instrument container's plenum insert; and
FIG. 12 is a front sectional elevation view of the plenum insert within the instrument container.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present disclosure describes a device suitable for prohibiting the introduction of microbial contaminants to a sterilization chamber of a high velocity dry heat sterilization device during an entire sterilization cycle and for ensuring such items, once sterilized, remain sterile when removed from the high velocity dry heat sterilization device. The preferred and described embodiment of the present invention is described below based on the accompanying drawings.
Referring to FIG. 1 , a high velocity hot air sterilizer 100 is provided which is suitable for receiving an instrument container 200 . The instrument container 200 is designed to receive, uniformly distribute, return, and recirculate high velocity hot air from the high velocity hot air sterilizer 100 to sterilize and depyrogenate wrapped and unwrapped medical and dental instruments in a containerized environment. As will be described, the high velocity hot air sterilizer 100 and the instrument container 200 have incorporated therein various structural features which provide for a closed and sealed, recirculating air handling system during the sterilization cycle that is impervious to the influx of external air and microbial contaminants during the course of the sterilization cycle and which provide the uniform circulation of high velocity hot air throughout the instrument container 200 to the held instruments and devices.
Referring to FIGS. 1 and 2 , the high velocity hot air sterilizer 100 includes an outer housing 101 , preferably formed from metal, which surrounds a heating chamber 109 . The heating chamber 109 is accessed for instrument container 200 insertion and removal via a door 103 and through a rectangular opening 110 formed in the outer housing 101 . The door 103 is hingedly attached to the rectangular opening 110 and is movable between an open position and a closed position. Although it is preferred that the door 103 be hinged horizontally, a vertical hinged configuration is also envisioned. Internal to the heating chamber 109 is a sliding rack 104 which carries an instrument container tray 105 . The sliding rack 104 is mounted in the heating chamber 109 and is movable between a contracted position and an extended position. The extended positioned is defined by the sliding rack 104 cantilevered over the open sterilizer door 103 for ease and proper insertion of an instrument container 200 onto the instrument container tray 105 . The contracted position is defined by the sliding rack 104 and instrument container tray 105 contracted within the heating chamber 109 such that the instrument container 200 is in the proper position to align the instrument container 200 within the heating chamber 109 to begin sterilization, as is described in greater detail below. With the sliding rack 104 in the contracted position, the sterilizer door 103 is moved to the closed position and is locked into place by turning a locking door handle 107 which activates a door lock 122 , thereby sealing a door gasket 106 tightly against the sterilizer door rim 102 until the completion of the sterilization cycle to prevent outside air from entering the heating chamber 109 .
Referring to FIGS. 2 and 3 , the heating chamber 109 is defined by a heating chamber wall 114 which defines a back, sides, top, and bottom of the heating chamber 109 and is constructed such as to preclude entry of outside air to the heating chamber 109 , thereby allowing the heating chamber 109 and the associated air handling system to remain airtight when the door 103 is in the closed position during a sterilization cycle. Encompassing the exterior of the heating chamber wall 114 is an insulating jacket structure consisting of an outer insulation wall 111 and an inner insulation wall 113 with an insulating material 112 situated between the inner insulation wall 113 and outer insulation wall 111 . The insulating jacket structure serves two purposes. The first purpose is to minimize heat loss from the heating chamber 109 during the sterilization cycle. The second purpose is to provide a heat barrier between the heating chamber 109 and the metal outer housing 101 of the high velocity hot air sterilizer 100 .
Referring to FIG. 3 , the high velocity hot air sterilizer 100 includes an air handling system which includes a circulating fan 115 , an electric heating element 132 , an air flow monitor 130 , an air pressure monitor 131 , and an air handling plenum 123 . The air handling system directs and monitors supply air to the instrument container 200 and receives exhaust air from the instrument container 200 . The air handling system is located adjacent the rear outside heating chamber wall 114 . The air handling plenum 123 is a chamber which houses the electrical heating element 132 and the fan 115 .
Referring to FIG. 3 , a pair of openings is formed through the back wall of the heating chamber 109 to the air handling plenum 123 . One of the openings serves as an air supply portal 126 which allows hot high velocity air to flow from the air handling system of the high velocity hot air sterilizer 100 into the instrument container 200 . The other of the openings serves as an air exhaust portal 118 which allows air to exhaust from the instrument container 200 to the air handling system of the high velocity hot air sterilizer 100 where the air is re-heated and brought back to velocity before recirculation back to the instrument container 200 . The air handling plenum 123 is air-tight and does not allow air infiltration or exfiltration except through the air supply portal 126 and the air exhaust portal 118 . Together, the air supply portal 126 and the air exhaust portal 118 serves as an air handling portal which allows air to enter and leave the air handling plenum 123 ; in the preferred embodiment, the air handling portal includes a pair of opening, though a single opening is envisioned.
Referring to FIG. 3 , an insulation barrier surrounds the heating chamber wall 114 and includes an outer insulation wall 111 and an inner insulation wall 113 between which is enclosed insulating material 112 . As shown in FIGS. 2 and 3 , the insulation barrier forms a five-sided barrier within the hot air sterilizer 100 and serves to insulate the contents of the heating chamber wall 114 . The sixth side of the insulation barrier defines an opening through which the instrument container 200 is insertable within the insulation barrier. The locking door 103 , when in the closed position, and the heating chamber wall 114 together define the heating chamber 109 . The locking door 103 , when in the closed position, forms a sealed interface with the heating chamber wall 114 to prevent air from entering the heating chamber 109 .
The air handling system is positioned at the rear of the heating chamber 109 and within the heating chamber wall 114 . The air handling system is primarily defined by the air handling plenum 123 which defines a pair of adjacent chambers at the rear of the heating chamber 109 , as best illustrated in FIG. 3 . The first chamber of the air handling plenum 123 includes the circulating fan 115 which is driven by the circulating motor 124 . As shown in FIG. 3 , the circulating motor is positioned outside of the heating chamber 109 . The circulating motor is joined to the fan 115 by a drive element, such as a shaft, which passes through the heating chamber 109 wall 114 and the insulation barrier, but is sealed to prevent air transfer to the heating chamber 109 . The second chamber of the air handling plenum 123 contains the heating element 132 , the air flow monitor 130 and the air pressure monitor 131 . The systems within the second chamber of the air handling plenum 123 are discussed in greater detail herein. The first chamber and the second chamber include an opening therebetween for freely communicating air between the first chamber and the second chamber.
A cooling cavity 121 , as shown in FIGS. 2 and 3 , is formed within the hot air sterilizer 100 and surrounds at least the rear, top and bottom of the heating chamber 109 . The cooling cavity 121 serves to insulate the metal outer housing 101 from escaped heat emanating from the heating chamber 109 or air handling plenum 123 and uses outside air recirculating through the cooling cavity by aid of a cooling fan 120 which draws outside air into the cooling cavity 121 where it is subsequently vented by the aid of passive cooling vents 119 at the sides of the high velocity hot air sterilizer 100 . All air within the cooling cavity 121 remains segregated from the heating chamber 109 .
Rubber feet/spacers 125 are located on both the exterior back and exterior bottom of the metal outer housing 101 and serve to provide ventilation space between the high velocity hot air sterilizer 100 and the wall or tabletop or other object which the high velocity hot air sterilizer 100 is positioned near during use.
Referring to FIGS. 3, 4A, and 4B , the high velocity hot air sterilizer 100 includes a sliding rack 104 and instrument container tray 105 which guides the instrument container 200 to the proper placement within the high velocity hot air sterilizer 100 for the engagement of the air supply portal 126 with the air supply valve plate 208 and the engagement of the air exhaust portal 118 with the air exhaust valve plate 214 . The high velocity hot air sterilizer 100 includes a push bar 117 which is joined to a chain drive 136 which serves to ensure that the container 200 is fully inserted in the heating chamber 109 . The container 200 includes a container guide slot 206 on the underside of the container. To assure that the instrument container 200 is fully inserted to the rear of heating chamber 109 and fully engaged with the air supply portal 126 ( FIGS. 2 and 3 ) and air exhaust portal 118 ( FIGS. 2 and 3 ) of the high velocity hot air sterilizer 100 , the chain drive 136 with attached push bar 117 is engaged into and along the container guide slot 206 and driven by a stepper motor 116 which is activated by closing and the locking the door 103 . FIG. 4A depicts the instrument container 200 partially inserted into the heating chamber 109 with the push bar 117 not yet engaged into the container guide slot 206 . FIG. 4B depicts the instrument container 200 fully inserted into the heating chamber 109 with the push bar 117 fully engaged into and along the container guide slot 206 . During insertion of the container 200 into the heating chamber 109 , the push bar 117 is driven by the chain drive into the container guide slot 206 until the push bar 117 becomes engaged with the container guide slot terminal end 207 , at which point the push bar 117 pushes the instrument container 200 to the rear of the heating chamber 109 , this position is defined as the fully inserted position. With the instrument container 200 in the fully inserted position, the rear face of the instrument container 200 contacts a pressure switch 127 , which is carried on the rear wall of the heating chamber wall 114 . The pressure switch 127 turns off the stepper motor 116 , locking the instrument container 200 in the fully inserted position. As shown in FIG. 2 , vertical pressure rollers 137 are mounted on the upper interior surface of heating chamber wall 114 and provide guidance to assure that the instrument container 200 does not elevate during the transit to the fully inserted position. One or more valve posts 135 protrude from the interior rear heating chamber wall 114 ( FIGS. 4A and 7 ). With the instrument container 200 in the fully inserted position, the valve posts 135 contact the air supply valve plate 208 ( FIGS. 4B and 8 ) and the air exhaust valve plate 214 ( FIG. 4B ) of the instrument container 200 to fully open both the air supply valve plate 208 ( FIGS. 4B, 6, and 8 ) and air exhaust valve plate 214 ( FIGS. 4B and 6 ) to allow proper airflow to and from the instrument container 200 . The air supply valve plate 208 and the air exhaust valve plate 214 are spring-loaded such that when the valve posts 135 do not contact the air supply valve plate 208 and the air exhaust valve plate 214 , the air supply valve plate 208 and the air exhaust valve plate 214 revert to the closed and sealed position ( FIG. 5A ), thereby preventing air from entering the instrument container 200 . With the door 103 in the closed position, the instrument container 200 is moved to and is held in the fully inserted position, thereby ensuring that when the door 103 is the closed position, the instrument container 200 is only capable of exchanging air with the air handling plenum 123 . With the instrument container 200 in the fully inserted position, the air handling portal and the container portal are held in sealed contact, and are an opening through which air is exchanged between the instrument container 200 and the air handling plenum 123 , further, the instrument storage chamber and the air handling plenum together define air-tight space which does not exchange air with the surroundings.
Referring to FIGS. 4A and 6 , the instrument container 200 is configured to accept and exhaust air provided from the high velocity hot air sterilizer 100 to sterilize medical and dental instruments, yet have the ability to prevent the influx of environmental microbial contaminants once the instrument container 200 is removed from heating chamber 109 . The instrument container 200 has the basic elements of any typical container used in the sterilization of medical or dental instruments: the container includes a sealable latchable, microbial impervious lid 202 ; four sides 203 , a bottom 204 , and lifting handles 205 with all construction and components having the ability to withstand the rigor of physical use and materials, preferably aluminum, stainless steel or similar material capable of withstanding temperatures of 375° F. to 420° F., which temperature range is the preferred temperature range of the air during the sterilization cycles described herein. Together, the four sides 203 and the bottom 204 define a surrounding wall which defines an instrument storage chamber within the instrument container 200 ; the surrounding wall is solid and air-tight except for the air-supply access portal 216 and the air-exhaust access portal 217 . Together, the air supply access portal 216 and the air exhaust access portal 217 serve as a container portal which allows air to enter and exit the instrument container 200 ; in the preferred embodiment, the container portal includes a pair of openings, though a single opening is envisioned. The surrounding wall also defines an open top (as shown in FIG. 6 ) through which instruments may be inserted in and removed from the instrument storage chamber. The lid 202 (as shown in FIGS. 4A and 4B ) forms an air-tight seal with the surrounding wall to prevent air from entering of leaving the instrument container 200 through the open top when the lid is in place. The lid 202 is removably and sealably mounted to the instrument container 200 to cover and seal the open top. With the lid in place, air is only able to enter and exit the instrument container 200 through the container portal—air is unable to pass through the surrounding wall, the lid 202 , or the interface between the lid 202 and the surrounding wall. The vertical pressure rollers 137 preferably contact the lid 202 , as shown in FIG. 2 , and serve to hold the container 200 in a preferred orientation within the high velocity hot air sterilizer 100 .
For successful sterilization of medical and dental instruments by high velocity hot air, it is necessary that the instrument container 200 receives supplied hot air at a high velocity, preferably 1500 to 3000 feet per minute, without the encumbrances of filters or other devices that reduce air velocity. Referring to FIGS. 4B and 6 , an air supply valve plate 208 and an air exhaust valve plate 214 are viewed in the open position allowing direct, unencumbered high velocity hot air to enter the instrument container 200 via the air supply access portal 216 and exit the instrument container 200 via the air exhaust access portal 217 . No filters are used with the instrument container 200 or the high velocity hot air sterilizer 100 . Filters are unnecessary since the air is segregated within the instrument container 200 and the air handling system.
Referring to FIGS. 3, 4B and 8 , with the instrument container 200 in the fully inserted position, the fixed posts 135 extend from the heating chamber wall 114 and protrude through the air supply access portal 216 and air exhaust access portal 217 to contact and push the air supply valve plate 208 and the air exhaust valve plate 214 to the open position.
Referring to FIG. 3 , a first air portal gasket 134 circumscribes the air supply portal 126 providing a sealed perimeter between the air supply portal 126 and the air exhaust access portal 217 . A second air portal gasket 134 circumscribes the air exhaust portal 118 providing a sealed perimeter between the air exhaust portal 118 and the air supply access portal 216 . Each of the portal gaskets 134 nests within respective portal gasket contours 215 which surround the respective air supply access portal 216 and air exhaust access portal 217 .
Referring to FIGS. 4B, 8, and 7 , with the air supply valve plate 208 in the open position, high velocity hot air enters the instrument container 200 only from the air handling plenum 123 during the sterilization cycle. FIG. 10 depicts the plenum insert 25 which is placed into the instrument container 200 , positioned to direct the hot, high velocity air through the interior air supply plenum 28 and to exhaust air through the interior air exhaust plenum 27 . The interior air supply plenum 28 completely encircles the bottom three-quarters of the instrument container 200 , having as interior wall of the instrument container 200 as its exterior wall and the exterior wall of the plenum insert 25 as its interior wall. The bottom of the instrument container 200 serves as the bottom of the interior air supply plenum 28 and exterior bottom of the interior exhaust plenum 27 serves as the top of the interior air supply plenum 28 . The interior exhaust plenum 27 encircles the top one-quarter of the instrument container 200 with the interior of the container lid 202 serving as the top of the interior exhaust plenum 27 . The container lid 32 and plenum cover flange 26 are mated with opposing gaskets to form a tight seal when the container lid 32 is securely latched into place ( FIG. 12 ).
Hot, high velocity airflow into the instrument container 200 is forced unidirectionally around the interior of the plenum insert 25 by means of a supply air plenum flange 31 . FIGS. 11A and 11B are side and front elevation views, respectively, of the plenum insert 25 , depicting the side view and front view of the supply air plenum flange 31 . As the air moves directional air supply vents 30 force the air into the interior of the plenum insert 25 that contains the instruments to be sterilized. The directional air supply vents 30 are slanted and fluted ( FIG. 10 ) to move the air in a circular and upward motion within the instrument container's 200 interior to provide uniformity of air distribution. Generating a slight negative air pressure to the interior exhaust plenum 27 by means of the circulating fan 115 ( FIG. 2 ) pulls air at the top of the interior of plenum insert 25 through the air exhaust vents 29 and redirects the exhaust air back to the air exhaust portal 118 where the spent air is discharged to the air handling system of the high velocity hot air sterilizer 100 to re-heat the air with the electric heating element 132 and to increase the velocity of the air for recirculation with the fan 115 .
Upon completion of the sterilization cycle and before the door 103 is opened, the instrument container 200 is separated from the back heating chamber wall 114 by the automatic reversal of the stepper motor 116 , moving the chain drive with attached push bar 117 to the front of the high velocity hot air sterilizer 100 , relieving the pressure exerted to the rear of the heating chamber 109 and allowing the spring-loaded air supply valve plate 208 and the air exhaust valve plate 214 to revert back to the closed position and uncoupling the instrument container 200 from the air supply portal 126 and air exhaust portal 118 and extracting the fixed posts 135 from the air supply access portal 216 and air exhaust access portal 217 .
Referring to FIGS. 5 and 9 , the valve assembly 40 consists of a circular valve plate 42 encompassed by a valve frame 41 . The circular valve plate 42 pivots unidirectionally, perpendicular to and within the circular valve frame 41 by means of two compression spring spindles 46 placed 180 degrees apart. The valve frame 41 has two hemispheric groves 47 , located on opposite sides of the valve frame 41 that allow the valve plate to set flush in the closed position. The valve plate 42 is sealed along the outer circumference of the valve plate against the inner circumference of the valve frame 41 by means of molded valve gasket 43 . The valve assembly 40 is mounted and sealed in the instrument container wall 201 . During the sterilization cycle the chamber wall gasket 44 mounted within a gasket collar 45 seals the juncture of the valve assembly against the rear chamber wall 114 to provide a sealed and air-tight perimeter when in the closed configuration.
Referring to FIG. 6 , access portal protective covers 218 provide protection to the air supply access portal 216 , the air supply valve plate 208 , the air exhaust access portal 217 , and the air exhaust valve plate 214 from accidental damage or intrusion and act as a secondary barrier to environmental microbial contaminants. The access portal protective covers 218 are movable along protective cover rails 219 . Following removal of the instrument container 200 upon completion of the sterilization cycle from the heating chamber 109 , the access portal protective covers 218 are manually moved across the air supply access portal 216 and air exhaust access portal 217 by sliding the access portal protective covers 218 along the protective cover rails 219 . In an alternative embodiment, the access portal protective covers 218 are opened and closed by mechanical action during insertion and removal of the instrument container 200 .
Referring to FIGS. 2 and 3 , hot air is generated and circulated to and through the instrument container 200 by the air handling system, which consists of a circulating fan 115 , an electric heating element 132 , and an air handling plenum 123 . The circulating fan 115 brings the air to a velocity necessary to achieve rapid sterilization as monitored by an air flow monitor 130 located in the air handling plenum 123 just downstream from the from the circulating fan 115 and the electric heating element 132 near the entrance to the air supply portal 126 . Air is blown over the electric heating element 132 to raise the temperature of the air to the desired temperature necessary for microbial kill at the required sterilization times. The electric heating element 132 is thermostatically controlled by two thermocouple monitors, an air supply thermocouple 128 and an air exhaust thermocouple 129 , to maintain the air within the heating chamber 109 within a desired temperature range. The air supply thermocouple 128 is located within the air supply portal 126 to monitor the temperature of the air as the air is directly supplied to the instrument container 200 . Air discharged from the instrument container 200 is monitored by the air exhaust thermocouple 125 located at the air exhaust portal 118 . To ensure the sterilization cycle initiates with air in the instrument container 200 at the proper sterilization temperature, both the air exhaust thermocouple 128 and air supply thermocouple 129 must be at the desired temperature to achieve sterilization before the sterilization cycle is activated.
Heated high velocity air circulates from the air handling plenum 123 which directs the air into the instrument container 200 via the air supply portal 126 and the open air supply valve plate 208 ( FIG. 3 ) for uniform distribution throughout the instrument container 200 as assisted by an internal air diversion insert plenum 25 . As hot high velocity air is supplied to the instrument container 200 , a portion of the air is returned to the circulating fan 115 and electric heating element 132 by way of the open air exhaust valve plate 214 and the air exhaust portal 118 . This continuous process continues throughout the sterilization cycle, keeping the sterilant air at its designated temperature and velocity during the whole of the sterilization cycle without influx of any outside microbiological contaminants to jeopardize the sterilization process. The air handling system remains closed and sealed, creating a slightly positive air pressure to preclude the influx of air into the air handling system if a seal were to fail. The slight positive air pressure differential is monitored with an air pressure monitor 131 located at the entrance of the air supply portal 126 to ensure the air handling system retains a positive pressure. If the air pressure becomes negative, this negative pressure will be measured by the air pressure monitor 131 , and the air pressure monitor 131 will provide an electronic signal which will be used to terminate the sterilization cycle. As apparent to those skilled in the art, the air handling system can also be designed to deliver and exhaust air not only from the sides of the instrument container 200 , but also from the top and bottom, separately or in conjunction to assure airflow requirements and heat distribution necessary to sterilize the contained instruments.
It is understood that while certain aspects of the disclosed subject matter have been shown and described, the disclosed subject matter is not limited thereto and encompasses various other embodiments and aspects. No specific limitation with respect to the specific embodiments disclosed herein is intended or should be inferred. Modifications may be made to the disclosed subject matter as set forth in the following claims. | A device and system is disclosed for sterilizing objects, commonly dental, medical, or veterinary instruments, by directing high velocity hot air into a container having pre-constructed plenums to direct, diffuse, and re-circulate the sterilizing agent uniformly throughout the chamber to effect sterilization of contained medical objects. More specifically, the invention employs high velocity hot dry air as the sterilizing agent, generating the heat and rapid airflow by means of a base unit. The high velocity heated air is forced into the medical instrument container where a removable air supply/return plenum directs the heated, rapidly flowing air uniformly throughout the container. During the sterilization process heated air temperature is maintained in the container by a continual re-circulating of exhaust air back to the base unit for re-heating and return to the container. Upon completion of the sterilization process the container is removed from the base unit, sealing air supply and exhaust air container portals to assure continued sterility of the contained instruments within the container. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to the U.S. provisional patent application identified by Ser. No. 60/274,761, filed on Mar. 9, 2001, and entitled “Method and System for Embedding Correlated Performance Measurements for Distributed Application Performance Decomposition,” the disclosure of which is incorporated by reference herein.
FIELD OF THE INVENTION
The present invention generally relates to distributed computing networks and, more particularly, to techniques for embedding correlated performance measurements in transactions associated with a distributed application for use in application performance decomposition.
BACKGROUND OF THE INVENTION
Measuring and decomposing performance application transactions often requires distributed instrumentation co-located with application components servicing or transporting the transaction. The application components are implemented on the various computing devices in the distributed network that are involved with (e.g., initiate, process, transfer, etc.) at least a portion of a transaction. The requirement for such co-located instrumentation results in separate streams of performance measurement data that need to be correlated to show the relative contribution of each application component's service time to the overall transaction's response time. Correlation using time of day is difficult as it requires synchronized time sources which tend to drift and which are problematic to keep synchronized over long periods of time. For performance measurements, one cannot easily derive accurate durations by applying functions to timestamps taken from different timing sources. Therefore, accurate duration calculations must occur based on timestamps from the same time source. This causes multiple timestamps and/or durations to be measured at varying locations in the transaction's path whenever a distributed application spans multiple time sources.
Correlation of these timestamps and durations is typically based on tagging them with correlation data which is later used to associate related measurements, see, e.g., U.S. Pat. No. 6,108,700, issued to Maccabee et al. on Aug. 22, 2000 and entitled: “Application End-to-End Response Time Measurement and Decomposition,” the disclosure of which is incorporated by reference herein. This introduces data management issues (e.g., storage, movement, and consolidation of distributed duration data) making correlation of distributed applications difficult and time consuming.
Further, techniques are known where embedded JavaScript is added to HTML (HyperText Markup Language) pages to measure how long it takes for the client to receive and render a web page. The system that adds the JavaScript can take timestamps which can later be compared with the information generated by the JavaScript to produce one layer of decomposition. However, intervening application components such as web proxies can not add their perspective of response time, therefore, this conventional method is limited to only a pair of participants (e.g., the client where the JavaScript runs and the server where the JavaScript was embedded). In addition, this embedded JavaScript method introduces JavaScript processing not normally in the HTML page, thus necessitating an alteration in the way the application operates.
Still further, a U.S. patent application identified as Ser. No. 09/637,330, filed on Aug. 10, 2000 and entitled “Method and Apparatus for Measuring Web Site Performance,” the disclosure of which is incorporated by reference herein, discloses a technique for extending the application data (payload) with logic to take measurements and report back it's findings. Hence, the application data must be modified to add the measurement and reporting logic. Also, the technique works only at the endpoints (e.g., application server and most notably at the client) of a transaction.
SUMMARY OF THE INVENTION
The present invention provides techniques for use in accordance with application performance decomposition which take advantage of the communications protocol used to carry a transaction between application components in a distributed computing network. Specifically, the invention extends the communications protocol by embedding data, such as timestamp and duration measurement data, in the protocol itself, rather than extending or altering the application or transaction data carried by the protocol as in existing approaches. Thus, the invention provides natural correlation of interactions of distributed application components on such transactions without modification to the application or transaction data. Because the correlation is performed in-line with the application component interactions, minimal data management overhead is required, and correlated performance decomposition is made possible in real-time for the transaction. Furthermore, subsequent processing stages of the distributed application can interpret the communications protocol to glean processing durations of previous stages in order to make decisions regarding treatment of the transaction.
In certain cases, communications protocols are designed for flexibility to adopt new features without breaking existing functions by using tagged data elements in variable length data compartments. These protocols lend themselves to this invention as the invention can add specially tagged measurement data without breaking the existing interpretation mechanisms for the protocol (e.g., the added data is ignored unless the protocol interpreter knows to look for it). One example of a communications protocol that can be used in accordance with the invention is the HyperText Transport Protocol (HTTP), although it is to be understood that the invention is not so limited. Also, while illustrative embodiments are explained below in the detailed description in the context of the World Wide Web, it is to be appreciated that the teachings of the invention may be implemented in other distributed computing environments.
In an illustrative embodiment of a format for embedded measurement data, the invention combines a well-defined keyword prefix with a variable suffix that identifies the timing source, followed by a colon delimiter and whitespace, followed by the timestamp and/or duration information. By “well-defined,” it is meant herein that the prefix is commonly defined or known between participating interpreters of the data, so as to allow them to, for example, parse the prefix. The combination of the well-defined prefix with the variable suffix allows multiple, uniquely identified application components to add their performance data to the protocol. Even cases where the applications are not uniquely identified are supported because the lines containing keywords with the well-defined keyword prefix can be sorted by duration to create the “onion-skin” layering of performance decomposition.
As mentioned above, conventional approaches to performance decomposition of distributed applications rely on collecting performance data at distributed locations and later transporting it for correlation using paths separate from the application itself. This results in deferred knowledge of transaction performance. The invention provides techniques to embed the measurement information with the same application it describes so completion of the transaction can occur substantially simultaneous, or at least contemporaneous, with availability of knowledge of the performance characteristics of the transaction. Because the invention provides for carrying correlated performance decomposition with the transaction, no separate storage and forwarding of performance data is required. Furthermore, because the invention captures the timestamp of the application component, a natural correlator within the domain of the application component's time source is available to other systems management monitors (e.g., for performance, capacity, availability, etc.). An optional transaction identifier can also be used as a correlator to other systems management data to extend the performance decomposition further during off-line analysis.
Furthermore, it is to be appreciated that multiple application components can participate by using this invention. That is, the invention allows any number of application components along the transaction's path to add their performance information, thereby providing n levels of performance decomposition. Furthermore, the invention does not necessitate altering the way the application operates. The invention rather extends the protocol carrying the application data, advantageously leaving the application data unaltered. This is significant as secured transmissions (e.g., HyperText Transport Protocol Secured (HTTPS) using Secure Socket Layer (SSL) protocol) or content that has been compressed using GZIP (a Mime-Type defining publicly available data compression) is unaffected by the invention. However, these types of transmissions are problematic for existing methods which attempt to introduce JavaScript to HTML or alter the application data in some way, as mentioned above in the background section, since the HTML may be encrypted or compressed and unable to be altered. Thus, a fundamental difference between the invention and application data-altering approaches, such as the embedded JavaScript method, is that the invention is non-intrusively altering the protocol used to carry the application data, whereas the existing methods are altering the application data itself, imposing special handling by the application. Only the protocol interpreters need be aware of the present invention, and those unaware will simply pass our extensions along without caring about their existence.
This is also the case with the above-mentioned technique which extends the application data or payload with logic to take measurements and report back it's findings. By contrast, the invention leaves the application data alone and instruments the protocol, i.e., the envelope carrying the payload. Another difference is the logic extension approach works only at the endpoints (e.g., application server and most notably at the client), whereas the present invention, as mentioned above, can be used by multiple nodes in the transaction path, each supplying their perspective of performance.
These and other objects, features and advantages of the present invention will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating the present invention in a client application/server application embodiment;
FIG. 2A is a diagram illustrating an HTTP request header according to an embodiment of the present invention;
FIG. 2B is a diagram illustrating a server-side HTTP reply header according to an embodiment of the present invention;
FIG. 2C is a diagram illustrating a client-side HTTP reply header according to an embodiment of the present invention;
FIG. 3 is a diagram illustrating a method of processing an untagged message according to an embodiment of the present invention;
FIG. 4 is a diagram illustrating a method of processing a tagged message according to an embodiment of the present invention; and
FIG. 5 is a diagram of an illustrative hardware embodiment according to the invention of a computing device for implementing an application component.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention will be explained below in the context of the World Wide Web (WWW) as an illustrative distributed computing network, and in the context of the HyperText Transport Protocol (HTTP) as an illustrative communications protocol. However, it is to be understood that the present invention is not limited to any particular computing network or any particular communications protocol. Rather, the invention is more generally applicable to any environment in which it is desirable to have correlated performance decomposition without altering the application or transaction data, and to have completion of a transaction occur substantially simultaneous, or at least contemporaneous, with availability of knowledge of the performance characteristics of the transaction. Thus, the present invention may be used in a distributed application comprising at least two application components separated and interacting via some form of communication. For example, while the form of communication illustratively described below is a network such as the Internet, the form of communication may alternatively be interprocess communication on a platform. One skilled in the art will realize various other scenarios given the inventive teachings disclosed herein.
Referring now to FIG. 1 , for an illustrative embodiment, assume the network is the Internet or Intranet 100 and the application components are an application running on a client 105 and an application running on a server 110 . Again, in an illustrative embodiment, assume the protocol being extended using this invention is HTTP defined by RFC 2098 and RFC 1945, the disclosures of which are incorporated by reference herein, the client application is a web browser (e.g., Netscape, Internet Explorer), and the server application runs on a web server (e.g., IBM's Apache, IIS (Internet Information Server from Microsoft), IHS (IBM HTTP Server)). The distributed application transaction comprises the client application making a request for content from the application server and the application server responding. Performance information is generated using this invention to measure the round trip response time from the client application's perspective, as well as to decompose the response time into the time taken by the server application to service the request and generate it's reply.
For HTTP, there is a defined sequence of information contained in lines of text delimited by line termination character sequences (typically carriage return and linefeed). The HTTP header contains one or more of these lines and is terminated with an empty line. This allows optionally present data to be carried in the header to help manage the underlying TCP (Transmission Control Protocol) socket communications, or to provide caching directives, or to provide contextual information such as the type and version of software being used by the issuer of the header (e.g., browser or server software). Information in these lines typically follows a format containing “keyword: value”. Therefore, HTTP interpreters are written to examine lines in the header, testing the keyword and, when appropriate, taking action based on the keyword and/or it's corresponding data (value). Because the WWW has undergone several iterations of HTTP and extensions thereto, HTTP interpreters are written to be flexible with regard to the presence or absence of expected keywords and will not breakdown when unanticipated keywords are presented. The present invention takes advantage of this by adding lines to the HTTP headers to carry performance measurement data, allowing the client to receive the server measurement duration in the HTTP Reply header. This is illustrated below in the context of FIGS. 1 , 2 A, 2 B and 2 C.
As shown in FIG. 1 , at the time the client application is ready to issue it's request, the client application takes or gets a timestamp 115 , labeled TC 1 , capturing the time of day (e.g., from a clock source accurately tracking time elapsed since the “epoch,” which refers to midnight, Jan. 1, 1970, Coordinated Universal Time), and optionally generates a transaction sequence identifier 120 , labeled TXSeq, to identify this request from all others occurring within a reasonably long time period (e.g., duplicate transaction identifiers are possible, provided the duplication occurs sufficiently far apart to permit reporting to differentiate them). This information is either added to the HTTP Request Header 200 , as shown in FIG. 2A , as additional lines 205 and 210 , respectively, for the time stamp (e.g., TS-WD_SOCKS-C46EC47E: 3A9A86C8.38C99) and transaction sequence identifier (e.g., TX-WD_SOCKS-C46EC47E: 3E8), or it is stored pending use by the client application when interpreting the reply forthcoming for this request.
In the exemplary timestamp line 205 , the keyword “TS-WD_SOCKS-C46EC47E” serves as a label or identifier of the client that generated this information. The keyword includes a well-defined prefix “TS-” that identifies the HTTP line which contains a timestamp and a variable suffix “WD_SOCKS-C46EC47E” that identifies the timing source from which the timestamp was taken. The colon and subsequent whitespace (blank space) are used to form the above-mentioned “keyword: value” format. “3A9A86C8.38C99” is the hexadecimal timestamp value where the number to the left of the decimal point is the number of seconds since the epoch and the number to the right of the decimal point is the fractional number of seconds since the epoch. Note that the “TS-” in the keyword generally denotes a timestamp.
Further, in the exemplary transaction sequence identifier line 210 , “TX-” is a well-defined keyword prefix that identifies the HTTP line which contains a transaction identifier. Thus, while “TS-” generally denotes a timestamp, “TX-” generally denotes a transaction identifier. “WD_SOCKS-C46EC47E” in line 210 is a variable suffix that identifies the specific source (domain) where the transaction identifier is relevant. It is to be understood that in this particular illustrative embodiment, a general-specific identifier is used, where “WD_SOCKS” classifies the source or domain and “C46EC47E” uniquely identifies an instance of this type of source or domain. “3E8” is the hexadecimal value identifying the transaction sequence.
It is to be appreciated that the combination of the well-defined prefix with the variable suffix allows multiple, uniquely identified application components to add their performance data (e.g., timestamp, duration, transaction sequence identifier, etc.) to the protocol. Even cases where the applications are not uniquely identified are supported because the lines containing keywords with the well-defined keyword prefix can be sorted by duration to create the “onion-skin” layering of performance decomposition.
“Onion-skin” layering describes a succession of “contain” relationships, e.g., like the outer skin of an onion contains the rest of the inner onion and each succeeding inner skin is said to contain the skins within it. The analogy here is that a transaction, initiated by a client and traversing through a proxy to a server, may be viewed as having at least three “layers,” i.e., the client layer being the outer most layer, the server being the inner most layer, and the proxy (which resides between the client and the server) being the middle layer.
As may typically be the case: (i) the elapsed time (duration) taken by the transaction to traverse from the client through the proxy and the server and back, will take the longest; (ii) the elapsed time taken by the server to process the transaction will be the shortest; and (iii) the elapsed time from receipt by the proxy of the transaction, transmission to the server and back to the proxy will be shorter than (i) but longer than (ii). These timing relationships result because the communications from an outer layer to an inner layer adds time.
Therefore, even if unique identifiers were not employed for each of the “layers” of processing being performed on the transaction, the durations may still be sorted and the relative positioning of the layers with respect to one another may still be understood, e.g., the largest duration being the closest to the transaction initiator, and the shortest duration being closest to the transaction server.
It is to be understood that the additional lines may optionally identify the client as the source that added these lines to the HTTP Request Header to permit later searching and updating of these lines. The HTTP Request containing this HTTP Request Header, along with other application data as required (e.g., POST data), is then sent by the client application 105 through the Internet 100 to the server application 110 .
It is to be understood that a main purpose of uniquely identifying the “author” of the line in the HTTP Request Header in the variable suffix is to permit that author to find it's line on the return trip to calculate the duration and update that line to store the duration, as will be explained below. This handles the case where the timestamping source does not have resources to store the initial timestamp and retrieve it from these resources to calculate the duration. The invention uses the header as a “per transaction” storage of the initial timestamp information. In most cases, the “author” of the line in the header is maintaining some information about the transaction, e.g., a proxy may maintain a map of interior sockets/ports to exterior sockets/ports so it can send data retrieved on an exterior socket on the corresponding interior socket, and later retrieve the reply from the interior socket and return it on the appropriate exterior socket. This mapping table may be expanded to hold the initial timestamp and later retrieve it to be used in conjunction with another timestamp to calculate the duration and write a single “completed” line to the reply header.
Upon receipt of the HTTP Request, the server application 110 interprets the HTTP Request, parsing any timestamp or transaction sequence identifier the request contains. The server application also takes a timestamp 125 , labeled TS 1 , interprets the HTTP Request Header, and begins processing the request. The information parsed from the HTTP Request Header as well as the timestamp are saved for later access when the server application is preparing it's response to the HTTP Request. It is to be understood that the present invention also supports the notion of application components that can act as both a server and a client, e.g., first receiving a request from another client, and then forwarding the request (or a related request) to another server. In this case, the invention may be used for each of these roles, e.g., adding a timestamp and a transaction sequence identifier to it's request, as well as forwarding any existing timestamp and transaction sequence identifier the server received in the new HTTP Request to the other server.
After some period of time, e.g., after the server has determined how to respond to the transaction's request, the server application 110 prepares an HTTP Reply to the HTTP Request containing an HTTP Reply Header 220 , as shown in FIG. 2B . This involves adding any timestamp or transaction sequence identifier lines saved from the HTTP Request Header (lines 205 and 210 , respectively), as well as taking a second timestamp 130 , labeled TS 2 . The two timestamps (TS 1 and TS 2 ) may be used to calculate a duration (e.g., duration=TS 2 −TS 1 ) and a line 225 (e.g., TS-APACHE-SRIRAMA: 3A9A86CC. 4E375.4D9DDA) is added to the HTTP Reply Header 220 identifying the server, the timestamp when it's processing began (TS 1 , which in this example is 3A9A86CC. 4E375) and the duration (which in this example is 4D9DDA).
In the exemplary timestamp line 225 , the keyword “TS-APACHE-SRIRAMA” includes the well-defined prefix “TS-” and the variable suffix which serves as an identifier of the timestamp source “APACHE-SRIRA.” Note that in this exemplary keyword, “APACHE” infers the type of server and “SRIRAMA” is a unique instance of this type of server. It is to be understood that use of this form of classification is not required by the invention, but rather illustrates a preferred way of classifying the data for reporting purposes, e.g., to report all durations from APACHE-type servers. Further, “3A9A86CC.4E375” in line 225 is the hexadecimal timestamp value where the number to the left of the decimal point is the number of seconds since the epoch and the number to the right of the decimal point is the fractional number of seconds since the epoch. “4D9DDA” is the hexadecimal value representing the duration (TS 2 −TS 1 ). It is to be understood that the present invention also supports the notion of supplying both timestamps, e.g., TS 2 and TS 1 , in lieu of a timestamp and a duration, since one pair can be derived from the other. The HTTP Reply Header 220 is then sent in the HTTP Reply to the client application 105 .
While the invention has been described above with regard to a particular illustrative format, it is to be understood that timestamp and transaction sequence information may be alternatively formatted and combined on the same header line provided the information conveys the concepts of the present invention. For example, in an alternative preferred embodiment, a TS-<identifier> line may be formatted to use decimal numbers and/or with tags identifying the values such as t=<timestamp value> or D=<duration value> or seq=<transaction sequence identifier>. One skilled in the art will realize other formats given the inventive teachings provided herein.
Upon receipt of the HTTP Reply containing the HTTP Reply Header 220 , the client application 105 takes another timestamp 135 , labeled TC 2 , and parses the HTTP Reply Header for lines containing the timestamp or transaction sequence identifier that the client had previously generated, or those generated by other application components acting on behalf of the transaction. In cases where the client application sent a timestamp line in it's HTTP Request Header 200 , the HTTP Reply Header's lines are reviewed to find the timestamp line previously generated by the client application (e.g., using the client identification information on the line(s)). In cases where a request timestamp was generated and held for later processing, it is retrieved for this transaction. A duration may be generated (duration=TC 2 −TC 1 ) to reflect the client perspective of the transaction's round trip response time. This may be added to the existing line, originally generated by the client, in the HTTP Reply Header 220 , thus forming a modified HTTP Reply Header 220 ′, as shown in FIG. 2C . The modified line is denoted as line 230 (e.g., TS-WD_SOCKS-C46EC47E: 3A9A86C8.38C99.1841478) in the HTTP Reply Header 220 ′. “1841478” denotes the client perspective of the transaction's round trip response time, while the rest of the information in line 230 is the same as in line 205 .
It is to be understood that, in cases where no line was previously generated by the client, a new line may be added to the HTTP Reply Header to form the modified Reply Header which may show the timestamp of the client's request and the duration (or, alternatively, the timestamp of the receipt of the response), identification information for the client, and another line containing a transaction sequence identifier. It is also to be understood that the present invention supports the notion of a timestamp, a timestamping source identification and a transaction sequence identifier being added in the same location (e.g., HTTP Header line) or in multiple locations (e.g., multiple HTTP Header lines).
Because there may be additional processing required to generate the complete response to the client's request, the server application may optionally take subsequent timestamps 140 for later association with the transaction, labeled TS 3 in FIG. 1 . However, because these may occur after the response has been generated to the client, they may be stored for off-line correlation with the transaction performance information contained in the reply. Similarly, upon receipt of subsequent response data from the server application, the client application may optionally take subsequent timestamps 145 for later association with the transaction, labeled TC 3 in FIG. 1 .
It is to be understood that the transaction sequence identifier may serve as a correlator to be used to search through logs or other data stores where subsequent timestamps, such as TS 3 information, are stored. In other words, the header being returned to the client will already have left by the time TS 3 is taken. So, if the client later wants to associate it's duration TC 3 −TC 2 with the server side duration TS 3 −TS 2 , it needs a correlator to look up this information. The TX-<identifier>: <sequence identifier> may be used for this purpose.
The resulting performance decomposition information contained in the reply may be used by the client to deduce information relating to services rendered by other application component(s) by examining the timestamps and/or durations. For example, the client's perspective of the duration of the request issuance through receipt of the reply may be reflected as TC 2 −TC 1 (labeled 150 in FIG. 1 ), and the duration of the server application's time to respond to the request as TS 2 −TS 1 (labeled as 155 in FIG. 1 ). The client may optionally determine the duration required to receive the entire response to it's request as TC 3 −TC 2 (labeled as 160 in FIG. 1 ), as well as the total transaction response time as TC 3 −TC 1 (labeled as 165 in FIG. 1 ).
Referring now to FIG. 3 , a general overview of a method for processing an untagged message according to an embodiment of the present invention is shown. An “untagged message,” as used herein, refers to a message that does not yet have performance measurement data embedded in the communications protocol in accordance with the present invention, for example, as explained above in the context of FIGS. 1 , 2 A, 2 B and 2 C. In step 300 , an untagged message is received. This may be, for example, a message for which processing has not yet begun within the “instrumented component.” An “instrumented component” refers to the component in the transaction's path that supplies the timestamp information. For example, a proxy may be used in front of the browser on the client machine to add timestamps since the browser's commercial code may not be able to be modified. The untagged message is then received by this proxy (having been generated by the browser) and the proxy, being an instrumented component, adds the timestamp information to the header before sending it on it's way toward the server. WD_SOCKS may be such a proxy running on the client.
In step 310 , a local timestamp is obtained, such as from a system clock. In step 320 , a tag is constructed that includes the timestamp information and the identity of the processing element that is adding the tag. The tag may preferably have the above-described format of “keyword: value,” e.g., TS-WD_SOCKS-C46EC47E: 3A9A86C8.38C99 as in FIG. 2A . The tag may also include a transaction sequence identifier, e.g.,TX-WD_SOCKS-C46EC47E: 3E8. This tag is added to the message, i.e., embedded into the communications protocol as explained above. In step 330 , processing is initiated for the message. This may involve sending the tag augmented message to other machines.
FIG. 4 illustrates a general overview of a method for processing a tagged message according to an embodiment of the present invention. A “tagged message,” as used herein, refers to a message that has performance measurement data embedded in the communications protocol in accordance with the present invention, for example, as explained above in the context of FIGS. 1 , 2 A, 2 B and 2 C. In step 400 , a tagged message is received. In step 410 , a local timestamp is obtained, such as from a system clock. In step 420 , the tag for the component processing the message is located, and the previously embedded timestamp is extracted. In step 430 , the elapsed time for processing the message is computed by subtracting the extracted timestamp from that obtained in step 410 . In step 440 , the elapsed time is tagged and embedded in the message. An example of such a tag may be TS-APACHE-SRIRAMA: 3A9A86CC. 4E375.4D9DDA, as shown in FIG. 2B .
FIG. 5 is a block diagram of a computing device or system, such as a workstation or server, wherein the present invention may be practiced. The computing device shown in FIG. 5 serves as an example of a client computer system upon which at least a portion of a client application (e.g., 105 in FIG. 1 ) may be executed, an example of a server computer system upon which at least a portion of a server application (e.g., 110 in FIG. 1 ) may be executed, as well as an example of any other computing device in a network employing the teachings of the present invention. The environment of FIG. 5 comprises a single representative computing device 500 , such as a personal computer, laptop, workstation, hand-held computer, information appliance, etc., including optionally present, related peripheral devices. The workstation 500 includes a microprocessor 502 or equivalent processing capability and a bus 504 to connect and enable communication between the microprocessor 502 and the components of the computing device 500 in accordance with known techniques. Note that in some computing devices there may be multiple processors incorporated therein.
The microprocessor 502 communicates with storage 506 via the bus 504 . Memory 508 , such as Random Access Memory (RAM), Read Only Memory (ROM), flash memory, etc., is directly accessible while secondary storage device 510 , such as a hard disk, and removable storage device 512 , such as a floppy diskette drive, CD ROM drive, tape storage, etc., is accessible with additional interface hardware and software as is known and customary in the art. The removable storage device 512 has associated therewith an appropriate type of removable media 514 , such as a diskette, CD, tape reel or cartridge, solid state storage, etc., that holds computer useable data and is a form of computer useable medium. Note that a computing device 500 may have multiple memories (e.g., RAM and ROM), secondary storage devices, and removable storage devices (e.g., floppy drive and CD ROM drive).
The computing device 500 typically includes a user interface adapter 516 that connects the microprocessor 502 via the bus 504 to one or more interface devices, such as a keyboard 518 , a mouse or other pointing device 520 , a display 522 (such as a CRT monitor, LCD screen, etc.), a printer 524 , or any other user interface device, such as a touch sensitive screen, digitized entry pad, etc. Note that the computing device 500 may use multiple user interface adapters in order to make the necessary connections with the user interface devices.
The computing device 500 may also communicate with other computing devices, computers, workstations, etc., or networks thereof through a communications adapter 526 , such as a telephone, cable, or wireless modem, Integrated Services Digital Network (ISDN) adapter, Digital Subscriber Line (DSL) adapter, Local Area Network (LAN) adapter, or other communications channel. This gives the computing device direct access to networks 528 (LANs, Wide Area Networks (WANs), the Internet, etc.), telephone lines 530 that may be used to access other networks or computers, wireless networks 532 , such cellular telephone networks, and other communication mechanisms. Note that the computing device 500 may use multiple communication adapters for making the necessary communication connections (e.g., a telephone modem card and a Cellular Digital Packet Data (CDPD)). The computing device 500 may be associated with other computing devices in a LAN or WAN, or the computing device can be a client or server in a client/server arrangement with another computer, etc.
The computing device 500 provides the environment where Operating System 534 , Middleware 536 , and Application 538 software execute tasks and may communicate with software on the same or on other computing devices. All these configurations, as well as the appropriate communications hardware and software, are known in the art.
As will be understood by one of ordinary skill in the art, computer programs such as described herein (e.g., Operating System 534 , Middleware 536 , and/or Application 538 software) are typically distributed as part of a computer program product that has a computer useable media or medium containing the program code. Therefore, “media,” “medium,” “computer useable medium,” or “computer useable media,” as used herein, may include a diskette, a tape, a compact disc, an integrated circuit, a programmable logic array (PLA), a remote transmission over a communications circuit, a remote transmission over a wireless network such as a cellular network, or any other medium useable by computers with or without proper adapter interfaces. Note that examples of a computer useable medium include but are not limited to palpable physical media, such as a CD ROM, diskette, hard drive and the like, as well as other non-palpable physical media, such as a carrier signal, whether over wires or wireless, when the program is distributed electronically. Note also that “servlets” or “applets” according to JAVA technology available from Sun Microsystems of Mountain View, Calif., would be considered computer program products.
Although the enabling instructions might be “written on” on a diskette or tape, “stored in” an integrated circuit or PLA, “carried over” a communications circuit or wireless network, it will be appreciated, that for purposes of the present invention described herein, the computer useable medium may be referred to as “bearing” the instructions, or the instructions (or software) may be referred to as being “on” the medium. Thus, software or instructions “embodied on” a medium is intended to encompass the above and all equivalent ways in which the instructions or software can be associated with a computer useable medium.
For simplicity, the term “computer program product” is used to refer to a computer useable medium, as defined above, which bears or has embodied thereon any form of software or instructions to enable a computer system (or multiple cooperating systems) to operate according to the above-identified invention.
The term “data structure” refers to a particular organization of meaningful data values that can be used in a predetermined fashion. For example, a network packet has a variety of different data elements that are used and accessed by communications networks and computer nodes for transporting the packet between different computer systems. The packet is a data structure and has a tangible embodiment in a computer useable medium when stored in a file, when loaded into system memory, when transported across a communications network, etc., in the same fashion as a computer program product.
It will be likewise appreciated that the computer hardware upon which the invention is effected contains one or more processors, operating together, substantially independently, or distributed over a network, and further includes memory for storing the instructions and calculations necessary to perform the invention.
Those skilled in the art will recognize that a system according to the present invention may be created in a variety of different ways known in the art. For example, a general purpose computing device as described in the context of FIG. 5 may be configured with appropriate software so that the computing device functions as described herein. Furthermore, discrete electronic components may be used to create a system that implements all or part of the functionality. Finally, note that combinations of multiple computing devices running appropriate software or discrete electrical components can be used in like fashion. Essentially, the hardware is configured (whether by software, custom-designed, etc.) to perform the functional elements making up the present invention.
It is to be appreciated that the WWW is considerably more complex than the example cited above with proxies and caching servers helping to extend the servicing and transport of transactions. Because the present invention identifies the time source and associates it with it's timestamp and duration information, multiple application components can employ the invention to add their duration measurements, resulting in multiple lines being added to the transactions HTTP header as it flows from the initiating client through these application components and is eventually returned. Examination of the header can occur at any point along the transactions path by application components to glean the invention's performance information. Specifically, during the return portion of the transaction path, an application component can review preceding application components durations and make decisions for the services it intends to render. Upon receipt of the transaction by the transaction's originator, the response time of the transaction can be measured as well as the decomposition into the durations of all preceding participating application components by examining the HTTP Reply header for the invention's keywords.
Although illustrative embodiments of the present invention have been described herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various other changes and modifications may be made by one skilled in the art without departing from the scope or spirit of the invention. | Techniques for use in accordance with application performance decomposition are provided which take advantage of the communications protocol used to carry a transaction between application components in a distributed computing network. Specifically, the invention extends the communications protocol by embedding data, such as timestamp and duration measurement data, in the protocol itself, rather than extending or altering the application or transaction data carried by the protocol as in existing approaches. Thus, the invention provides natural correlation of interactions of distributed application components on such transactions without modification to the application or transaction data. Because the correlation is performed in-line with the application component interactions, minimal data management overhead is required, and correlated performance decomposition is made possible in real-time for the transaction. Furthermore, subsequent processing stages of the distributed application can interpret the communications protocol to glean processing durations of previous stages in order to make decisions regarding treatment of the transaction. | 7 |
This is a continuation of application Ser. No. 525,389 filed Nov. 20, 1974, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a game board and the associated equipment necessary for playing a game thereon. In particular, the equipment is adapted for playing a variation of the game of checkers. Checkers, although an enjoyable parlor game, tends to become unduly repetitious due to the fixed rules of the game and layout of the board. This is particularly so when the same players regularly oppose each other. Another drawback of checkers is that the level of strategy involved and the opportunities for applying strategy are severely limited.
Variations on checker-type games are known, as for example, U.S. Pat. No. 1,400,520 to Bugenhagen. In this game a fixed obstacle is printed on a checkerboard. This obstacle or cruciform permits a piece landing on a square adjacent the cruciform to move to any other square adjacent to the cruciform. The equipment permits no possibility of varying the arrangement for each new game.
In U.S. Pat. Nos. 1,526,017 to Searle and 2,162,876 to Barton, various barrier type games are disclosed. In Barton, removable tiles are utilized to fit over discrete areas of the game board. As the game progresses, increasing numbers of barriers are placed on the game board with the object of completely boxing in one player. In Searle, immovable preprinted L-shaped barriers are utilized to disrupt the movement of playing pieces on an oversized playing board. See also U.S. Pat. No. 3,820,791 assigned to the present assignee and directed to a vector tile game.
It is accordingly an object of the present invention to provide a variation of the game of checkers in which the game board is varied before each game so that interest in the game is maintained at a higher level and for a longer period of time.
It is another object of the present invention to provide a variation of the game of checkers introducing an additional element for controlling the moves of the playing pieces whereby the permissible moves are different for each game.
It is another object of the present invention to provide a variation of the game of checkers wherein the placement of direction limiting tiles on the game board involves the use of strategy and subsequent movement of playing pieces onto these tiles requires deeper insight into the ramifications thereof than is required in a checkers game.
Other objects and advantages of the invention will be apparent from the concluding portion of the specification.
SUMMARY OF THE INVENTION
The present specification discloses a game board apparatus including a game board similar to a checkerboard except that the center two rows are omitted. In place of the center two rows, a channel is provided for receiving two rows of vector tiles therein. The vector tiles have two or more directions indicated on them from among eight possible directions, namely, vertically up and down, horizontally left or right, and the four diagonal directions.
the game is played with the same number of playing pieces, preferably transparent playing pieces, as in the game of checkers. When a playing piece moves onto one of the vector tiles, it is thereafter constrained to move only in the directions indicated by the vectors on the tile. In some cases this may hinder movement while in other cases it may permit additional degrees of freedom in that a game piece can move backwards if a vector tile so permits.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the game board according to the present invention;
FIG. 2 is a plan view of the game board after the vector tiles have been placed in the recessed channel;
FIG. 3 is a perspective view of a vector tile;
FIG. 4 is a sectional view taken along the lines 4--4 of FIG. 2;
FIG. 5 is a sectional view taken along the lines 5--5 of FIG. 2;
FIG. 6 is a perspective view of a playing piece according to the present invention;
FIG. 7 is a sectional view through a playing piece along the lines 7--7 of FIG. 6;
FIG. 8 is a plan view of the game board having the vector tiles therein and the playing pieces in the starting position;
FIG. 9 is a partial plan view illustrating movement of the playing pieces on the vector tiles;
FIG. 10 is a view similar to FIG. 9 illustrating further details of movement of the playing pieces on the vector tiles; and
FIG. 11 is a view illustrating the manner in which a playing piece is "kinged" when it reaches the far end of the playing surface.
DETAILED DESCRIPTION
Referring now to FIGS. 1-7, the game board equipment according to the present invention is illustrated. The equipment includes a game board 20 having a plurality of discrete playing areas, preferably squares, thereon and arranged in a row and column manner; that is, there are three rows, A, B and C of discrete squares on either side of the board. As in checkers, every other square in a row is differentiated by being of a different color, texture or otherwise shaded to distinguish it from the immediately adjacent square in that row. Thus, for example, square 22 may be clear while square 24 may be textured or of a different color.
Unlike a standard checkerboard, the present game board 20 does not have permanent rows of squares across the entire surface. The middle two rows of a normal checkerboard are omitted and in their place a depression or channel 26 is provided. The channel 26 has a plurality of grooves 27 therein to define discrete locations for the reception of vector tiles such as vector tile 28 illustrated in FIG. 3.
It will be appreciated from a comparison of FIGS. 1 and 2 that prior to playing the game, a plurality of vector tiles, preferably 16, are placed in the channel 26, each vector tile being placed over one of the discrete areas defined by the grooves 27. When the vector tiles have been so placed, the board appears as indicated in FIG. 2. It will be noted that all of the vector tiles are placed in the channel with an orienting mark or dot 30 facing towards the same side of the board.
Referring to FIG. 5, a cross section through the game board of FIG. 2 is indicated showing a preferred construction of the game board in order to facilitate low cost manufacture. Preferably the standard checkerboard columns are printed or embossed on raised surfaces 32 on either side of the channel 26. Preferably the raised surfaces are hollow underneath to reduce the amount of material necessary to manufacture the game board. Similarly, as indicated in FIG. 4, the vector tiles 28 are also manufactured as hollow squares. It will be appreciated that the game board, the vector tiles as well as the playing pieces, to be described, can all be manufactured from various materials such as plastic, wood, etc., and, in the case of plastic, the equipment can be turned out by stamping, extrusion, molding, or other well known techniques.
the 16 vector tiles, such as vector tile 28 of FIG. 3, have embossed thereon the orientating dot 30 indicating the position in which the tile must be placed on the board and a vector 34. The vector 34 defines for each tile the directions in which a playing piece resting thereon may be moved. Various examples of this are indicated in FIGS. 8-10 but a perusal of FIG. 2 indicates that when the vector tiles are correctly placed in the channel, an impediment to normal movement of the playing pieces is presented. In effect, the vector tiles control the movement thereacross and form an obstacle or barrier to normal movement of the playing pieces.
Before the playing of each game, the vector tiles are removed from the channel and, depending upon the rules in effect, are replaced in various different combinations, either one at a time by alternating players to permit strategy or by sheer chance placement of the tiles whereby they are picked up one at a time and placed into the channel without looking at them.
Referring now to FIGS. 6 and 7, one of the playing pieces adapted for use with the present invention is illustrated. The playing pieces are preferably formed from a plastic material, as is the game board, and may be molded or otherwise produced. The playing pieces preferably have a doughnut shaped portion 40 attached to a square portion 42. Preferably the diameter of the doughnut shaped portion 40 is equal to the width and length dimension of the square 42.
The shape of the playing pieces can differ from this; the only purpose in differentiating the top and bottom of the playing pieces is that inversion or reversal of a playing piece must indicate the piece is upside down. In the game, the inversion of a playing piece so that the doughnut-shaped member 40 is on the bottom indicates that the piece has crossed the entire board and become a "king" as defined in the ordinary game of checkers. By providing such a vertically differentiated playing piece it is not necessary to place one playing piece on top of another to indicate a king as is commonly done in checkers.
As indicated by FIG. 7, the playing pieces can be of a one-piece molded construction. An important aspect of the playing pieces is that they be transparent so that when they are on the vector tiles, the permissible directions of movement can be seen through the playing pieces. In order to differentiate between each side's playing pieces, it is preferable that one set of playing pieces be of clear material while the other set of playing pieces be of a slightly tinted material which, although permitting observation of the vector tiles, differentiates them from the clear playing pieces. It has been found that a yellowish-tinted playing piece is ideal for this purpose.
Referring now to FIGS. 8-11, the rules of the game will be explained along with additional details of the equipment. At the outset it should be noted that while the playing pieces are set up on the board in the same manner as checkers, the permissible moves for each playing piece, when not controlled by the vector tiles, differs from checkers. Each playing piece can move straight forward or diagonally forward, whereas in checkers, the playing pieces can only move diagonally forward.
To begin playing the game, preferably the players remove the barrier tiles from the channel 26 and then, depending on whether they are to be returned to the channel by random selection or by strategic placement, they are place one at a time in the channel. The players alternate placing the vector tiles in the channel. When all of the vector tiles have been placed in the channel, the playing pieces are then positioned on the playing surface as shown in FIG. 8. There are 12 playing pieces for each player, and they are initially arranged in the manner of a checkers game.
To begin play, each player is allowed to move one of his playing pieces in one of the three forward directions. A piece may move on any square whether textured or clear. As soon as a piece moves onto a vector tile, however, that piece can no longer move in the normal manner but can only move in the directions indicated by the vector 34 on the tile. Further, the piece can jump only in the directions permitted by the vector 34. A playing piece which passes through the barrier to the opponent's side is made a "king" if it reaches the very last row on the opponent's side. When this happens, the piece is inverted so that the square portion 42 is upward to identify it as a king. A king can move in any direction forward and back on any square unless and until it is moved onto the vector tiles. On the vector tiles a king, as is a regular piece, is constrained to move only in the directions permitted by the particular vector tile.
Jumping another player in this game is similar to checkers; however, a player may jump or refrain from jumping as he sees fit. In the vector tile rows, it is possible that a situation can be set up, because of the vectors, where one player can jump the other but not vice versa (see FIG. 10). When a regular playing piece lands on a vector tile which indicates movement in a backward direction, that piece can so move in spite of the fact that otherwise regular playing pieces can only move in the forward directions.
Referring to FIG. 9, there is illustrated the movements of playing pieces 50 and 52 onto different vector tiles. Playing piece 50, after landing on vector tile 54, can on subsequent moves, move only onto vector tile 56 or 58. Similarly, playing piece 52, after landing on vector tile 60 can only move back to square 62 or forward to vector tile 64.
It will be seen that where a playing piece must move onto another vector tile, further constraints on future movements are imposed upon the playing piece. Thus in effect, a playing piece can become stuck or entangled in the barrier formed by the vector tiles. This introduces a new and exciting element into the game which requires skill on the part of the players to anticipate the sequence of moves that will result from an initial move onto a vector tile. Furthermore, in an attempt to capture or jump another player's piece on the vector tiles, it will be necessary for a player to anticipate the other player's responses and forced moves due to the vectors. Since the vectors are changed at the beginning of each game, a constantly challenging and continually changing game is presented.
Referring now to FIG. 10, a situation wherein playing piece 70 can jump playing piece 72, not vice versa, is illustrated. Since the playing piece 70 is on vector tile 74, it can jump playing piece 72. Playing piece 72, however, is constrained to move only diagonally forward or backward by the vector tile 76 and accordingly, cannot jump playing piece 70.
Finally, referring to FIG. 11, the process of "kinging" a playing piece is illustrated. Playing piece 80, having reached the last row of the opponent's side of the board, is flipped over so that the square portion 42 is up and is then regarded as a king. It can then move in any direction on the regular tiles to jump the opponent's playing pieces as in the regular game of checkers.
While I have shown and described embodiments of this invention in some detail, it will be understood that this description and accompanying illustrations are offered merely by way of example, and that the invention is to be limited in scope only by the appended claims. | A game board apparatus is disclosed for playing a variant of the game of checkers. The game board is similar to a checkerboard, having alternating light and dark colored squares or alternatively, plain and textured squares. Unlike checkers, however, the two center rows of the game board are replaced by a channel adapted to receive two rows of vector tiles therein. The vector tiles alter the normal movement of playing pieces thereon. A piece landing on a vector tile is constrained to move only in the directions indicated by the particular directional indicia on the tile. At the start of each game, the vector tiles are removed from the channel and replaced in a different order thereby to vary the movement constraints for the next game. | 0 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to pipe joints, and more particularly to a joint for connecting pipes of synthetic resin material such as nylon or of a soft metal such as copper which serve as a conduit for fluids.
(2) Description of the Prior Art
There has been known in the art a push-in type pipe joint which can connect a pipe with a suitable strength simply by inserting one end of the pipe axially into a bore of a joint casing which, for instance, accommodates an annular plate or a ring tiltably for locking engagement with the inserted end of the pipe. With this type of pipe joint, the pipe is easily inserted into the joint by guiding the connecting end of the pipe concentrically with the opening of the annular plate or ring which, once the pipe is inserted, is tilted relative to the axis of the pipe by the action of a spring to hold the circumference of the pipe clampingly with its inner peripheral portions. The annular plate or ring is tilted in such a direction that its inner peripheral portions will bite on the circomference of the pipe with a greater force if the pipe is pulled outward or in a disconnecting direction, securely holding the pipe in the connected position.
Such pipe joints thus far have been required to employ a tilting plate or ring which has an inside diameter sensibly larger than the outside diameter of the pipe in order to facilitate pipe insertion through the tiltable plate or ring. In addition, the tiltable plate or ring is required to have a thickness greater than a certain value in order to ensure secure biting action of the inner peripheral edge portions of the disc or ring. Consequently, the disc or ring has to be tilted through a relatively large angle to perform the above-mentioned clamping function. These requirements are very disadvantageous to the compactness of the joint. Any pipe joint is desired to have a compact construction since otherwise it would unduly bulge out when mounted to connect a pipe to hydraulic equipments such as valves and piston-cylinders. A bulky joint is susceptible to damages by hitting upon nearby structures and could be an obstacle to operations or piping work in a narrow space. With regard to the compactness, the above-mentioned conventional pipe joint has large limitations inherent to its construction.
In order to detach the pipe from the conventional joint mentioned above, a release pin which is associated with the annular plate or ring is operated to return the tilted plate or ring into the upright coaxial position, setting the pipe loose. However, this procedure is troublesome and sometimes difficult since in most cases the pipe joints employ very small release pins to cope with the outside diameters of the pipes which are generally 18 mm or less, along the circumference of the pipe.
The conventional pipe joint has another drawback in that it is relatively complicated in construction and presents problems during automatic mechanical assembling process, including the problem of biased load on the spring.
It is therefore an object of the present invention to provide a pipe joint which permits of easy connection and disconnection of a pipe without using any tool.
It is another object of the present invention to provide a pipe joint employing a radially displaceable clamp ring which is located in the pipe passage in the joint casing and provided with a sharp edge around the inner periphery thereof to clampingly bite on the circumference of a pipe when the clamp ring is pressed into an eccentric position after pipe insertion thereby automatically holding the pipe in the connected position.
It is still another object of the present invention to provide a pipe joint employing a release ring which is slidably fitted at the entrance of the pipe passage and which is easily manipulatable from outside to push the clamp ring into a concentric position thereby releasing the pipe from the clamping action of the sharp edge of the clamp ring to allow extraction of the pipe without using any tool.
It is a further object of the present invention to provide a pipe joint in which the biting action of the sharp edge becomes stronger by displacement of the clamp ring when the joint is subject to a force which tends to extract the pipe therefrom, thereby producing a greater resistance to such extracting force.
It is a further object of the present invention to provide a pipe joint of a simple and compact construction which can securely hold a pipe in the connected position simply through eccentric displacement of a clamp ring.
It is still another object of the present invention to provide a pipe joint constituted by component parts which are easily obtainable by simple operations on a press or a lathe to allow mass production at low costs.
It is a further object of the present invention to provide a pipe joint which can cope with pipes with a larger tolerance in outer diameter, as compared with the conventional counterparts.
SUMMARY OF THE INVENTION
According to the present invention, the foregoing objects are achieved by a pipe joint which comprises: a casing having a hollow cylindrical pipe receiving portion defining therein a pipe passage axially through the entire length thereof; a clamp ring located within the pipe receiving portion to circumvent the pipe passage and radially displaceable by movement along the inner periphery of the pipe receiving portion, the clamp ring having a sharp edge around the inner periphery thereof to bite on the circumference of a pipe inserted into the pipe passage; a tapered surface provided at least on the inner periphery of the pipe receiving portion or on the outer periphery of the clamp ring to displace the clamp ring slidingly between an outer eccentric position and an inner concentric position relative to the axis of the pipe passage; a spring provided within the casing to urge the clamp ring toward the outer eccentric position; and a release ring slidably and concentrically fitted into the entrance of the pipe receiving portion and manipulatable from outside to push the clamp ring toward the inner concentric position.
With a pipe joint of this construction, upon inserting a pipe, the clamp ring is pushed into an inner concentric position against the biasing force of the spring to allow passage therethrough of the pipe. As soon as the pipe is fully inserted into a connected position, the clamp ring is pressed toward the outer eccentric position by the action of the spring clamping the pipe in the connected position with part of the sharp edge on the inner periphery thereof. The clamping force is increased all the more in the event a force which tends to extract the pipe is applied thereto, thereby securely holding the pipe in the connected position.
In order to disconnect the pipe from the joint, the release ring is pushed into the joint casing whereupon the clamp ring is moved into the inner concentric position, releasing the pipe from the clamping action of its sharp edge to allow extraction of the pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings which show by way of example preferred embodiments of the present invention and in which:
FIG. 1 is a longitudinal section of a pipe joint according to the present invention, showing same in free state;
FIG. 2 is a view similar to FIG. 1 but showing the joint as connecting a pipe;
FIG. 3 is a longitudinal section of a modification of the pipe joint of FIG. 1, having an auxiliary clamp ring mounted on the joint casing;
FIG. 4 is a longitudinal section of a pipe joint which constitute another embodiment of the present invention;
FIG. 5 is a longitudinal section of a modification of the pipe joint of FIG. 4;
FIG. 6 is a front elevation of a leaf spring employed in the pipe joint according to the present invention;
FIG. 7 is a view similar to FIG. 1 in which the leaf spring of FIG. 6 is used instead of a coil spring;
FIG. 8 is a longitudinal section of a modification of the pipe joint of FIG. 7; and
FIG. 9 is a fragmentary section showing the pipe joint of the invention which is installed within a housing of a valve.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, designated at 1 is a hollow joint casing substantially of a cylindrical shape which has a sleeve 2 fitted in securely at the entrance of a cylindrical pipe receiving portion 1a. The sleeve 2 is tapered toward its inner end to have an inwardly diversing inner periphery as indicated at 3. In engagement with the tapered surface 3 of the sleeve 2 is a complementarily tapered surface 5 of a clamp ring 4 of a smaller diameter which is urged toward the outer end of the pipe receiving portion 1a by a coil spring 6 and radially displaceable by movement along the tapered surface 3. The clamp ring 4 has a counter tapered surface 7 on its inner periphery which is disposed eccentrically with the axis of the pipe to be received in the pipe receiving portion 1a, forming at the inner end a sharp edge 9 which will clampingly bite on the circumference of the pipe 8 as will be described hereinlater.
One end portion of a release ring 10 with an annular flange 10a is slidably fitted concentrically in the sleeve 2 on the outer side of the clamp ring 4, the other end being projected out of the casing 1 and manipulatable to push the clamp ring 4 from outside. The release ring 10 is prevented from coming off the sleeve 4 by the annular flange 10a at the inner end of the release ring which is stopped by abutment against an inner flange 2a at the outer end of the sleeve 2.
If desired, the sleeve 2 may be formed integrally with pipe receiving portion 1a. In FIG. 1, the reference numeral 11 denotes a retainer, 12 a sealing O-ring and 13 an external thread for connection to an equipment on which the pipe joint is to be mounted.
For connecting the pipe 8 with the joint shown above, it is inserted from an opening 10b of the release ring 10 to abut against the tapered surface on the inner periphery of the clamp ring 4. The abutment of the pipe 8 against the clamp ring 4 takes place since the counter taper 7 on the latter is disposed eccentrically relative to the axis of the pipe receiving portion 1a although the outer periphery of the clamp ring 4 is normally engaged by the tapered surface 3 on the inner periphery of the sleeve 2 in concentrical relation with the axis of the pipe receiving portion 1a. Under these circumstances, if the pipe is further pushed in, the clamp ring 4 is radially displaced during its inward movement along the tapered surface 3, tending to bring the opening defined by the counter taper 7 into concentric relation with the pipe 8. While the clamp ring 4 is moved into a concentric position, the pipe 8 is passed through the clamp ring 4 into the position shown in FIG. 2.
When the pipe 8 is fully inserted into the position of FIG. 2, the clamp ring 4 is pressed against the tapered surface 3 of the sleeve 2 by the action of the spring and displaced along the tapered surface 3, tending to return to the initial position in which the outer periphery of the clamp ring 4 is disposed concentrically with the joint casing 1. As a result, the sharp edge 9 on the inner periphery of the clamp ring 4 is pressed against the circumference of the pipe, clamping the latter in the connected position. In this instance, it is also possible to make arrangements to clamp the pipe 8 in the connected position by a sharp edge which is provided along the edges of the flanged inner end 10c of the release ring 10.
In this state, if a force which tends to extract the pipe is applied, the displacement of the clamp ring 4 is encouraged all the more, causing the sharp edge 9 to bite on the pipe 8 with greater force to produce a greater resistance to such force.
In order to extract the pipe 8, the release ring 10 is pushed in to move inward the clamp ring 4 which then becomes radially displaceable to a certain extent according to the width of the gap between the outer periphery of the clamp ring 4 and the tapered surface 3 of the sleeve 2, as a result the sharp edge 9 setting the pipe 8 loose to allow extraction thereof.
In FIG. 3 which shows a modification of the pipe joint of FIGS. 1 and 2, a pipe receiving portion 101a of a joint casing 101 has auxiliary ring 113 and a release ring 114 which are slidably fitted in the pipe receiving portion 101a in concentrical relation therewith and provided with sharp edges 113a and 114a along the respective inner peripheries thereof. A radially displaceable clamp ring 104 is interposed between the just-mentioned two rings 113 and 114.
Therefore, in this modification, the pipe is clamped in the connected position by the biting actions of the sharp edges 109, 113a and 114a on the inner peripheries of the respective rings 104, 113 and 114.
FIG. 4 illustrates another embodiment of the invention, wherein a sleeve 302 which is fitted in a cylindrical pipe receiving portion of a joint casing 301 is provided with a tapered surface 302a on its inner periphery eccentrically with the axis of the joint casing 301. Fitted slidably within the sleeve 302 is a clamp ring 303 which is provided on its outer periphery with a tapered surface 303a complementary to the tapered surface 302a of the sleeve 302 and on its inner periphery with a conncentric counter-tapered surface 303b, forming a sharp edge 303c therearound. The clamp ring 303 is urged toward the mouth end 301b of the casing by the action of a spring 304. One end of a release ring 305 with an annular outer flange 305a is slidably fitted in the sleeve 302 and stopped therein by an annular inner flange 302b at the outer end of the sleeve 302.
The clamp ring 303 is not necessarily required to have a tapered surface on the outer periphery thereof, which may be formed in any other arbitrary shape as long as it has a contacting surface which is slidable along the tapered surface 302a on the sleeve 302 as shown in FIG. 5.
Referring now to FIGS. 6 to 8, there are shown embodiments of the invention which employ an annular leaf spring 401 instead of the coil spring of the foregoing embodiments. The leaf spring 401 has along its inner periphery a number of tongues 403 which are lanced out of a circular web 302 as shown in FIG. 6. FIG. 7 shows the annular leaf spring 401 as mounted in position within the joint casing, from which it will be understood that the use of the annular spring 401 allows to reduce the distance between the clamp ring 501 and the retainer 502.
The pipe joint of FIG. 8 is a modification of the embodiment of FIG. 7, in which the annular leaf spring 401 is likewise mounted within the joint casing but the tapered surface 602 on the outer periphery of the clamp ring 601 is contacted with a stepped portion 603a on the inner periphery of the sleeve 603.
In the embodiment of FIG. 9, the joint casing is provided within a valve housing 805 in direct communication with a fluid port thereof. Within a cylindrical casing 801 which is open at opposite ends, a spring 802, a clamp ring 803 and a release ring 804 are arranged in a manner similar to the embodiment of FIG. 7. The casing 801 is embedded through a seal member 808 in a bore 807 which is provided in the valve housing immediately on the outer side of a valve portion 806 to which a pipe is to be connected. The casing 801 is fixed in the bore 807 by threaded engagement therewith or by other suitable means. With this arrangement, substantially the whole joint assembly is implanted within the valve housing without projecting outside, so that the pipe can be connected directly to the valve, extremely facilitating the pipe connections or disconnections for altering the fluid passages.
Although the embodiments of the present invention has been described in relation with a valve, it is apparent that the pipe joint of the invention can be likewise applied to fluid ports of hydraulic cylinders or of other equipments. | A pipe joint having a radially displaceable clamp ring located within a cylindrical joint casing to circumvent a pipe passage along which a pipe is to be inserted, the clamp ring being movable between an inner concentric position and an outer eccentric position and provided with a sharp edge around the inner periphery thereof. Upon inserting a pipe into the joint casing, the clamp ring is pushed into the inner concentric position to allow passage of the pipe and, as soon as the pipe is fully inserted into a connected position, the clamp ring is pressed toward the outer eccentric position by a spring, clamping the pipe securely in the connected position by the sharp edge on the inner periphery of the ring. | 5 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to an improvement to a reflecting mirror (hereinafter referred to as “reflector”) used for a light source of a projector such as a liquid crystal projector and an overhead projector or the like.
[0002] A projector such as a liquid crystal projector or an overhead projector or the like irradiates light from a light source onto an object (which corresponds to an image display device such as a liquid crystal panel in the case of a liquid crystal projector) and projects the light modulated by this object onto a screen, etc. using an optical device to display the image. This light source has a configuration combining a light emitting lamp and a reflector to irradiate the light of this lamp and condense it in a specific direction. As the lamp for this light source, a short-arc type metal halide lamp with a metal halide sealed in a light emitting tube and with a short inter-electrode distance was previously used. On the other hand, as the reflector of the light source, a reflector with a heat-resistant glass inner wall coated with a multi-layer film of titanium oxide and silicon dioxide was previously used. Then, the metal halide lamp was replaced by an ultra-high pressure mercury lamp, which realizes high brightness easily, or a xenon lamp, which provides high color rendering, and these are used widely. Among them, this ultra-high pressure mercury lamp improves the light emitting efficiency and realizes high brightness by elevating the vapor pressure of mercury to 200 atm or higher while the lamp is lit. Furthermore, by mixing additives other than mercury, the ultra-high pressure mercury lamp improves its spectral distribution characteristic and realizes high color rendering.
[0003] However, this high pressure mercury lamp is under severe restrictions on its operating temperature. There is also a problem that using the high pressure mercury lamp outside its optimal designed range reduces the light emitting efficiency as well as the life of the lamp tube.
[0004] The reflector used for this projector light source used to be obtained by applying press molding to heat resistant glass with a small coefficient of thermal expansion, then coating the inner wall of the reflector with an aluminum-evaporated film having a reflectance of approximately 90% and applying antioxidant treatment to this surface. In response to a demand from the market in recent years for a reflector that will realize higher brightness, a reflecting surface used for the reflector is provided with an optical multi-layer film made up of TiO 2 and SiO 2 capable of providing higher reflectance. Luminous flux emitted from this reflector is generally transformed to parallel or convergent luminous flux. Thus, the mainstream of the shape of the reflecting surface of the reflector is paraboloidal or ellipsoidal.
[0005] The spatial distribution of light emitted from a light source is equalized through a lighting optical system. The uniformly distributed light is irradiated onto an image display device with pixels arranged in a matrix form such as a liquid crystal panel or DMD (Digital Micro Mirror Device). The image display device forms an image based on a television signal supplied or a video signal from a computer and modulates the above-described uniformly distributed light on a pixel-by-pixel basis. The modulated light is magnified by a projection lens and projected onto a screen, etc. A display device in such a configuration with no screen is called a “projection type image projector (front projector)” and a display device with a screen is called a “rear projection type image display device”. These projection type display devices are widely spread in the market as display devices suited to providing large screens.
[0006] FIG. 1 is a sectional view of a general light source for a projector using an ultra-high pressure mercury lamp as the light source. In the case of a light emitting tube in the power consumption 100 W class, the inner volume of a quartz glass light emitting tube 1 is 55 μl, electrodes 2 are sealed at both ends and the arc length between the electrodes is set to 1 to 1.4 mm. The light emitting tube 1 contains mercury as a light emitting substance and hydrogen bromide together with argon as starting aid gases with a predetermined ratio between the two gases. A molybdenum foil 4 is welded to an electrode central axis 3 , forming an electrode sealed section 5 . A base 6 is attached to the electrode sealed section 5 on the reflector bottom opening side. This base 6 is adhered or fixed to, through cement 8 , the bottom of a reflector 7 , on the inner surface of which a multi-layer reflection film is formed so that visible light is reflected and infrared rays are allowed to pass. In this case, the base 6 is fixed in such a way that the quasi-focal point of the reflector lies on the extension of the arc axis of the light emitting tube 1 . Front plate glass 9 having almost the same coefficient of thermal expansion as that of the reflector 7 is set in the flange section of the front opening of this reflector 7 . In the event of a burst of the light emitting tube, this front plate glass 9 is intended to prevent fragments of the light emitting tube from flying in all directions and reflection preventive coating is applied to both sides of the front plate glass 9 .
[0007] FIG. 2 shows a mode of use of the projector light source shown in FIG. 1 when it is used as the light source for an actual optical apparatus such as a liquid crystal projector or overhead projector. In FIG. 2 , the same components as those in FIG. 1 are assigned the same reference numerals and explanations thereof are omitted.
[0008] A cooling fan 10 is set on one side of or behind the projector light source and a desired cooling effect can be obtained by blowing air toward the reflector 7 . Another method is to suction the air around the light source heated by lighting of the lamp and thereby produce an air flow to cool the reflector.
SUMMARY OF THE INVENTION
[0009] A desired shape of the reflector used for the projector light source using the above-described conventional technology is obtained by applying press molding to heat resistant glass. This heat resistant glass has less fluidity than resin and it is difficult to control temperature or weight of materials when press molding is applied to heat resistant glass. Moreover, since warm water or oil with large specific heat cannot be used to adjust temperature of the die, the conventional reflector has poor shape stability compared to general thermoplastic or thermohardened plastic materials.
[0010] FIG. 12 shows a block diagram of a two-piece reflector obtained by connecting a reflector 7 a whose reflecting surface is ellipsoidal in cross section and a reflector 7 b whose reflecting surface is circular in cross section (116 mm in diameter (radius of reflecting surface: 54 mm), 100 mm depth) and connecting the reflector 7 a and the base 6 of the light-emitting tube 1 , which is the light source, using cement. In FIG. 12 , the same components as those in FIG. 1 are assigned the same reference numerals and explanations thereof are omitted.
[0011] In order to confirm the accuracy of the shape of the reflector used for the projector light source, heat resistant glass was subjected to press molding and a prototype of the reflector 7 b shown in FIG. 12 was created. As a result, the molding accuracy exceeded 700 μm, though the die was designed to have draft of 3 degrees, contraction of the molded product caused the reflector opening to have a quasi-vertical surface, which degraded mold releasing performance. Consequently, the molded product was deformed by 1300 μm into a saddle shape and it was impossible to obtain satisfactory performance.
[0012] Thus, the conventional reflector obtained by applying press molding to heat resistant glass has a problem with molding performance (die transfer performance or reproducibility), making it unavoidable to form a monotonous ellipsoidal or paraboloidal inner surface. In this way, the reflector made of heat resistant glass using the conventional technology has a first problem that it is not possible to stably obtain an accurate shape of the reflecting surface close to the designed shape.
[0013] Furthermore, the reflector made of heat resistant glass using the conventional technology is subjected to press molding, and therefore the drafting direction when the product is extracted from the die is limited to two directions, upward and downward. This causes a second problem that it is impossible to have a complicated shape such as providing projections and depressions on the outer wall surface of the reflector.
[0014] The present invention has been achieved in view of the problems in the above-described conventional technology. The invention provides a projector light source provided with a reflector, which features high accuracy, excellent molding and processing performance, and a projector equipped therewith.
[0015] More specifically, as described in claim 1 , the invention is characterized by molding the reflector using a heat resistant organic material in which high heat conductive substances are mixed. Moreover, as described in claims 9 and 10 , the outer surface of the reflector is provided with projections such as a heat radiating fin. This allows heat generated when the discharge lamp is turned on to be transmitted to the heat radiating fin through high heat conductive substances mixed in the reflector, making it possible to dissipate heat to the outside efficiently. This improves the cooling efficiency of the light source.
[0016] Attaching this heat radiating fin in a direction parallel to the air flow generated by the cooling fan (roughly the direction of light axis of the reflector) allows extremely efficient heat radiation.
[0017] Specific materials usable for the reflector are described in claim 11 . That is, heat resistant organic materials to be used include a mixture of low contraction unsaturated polyester resin with thermoplastic polymer, hardener, filler, glass fiber or inorganic filler. Furthermore, high heat conductive substances mixed into this heat resistant organic material and used to improve heat conductivity include alumina hydroxide. A molded product resulting from molding the thermohardened resin (hereinafter referred to as “BMC (Bulk Molding Compound)”) which is a mixture of the heat resistant organic material and high heat conductive substances allows accurate weight control or temperature control of the die and materials. This provides not only high shape accuracy but also excellent molding stability.
[0018] Thus, even if the shape of the inner surface of the reflector is changed from the conventional ellipsoidal or paraboloidal surface to a complicated shape including non-spherical and high-order coefficients as described in claims 3 , 12 and 14 , it is possible to obtain an accurate reflecting surface. Moreover, the BMC is capable of sliding the die from a plurality of directions such as a side core and vertical slide core die, making it possible to obtain high molding performance even with a complicated appearance. The projection type image projector or rear projection type image projector using the projector light source equipped with the reflector using the aforementioned technical means improves the light condensing efficiency, and can thereby obtain clear and satisfactory image characteristics.
[0019] The other objects, features and advantages of the present invention will become more apparent from the following detailed description of a preferred embodiment of the present invention with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a sectional view of a general projector light source using an ultra-high pressure mercury lamp as a light emitting source;
[0021] FIG. 2 is a layout plan showing a mode of use as an optical apparatus light source for a liquid crystal projector, etc.;
[0022] FIG. 3 to FIG. 8 are outside views each showing an embodiment of a projector light source according to the invention;
[0023] FIG. 9 and FIG. 10 illustrate a positional relationship between the projector light source of the invention and a cooling fan;
[0024] FIG. 11 and FIG. 12 are sectional views of the projector light source;
[0025] FIG. 13 is an enlarged view of a section of the bulb and its periphery of an ultra-high pressure mercury lamp;
[0026] FIG. 14 illustrates a light emitting energy distribution of the bulb and its periphery while the ultra-high pressure mercury lamp is lit;
[0027] FIG. 15 illustrates a light distribution characteristic of a DC-driven ultra-high pressure mercury lamp;
[0028] FIG. 16 illustrates a light distribution characteristic of an AC-driven ultra-high pressure mercury lamp;
[0029] FIG. 17 illustrates a spectral energy distribution of a general ultra-high pressure mercury lamp;
[0030] FIG. 18 illustrates a non-spherical shape;
[0031] FIG. 19 illustrates a layout of a lighting optical system of a liquid crystal projector using the projector light source according to the invention; and
[0032] FIG. 20 and FIG. 21 are sectional views in the vertical direction of a rear projection type image display device equipped with a projection optical system according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] With reference now to the attached drawings, an embodiment of the present invention will be explained below.
[0034] As a material of the reflector of the present invention, it is preferable to use, for example, Rigorack BMC (RNC-428) made by Showa Polymers Co., Ltd. obtained by mixing low contraction unsaturated polyester resin, which is a heat resistant organic material, with thermoplastic polymer as a low contraction agent, hardener, filler, glass fiber and inorganic filler, etc. to improve heat resistance. RNC-428 uses calcium carbonate as a filler and has heat conductivity as high as 0.5 W/m·k°. RNC-841 made by the above-described company mixes alumina hydroxide as a filler aiming at further improved heat conductivity has heat conductivity of 0.8 W/m·k°, which is approximately 1.6 times that of RNC-428.
[0035] To confirm the shape accuracy of the reflector used for the projector light source of the present invention, a prototype of the spherical reflector shown by reference numeral 7 b in aforementioned FIG. 12 (diameter: 116 mm (radius of the reflecting surface: 54 mm), depth: 100 mm) was created using Rigorack BMC (RNC-428) made by Showa Polymers Co., Ltd. As a result, a maximum deviation from the designed shape was 10 μm, high precision temperature adjustment and weight control accuracy of the die were 0.5% or below and it was possible to suppress inter-lot variations to 3 μm or below. The BMC also shows excellent mold releasing performance even if its molded surface is quasi-vertical and has excellent transfer performance such that its draft (minimum required gradient when a molded product is extracted from its die) is almost unnecessary. That is, it is possible to stably obtain the shape of the reflecting surface of an accurate reflector close to the designed shape.
[0036] Then, advantages in adopting a shape of the inner wall (reflecting surface) of the reflector 7 , which includes coefficients of the fourth or higher order, will be explained. Z(r) shown in Formula 1 denotes the height of the reflecting surface when the direction from the bottom face to the opening of the reflector (axis of the lamp bulb of the light emitting tube) is regarded as the Z-axis and the radial direction of the reflector is regarded as the r-axis as seen in FIG. 18 which illustrates a definition of the lens shape. Here, r denotes the distance in the radial direction, RD denotes the radius of curvature, CC, AE, AF, AG, AH, . . . , A denote arbitrary constants and n denotes an arbitrary natural number. Therefore, when coefficients CC, AE, AF, AG, AG, AH, etc. are given, the height of the reflector surface, that is, the reflector shape is determined according to Formula 1.
Z ( r )=(1 /RD ) r 2 /[1+√{square root over (1−(1| CC ) r 2 (1 /RD ) 2 )}]+ AE·r 4 +AF·r 6 +AG·r 8 +AH·r 10 + . . . +A·r n [Formula 1]
[0037] In above Formula 1, when the cross-section of the reflecting surface of the conventional reflector is circular, only RD is given and CC=0; when paraboloidal, RD is given and CC=−1; when ellipsoidal, RD is given and if the value of CC is −1<CC<0, it is possible to define an ellipsoid which is rotationally symmetric with respect to the major axis and if 0<CC, it is possible to define an ellipsoid which is rotationally symmetric with respect to the minor axis.
[0038] On the other hand, the reflector of the present invention can easily obtain high shape accuracy as described above, even if it has a complicated shape including fourth or higher order coefficients as shown in Formula 1, the reflector of the present invention can obtain an accurate reflecting surface.
[0039] FIG. 11 is a block diagram showing the reflector 7 whose reflecting surface is paraboloidal in cross section connected with the base 6 of the light emitting tube 1 with cement. On the other hand, FIG. 12 is a block diagram showing a two-piece reflector obtained by connecting a reflector 7 a whose reflecting surface is ellipsoidal in cross section and a reflector 7 b whose reflecting surface is circular in cross section and connecting the reflector 7 a and the base 6 of the bulb 1 with cement. In FIG. 11 and FIG. 12 , the same components as those in FIG. 1 are assigned the same reference numerals and explanations thereof are omitted.
[0040] The shapes of the reflecting surfaces of both reflectors are conventionally designed assuming that the light emitting source is a point light source, but the actual light source is not a point light source and has a certain energy distribution and limited dimensions. Furthermore, it has an asymmetric light distribution characteristic.
[0041] A specific example will be shown below. FIG. 13 is an enlarged view of a section of the bulb and its periphery of an AC driven ultra-high pressure mercury lamp of the projector light source shown in FIG. 1 . FIG. 14 illustrates a light emitting energy distribution while the lamp is lit. In FIG. 13 , a pair of electrodes 2 exist inside the quartz glass light emitting tube 1 , there is an inter-electrode gap (arc length) of a limited length of 1.0 mm to 1.4 mm for a 100 W class bulb. Furthermore, as shown in FIG. 14 , the light-emitting energy distribution in the periphery of the bulb while the lamp is lit is not uniform and the peripheries of the two electrodes are brightest (shown by a and b).
[0042] FIG. 15 illustrates a light distribution characteristic of a DC-driven ultra-high pressure mercury lamp and FIG. 16 illustrates a light distribution characteristic of an AC-driven ultra-high pressure mercury lamp. The light distribution characteristic of the light emitting tube 1 is asymmetric with respect to the axis (90° to 270° in the figure) orthogonal to the lamp axis (0° to 180° in the figure) as shown in FIG. 15 and FIG. 16 . The distribution characteristic of the DC-driven ultra-high pressure mercury lamp shown in FIG. 15 in particular shows greater asymmetry than the AC-driven ultra-high pressure mercury lamp shown in FIG. 16 .
[0043] This is because the anode of the DC-driven ultra-high pressure mercury lamp generally has greater dimensions than those of the cathode and part of light is intercepted on the anode side.
[0044] As described above, the actual ultra-high pressure mercury lamp is regarded not as a point light source but as having two light sources and it is preferable that the reflector used in combination with the ultra-high pressure mercury lamp be of a shape having a plurality of focal points. In order for the reflector to have a plurality of focal points, it is an indispensable condition to have coefficients of the fourth or higher order in above-described Formula 1. In the case where the arc length exceeds 1.8 mm, the efficiency is reduced instead.
[0045] The advantages of adopting a shape including coefficients of the fourth or higher order for the inner wall surface (reflecting surface) of the reflector have been described so far. Since the present invention can stably obtain the accurate shape of a reflecting surface of a reflector close to the designed shape, it is possible to adopt a shape including coefficients of the fourth or higher order for the inner wall surface (reflecting surface) of the reflector.
[0046] FIG. 17 illustrates a spectral energy distribution of a general ultra-high pressure mercury lamp. Since a strong spectrum exists in the vicinity of blue 405 nm, it is preferable to have a half-value breadth (transmittance of 50%) wavelength of a UV cut filter of 420 nm or more. Moreover, the spectral energy also exists in the infrared area of 800 nm or greater (not shown), and therefore it is preferable that the reflecting film of the reflector have a characteristic so that light in the infrared area is allowed to pass, once absorbed by the reflector and then heat is dissipated to the outside. For this purpose, using a black color for the base material of the reflector makes it possible to obtain a high absorption characteristic.
[0047] As mentioned above, the present inventor et al. made a prototype of the spherical reflector (radius: 54 mm) indicated by reference numeral 7 b of the two-piece reflector shown in FIG. 12 using Rigorack BMC (RNC-428) made by Showa Polymers Co., Ltd. and confirmed the shape accuracy. Furthermore, the present inventor et al. evaporated aluminum onto the inner surface to make it as the reflecting surface and measured temperatures on the reflecting surface and outer wall surface of the reflector when a 200 W ultra-high pressure mercury lamp was fixed to the reflector having a focal distance of 30 mm and turned on. The result showed that the temperature on the reflecting surface was 132° C. and the temperature on the outer wall surface was 83° C. in a non-wind condition at a room temperature of 20° C., which was a satisfactory result in making a prototype capable of attaining a margin close to 70° C. over 200° C. of thermal deformation temperature of the material. However, when the distance from the bulb to the inner wall surface of the reflector is taken into account, if the focal distance is 4 mm or below, there will be no longer margin over the heat resistance temperature. Moreover, it goes without saying that the heat resistance is questionable because even if input power exceeds 250 W, there will be no longer margin over the heat resistance temperature.
[0048] The BMC die is capable of sliding the die from a plurality of directions such as a side core and vertical slide core, which makes it possible to obtain high molding performance even with a complicated appearance. Using this, the invention adopts a complicated shape for the outer wall of the reflector provided with a heat radiating fin to improve heat resistance using this heat radiating fin.
[0049] FIG. 3 shows an embodiment where a heat radiating fin is provided on the outer wall of the reflector. As shown in FIG. 3 , providing the heat radiating fin 11 on the outer wall surface of the reflector 7 makes it possible to obtain higher heat dissipation performance. In FIG. 3 , the same components as those in FIG. 1 are assigned the same reference numerals and explanations thereof are omitted.
[0050] Furthermore, as shown in FIG. 4 , in addition to the heat radiating fin 11 provided on top of the outer wall surface of the reflector 7 , adding another heat radiating fin 12 to the bottom face can further improve the heat dissipation efficiency.
[0051] Furthermore, as shown in FIG. 5 , providing the heat radiating fins 11 and 12 on the top and bottom faces of the outer wall surface of the reflector 7 and additional heat radiating fins 13 (the heat radiating fin on the right side on the outer wall surface is not shown) to the right and left sides of the outer wall surface with respect to the axis of the light emitting tube lamp bulb as the symmetric axis further makes it possible to obtain higher heat dissipation efficiency. The same components in FIG. 4 and FIG. 5 as those in the foregoing drawings are assigned the same reference numerals and explanations thereof are omitted.
[0052] FIG. 9 shows a mode of use when the reflector of the invention shown in FIG. 5 is used as a light source for an actual optical apparatus such as a liquid crystal projector or overhead projector. The cooling efficiency can further be enhanced by providing a cooling fan 10 behind the projector light source and letting it blow air onto the reflector 7 . The same components in FIG. 9 as those in the foregoing drawings are assigned the same reference numerals and explanations thereof are omitted.
[0053] As another method, it is also possible to create an air flow by suctioning the air around the light source warmed by lighting of the lamp to cool the apparatus.
[0054] FIGS. 6 to 8 show other embodiments of the reflector of the present invention. In FIGS. 6 to 8 , reference numerals 14 to 16 denote heat radiating fins and the same components as those in the foregoing drawings are assigned the same reference numerals and explanations thereof are omitted.
[0055] As shown in FIG. 6 , there is provided a heat radiating fin 14 for the reflector which is orthogonal to the axis of the lamp bulb of the light emitting tube on top of the outer wall surface of the reflector 7 . Furthermore, as shown in FIG. 7 , it is also possible to improve the heat dissipation efficiency by adding another heat radiating fin 15 to the bottom of the outer wall surface of the reflector 7 in addition to the heat radiating fin 14 provided on top of the outer wall of the reflector 7 . Furthermore, as shown in FIG. 8 , providing heat radiating fins 14 and 15 on the top and bottom faces of the outer wall surface of the reflector 7 and additional heat radiating fins 16 (the heat radiating fin on the right side on the outer wall surface is not shown) to the right and left sides of the outer wall surface with respect to the axis of the light emitting tube lamp bulb as the symmetric axis further makes it possible to obtain higher heat dissipation efficiency.
[0056] FIG. 10 shows a mode of use when the reflector of the present invention shown in FIG. 8 is used as a light source for an actual optical apparatus such as a liquid crystal projector or overhead projector. More specifically, FIG. 10 shows a positional relationship between the reflector and the cooling fan according to the present invention. The cooling efficiency can further be enhanced by providing a cooling fan 10 below the projector light source and letting it blow air onto the reflector 7 . In FIG. 10 , the same components as those in the foregoing drawings are assigned the same reference numerals and explanations thereof are omitted. As another method, it is also possible to create an air flow by suctioning the air around the light source warmed by lighting of the lamp to cool the apparatus.
[0057] The orientation of the heat radiating fin is different between FIGS. 3 to 5 and FIGS. 6 to 8 , but when the light source of the present invention is attached to a projection image display device as a projector light source, it is natural that the heat radiating fin should be provided in parallel to the flow of wind generated by the cooling fan. By doing so, it is possible to provide extremely high efficient heat dissipation.
[0058] On the other hand, in the projector light source according to the present invention the average thickness of the reflector is gradually increased from the front opening to the bottom opening (section where the light emitting tube is housed) for the purpose of preventing a burst of the ultra-high pressure mercury lamp. This prevents fragments of the bulb glass due to the burst of the light emitting tube from flying in all directions. Such consideration is given because in the event of a burst of the bulb glass of the light emitting tube, the opening at the bottom of the reflector close to the light emitting tube receives a strong shock. The minimum required thickness of the reflector is 2 mm, and 3 mm is preferable when primary importance is attached to the molding performance. Furthermore, it is preferable that the opening at the bottom close to the bulb have an average thickness of 5 mm. An experiment shows that when the lamp bulb of the light emitting tube was burst while the lamp bulb was in use, no fragments flied to the outside when the above-described BMC reflector had a thickness of 5 mm or greater.
[0059] Furthermore, a front plate glass 9 for preventing scattering made of a material different from that of the reflector 7 is provided for the front opening to prevent fragments of the bulb glass due to a burst of the lamp from flying toward the lighting optical system. Applying reflection preventive coating to both sides of this front plate glass 9 alleviates reflection loss. By the way, a reflection preventive coat is evaporated onto both sides of the front plate glass, but when the inner absorption rate of the above-described front plate glass exceeds 5%, the reflection preventive coat may be subject to microcracks, etc. due to thermal expansion of the front plate glass with use for an extended period of time. It is therefore preferable to use the front plate glass of a material that minimizes internal absorption.
[0060] The specific embodiments of the invention using an ultra-high pressure mercury lamp have been explained so far, but it goes without saying that the same effects can also be obtained when a xenon lamp with excellent color rendering is used.
[0061] FIG. 19 illustrates an example of a lighting optical system of a liquid crystal projector using the projector light source according to the invention. In FIG. 19 , an integrator optical system 20 (hereinafter described as “multi-lens array”) is provided with a first multi-lens array 20 a , a polarization beam splitter and a second multi-lens array 20 b . The first multi-lens array 20 a is designed to split an incident luminous flux into a plurality of luminous fluxes through a plurality of square lens elements arranged in a matrix form. The polarization beam splitter is provided for each of the plurality of lens elements and designed to magnify the plurality of luminous fluxes split by the first multi-lens array 20 a and irradiate them onto the liquid crystal panel with one flux superimposed on another. The second multi-lens array 20 b has the polarization conversion function of emitting desired polarized wave using a ½λ phase difference plate. This projector light source 40 and multi-lens array 20 constitute a polarization lighting apparatus that emits desired polarized wave components. Here, the projector light source 40 is related to the embodiment of the present invention shown in FIGS. 3 to 8 and is provided with a heat radiating fin 14 which is orthogonal to the lamp axis. To one side of this projector light source 40 there is positioned the cooling fan 10 , which supplies cooling air in the direction parallel to the direction in which the heat radiating fin 14 is attached. This allows the temperature of this projector light source 40 to be controlled to a desired temperature.
[0062] Then, an operation of each component of the optical system shown in FIG. 19 will be explained. A white luminous flux from the projector light source 40 is emitted through the multi-lens array 20 as luminous fluxes with desired polarized wave components, reflected by a reflection mirror 21 and entered into condenser lens 22 . The condenser lens 22 condenses the luminous fluxes split by the multi-lens array 20 on liquid crystal panels 31 a , 31 b and 31 c corresponding to red, green and blue, respectively with one luminous flux superimposed on another and provides uniform illumination in this way. The luminous fluxes that have passed through the condenser lens 22 are separated into red, green and blue color beams by dichroic mirrors 23 and 25 and introduced to the liquid crystal panels 31 a , 31 b and 31 c , respectively. The color beams separated by the dichroic mirror 25 are reflected by the reflection mirrors 27 and 29 and introduced to the liquid crystal panel 31 a . Thereby, since the color beam introduced to the liquid crystal panel 31 a has a longer light path than other color beams in this way, the light path length and magnitude of luminous flux of this color beam are corrected by field lenses 26 , 28 and 30 . The color beams introduced to the liquid crystal panels 31 a , 31 b and 31 c are subjected to light modulation by image signals (not shown), transmitted and color-combined by a beam combination prism 32 . The color-combined beam is magnified by a projection lens 101 and projected onto a screen (not shown).
[0063] Then, FIGS. 20 and 21 are vertical sectional views showing main parts of a rear projection type image display device equipped with the projection optical system of the present invention and is constructed in such a way that an image captured by an optical unit 100 is magnified by a projection lens 101 and projected onto a screen 102 through a loopback mirror 104 . FIG. 20 shows a configuration of a cabinet 103 with a reduced set height and FIG. 21 shows a configuration of the cabinet 103 with a reduced set depth.
[0064] Thus, the present invention forms a light source reflector using a heat resistant organic material mixed with high heat conductive substances, and can thereby obtain high molding performance and efficiently transmit heat produced by light emission of the lamp to the outside. Thus, the present invention allows the reflecting surface to have a complicated shape such as a non-spherical surface and thereby has the special effects of improving the lamp condensing efficiency and improving the light source cooling efficiency as well.
[0065] This embodiment has described a transmission type liquid crystal panel as an example of an image display device, but it goes without saying that a reflection type liquid crystal panel or DMD can also be used. Moreover, the material of the reflector described in this embodiment is a mere example and it is self-evident that various materials can also be used within the scope indicated by the appended claims and the modes thereof are also within the scope of the present invention.
[0066] It should be further understood by those skilled in the art that the foregoing description has been made on embodiments of the invention and that various changes and modifications may be made in the invention without departing from the spirit of the invention and scope of the appended claims. | A projector light source which facilitates molding of a reflector for obtaining a complicated reflecting surface and provides an improved cooling efficiency, which is characterized by molding the reflector of the light source using heat resistant plastic mixed with a high heat conductive material, whereby a molding accuracy is drastically improved compared to a heat resistant glass reflector, and a highly efficient light source is implemented by increasing a degree of design freedom using a high-order non-spherical reflecting surface. Furthermore, heat conductivity is increased by the use of a high heat conductive material for the reflector and heat dissipation to an outside is facilitated. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a 35 USC 371 application of PCT/EP2009/050753 filed on Jan. 23, 2009.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a capsule support arrangement for a filling and closing machine, in particular for medical applications.
2. Description of the Prior Art
Filling and closing machines are known, for instance from pharmaceutical applications, in which capsules in which an upper capsule part is slipped onto a lower capsule part are filled, for instance with a medication. The capsules are delivered empty and are then filled and closed incrementally at a plurality of stations on a conveyor wheel. At the various stations, quality and intactness tests can then for instance be performed. The known machines have fundamentally proven themselves over time. In laboratory areas, however, there are applications in which the known machines cannot be used in a targeted way, since the known machines are designed for the highest possible throughput. In the laboratory field, however, it is often necessary to fill only a small batch of capsules of a certain size. Although it is fundamentally possible to retrofit known machines, so that instead of one capsule size a different capsule size can be filled, nevertheless such retrofitting is very complicated and expensive. For the conveyor wheel in particular, many different capsule support arrangements have to be replaced in order to make conveying possible.
ADVANTAGES AND SUMMARY OF THE INVENTION
The capsule support arrangement according to the invention has the advantage over the prior art of furnishing a simple, economical embodiment, particularly for filling and closing machines of capsules in laboratory areas. According to the invention, in particular a fast change of capsule sizes can be achieved without problems and in a simple way. Moreover, by means of the capsule support arrangement of the invention, simple retrofitting of already existing filling machines can also be done. This is attained according to the invention by providing that the capsule support arrangement has an upper part segment and a lower part segment. The upper part segment and the lower part segment each have at least one first receiving opening with a first diameter and one second receiving opening with a second diameter. The diameters of the two receiving openings are different. As a result, it is possible, once a filling operation has been completed, for a further filling operation to be performed immediately for capsules of a different diameter.
Also preferably, the capsule support arrangement has a delivery magazine, again with at least one first receiving opening with a first diameter and one second receiving opening with a second diameter. The first diameter of the delivery magazine corresponds to the first diameter of the upper part segment, and the second diameter corresponds to the second diameter of the upper part segment. The lower part segments each have somewhat smaller diameters than the upper part segments.
Also preferably, the upper part segment, the lower part segment, and the delivery magazine have at least five receiving openings with different diameters. As a result, a filling machine can be designed for filling five different capsule sizes.
Preferably, the capsule support arrangement further includes a sorter with curved contact faces, which are adapted to various capsule lengths.
Also preferably, the capsule support arrangement has a sorting block with recesses for different capsule sizes.
Also preferably, the capsule support arrangement includes an insertion unit with a plurality of insertion punches, which each have a curved contact face. By means of the insertion punch, a capsule can be transferred or inserted into an upper part segment. The insertion punches with the curved contact faces each have radii which correspond to the radii of the associated receiving openings. As a result, a secure transfer of the capsules to the upper part segments or lower part segments is achieved. Further conveyance of a lower part of the capsules is achieved preferably by means of underpressure or a vacuum, in order to transfer a lower capsule part into the lower part segment.
Preferably, for each of the receiving openings one closure element is provided, for closing the individual receiving openings. As a result it is ensured that a capsule to be filled will not mistakenly be delivered to a receiving opening with the wrong diameter.
The invention furthermore relates to a filling and closing machine for capsules having a capsule support arrangement of the invention. The filling and closing machine is preferably used in laboratory areas for pharmaceutical applications. In particular, it is possible for small batches of capsules to be filled with a medication, as is necessary for instance in pharmaceutical development laboratories or in research facilities.
BRIEF DESCRIPTION OF THE DRAWINGS
One preferred exemplary embodiment of the invention will be described below in detail, in conjunction with the accompanying drawings. In the drawings:
FIG. 1 is a schematic top view on a filling and closing machine in accordance with an exemplary embodiment of the invention;
FIG. 2 is a schematic sectional view of a capsule support arrangement in an exemplary embodiment of the invention;
FIG. 3 is a schematic top view on a delivery magazine of the capsule support arrangement shown in FIG. 2 ; and
FIG. 4 is a schematic side view of the capsule support arrangement of FIG. 2 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Below, in conjunction with FIGS. 1 through 4 , a capsule support arrangement 20 and a machine M for filling and closing capsules 30 will be described.
FIG. 1 shows the schematic layout of the filling and closing machine M; the machine includes a rotatable conveyor wheel F, on which stations 1 through 12 are disposed along the path of revolution of the conveyor wheel. At 1 , the empty capsules that are to be filled are taken from a reservoir and aligned and delivered to the machine In the process the capsules are separated, so that an upper part and a lower part of the capsules are disposed separately. At station 3 , station 5 , and station 7 , filling stations are provided in which the lower parts of the capsules can be filled. Station 8 is a station for detecting flaws; defective capsules are rejected. Closure of the capsules is done in station 10 , and ejection is done in station 11 . Station 12 is a cleaning station. It should be noted that the machine may provide still other stations, particularly for checking the fill level of the capsules, closure security, and so forth.
In FIG. 1 , twelve upper part segments 21 are schematically shown, which each have five recesses 21 a . The five recesses 21 a each have different diameters, so that each can receive only one predetermined capsule size. FIG. 2 schematically shows the capsule support arrangement 20 . As can be seen from FIG. 2 , the capsule support arrangement 20 includes an upper part segment 21 , a lower part segment 22 , a sorting block 23 , a sorting rake 24 , and a delivery magazine 25 . An insertion unit with a plurality of insertion punches 26 disposed parallel to and next to one another is also provided.
FIG. 3 schematically shows a top view on the delivery magazine 25 . As can be seen in FIG. 3 , the delivery magazine 25 has five recesses 25 a , 25 b , 25 c , 25 d and 25 e, which each have different diameters. The diameters are selected such that each recess can receive precisely one capsule diameter. The capsules 30 are delivered from a reservoir, not shown, in which they are disposed in random order. The capsules 30 are closed and include an upper part 30 a and a lower part 30 b . Each of the insertion punches 26 includes a curved contact face 27 , for inserting a capsule into an upper part segment 21 .
The function of the capsule support arrangement 20 of the invention is as follows. In the first step, the random capsules are delivered from the reservoir to the delivery magazine 25 , which is indicated in FIG. 2 by the arrow A. The delivery magazine 25 includes five recesses 25a-25e, which are each closable by means of a closing element, not shown. If the capsule having the largest diameter is to be filled, however, it is possible to dispense with the closing elements, since because of their large diameter the capsules do not fit into the other recesses 25 b - 25 e.
The delivery magazine 25 is disposed movably in the vertical direction, so that it can always be moved into the reservoir at certain time intervals in order to separate capsules 30 .
As can be seen from FIG. 2 , the capsules 30 from the delivery magazine 25 reach a sorting block 23 . In the sorting block 23 , the delivered capsules are aligned, being rotated by 90° by means of the sorting rake 24 , so that they are arranged lying horizontally. This is indicated in FIG. 2 by the arrow C. As indicated by the double arrow B, the sorting rake 24 can be moved back and forth in the horizontal direction and by means of a protruding tip 24 a , it can rotate the capsules by 90° in the appropriate direction. The sorting rake 24 has curved contact faces and is adapted to the particular capsule length. Once the capsule 30 has been rotated, the sorting rake 24 thrusts the capsules in FIG. 2 to the right beneath one of the insertion punches 26 . Each insertion punch 26 is movable in the vertical direction, as indicated by the double arrow D. The insertion punch 26 has a protruding region 26 a , which comes into contact first with the capsule 30 . As a result, the capsule 30 is rotated once again by 90°, in such a way that the upper part 30 a of the capsule 30 comes into contact with the curved contact face 27 . The insertion punch 26 is then moved farther downward, until the capsule 30 is positioned entirely inside the upper part segment 21 . The upper part segment 21 has five recesses 21 a , which are embodied as stepped bores in such a way that the upper part 30 a rests on the shoulder 21 b of the stepped bore and thus cannot be pushed any farther downward in the vertical direction. Once the capsule 30 is disposed in the upper part segment 21 in this way, the lower part 30 b of the capsule 30 is aspirated by means of underpressure, so that the lower part 30 b is disposed in a stepped bore 22 a of the lower part segment 22 . A smaller diameter of the stepped bore 22 a is selected, such that the lower part 30 b is not aspirated through it. As a result, the capsule 30 is opened, so that in the following stations checking for damage and filling of the capsules can be done.
If a different batch of capsules is now to be filled, then according to the invention there is no need to replace the upper part segment, lower part segment, delivery magazine, sorting rake 24 , or sorting block 23 . Care must merely be taken at the delivery magazine 25 to ensure that those recesses 25 a - 25 e that do not correspond to the diameter of the capsules to be filled are closed. For instance, if now only very small capsules are to be filled, then the recesses 25 a - 25 d are closed, and only the recess 25 e in the delivery magazine 25 stays open. It is thus prevented that the small capsules 30 will be introduced into the wrong recess and capsules will be delivered to the sorting block 23 only via the recess 25 e . It should be noted that a separate insertion punch 26 is provided at the sorting block 23 for every diameter of the capsules, the insertion punch being adapted especially to those capsules. This can be seen in FIG. 4 , in which the insertion punches 26 are arranged next to one another in a row corresponding to the opening diameters of the delivery magazine 25 and the upper part segment 21 . In addition, the sorting block 23 also has recesses for various capsule sizes.
Thus the machine according to the invention is especially well suited to use in a laboratory, in which only small batches, for instance for sampling purposes, have to be filled and in which many capsules of different sizes have to be manipulated. Then a complicated conversion of the machine is unnecessary, and furthermore there is no need to keep an inventory on hand for various format sets relating to the delivery magazine, the sorting rake, the sorting block, the upper part segments, and the lower part segments. Of the multiple capsule passages through the machine present in the exemplary embodiment, only one at a time is used, depending on the capsule size, and the others are prevented from being used, for instance by means of coverings.
The foregoing relates to the preferred exemplary embodiment of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims. | The present invention relates to a capsule support arrangement for a filling and closing machine for two-part capsules with a capsule upper part and a capsule lower part. The capsule support arrangement includes an upper part segment for receiving capsule upper parts and a lower part segment for receiving capsule lower parts. The upper part segment and the lower part segment respectively have at least one first receiving opening with a first diameter and a second receiving opening with a second diameter, the first diameter differing from the second diameter. | 0 |
FIELD OF INVENTION
[0001] The present invention relates to nozzles used for the injection and atomization of black liquor that is combusted in a chemical recovery boiler.
BACKGROUND OF THE INVENTION
[0002] Black liquor is a fluid that is the by product of the pulping process. This fluid contains both organic and inorganic material resulting from the pulping of wood. Black Liquor is burnt in a special boiler where the heat from the organic matter is used to generate steam and the inorganic matter is reduced to extract the pulping chemicals which are then returned to the pulping process. In order to ensure the proper combustion and chemical recovery the liquor has to be atomized to an optimum size. This depends on the boiler geometry as well as operating parameters such combustion air flow, liquor flow rate, injection pressure and temperature.
[0003] In accordance with the prior art, black liquor is sprayed into the boiler through dedicated nozzles. FIG. 1 is a schematic of the most widely used nozzle, the splash plate 10 . Other nozzles types that have been used are used the V-jet 20 shown in FIG. 2 and more recently the beer can 30 shown in FIG. 3 . The latter has come about as a result of new developments in boiler combustion.
[0004] In the case of the splash plate nozzle the black liquor is delivered through the pipe 14 which is mounted to the inlet orifice 11 on the nozzle body 13 . The fluid leaves the nozzle through the discharge orifice 12 . Both the inlet and discharge orifices 11 and 12 are an integral part of the nozzle body 13 . The fluid upon leaving the orifice impacts on the splash plate 15 where it spreads out to form a sheet that eventually breaks up into droplets that burn.
[0005] For the V-jet nozzle 20 the fluid is delivered through pipe 24 which is mounted to the inlet orifice 21 found on the nozzle body 23 . The fluid leaves the nozzle through the discharge orifice 22 . Both the inlet and discharge orifices 21 and 22 are an integral part of the nozzle body 23 . Fluid traveling through the discharge orifice contracts and spreads out like a fan forming a thin sheet that eventually breaks up into droplets that burn.
[0006] For the beer can nozzle 30 the fluid is delivered through pipe 34 which is mounted to the inlet orifice 31 found on the nozzle body 33 . The fluid leaves the nozzle through the discharge orifice 32 . Both the inlet and discharge orifices 31 and 32 are an integral part of the nozzle body 33 . Fluid traveling through the inlet orifice 31 travels down a small transition channel 35 and enters the inner cavity 36 of the nozzle body 33 at a point tangential to the cavity wall. The fluid swirls around the cavity and eventually leaves the nozzle body 33 through the discharge orifice 32 found at the bottom of the nozzle body. The fluid leaving the discharge orifice spreads like a cone which eventually breaks up into droplets that burn.
SUMMARY OF THE INVENTION
[0007] In accordance with the invention, a nozzle for the spraying of black liquor in a recovery boiler is provided, where the discharge orifice of the nozzle can easily be varied without having to change the entire nozzle. This enables one to fine tune the atomization to the specific combustion setup at that time and place.
[0008] The subject matter of the present invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. However, both the organization and method of operation, together with further advantages and objects thereof, may best be understood by reference to the following description taken in connection with accompanying drawings wherein like reference characters refer to like elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 : Cross section of prior art splash plate nozzle.
[0010] FIG. 2 : Cross section of prior art V-jet nozzle.
[0011] FIG. 3 : Schematic of prior art beer can nozzle.
[0012] FIG. 4 : Cross section of variable orifice beer can.
[0013] FIG. 5A : Bottom view of the discharge end of the variable orifice beer can.
[0014] FIG. 5B : Detail view of roll pin and orifice disk from FIG. 5A .
[0015] FIG. 6 : Cross section of the variable orifice V-jet.
[0016] FIG. 7 : Another variation for the V-jet nozzle.
DETAILED DESCRIPTION
[0017] In order to optimize the combustion and chemical reduction it may be necessary for one to change the orifice size to vary the injection pressure or vary the flow rate. For all of the prior art nozzles above, the discharge orifice is an integral part of the nozzle body which would therefore require one to change the entire nozzle body in order to change the orifice. In another instance it may be necessary to change the orifice due to wear which results in the increase in flow area and/or change in shape. With the nozzle arrangement in accordance with the invention disclosed here one has to only change a single piece that bears the opening for the discharge orifice in order to change the orifice size.
[0018] FIGS. 4 & 5 shows the arrangement of a beer can type nozzle 40 in accordance with this invention. FIG. 4 shows the cross section through the nozzle while FIG. 5A shows a view of the bottom end of the nozzle 50 with the details for the variable orifice. FIG. 5B gives a more details view of a section of the arrangement in FIG. 5A . In the case of the beer can nozzle 40 the fluid is delivered through a pipe 41 which is mounted to the inlet orifice 45 found on the nozzle body 42 . According to FIG. 5A the fluid entering through 41 travels through the passage 51 and enters the body at the top of the inner cavity 46 of the nozzle while traveling tangent to its wall. The fluid swirls around the inner cavity as illustrated by the path 52 and is finally ejected through the orifice the orifice 44 . The orifice is made by drilling a hole on the orifice disk 43 . Unlike the prior art 30 in FIG. 3 , this disk is not an integral part of the nozzle body 42 . It is a totally independent component which is placed in a recess at the exit end of the nozzle. When the nozzle is in use the orifice disk faces down. A snap ring 48 prevents it from falling out of the nozzle body. In order to achieve the swirling flow inside the nozzle the discharge orifice should lie rotationally in the quadrant furthest away from the inlet orifice. In order to maintain this position the orifice plate is held securely by pin 49 that has part of its circumference engaged with disk 43 while the remainder engaged with the housing 42 . In liu of the pin a flat face could be cut on the perimeter of the disk. A corresponding flat face would be cut in the nozzle body as well. In either case, the pin or flat face and the orifice hole are set 180° apart and the lie along the line 52 which is at an angle of 45° from the center line of the inlet orifice 54 . The pin is inserted into a hole in the housing. The depth of the hole is selected such that the pin does not protrude beyond the surface of the disk. It is important to have the pin flush with the outer surface of the disk in order to properly seat the snap ring. While it is possible to hold the disk by cutting a male thread on the edge of the disk corrosion and thread distortion due to heat does not make it very practical. In order to enable one to operate the nozzle in the environment of a chemical recovery boiler while maintaining the ability to change the orifice diameter by swapping out the orifice disk the nozzle housing are made of different materials which have substantially different thermal expansion coefficients. The thermal expansion coefficient of the disk is greater than that of the nozzle housing. The disk diameter and the recess diameter in the nozzle body are carefully controlled so that at room temperature (˜20° C.) a specific gap 47 is maintained between the two of them. The black liquor delivered to the nozzle is in the range of 100-130° C. Therefore at elevated temperatures the disk would expand more than the housing hence closing the gap 47 ensuring a seal of the inner chamber 46 . When the nozzle is taken out of service and the temperature lowered to room temperature the disk will shrink to its original size which in turn will enlarge the clearance between these two components enabling one to swap out the disk thereby changing the orifice diameter.
[0019] FIG. 6 shows a V-jet nozzle 60 fitted in a manner according to this invention. Fluid enters the nozzle through pipe 61 which is mounted to the inlet orifice 65 on body 62 . Sandwiched in between the pipe 61 and the nozzle body 62 is the orifice insert 63 . Fluid passes from the pipe into the inner cavity 66 and is then ejected through the discharge orifice 64 . The insert has a shoulder 69 which butts up against the shoulder 68 located at the end opposite inlet orifice. In order to keep the specific orientation of the spray from a V-jet insert 63 is free to rotate in side the nozzle body. Once the orientation of the orifice 64 has been finalized the nozzle body is tightened up against the pipe through matching threads on the pipe and nozzle body. A sloped interface 67 between the orifice insert and the pipe ensures the fluid does not leak out of the nozzle body.
[0020] FIG. 7 illustrates another variation of the V-jet nozzle.
[0021] Thus, in accordance with the invention, a nozzle arrangement is provided to enable changing of orifice properties to adjust flow and spray pattern without requiring the replacement of the entire nozzle body. This can provide lower cost operation and maintenance, for example. Further, the orifice properties may be changed to provide desired drop sizes and droplet velocities in the spray for optimum combustion in the recovery boiler.
[0022] While plural embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the invention in its broader aspects. The appended claims are therefore intended to cover all such changes and modifications as fall within the true spirit and scope of the invention. | A nozzle for the spraying of black liquor in a recovery boiler has discharge orifice inserts that can be removed and replaced with other inserts, to provide variable spray patterns, by changing the size and/or shape of the orifice of the nozzle, without requiring replacement of the entire nozzle body, to enable fine tuning of the atomization of the spray. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 62/280,440, filed Jan. 19, 2016, the contents of which are hereby incorporated by reference in its entirety.
FIELD
[0002] This invention relates to rain gutters and similar structures for keeping leaves and other debris out of rain gutters. More particularly, this invention relates to an extension system to a fixed sized gutter guard for fitment into larger gutters.
BACKGROUND
[0003] In today's gutter protection technology, a gutter guard size is matched to a corresponding gutter size. For example, for a six inch gutter, a gutter guard that is slightly wider than 6 inches (so as to span onto the roof) is required. Gutter guards, also known as gutter covers and gutter protection systems, are installed on top of rain gutters that are attached to the edge, or near the edge of a roof-line for keeping leaves, pine needles and other organic debris out of the gutter.
[0004] Conventional gutter guards are water permeable, weather resistant and have predetermined widths for fitting different size gutters, thus for a particular gutter, an equivalently sized guard is required. Typical gutter widths at the top opening mouth of the gutter are 4 inches, 5 inches or 6 inches. Commercial grade gutters are generally wider than 6 inches. The difficulty with having a predetermined sized gutter guard for each sized gutter, is that there are significant costs in manufacturing all the appropriate sizes and the concomitant need for additional space for stocking the various sizes. Similarly, various box sizes for packaging each gutter guard for shipping is required.
[0005] In view of the prior art approach described above, various systems and methods are detailed below that allow for robust fitment of a extension to smaller gutter guards to fit larger gutters.
SUMMARY
[0006] The following presents a simplified summary in order to provide a basic understanding of some aspects of the claimed subject matter. This summary is not an extensive overview, and is not intended to identify key/critical elements or to delineate the scope of the claimed subject matter. Its purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.
[0007] In one aspect of the disclosed embodiments, a size-adjustable debris preclusion device for securing to a top of a roof gutter attached to a building for keeping leaves and other debris out of the roof gutter is provided, comprising: a debris and leaf precluding gutter cover with a gutter lip end and an opposing roof-side end, sized to cover at least one of a portion of and all of a longitudinal section of a roof gutter's top, the cover having a fixed, non-adjustable width, wherein the roof-side end is shaped with a mating feature to a corresponding end; and a debris and leaf precluding, low-profile gutter cover extension having a roof end and the corresponding end, the corresponding end having a complementary shape to the gutter cover's shaped end's mating feature, so as to permit a joining of the ends to maintain a debris and leaf precluding barrier between the gutter cover and extension, wherein, when the gutter cover and extension are mated, form an extended gutter cover that entirely covers and is self-supporting over the roof's gutter top and a junction of the gutter cover and extension is low-profile, to permit water flow across a top of the junction.
[0008] In another aspect of the disclosed embodiments, the above device is provided, further comprising a screw or adhesive disposed into or between the cover's mating feature and extension's complementary shape; and/or wherein the mating feature has a shape of at least one or more fingers with one or more short protrusions extending from the one or more fingers, wherein the protrusion operate to lock the finger into or onto the extension's complementary shape; and/or wherein a shape of the roof end of the extension is opposite the complementary shape, so as to permit joining of another extension to the roof end of the extension; and/or further comprising one or more longitudinal markings along a top surface of the extension, indicating a distance or approximate gutter size; and/or wherein the longitudinal markings are shaped as troughs to fit a protrusion; and/or wherein the complementary shape of the extension further includes a bottom supporting foot, extending downward; and/or wherein the extension is in the form of an L with an upper substantially vertical portion and lower substantially horizontal portion is roof-side, wherein the horizontal portion includes the complementary shape; and/or wherein the upper portion has a bent portion adapted to rest on a roof end; and/or wherein the bent portion operates as a drip edge; and/or further comprising a gutter; and/or the extension is formed from a metal or plastic; and/or wherein at least one of the gutter cover and extension is weather resistant; and/or wherein the gutter cover is water permeable.
[0009] In another aspect of the disclosed embodiments, a debris preclusion extension device for attachment to a gutter cover secured to a top of a roof gutter attached to a building for keeping leaves and other debris out of the roof gutter is provided, comprising: a debris and leaf precluding, low-profile gutter cover extension having a roof side end and a gutter cover side mating end, the mating end having a shape that is configured to attach to a gutter cover's roof-side end and shaped to permit a joining of the ends to maintain a low profile over a junction between the gutter cover and the extension.
[0010] In yet another aspect of the disclosed embodiments, a method for precluding leaf and other debris from entering a roof gutter that is attached to a building is provided, comprising: forming a debris and leaf precluding, gutter cover with a gutter lip end and an opposing roof-side end, wherein the roof-side end is shaped with a mating feature to a corresponding end; forming a debris and leaf precluding, low-profile gutter cover extension having a roof end and the corresponding end, the corresponding end having a complementary shape to the gutter cover's shaped end's mating feature; joining the gutter cover with the extension by inserting the cover's roof-side shaped end into the extension's corresponding end, to maintain a debris and leaf precluding barrier between the gutter cover and extension; and securing the joined gutter cover and extension over a gutter, with the extension's roof end placed under a roof covering.
[0011] In yet another aspect of the disclosed embodiments, the method above is provided, further comprising joining an additional extension to the extension to cover the gutter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1A is a side view illustration of an exemplary extension and roof-side end section of a gutter guard.
[0013] FIG. 1B is a side view of a reversal of the shapes shown in FIG. 1A .
[0014] FIG. 1C is an illustration of another embodiment showing an extension with lower lip and matching gutter guard end.
[0015] FIG. 1D is a side view of ends of extension and gutter guard, having a plurality of interlocking structures.
[0016] FIG. 2A is an illustration showing a complete side view of an exemplary extension attached to a gutter guard.
[0017] FIG. 2B is an illustration showing a top view of an exemplary extension attached to a gutter guard.
[0018] FIG. 3 is a side view illustration of a roof gutter with exemplary gutter guard system attached.
[0019] FIG. 4 is a side view illustration of a gutter guard system that is a variation of the system shown in FIG. 3 .
[0020] FIG. 5 is a side view illustration showing another embodiment, wherein the gutter is very wide
DETAILED DESCRIPTION
[0021] In various embodiments, a Gutter Guard Extension is described with a low profile, that they can be shipped in the same box as a standard gutter guard. This, of course, allows one to have a single sized gutter guard for multiple gutter sizes. This reduces product cost since less different-sized gutter guards are required, reduces shipping costs since only a single-sized box can be used, all of which reduces storage costs.
[0022] The exemplary extensions allow the mating gutter guard to slide under the roof shingles or to fasten it along the back of the gutter, in accordance with typical mounting procedures. Depending on the gutter-to-roof scenario, various extension shapes would be used. The exemplary extensions can also be designed to protrude down from the gutter guard to the bottom of the gutter to assist in supporting the gutter guard for larger size commercial grade gutters, which typically span a gutter width of greater than 6 inches.
[0023] The exemplary extensions can be made out of aluminum, steel, copper or other metals and even plastics. The materials can be molded or extruded into the shape of the extension needed or the use of a press (or other piece of bending metal equipment) to bend the material into the shape of the extension desired. The exemplary extensions can be “solid” or permeable, mesh-like or any combination thereof. The exemplary extensions can be weather resistant and/or water permeable, if so desired.
[0024] The exemplary embodiments overcome the deficiencies in the prior art via the utilization of an extension accessory that attaches to the roof-side edge of a gutter guard to lengthen it (adjust its size) so it can fit a larger gutter. By lengthening a fixed size gutter guard with the extension, there is no need to fabricate a separate full size gutter guard for spanning the larger gutter. As an example, most standard size gutter guards are approximately 5.5 inches in width and will fit a 5 inch gutter or smaller, but will not fit a larger size 6 inch gutter. By coupling or fixing an extension on the “back” of the 5.5 inch gutter guard, it can now become 6.5 inches, for example, in length for fitment to a 6 inch wide gutter. Additionally, the mating structures described herein avoid significant vertical protrusions of the extension-to-gutter guard connection, so as to minimize the obstruction and/or retention of debris that may travel from the roof to the gutter guard.
[0025] FIG. 1A is a side view illustration of an exemplary extension 100 and roof-side end section 2 of gutter guard 110 . The extension 100 has a mouth or opening 1 that is shaped to mate to the roof-side end 2 of gutter guard 110 . The front of the mouth 1 has at least one tooth or protrusion 3 , (shown here, in this example, with upper and lower protrusion), which allows the extension 100 to be interlocked onto the gutter guard end's 2 receiving trough(s) or receptacle(s) 4 (shown here with an opposite receptacle 5 ). With sufficient rigidity of the constituent end 2 and mouth 1 material, this mating method works very well enough to allow, for example, a “snapping” in of the pieces. Of course, in various other embodiments, the joining fitment can be via any structure or mechanism that allows the ends to be secured fixed to each other. For example, in some embodiments, the pieces can be joined by laterally sliding the pieces into each other, or via a twisting or other action.
[0026] FIG. 1A 's extension 100 also contains a similar configuration of receptacle(s) 7 and 6 at a distal end, to accommodate another extension (not shown) to be attached to the distal end of the extension 100 . Thus, several extensions may be joined end-to-end to provide the desired width. It should be apparent, that with this design, various prior art approaches utilizing fastening tools, adhesives, mechanical fasteners (screws, rivets, etc.) are not needed to span gutters that have widths of 6 inches and greater.
[0027] Troughs 8 , 9 , 10 and 11 are optional (running a length or partial length) and if used can be spaced as measurement guides. As an example, they could be spaced 0.25 inches apart. (Of course, other spacings are possible and fully within the purview of this disclosure.) This can help the installer understand dimensions more quickly in certain applications.
[0028] In view of the embodiment shown in FIG. 1A , it should be understood that various modifications and alterations to the end shape and matting end shape of the pieces can be made, while providing a similar or equivalent result without departing from the spirit of this this disclosure.
[0029] For example, FIG. 1B is a side view of a reversal of the shapes shown in FIG. 1A . That is, extension 12 has a tongue or finger that is similar to FIG. 1A 's gutter guard end 2 , which is mated to gutter guard 13 with mating mouth opening 14 (corresponding to FIG. 1A 's extension's 100 mouth 1 ).
[0030] FIG. 1C is an illustration of another embodiment showing an extension with lower lip 15 and matching gutter guard end 16 that connects together by the use of a screw, bolt or other type of fastener 17 . Instead of interlocking together, gutter guard end 16 lays on top of extension lip 15 , or visa versa. It should be apparent that the top surface of the interface between the two pieces is fairly unobstructed, thus allowing easy flow of debris from the extension to the gutter guard. Thus, a low profile design is shown herein.
[0031] It should also be appreciated that while the various embodiments shown here for the extension illustrate a “solid” surface, it is understood that the extension may be non-solid, water permeable so as to act as a debris and leaf precluding structure. That is, the extension may be designed to operate also with gutter guard like features, in tandem with the adjoining gutter guard. Thus, it is understood that the shapes, material, design, structure of the extension may be varied as according to design preference, without departing from the spirit and scope of this disclosure.
[0032] It should be apparent that the exemplary design can be modified or changed, if so desired, to allow an exemplary extension 100 to be end-mounted to or attached to a gutter guard 110 that does not have the shaped end 2 shown in the above FIGS. That is, it is fully envisioned the exemplary extension 100 can be modified with a generic opening that is tailored to fit over a conventional gutter guard's end. Therefore, any mechanism or design that allows an extension to be “attached” to the end of a gutter guard (whether specifically designed for the extension or designed without any considerations for an extension) is understood to be within the spirit and scope of this disclosure.
[0033] FIG. 1D is a side view of ends of extension 18 and gutter guard 19 , having a plurality of interlocking structures. This embodiment is similar to FIG. 1A 's but with multiple mating tongues or fingers. Extension 18 is shown with three fingers with protrusions 18 a , 18 b , and 18 c with voids 22 and 23 therebetween. The voids 22 , 23 of extension 18 match with gutter guard's 19 interstitial fingers 21 and 24 and “lock” into each other, aided by protrusions 18 a , 18 b , 18 c fitting into gutter guard's 19 receptacles 19 a , 19 b , 19 c . Of course, a reversal of the structures may be implemented, if so desired. Additionally, more or less protrusions and voids, shapes, etc. may be implemented.
[0034] Depending the shape, length, type of material used, the amount of force to require locking may vary. Further, the term lock here, or locking is understood to indicate that the interlocked ends are secured to each other and will not easily “slip” out once engaged, and may require significant effort or twisting to unlock the ends. Of course, the number of shapes, the kind of shapes, lengths, direction, etc. of the tongues or fingers, extensions, voids, receptacles may differ from what is shown and is understood to be within the scope of one of ordinary skill in the art.
[0035] FIG. 2A is an illustration showing a complete side view of an exemplary extension 30 attached to a gutter guard 40 , and is understood to be self-explanatory.
[0036] FIG. 2B is an illustration showing a top view of an exemplary extension 30 attached to gutter guard 40 . Here, the extension 30 is shown as being solid, though it is understood that it is not a requirement. While FIG. 2B shows a mesh-like gutter guard 40 , any shape, design, form for the gutter guard 40 may be utilized. Aspects of this illustration and embodiment are understood to be self-explanatory.
[0037] FIG. 3 is a side view illustration of a roof gutter 360 with exemplary gutter guard system attached. Gutter 360 is mounted to a fascia board 350 connected to the roof 330 and rafter 320 . The gutter's 360 opening is covered with gutter guard 40 (overlapping the gutter's front lip 331 ) that is of insufficient length to cover the gutter's opening, but is bridged to the roof edge 32 via exemplary extension 30 mated to a roof-side end of the gutter guard 40 . The extension 30 allows the gutter guard 40 to fully span from the front lip of the gutter 331 to the upper roof edge 32 .
[0038] FIG. 4 is a side view illustration of a gutter guard system that is a variation of the system shown in FIG. 3 . In this embodiment, the gutter guard extension 34 is formed into a bent L shape with an upper lip 33 that fits over the fascia 450 or on the roof 38 (below shingles), with a lower “horizontally” oriented portion 35 that has a matting end to interlock into gutter guard 37 . Extension 34 rides into the fascia-side back edge 39 of gutter 460 , which is attached to fascia 450 . This extension type can fasten to the fascia 450 or rafter 420 by the use of a screw or nail 36 . As can be seen, this embodiment contemplates a gutter 460 that is mounted at a “lower” point of the roof end than the gutter shown in FIG. 3 .
[0039] The extension surfaces 33 , 34 and 35 can also be used as a drip edge barrier so rainwater does not travel up the roof-line. In this configuration, the back edge 39 of the gutter 460 does not reach the top of the roof edge 40 , so a drip edge material is appropriate. In this scenario the exemplary extension serves two purposes, it functionally extends the gutter guard 37 to span the top of the gutter 460 to the roof 38 and also acts as a drip edge barrier. A drip edge is often used by roofers or gutter installers when there is a gap of exposed wood (the roof sheeting or fascia 450 ), where rainwater can leak back. The drip edge prevents rainwater from leaching back into the home and prevents the fascia's wood from rotting.
[0040] If the roofing material is a heavy covering, like a concrete tile, or stiff (such as terra cotta, etc.), it cannot be easily lifted up from the fascia to slide an extension 33 lip under it. In this scenario, the extension's lip 33 would not be part of the extension 34 . That is, the extension would be composed of surfaces 34 and 35 , only. In some embodiments, lip 33 would be cut or removed from the extension, or the extension itself would only be fabricated with surfaces 34 and 35 .
[0041] Various modifications may be made, for example, it some embodiments, the extension may be formed from a stronger or stiffer material so as to act as a better supporting structure for the gutter guard. That is, the gutter guard may only be stiff enough for a gutter that it is sized for, and an attempt to use a larger gutter guard will necessitate a different type or material for the gutter guard (as it must be supported over a longer span, otherwise it will collapse into the gutter). In these situations, the extension may provide the necessary stiffness to span the larger gutter without requiring a different (material) gutter guard.
[0042] FIG. 5 is a side view illustration showing another embodiment, wherein the gutter 45 is very wide (for example, 10 inches wide). Here, an exemplary extension 41 “supports” itself and the gutter guard 537 via a downward leg support 43 that rests on the bottom of the gutter 45 . The bottom of downward leg 43 has a foot 44 that rests on the bottom of the gutter 45 . An adhesive or sealant can be used to help secure the foot 44 to the bottom of the gutter 45 , if necessary.
[0043] It should be understood that while cross-sectional views are presented herein, with features relating to the fingers, extensions, troughs, etc. as part of the cross section, the features described may be limited, in some embodiments, to certain lengths or sections of the gutter guard and extension. That is, it is fully envisioned that one or more of the exemplary features may occur at intervals along an entire length of the extension or cover. It is also envisioned that neighboring gutter guards (at their terminal sides) may be bridged with a single extension to provide an “independent” support, and one or more of the exemplary features may be adapted, changed, modified to better strengthen these terminal side junctions. As a non-limiting example, ends of the terminal side junctions may have a plurality of fingers while mid-sections of the gutter guards have a singular finger configuration.
[0044] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. Therefore, various modifications to the shape and design of the embodiments disclosed, which provide similar functionalities are understood to be within the spirit and scope of this disclosure. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope being indicated by the following claims. | An extendable, debris and leaf precluding gutter cover with a gutter lip end and an opposing roof-side end, has a fixed, non-adjustable width, wherein the roof-side end is shaped with a mating feature to a corresponding end. A weather resistant, debris and leaf precluding, low-profile gutter cover extension is matched to the gutter cover, having a roof end and the corresponding end with a complementary shape to the gutter cover's shaped end's mating feature. This permits joining the ends to maintain a debris and leaf precluding barrier between the gutter cover and extension. When the gutter cover and extension are mated, they form an extendable gutter cover that entirely covers and is self-supporting over the roof's gutter top and a junction of the gutter cover and extension is low-profile, to permit debris flow across a top of the junction. | 4 |
RELATED APPLICATION
[0001] This application is related to Canadian Patent application 2,257,437 which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to improved cam contacting devices for use in internal combustion engines and preferably for use in internal combustion engines having variable valve timing. In particular, the use of ceramics including silicon nitride and silicon carbide have been demonstrated as providing effective cam contacting surfaces allowing an axially displaceable cam shaft having a variable profile cam to be run with resulting improvements in idle speed and volumetric efficiency.
BACKGROUND OF THE INVENTION
[0003] The design of an internal combustion engine requires numerous trade-offs between conflicting design or performance parameters and particularly with respect to valve timing.
[0004] For example, in the design of an engine, a designer may wish to minimize exhaust emissions and provide increased fuel economy without compromising satisfactory engine performance. In the past, the design of such an engine would be limited by such conflicting parameters leading the designer to compromise with the design to achieve a balance between the parameters. As such, designers will often focus on a primary performance goal (such as lower emissions) which may be to the detriment of desired engine performance (such as torque or idle stability). Such compromises are often caused by the lack of the designer's ability to incorporate breathability into the engine, that is an optimal intake of fuel and air and the exhaust of spent gases after combustion.
[0005] The breathability of an engine is primarily determined by the physical structure of the cam shaft, cam lobes, valve lifters (and the associated push-rods, rocker arms, if applicable). In particular, the physical shapes or profiles of the cams and their relative orientation with respect to one another determine the timing of the intake and exhaust valve opening, the duration of opening, and the timing of valve closure which, along with the orientation of respective intake and exhaust valves about the camshaft, determine the power map of the cylinder.
[0006] As a result of the high-temperature, high-pressure and mechanical speed of the working environment as well as the physical complexity of these components, adjustment of valves during operation of the engine is difficult and accordingly, most engines utilize a fixed cam timing system wherein the relative timing between valve opening and closure does not vary with engine speed. As a result, fixed cam timing engines require trade-offs between the performance parameters of the engine.
[0007] More specifically, the camshaft function is to open and close valves at the proper time, to fill the cylinders before combustion and to empty them after combustion. The cams are mounted on the camshaft and have a profile which determines the timing of valve opening, the duration of opening and the timing of valve closing. The lifters are in intimate contact with the cam surface and ride the cam surface in order to impart opening/closing forces to the valves. The opening and closing of valves is thereby timed to the rotation of the camshaft which in turn is controlled by the crankshaft.
[0008] Accordingly, the physical dimensions or shapes of the cams, lifters and the orientation of the cams with respect to one another are parameters which can be varied in order to obtain desired engine performance.
[0009] With respect to the physical dimensions or design of a cam, the following terms are generally used to describe the shape of a cam and the physical movements of a valve. For example, the base circle of the cam defines the period that the valve is closed, the clearance ramp defines the time of transition between closure and measurable valve lifting, the flank or ramp provides the time for and characteristics of valve opening, the nose defines the time of full valve opening and maximum opening displacement and the duration defines the time that the valve is off its seat.
[0010] Each of these parameters of a cam cannot be independently controlled during engine operation and therefore require compromises between what the physical dimensions of a cam will allow in relation to the other parameters. For example, duration is a compromise between opening the valves long enough to fill and/or evacuate the cylinders to the loss of dynamic compression by opening the valves too long and increasing lift increases power but is limited by lifter diameter.
[0011] With respect to the design of lifters (or tappets), the technology of lifters is variable between engines. Generally, the primary goals of the design of a lifter is to maintain contact between the lifter surface and cam surface while minimizing noise during operation. There are two main classes of lifters, solid and hydraulic with each class providing variable contact ends including flat, mushrooms and rollers. The use of hydraulic lifters generally reduces valve lash and noise. A flat tappet-cam normally has a slight taper across its surface whereas the corresponding tappet end surface is normally marginally convex in order to compensate for mis-aligned lifter bores.
[0012] Another class of lifters are roller lifters which include a wheel or roller in contact with the cam. Roller lifters allow for highly aggressive ramp profiles and, as a result, require high valve spring tensions to keep the roller in contact with the cam. Roller lifters also reduce frictional losses between the lifter and cam and thereby will increase the overall power or efficiency of the engine.
[0013] Mushroom lifters have a bulge at the end and are used to provide more lift per duration.
[0014] The relative orientation of the intake and exhaust cams with respect to one another contributes to defining the power map of the engine. Specifically, the lobe separation angle or overlap determines the time during which the intake and exhaust valves are opened simultaneously, wherein a wider lobe separation angle generally improves idle quality, idle vacuum and top-end power whereas a narrower lobe separation angle decreases idle quality but provides better mid-range torque.
[0015] Degreeing a cam is also a parameter which can be used to affect engine performance and refers to altering the point where the cam activates the valves in relation to the crankshaft. Specifically, retarding the cam shaft, that is, opening a valve later relative to the crankshaft moves the power up the rpm band and can increase horsepower while decreasing lower end torque. In contrast, advancing the cam shaft (opening the valves earlier) has the opposite effect.
[0016] In order to address some of the problems associated with fixed cam timing, variable cam timing systems have been designed. Generally, such systems provide a cam lobe having a three-dimensional surface and a lifter which is allowed to move axially over the three-dimensional cam surface. Accordingly, the axial position of the camshaft will determine the specific cam profile which controls valve timing. Variable valve timing thereby permits the alteration of valve timing during the operation of the engine allowing engine performance to be modified to match operating conditions. Variations in the relative shapes of a cam within a variable cam system can enable any one of independently phasing the intake cams, independently phasing the exhaust cams, phasing the intake and exhaust equally or phasing the exhaust and intake cams independently of one another.
[0017] For example, by diluting the in-cylinder mixture by reducing fuel intake characteristics by providing shorter intake times increases fuel economy but decreases the torque response of the engine. In contrast, by enriching the in-cylinder mixture by increasing fuel intake times by providing more lift and duration leads to an increase in horsepower. A variable valve timing system can accommodate such conflicting objectives by providing different timing profiles depending on the rpm of the engine thereby contributing to improving the breathability of the engine and increasing the manifold pressure.
[0018] In high performance applications, the current state-of the-art recognizes the single axis roller or wheel based lifter as the optimal performance enhancing device for valve train operation. However, as the desire for higher engine rpm has grown, it has been found that wheel based lifters will fail under the higher tension springs utilized in the higher rpm engines. Typically, failure occurs in two ways; roller bearing failure in the wheel itself and/or the catastrophic failure of the lifter, both a result of wheel “flat spotting” which produce valve lifter and valve train vibration.
[0019] Furthermore, existing wheel-based lifter designs do not provide direct delivery of lubrication to the roller bearing but rather lubrication occurs indirectly which decreases the ability to dissipate heat from the bearing surfaces. Accordingly, bearing life may be reduced as the wheel may be in direct contact with the bearing race with minimal oil film between the two surfaces.
[0020] To achieve maximum bearing life in a single axle based system, the designer must balance three parameters given that the wheel diameter is maximized within the confines of the lifter body. These three factors are roller bearing diameter, axle diameter and wheel thickness. Each of these parameters must be varied to minimize the compressive and contact stresses on the bearing surfaces, minimize the stresses in the axle and minimize the deflection of the axle which directly affects the contact stresses within the roller bearings.
[0021] While past variable valve timing systems have been disclosed, for example in U.S. Pat. No. 2,969,051, German publication DE 197 55 937, Swiss publication DE 304494 and U.S. Pat. No. 2,307,926, the lifter/cam contacting systems have experienced neither widespread implementation or success. The reason for this lack of success is postulated to be a result of failures experienced in the actual implementation of such systems. That is, within the harsh operating conditions of an internal combustion engine, it is speculated that previous variable valve timing systems experience bearing failure within the bearings/races of these systems.
SUMMARY OF THE INVENTION
[0022] In accordance with the invention, there is provided a cam contacting device having improved thermal properties for use in an internal combustion engine. Various properties of the cam contacting material which enable its use are disclosed. These include any one or a combination of a density less than 6 g/cc (preferably about 3.1-3.2 g/cc), a Young's modulus greater than 310 Gpa (preferably about 310450 Gpa), a Vickers hardness greater than 1150 (Hv) (preferably 1650-2850 (Hv)), a coefficient of thermal expansion less than 10.5×10 −6 /degree Celsius (preferably about 3.1-5.5×10 −6 /degree Celsius), a thermal conductivity less than 50 W/m K (preferably about 22-26 W/m K), a Weibull modulus greater than 12 (preferably about 12-18), and an abrasive wear resistance greater than 900 (preferably about 947-1263)
[0023] In more specific embodiments, the cam contacting device is a ball bearing within a bearing race and support wherein the coefficient of thermal expansion of the ball bearing is less than the coefficient of thermal expansion of the bearing race and support and more specifically where the cam contacting device is a ceramic ball bearing within a steel bearing race and support.
[0024] In one embodiment, the cam contacting device is a silicon nitride or silicon carbide ball bearing.
[0025] Specific cam contacting material may include any one of CERALLOY 147-31E, 147-31N, 147-1E, or 147-1.
[0026] In a further embodiment, the cam contacting device includes a lubrication system for providing lubrication to the cam contacting device/cam interface.
[0027] In a further still embodiment, the invention relates to the use of a cam contacting device as described above in an internal combustion engine having variable profile cams.
[0028] Further still, the invention provides an internal combustion engine having cylinders, a rotating camshaft, valves and valve lifters in operative communication between the valves and rotating camshaft, further comprising a variable profile camshaft and valve lifters linearly displaceable with respect to one another wherein the valve lifters include a silicon nitride bearing for operative contact with the rotating camshaft and which may include a valve seat having fuel injection ports within the valve seat for injecting fuel into the cylinders;
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] These and other features of the invention will be more apparent from the following description in which reference is made to the appended drawings wherein:
[0030] [0030]FIG. 1A is a schematic diagram of roller lifter in accordance with the invention;
[0031] [0031]FIG. 1B is a schematic diagram of an assembled and unassembled ball bearing lifter in accordance with the invention;
[0032] [0032]FIG. 1C is a schematic diagram of a semi-spherical solid lifter in accordance with the invention;
[0033] [0033]FIG. 1D shows an end view of a variable valve timing camshaft with both a fixed centreline and with a variable centreline;
[0034] [0034]FIG. 2 is a schematic diagram of a combined overhead camshaft system with a spherical bearing valve depressor and valve seat fuel injector;
[0035] [0035]FIG. 3 is a photograph showing wear patterns of a steel ball-bearing lifter which has been run in an engine in comparison to a steel ball-bearing lifter which has not been run in an engine;
[0036] [0036]FIG. 4 is a photograph showing the wear patterns of a ceramic bearing lifter and steel bearing lifter; and,
[0037] [0037]FIG. 5 is a photograph showing the wear patterns of a steel radiused wheel lifter and ceramic bearing lifter.
DETAILED DESCRIPTION OF THE INVENTION
[0038] General Overview
[0039] The Figures show various designs of cam contacting devices for use in internal combustion engines and specifically adapted for a variable valve timing engine as well as test results from the use of cam contacting devices in accordance with the invention within a variable valve timing engine.
[0040] [0040]FIGS. 1A, 1B and 1 C shows three designs for cam contacting devices in accordance with the invention including a radiused wheel lifter, a spherical bearing lifter and a solid semi-spherical lifter. FIG. 1D shows an end view of a variable valve timing camshaft with both a fixed centreline 1 and with a variable centreline 2 . Within the context of this description, cam contacting device is intended to mean any device within an internal combustion engine which contacts or follows the outer surface of a rotating cam so as to directly or indirectly affect valve opening and closing. Accordingly, cam contacting device may include valve lifters, rocker arms or cam-followers directly configured to a valve stem.
[0041] With reference to FIG. 1A, a radiused wheel lifter 3 is shown with side and front views. In this design, a roller wheel is fixed in the end of the lifter with bearings allowing the roller wheel to rotate about a fixed axis in the lifter base.
[0042] With reference to FIG. 1B, a ball bearing valve lifter 4 is shown in an assembled 10 and disassembled showing a hydraulic damping system 5 , bearing retainer 6 and spherical bearing 7 . 35 shows a lubrication port and 36 shows the inner receiving surface of the lifter.
[0043] With reference to FIG. 1C, a solid semi-spherical lifter 8 is shown having a semi-spherical end with a lubrication port 37 for delivery of lubrication to the cam-contacting device/cam interface.
[0044] [0044]FIG. 2 shows a schematic diagram of a combined overhead camshaft system with a spherical bearing valve depressor 16 and valve seat fuel injector 20 . The system includes a varable profile cam 15 in an overhead cam layout, an overhead valve depressor 16 with spherical bearing (or a radiused wheel or half-sphere as described above), a cylinder head 17 , a valve 18 and valve spring 19 . The valve seat 20 may include fuel injector nozzles 21 with fuel delivery line 22 . The intake port 23 delivers air to the cylinder through valve 18 . The valve depressor 16 may include spherical bearing race 24 seated on a bearing housing 25 and valve spring retainer 26 .
[0045] Cam Contacting Device Materials
[0046] Specific designs of the lifter including ceramic bearings selected from silicon nitride and silicon carbide were tested within an internal combustion engine (ICE) having a fixed profile camshaft and within an ICE having a variable profile camshaft. Other ceramic materials and their properties are shown in comparison Table 1.
TABLE 1 Bearing Steel/Ceramic Comparison Table Silicon Nitride Bearing Si 3 N 4 Silicon Steel Product Ceralloy Carbide Alumina Zirconia AISI Alloy Units 147-31N SiC Al 2 O 3 ZrO 2 Y-PSZ 52100 Reference (see (1) (1) (2) (3) (1) (2) (3) (3) (6) (2) (3) (4) below) (6) Density (g/cc) 3.2 3.14-3.20 3.70-3.99 5.9 7.8 Young's (Gpa) 310 390-450 350-460 205-210 208-210 Modulus Compressive (Mpa) 2500 (6) 3900 3000 Strength Poissons Ratio 0.27 0.14-0.17 0.22-0.23 0.31 0.3 Fracture (Mpa · 5.8 2.5-6.7 3.8-5.2 7.5-12 18 Toughness M){circumflex over ( )}½ Vickers (Hv) 1800 1650-2850 2000 1150-1400 700 Hardness Thermal (10{circumflex over ( )}−6/° C.) 3.1 3.4-5.5 5.5-10.2 10-10.5 12.5 Expansion Coefficient Thermal (W/m · K) 26 22-200 28-35 >2.0-3.1 50 Conductivity Flexural (Mpa) 800 375-634 350-460 1100-1300 2500 Strength Thermal Shock (° C.) 610 157-500 200-280 280-300 Resistance Weibull >15 12-18 12-13 25 0.24-7.87 Modulus Abrasive Wear (7) 1110 947-1263 610 689 Resistance
REFERENCES
[0047] (1) Ceradyne Inc. Silicon Nitride Properties
[0048] (2) Research and Development of Bearings for Special Environments Hiroyuki Ito, Basic Research and Development Center Shigeki Matsuiiaga, Precision Bearing Technology Department NSK Corporate Website
[0049] (3) Ceramic Materials for Special Environments Shin Niizeki, Bearing Technology Center NSK Corporate Website
[0050] (4) Effects of extreme pressure additives in lubricants on beating fatigue life. H. P. Nixon, The Timken Co. Canton Ohio Corporate website
[0051] (5) Thermal Conductivity of Ceramic and Ceramic Coatings Andrew Slifka http://www.boulder.nist.gov/div853/Annual%20Report%202000%20HTML/P23.html
[0052] (6) http://www.doceram.com/e_mat3.htm
[0053] (7) Awr=FT{circumflex over ( )}½×H{circumflex over ( )}1.43×Em{circumflex over ( )}−0.8
[0054] An initial evaluation of the ceramic ball bearing lifter design was tested at Isky Cams Inc. in the Los Angeles county area. The lifter (hereinafter lifer 1 ) used a ceramic bearing obtained from Ceradyne Inc. was made of CERALLOY 147-3 IN material.
[0055] Lifter 1 was initially tested within the engine without engine combustion using a SPINTRON control system as this machine provided the best opportunity for lifter evaluation without the danger of engine damage in the event of lifter failure. The first evaluation was conducted with low pressure valve springs; 200 lbs/inch, to initially determine if the higher contact loads of the lifter/cam surface interface would result in camshaft scoring. The test cycle was completed in 8 hours and no damage to the lifter or camshaft was evident. A second evaluation was then conducted using a NASCAR (North American Stock Car) specification valve spring with a higher pressure of 800 lbs/inch. This test was also conducted over 8 hours and no damage was observed in either the lifter or the cam lobe.
[0056] A second phase of evaluation was conducted on a Chevrolet V8 engine; ZZ4 P/N 24502609, under actual running conditions. This test used two different lifter designs, the ball bearing and the radiused wheel and also to evaluate a material variation in the ball bearing design. FIGS. 3, 4 and 5 show the results of these tests and Table 2 summarizes the lifter/test design.
TABLE 2 Lifter # Design Material Supplier 1 Ball Bearing lifter with Ceralloy 147-31N Lifter body - lubrication to race silicon nitride Shaver Engines Ball Bearing- Ceradyne 2 Ball bearing lifter with #52-100 Alloy steel Lifter body - lubrication to race Shaver Engines Ball Bearing - Timken 3 Radiused lifter #52-100 Alloy steel Lifer body and wheel - Shaver Engines
[0057] The test was conducted at the Shaver Engine facility in Torrance Calif. The three different designs were placed in the test engine using high performance springs (p/n 10134358 rated at 356 lbs/inch). The engine was started and under load the rpm was controlled and set at 2000 rpm. After 2 minutes, a noticeable miss was detected and the engine operation was suspended. The engine was immediately disassembled and the components inspected.
[0058] [0058]FIG. 3 shows the wear on the steel ball lifter (lifter 2 ) in comparison with the original steel ball. FIG. 4 shows lifter 1 (left) and lifter 2 (right). As shown, lifter 1 has no material loss and has not degraded the camshaft lobe in any way. Lifter 2 has suffered extensive material loss and has further degraded the cam lobe appreciably.
[0059] [0059]FIG. 5 shows lifter 3 (left and centre) and lifter 1 (right). In this case, we see no damage to either the lifter or the camshaft lobe from the test.
[0060] Subsequently, the engine was reassembled with lifters 1 and 3 and a new camshaft with the same specification was installed and the testing was continued for 6 hours at various rpm's (idle to 6000) and loads. The tested engine produced the same horsepower and torque levels specified and no problems in engine operation were detected. Upon completion, the engine was disassembled and lifters and camshaft were measured for wear. There was no appreciable wear on either the lifters or camshaft lobes.
[0061] Variable Cam Lobe Profile Test
[0062] A full test of an engine with a variable profile camshaft was tested as follows:
[0063] Engine Tested: Chevrolet LS-15.7 L Overhead Valve Pushrod Engine
[0064] Compression: 10:1
[0065] Bore×Stroke: 99.00×92.00 mm
[0066] Sequential Injection
[0067] Prior to modification the engine had a horsepower rating of 345 @5400 rpm and an idle speed of 700 rpm.
[0068] The engine was modified to include a variable profile camshaft and hydraulic actuation system for linear displacement of the camshaft. The variable profile lobes of the camshaft varied lift, duration and degreeing (7 degrees). The cam contacting devices for all 16 valves of the engine were modified to include a silicon nitride ball bearing (Ceralloy 147-31N). Spring pressures of 350 pounds were utilized.
[0069] The engine was run initially for 5 minutes, shut-down, and run again for 45 minutes during which the camshaft was axially displaced between two extreme ends of the lobes as the engine was run from low rpm to high rpm.
[0070] With the modified camshaft, the engine horsepower was measured at 420 hp @5400 rpm and the lowest idle speed obtained was 400 rpm. The overall increase in volumetric efficiency (VE) was calculated to be 25%
[0071] Attempts to reduce the idle below 400 rpm were unsuccessful as the Electronic Control Module (ECM) configured to the engine consistently overrode the tuning being applied. That is, as attempts to reduce idle speed below 400 were made, the idle air control module (ICM) of the controller would apply fuel to increase idle speed. Based on the cam profile utilized for idle, it is envisaged that idle speeds as low as 200 rpm can be achieved.
[0072] Following the engine run, the engine was disassembled and examined. The camshaft and cam contacting devices showed no evidence of wear.
[0073] Discussion:
[0074] The original lifter tests demonstrate that a cam contacting device having a fine point of contact with a camshaft can survive very high point pressures while operating within an ICE. Specifically, the use of ceramic silicon nitride bearings provide effective cam-contacting devices with fixed profile camshafts. The original lifter tests further demonstrate that the use of a lubricated steel bearing as a cam contacting device is ineffective and will quickly lead to the cam contacting device failure.
[0075] The variable profile camshaft tests demonstrate that a cam contacting device having a fine point of contact can effectively enable the operation of variable valve timing system having a continuously variable cam profile. The practical results of this test demonstrated that idle speed can be significantly reduced and overall engine volumetric efficiently significantly increased as compared to a fixed cam profile engine.
[0076] Discussion of Steel and Ceramic Bearings
[0077] The failure of the steel ball appears to be from galling (i.e. localized welding) of the steel ball to the steel valve body. Once galling started, the ball would intermittently slide and roll both in the pocket and on the camshaft. This galling and sliding action of the ball would account for its uniform wear (0.042″). This unintended sliding action of the ball against the camshaft resulted in the severe damage (i.e. groove) to the camshaft that was seen.
[0078] The success of the ceramic (Silicon Nitride) ball appears to be a result of the lower coefficient of friction and superior heat dissipation properties of the ceramic. Since the ceramic ball did not gall, it would continue to roll in its pocket and rolling contact with the camshaft would be maintained. This would account for the minimum damage/wear seen on the camshaft. When the ball rolls on the camshaft, it must slide in the pocket of the lifter body. There is consequently some friction, and heat generation inherent in this design. However, with the lower coefficient of friction of the ceramic, the heat generation as compared to steel is less. Moreover, the oil supplied through the lifter to the sliding surface between the ball and the lifter body would further reduce this friction as well as cool the ball.
[0079] Still further, since the ceramic ball is more rigid than the metal ball, it would not deform as much underload. Consequently, the heat generated internally in the ball would also be less in the ceramic ball.
[0080] The steel roller assembly has roller elements within it. Consequently, there would be rolling action of the roller against the camshaft. As was the case with the ceramic ball, the wear on the camshaft would be therefore minimized. Work hardening would occur on the camshaft as a result of the contact stress. This is most likely the cause of the narrow band that was seen on the camshaft for both the roller and ceramic ball setup. Since the steel roller assembly is dominated by rolling action and no sliding action, the friction, and consequently heat generation, would be minimal.
[0081] For the silicon nitride ball:
[0082] a) The total friction on the ball is less than that of a steel ball.
[0083] b) The lower level of friction will generate less heat at the ball contact surfaces than a steel ball.
[0084] c) Heat generated at the ball-cam and the ball-cup ( 36 ) interfaces will find its primary dissipation path through the steel interfaces rather than the ball as the thermal conductivity of the ball is significantly lower than that of the steel cup with the oil supplied to the ball/lifter providing further cooling.
[0085] d) The steel contact surfaces will therefore heat up more so than the ball.
[0086] e) The steel contact surfaces will therefore expand more than the ball due to the increased heat and the higher coefficient of expansion.
[0087] f) Given the different expansion coefficients, the ball will always remain smaller than the surrounding cup. Therefore, the ball should not seize due to heat buildup.
[0088] g) The mark on the cam was probably a result of the contact interface heat effectively work hardening the cam.
[0089] For the steel ball:
[0090] a) The total friction on the ball will be greater than that of silicon nitride ball.
[0091] b) The higher level of friction will generate more heat at the ball contact surfaces than the silicon nitride ball.
[0092] c) Heat generated at the ball-cam and the ball-cup ( 36 ) interfaces will dissipate through the ball as well as the contact surfaces with the oil supplied to the ball/lifter interface providing further cooling.
[0093] d) The steel contact surfaces with therefore heat up as the ball heats up.
[0094] e) The steel ball that contacts both the cam and the cup could heat up faster than the cup due to contact with the cam. If the ball heats up faster than the cup, the ball would expand faster than the cup increasing friction and possibly start to seize in the cup.
[0095] f) Given the same expansion coefficients, the ball may seize in the cup if the ball heats up faster than the cup.
[0096] g) The wear on the cam, ball, and cup was probably a result of the ball starting to seize (gall) in the cup effectively increasing friction and wear on all three surfaces.
[0097] For the steel (radiused) wheel:
[0098] a) The total friction on the steel wheel will be greater than that of silicon nitride ball.
[0099] b) The higher level of friction will generate more heat at the wheel contact surfaces than the silicon nitride ball.
[0100] c) Any heat generated at the wheel-cam and the wheel-roller ( 4 ) interfaces will dissipate through the wheel rim as well as the contact surfaces.
[0101] d) The steel contact surfaces with therefore heat up as the ball heats up.
[0102] e) The steel wheel has a smaller contact point than the silicon nitride ball and will generate more heat for a given spring load than the ball.
[0103] f) The steel wheel has a large amount of clearance to the supporting lifter surfaces.
[0104] g) The wheel, under thermal expansion, would not contact any of the surrounding lifter surfaces therefore the steel wheel should not seize (gall) as the steel ball did.
[0105] h) Heat generated in the wheel rim can only be dissipated through the cam and the roller bearings; there is no forced oil-cooling bath.
[0106] i) The steel wheel will get hotter than the silicon nitride ball due to higher levels of friction and less lubricating oil.
[0107] j) The mark on the cam was probably due to the high level of heat transferred at the wheel-cam interface. The cam was being effectively work hardened by the heat of friction and contact pressure. The mark was more extensive than the silicon nitride ball due to higher temperature and pressure at the cam contact point.
[0108] In conclusion, the success of the silicon nitride may be a result of a hardening of the cam lobe metal as a result of the heat generated by the contact of ceramic and metal as well as the thermal conductivity, thermal expansion coefficient as other material property differences as outlined in Table 1. | The invention relates to improved cam contacting devices for use in internal combustion engines and preferably for use in internal combustion engines having variable valve timing. In particular, the use of ceramics including silicon nitride and silicon carbide have been demonstrated as providing effective cam contacting surfaces allowing an axially displaceable cam shaft having a variable profile cam to be run with resulting improvements in idle speed and volumetric efficiency. | 5 |
Statement as to Rights to Inventions made under Federally-Sponsored Research and Development
This invention was made with Government support under contract DE-AC05-960R22464 awarded by the U.S. Department of Energy to Lockheed Martin Energy Research Corporation and the Government has certain rights in this Invention.
FIELD OF THE INVENTION
The present invention relates to a gas monitor, more particularly, to a continuous gas monitor for a gas analyzer.
BACKGROUND OF THE INVENTION
Previous real time gas monitors, such as the one previously developed and patented, U.S. Pat. No. 5,272,337, by the inventors of the present invention, have been subject to operational degradation from pressure fluctuation, chemical memory effects, and difficulty in tuning, with the memory effects being the most difficult problem to overcome. Such gas monitors cannot operate where a strong vacuum is required, due to the perturbations of the vacuum on the mixing of the gas sample with helium buffer gas, the mix being required for successful analysis of the gas sample by a mass spectrometer. Although such gas monitors can be used to sample the effluent from a much stronger vacuum pump in situations where such a vacuum is required (sampling through long, small diameter transfer lines), the heads of even the most invert vacuum pumps tend to retain significant amounts of the chemicals sampled through adsorption of the chemicals into the head and diaphragm materials. The present in-line real time gas monitor overcomes this problem through a unique design which permits in-line sampling, even in situations where a significant vacuum is necessitated.
OBJECTS OF THE INVENTION
Accordingly, it is an object of the present invention to provide a gas monitor for analyzing gas samples continuously in real time. Further and other objects of the present invention will become apparent from the description contained herein.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, a new and improved continuous in-line gas monitoring system comprises: an in-line monitor, a source of sample gas, a supply of carrier gas having a carrier gas outlet port, a gas analyzer having a gas inlet port and a vacuum source having a gas inlet port.
The in-line monitor comprises: a sample gas passage having a gas inlet port and a gas outlet port, a carrier gas passage having a gas inlet port and a gas outlet port, a gas analyzer passage having a gas outlet port and a gas inlet port, a vacuum passage having a gas outlet port and a gas inlet port, a first gas mixing passage having a gas inlet port and a gas outlet port, a second gas mixing passage having a gas inlet port and a gas outlet port and a sample gas transfer means for simultaneous positioning the first gas mixing passage and the second gas mixing passage from a first position to a second position. The first position causes positioning and connecting of the first gas mixing passage with the sample gas passage and the vacuum passage and the second gas mixing passage with the carrier gas passage and the gas analyzer passage. The second position causes positioning and connecting of the first gas mixing passage with the carrier gas passage and the gas analyzer passage and the second gas mixing passage with the sample gas passage and the vacuum passage. The positioning and connecting of the sample gas passage, the first gas mixing passage and the vacuum passage provides for the sample gas to be transferred into and through the sample gas passage, the first gas mixing passage and the vacuum passage by the vacuum source filling the first gas mixing passage with the sample gas at a reduced pressure. The positioning and connecting of the carrier gas passage, the second gas mixing passage and the gas analyzer passage provides for the carrier gas from the carrier gas source to be transferred into and through the carrier gas passage, second gas mixing passage and the gas analyzer passage filling the second gas mixing passage with the carrier gas at a pressure greater than the reduced pressure of the sample gas contained in the first gas mixing passage. The simultaneous positioning of the first gas mixing passage and the second gas mixing passage from a first position to a second position causes the sample gas contained in the first gas mixing passage to mix with the carrier gas flowing through the carrier gas passage into the first gas mixing passage containing the sample gas and through the gas analyzer passage into the gas analyzer and causes the carrier gas contained in the second gas mixing passage to mix with the sample gas flowing through the sample gas passage into the second gas mixing passage containing the carrier gas and through the vacuum passage into the vacuum source. A reciprocating of the simultaneous positioning of the first gas mixing passage and the second gas mixing passage through a sufficient duty cycle rate causes a mixing of the sample gas with the carrier gas forming a sample gas mixture because of a difference in the gas pressure of the sample gas and the gas pressure of the carrier gas.
At the first position the sample gas is in communication with the inlet port of the sample gas passage, the gas outlet port of the sample gas passage is connected to the gas inlet port of the first gas mixing passage, the gas outlet port of the first gas mixing passage is connected to the gas inlet port of the vacuum passage and the gas outlet port of the vacuum passage is connected to the gas inlet port of the vacuum source and the gas inlet port of the carrier gas passage is connected to the gas outlet port of the supply of carrier gas, the gas inlet port of the second gas mixing passage is connected to the gas outlet port of the carrier gas passage, the outlet port of the second gas mixing passage is connected to the gas inlet port of the gas analyzer passage, the gas outlet port of the gas analyzer passage is connected to the gas inlet port of the gas analyzer.
At the second position the sample gas is in communication with the inlet port of the sample gas passage, the gas outlet port of the sample gas passage is connected to the gas inlet port of the second gas mixing passage, the gas outlet port of the second gas mixing passage is connected to the gas inlet port of the vacuum passage and the gas outlet port of the vacuum passage is connected to the gas inlet port of the vacuum source and the gas inlet port of the carrier gas passage is connected to the gas outlet port of the supply of carrier gas, the gas inlet port of the first gas mixing passage is connected to the gas outlet port of the carrier gas passage, the outlet port of the first gas mixing passage is connected to the gas inlet port of the gas analyzer passage, the gas outlet port of the gas analyzer passage is connected to the gas inlet port of the gas analyzer.
In accordance with another aspect of the present invention, a new and improved method for continuously monitoring a gas sample with a gas analyzer comprises the following steps:
Step 1--A continuous in-line gas monitoring system is provided. The continuous in-line gas monitoring system comprises: an in-line monitor, a source of sample gas, a supply of carrier gas having a carrier gas outlet port, a gas analyzer having a gas inlet port and a vacuum source having a gas inlet port.
The in-line monitor comprises: a sample gas passage having a gas inlet port and a gas outlet port, a carrier gas passage having a gas inlet port and a gas outlet port, a gas analyzer passage having a gas outlet port and a gas inlet port, a vacuum passage having a gas outlet port and a gas inlet port, a first gas mixing passage having a gas inlet port and a gas outlet port, a second gas mixing passage having a gas inlet port and a gas outlet port and a sample gas transfer means for simultaneous positioning the first gas mixing passage and the second gas mixing passage from a first position to a second position. The first position causes positioning and connecting of the first gas mixing passage with the sample gas passage and the vacuum passage and the second gas mixing passage with the carrier gas passage and the gas analyzer passage. The second position causes positioning and connecting of the first gas mixing passage with the carrier gas passage and the gas analyzer passage and the second gas mixing passage with the sample gas passage and the vacuum passage. The positioning and connecting of the first gas mixing passage with the sample gas passage and the vacuum passage provides for the sample gas to be transferred into and through the sample gas passage, the first gas mixing passage and the vacuum passage by the vacuum source filling the first gas mixing passage with the sample gas at a reduced pressure. The positioning and connecting of the first gas mixing passage with the carrier gas passage and the gas analyzer passage provides for the carrier gas from the carrier gas source to be transferred into and through the carrier gas passage, the second gas mixing passage and the gas analyzer passage filling the second gas mixing passage with the carrier gas at a pressure greater than the reduced pressure of the sample gas contained in the first gas mixing passage. The simultaneous positioning of the first gas mixing passage and the second gas mixing passage from a first position to a second position causes the sample gas contained in the first gas mixing passage to mix with the carrier gas flowing through the carrier gas passage into the first gas mixing passage containing the sample gas and through the gas analyzer passage into the gas analyzer and causes the carrier gas contained in the second gas mixing passage to mix with the sample gas flowing through the sample gas passage into the second gas mixing passage containing the carrier gas and through the vacuum passage into the vacuum source. A reciprocating of the simultaneous positioning of the first gas mixing passage and the second gas mixing passage through a sufficient duty cycle rate causes a mixing of the sample gas with the carrier gas because of a difference in the gas pressure of the sample gas and the gas pressure of the carrier gas. At the first position, the sample gas is in communication with the inlet port of the sample gas passage. The gas outlet port of the sample gas passage is connected to the gas inlet port of the first gas mixing passage. The gas outlet port of the first gas mixing passage is connected to the gas inlet port of the vacuum passage and the gas outlet port of the vacuum passage is connected to the gas inlet port of the vacuum source. The gas inlet port of the carrier gas passage is connected to the gas outlet port of the supply of carrier gas. The gas inlet port of the second gas mixing passage is connected to the gas outlet port of the carrier gas passage. The outlet port of the second gas mixing passage is connected to the gas inlet port of the gas analyzer passage. The gas outlet port of the gas analyzer passage is connected to the gas inlet port of the gas analyzer. At the second position the sample gas is in communication with the inlet port of the sample gas passage. The gas outlet port of the sample gas passage is connected to the gas inlet port of the second gas mixing passage. The gas outlet port of the second gas mixing passage is connected to the gas inlet port of the vacuum passage. The gas outlet port of the vacuum passage is connected to the gas inlet port of the vacuum source. The gas inlet port of the carrier gas passage is connected to the gas outlet port of the supply of carrier gas. The gas inlet port of the first gas mixing passage is connected to the gas outlet port of the carrier gas passage. The outlet port of the first gas mixing passage is connected to the gas inlet port of the gas analyzer passage. The gas outlet port of the gas analyzer passage is connected to the gas inlet port of the gas analyzer.
Step 2--The inlet port of the sample gas passage is positioned at a gas sample source.
Step 3--A flow of the carrier gas is provided into the carrier gas passage.
Step 4--The vacuum source is provided at the gas outlet port of the vacuum passage.
Step 5--The gas analyzer is provided at the gas outlet port of the gas analyzer passage.
Step 6--The sample gas transfer means is activated to simultaneously position the first gas mixing passage and the second gas mixing passage from the first position to the second position in a reciprocating fashion to provide a continuous flow of the gas sample, a continuous mixing of the carrier gas with the gas sample forming a sample gas mixture and a continuous flow of the sample mixture to the gas analyzer.
Step 7--The gas sample containing the sample gas mixture is analyzed with the gas analyzer.
BRIEF DESCRIPTION OF THE DRAWING
In the drawings:
FIG. 1. is a cross-sectional view of an in-line gas monitoring system showing the first position of the gas passages of the in-line monitor in accordance with the present invention.
FIG. 2. is a cross-sectional view of an in-line gas monitoring system showing the second position of the gas passages of the in-line monitor in accordance with the present invention.
FIG. 3. is a cross-sectional view of another embodiment of an in-line gas monitoring system in accordance with the present invention.
For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following disclosure and appended claims in connection with the above described drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The in-line gas monitoring system comprises an in-line gas monitor coupled together with a mass spectrometer, a carrier gas source and a vacuum source to enable an operator to monitor an atmosphere continuously. The in-line gas monitor operates by mixing a gas sample, such as air, with a carrier gas, such as helium, in two complementary gas passages embedded in a manifold which includes four 3-way solenoid valves having valve activating means or a rotating member having two complementary gas passages which rotates within a manifold. A vacuum source connected to the in-line monitor provides a negative pressure within the in-line monitor which causes an outside source of gas to be continuously drawn into the in-line monitor and out through the vacuum source as a flush gas. At the same time a continuous flow of carrier gas, such as helium, is provided within the in-line monitor which mixes with the gas sample every time the two complementary gas passages are exchanged by the activation of the two sets of solenoid valves or the rotation of the rotating member within the manifold. The differential pressure between the gas sample within the in-line monitor and the carrier gas causes the two gases to mix thoroughly. There are two path ways for the incoming gas sample and the carrier gas to be mixed and carried into a gas analyzer. The first position of the gas mixing passages is shown in FIG. 1 and and the second position of the gas mixing passages is shown in FIG. 2. The gas sample mixes with the carrier gas when two solenoid valve activating means activate the two sets of solenoid valves or when the rotating member rotates 180 degrees as shown in FIG. 3.
The operation of the in-line air monitor of the present invention is based on the generation of a pressure differential between the air sample drawn into the manifold by the vacuum pump and the subsequent helium carrier gas injection, which moves the air sample into an ion trap mass spectrometer. The ion trap mass spectrometers operate by sweeping the ions from the analyzer on a time scale of milliseconds. In the optimized operation of the air monitor, the vacuum pump draws an air sample into a gas passage through a needle valve. The needle valve is partially closed, creating a partial vacuum in the gas passage. When the gas passages are reciprocated, the helium carrier gas is introduced under pressure into the gas passage containing the air sample at a partial vacuum. The helium carrier gas and air sample are turbulently mixed, with the mixture being introduced into the mass spectrometer for analysis. The mixture is necessary to ensure proper analysis, as too much helium dilutes the sample and too much air sample causes signal degradation.
If the air monitor is operated without the proper partial vacuum (pressure differential between the helium carrier gas and the air sample) in the gas passages, the introduction of the helium carrier gas into the gas mixing passage after the air sample is resident in the gas mixing passage, will result in the air sample and the helium carrier gas being introduced into the ion trap mass spectrometer as separate slugs of gas rather than as an essentially homogeneous mixture of the helium carrier gas and the air sample. Separate slugs of the helium carrier gas and the air sample entering the ion trap mass spectrometer causes signal degradation because the ion trap mass spectrometer sees either sample or helium carrier gas, rather than the essentially homogeneous mixture of the helium carrier gas and the air sample required for an appropriate analysis of the air sample.
The in-line gas monitor is unique in its ability to function in-line with a transfer line under a vacuum. It is also more sensitive and much more easily tuned than the gas monitor discussed in U.S. Pat. No. 5,272,337. The in-line gas monitor of the present invention can be constructed as a high temperature gas monitor for use as a stack gas monitor on incinerators, furnaces or other high temperature exhaust gas streams.
In addition, the in-line gas monitor of the present invention can be used to monitor industrial/chemical processes, the levels of chemicals in work-place air, stack gases, soil gases, as a locator of point pollution sources, to track plumes of chemicals in air, etc.
Shown in FIGS. 1 and 2 is continuous in-line gas monitoring system 10 comprising in-line monitor 12; sample gas transfer means 32 and 33 of in-line monitor 12; carrier gas supply 14, such as a cylinder of helium connected to a regulator and a flow control valve, having carrier gas output port 16 and gas passage 26; gas analyzer 18, such as a ion trap mass spectrometer as described in U.S. Pat. No. 5,272,337 to Thompson et al incorporated herein by reference thereto, having a gas inlet port 20 and gas passage 30; and vacuum source 22, such as a vacuum pump, having inlet port 24 and gas passage 28. Carrier gas supply 14 is connected to in-line gas monitor 12 by carrier gas passage 26. Vacuum source 22 is connected to in-line monitor 12 by gas passage 28. Gas analyzer 18 is connected to in-line monitor 12 by gas passage 30.
Shown in FIG. 1 is in-line gas monitor 12 in a first position and shown in FIG. 2 is in-line gas monitor 12 in a second position. Shown in FIG. 1 and FIG. 2 is sample gas transfer means 32 and 33 of in-line monitor 12. Sample gas transfer means 32 comprises first 3-way solenoid valve 34, second 3-way solenoid valve 36 and first solenoid valve activating means 42 such as a solenoid valve driver which actuates the pair of solenoid valves 34 and 36. Sample gas transfer means 33 comprises third 3-way solenoid valve 38, fourth 3-way solenoid valve 40 and second solenoid valve activating means 44, such as a solenoid valve driver which actuates the pair of solenoid valves 38 and 40. The activation of first solenoid valve activating means 42 and of second solenoid valve activating means 44 occurs in a reciprocating fashion, so that there is always flow through in-line gas monitor 12 via the gas passages of the first position of in-line gas monitor 12 shown in FIG. 1 or through the second position of in-line gas monitor 12 shown in FIG. 2. The duty cycle for solenoid valve pairs 34, 36 and 38, 40 is varied by tuning with a potentiometer and is typically 0.2 to 0.7 seconds.
Shown in FIG. 1 and 2 is in-line monitor 12 comprising: sample gas passage 46 8 having sample gas inlet port 48, first sample gas outlet port 50 and second sample gas outlet port 52, carrier gas passage 54 having gas inlet port 56, first gas outlet port 58 and second gas outlet port 60, gas analyzer passage 62 having gas outlet port 64, first gas inlet port 66 and second gas inlet port 68, vacuum gas passage 70 having a gas outlet port 72, first gas inlet port 74 and second gas inlet port 76, first gas mixing passage 78 having gas inlet port 80 and gas outlet port 82, second gas mixing passage 84 having gas inlet port 86 and gas outlet port 88, sample gas transfer means 32 for transferring sample gas and sample gas transfer means 33 for transferring sample gas. First sample transfer means 32 comprises first 3-way solenoid valve 34, second 3-way solenoid valve 36 and first solenoid valve activating means 42. Second sample gas transfer means 33 comprises third 3-way solenoid valve 38, fourth 3-way solenoid valve 40 and second solenoid valve activating means 44.
First 3-way solenoid valve 34 is connected to first sample gas outlet port 50 of sample gas passage 46, first sample gas outlet 58 of carrier gas passage 54 and gas inlet port 80 of first gas mixing passage 78. Second 3-way solenoid valve 36 is connected to first gas inlet port 66 of gas analyzer passage 62, first gas inlet port 74 of vacuum gas passage 70 and gas outlet port 82 of first gas mixing passage 78. Third 3-way solenoid valve 38 is connected to second sample gas outlet port 52 of sample gas passage 46, second gas outlet port 60 of carrier gas passage 54 and gas inlet port 86 of second gas mixing passage 84. Fourth 3-way solenoid valve 40 is connected to second gas outlet port 76 of vacuum gas passage 70, second gas inlet port 68 of gas analyzer passage 62 and gas outlet port 88 of second gas mixing passage 84.
Sample gas transfer means 32 and 33 transfer sample gas by simultaneous positioning first gas mixing passage 78 and second gas mixing passage 84 from a first position to a second position. The first position causes positioning and connecting of first gas mixing passage 78 with sample gas passage 46 and vacuum passage 70 which is connected to gas passage 28 of vacuum source 22 at vacuum source inlet 24 and causes positioning and connecting of second gas mixing passage 84 with carrier gas passage 54 and gas analyzer passage 62. Gas analyzer passage 62 is connected to gas passage 30 of gas analyzer 18 at gas inlet port 20 of gas analyzer 18. The second position causes positioning and connecting of first gas mixing passage 78 with carrier gas passage 54 and gas analyzer passage 62 and causes positioning and connecting of second gas mixing passage 84 with sample gas passage 46 and vacuum passage 70. The positioning and connecting of sample gas passage 46, first gas mixing passage 78 and vacuum passage 62 provides for sample gas 37 to be transferred into and through sample gas passage 46, first gas mixing passage 78 and vacuum passage 70 by vacuum source 22 filling first gas mixing passage 78 with sample gas 37 at a reduced pressure (see FIG. 1). The positioning and connecting of carrier gas passage 54, second gas mixing passage 84 and gas analyzer passage 62 provides for carrier gas 79 from carrier gas source 14 to be transferred into and through carrier gas passage 54, second gas mixing passage 84 and gas analyzer passage 62 filling second gas mixing passage 84 with carrier gas 79 at a pressure greater than the reduced pressure of sample gas 37 contained in first gas mixing passage 78. The simultaneous positioning of first gas mixing passage 78 and second gas mixing passage 84 from a first position to a second position causes sample gas 37 contained in first gas mixing passage 78 to mix with carrier gas 79 flowing through carrier gas passage 54 into first gas mixing passage 78 containing sample gas 37 and through gas analyzer passage 62 into gas analyzer 18 and causes carrier gas 79 contained in second gas mixing passage 84 to mix with sample gas 37 flowing through sample gas passage 46 into second gas mixing passage 84 containing carrier gas 79 and through vacuum passage 70 into vacuum source 22. A reciprocating of the simultaneous positioning of first gas mixing passage 78 and second gas mixing passage 84 through a sufficient duty cycle rate causes a mixing of sample gas 37 with carrier gas 79 forming sample gas mixture 35 comprising a mixture of sample gas 37 and carrier gas 79 because of a difference in the gas pressure of sample gas 37 and the gas pressure of carrier gas 79.
At the first position, shown in FIG. 1, sample gas 37 is in communication with inlet port 48 of sample gas passage 46. Sample gas passage 46 is connected to first gas outlet port 50 of sample gas passage 46. First gas outlet port 50 of sample gas passage 46 is connected to gas inlet port 80 of first gas mixing passage 78 through first 3-way solenoid valve 34. First gas mixing passage 78 is connected to gas outlet port 82 of first gas mixing passage 78. Gas outlet port 82 of first gas mixing passage 78 is connected to gas inlet port 74 of vacuum passage 70 through second 3-way solenoid valve 36. Gas inlet port 74 of vacuum passage 70 is connected to vacuum passage 70. Vacuum gas passage 70 is connected to gas passage 28 of vacuum source 22 at gas outlet port 72 of vacuum gas passage 70. Vacuum passage 28 is connected to vacuum source 22 at gas inlet port 24 of vacuum source 22. Carrier gas 79 is in communication with carrier gas outlet port 16 of carrier gas supply 14. Carrier gas outlet port 16 is connected to gas passage 26 of carrier gas supply 14. Gas inlet port 56 of carrier gas passage 54 is connected to gas passage 26 of carrier gas supply 14. Carrier gas passage 54 is connected to second gas outlet port 60. Second gas outlet port 60 of carrier gas passage 54 is connected to gas inlet port 86 of second gas mixing passage 84 through third 3-way solenoid valve 38. Gas inlet port 86 of second gas mixing passage 84 is connected to second gas mixing passage 84. Second gas mixing passage 84 is connected to gas outlet port 88 of second gas mixing passage 84. Gas outlet port 88 of second gas mixing passage 84 is connected to gas inlet port 68 of gas analyzer passage 62 through fourth 3-way solenoid valve 40. Gas inlet port 68 of gas analyzer passage 62 is connected to gas analyzer passage 62. Gas analyzer passage 62 is connected to gas outlet port 64 of gas analyzer passage 62. Gas outlet port 64 of gas analyzer passage 62 is connected to gas passage 30 of gas analyzer 18. Gas passage 30 of gas analyzer 18 is connected to gas inlet port 20 of gas analyzer 18 and gas inlet port 20 of gas analyzer 18 is connect to gas analyzer 18.
At the second position, shown in FIG. 2, sample gas 37 is in communication with inlet port 48 of sample gas passage 46. Sample gas passage 46 is connected to second gas outlet port 52 of sample gas passage 46. Second gas outlet port 52 of sample gas passage 46 is connected to gas inlet port 86 of second gas mixing passage 84 through third 3-way solenoid valve 38. Gas inlet port 86 of second gas mixing passage 84 is connected to second gas mixing passage 84. Second gas mixing passage 84 is connected to gas outlet port 88 of second gas mixing passage 84. Gas outlet port 88 of second gas mixing passage 84 is connected to gas inlet port 76 of vacuum gas passage 70 through fourth 3-way solenoid valve 40. Gas inlet port 76 of vacuum gas passage 70 is connected to gas outlet port 72 of vacuum gas passage 70. Gas outlet port 72 of vacuum gas passage 70 is connected to gas passage 28 of vacuum source 22. Gas passage 28 of vacuum source 22 is connected to inlet port 24 of vacuum source 22. Carrier gas 79 is in communication with carrier gas outlet port 16 of carrier gas supply 14. Carrier gas outlet port 16 is connected to gas passage 26 of carrier gas supply 14. Gas inlet port 56 of carrier gas passage 54 is connected to gas passage 26 of carrier gas supply 14. Carrier gas passage 54 is connected to first gas outlet port 58 of carrier gas passage 54. First gas outlet port 58 of carrier gas passage 54 is connected to gas inlet port 80 of first gas mixing passage 78 through first 3-way solenoid valve 34. Gas inlet port 80 of first gas mixing passage 78 is connected to first gas mixing passage 78. First gas mixing passage 78 is connected to gas outlet port 82 of first gas mixing passage 78. Gas outlet port 82 of first gas mixing passage 78 is connected to first gas inlet port 66 of gas analyzer passage 62 through second 3-way solenoid valve 36. First gas inlet port 66 of gas analyzer passage 62 is connected to gas analyzer passage 62. Gas analyzer passage 62 is connected to gas outlet port 64 of gas analyzer passage 62. Gas outlet port 64 of gas analyzer passage 62 is connected to gas passage 30 of gas analyzer 18. Gas passage 30 of gas analyzer 18 is connected to gas inlet port 20 of gas analyzer 18 and gas inlet port 20 of gas analyzer 18 is connected to gas analyzer 18.
Flush gas 103 that is being pulled into vacuum source 22 is selected from the group consisting of gas sample 37, carrier gas 79, sample gas mixture 35 and mixtures thereof and is pulled. into vacuum source 22 through gas passage 28 of vacuum source 22.
The gas carrying passages of the in-line gas monitor can be made from tubing or holes drilled in blocks of material used to fabricate the in-line gas monitor. The materials used for the in-line monitor which come in contact with the sample gas should be made from a material not corroded by or a contaminate to the sample gas.
First solenoid valve activating means 42, such as a pulsed solenoid driver, is connected to first 3-way solenoid valve 34 and second 3-way solenoid valve 36. Second solenoid valve activating means 44, such as a pulsed solenoid driver, is connected to third 3-way solenoid valve 38 and fourth second 3-way solenoid valve 40.
To continuously analyze a gas source the continuous in-line monitor sample gas inlet port is positioned at a gas sample source. Carrier gas supply is connected to the in-line monitor and a flow of carrier gas is provided. A vacuum pump is hooked up to the in-line monitor at the gas outlet port of the vacuum gas passage of the in-line monitor and turned on to provide a partial vacuum within the vacuum gas passage to draw sample gas into the in-line monitor through the sample gas passage and alternately through the first gas mixing passage and then through the second gas mixing passage of the in-line monitor. An ion trap mass spectrometer is attached to in-line monitor. The two pulsed solenoid drivers operating the four 3-way solenoid valves are activated at a duty cycle of from about 0.2 to about 0.7 seconds for activating the first position of the four 3-way solenoid valves forming the first position of the gas passages then the second position of the four 3-way solenoid valves forming the second position of the gas passages; thereby, reciprocating between the two positions. The gas sample contained in the continuous flow of sample gas coming from the in-line monitor is analyzed with the mass spectrometer.
Shown in FIG. 3 is continuous in-line gas monitoring system 400 which is another embodiment of the continuous in-line gas monitoring system of the present invention. continuous in-line gas monitoring system 400 comprises in-line monitor 402, vacuum source 404, gas analyzing means 406 and carrier gas supply means 408 for providing carrier gas 407. In-line monitor 402 comprises housing member 410 having first member 412 and second member 414, rotating member 416 contiguous within housing member 410, gas sealing means 417 for providing a gas seal between first member 412 and second member 414 of housing member 410, bearing means 418 for providing a bearing between rotating member 416 and first member 412 of housing member 410, gas seal bearing means 420, such as an "O" ring, for providing a gas seal and a bearing between housing member 410 and rotating member 416, and sample gas transfer means 422, such as an electric or pneumatic motor, for providing a rotating motion to rotating member 416 within housing member 410. Housing member 410 comprises sample gas inlet port 424, carrier gas inlet port 426, gas analyzer outlet port 428, vacuum outlet port 430, sample gas passage 432, carrier gas passage 434, gas analyzer passage 436 and vacuum passage 438. Rotating member 416 comprises first gas mixing passage 440, second gas mixing passage 442 and a sample gas transfer means 416, such as an electric or pneumatic motor driven rotating member, for transferring at a given duty cycle the sample gas from a first position to a second position of first gas mixing passage 440 and second gas mixing passage 442. Such duty cycle occurs every 180 degrees rotation of rotating member 416 in which first gas mixing passages 440 and second gas mixing passage 442 align with sample gas passage 432 and vacuum passage 438 and with carrier gas passage 434 and gas analyzer passage 436. In the first position first gas mixing passage 440 is aligned with sample gas passage 432 and vacuum passage 438 and second gas mixing passage 442 is aligned with carrier gas passage 434 and gas analyzer passage 436. In the second position first gas mixing passage 440 is aligned with carrier gas passage 434 and gas analyzer passage 436 and second mixing passage 442 is aligned with sample gas passage 432 and vacuum passage 438. The mixing of the carrier gas with the sample gas is caused by the same differential in pressures as was explained for continuous in-line gas monitoring system 10 of the present invention. The mixed carrier gas/sample gas is analyzed in gas analyzer 406, such as a ion trap mass spectrometer as described in U.S. Pat. No. 5,272,337 to Thompson et al incorporated herein by reference thereto. Sample gas mixture 403 that is being pulled into vacuum source 404 and being carried into gas analyzer 406 is selected from the group consisting of sample gas 401, carrier gas 407 and mixtures thereof. Vacuum source 404 is operatively connected to vacuum outlet port 430 of housing member 410. Gas analyzing means 406 is operatively connected to gas analyzer outlet port 428 of housing member 410. Carrier gas supply means 408 is operatively connected to carrier gas inlet port 426 of housing member 410.
While there has been shown and described what is at present considered the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appended claims. | An in-line gas monitor capable of accurate gas composition analysis in a continuous real time manner even under strong applied vacuum conditions operates by mixing an air sample with helium forming a sample gas in two complementary sample loops embedded in a manifold which includes two pairs of 3-way solenoid valves. The sample gas is then analyzed in an ion trap mass spectrometer on a continuous basis. Two valve drivers actuate the two pairs of 3-way valves in a reciprocating fashion, so that there is always flow through the in-line gas monitor via one or the other of the sample loops. The duty cycle for the two pairs of 3-way valves is varied by tuning the two valve drivers to a duty cycle typically between 0.2 to 0.7 seconds. | 6 |
This is a continuation of application Ser. No. 844,378, filed Oct. 21, 1977 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a two-stroke internal combustion engine of the double intake type to avoid the losses of carburetted mixture through the exhaust, with a view to reducing pollution and fuel consumption.
SUMMARY OF THE PRIOR ART
The present two-stroke engine has the double drawback of having a high specific consumption and of being a considerable source of pollution. These drawbacks are mainly caused by the losses of unburnt fuel through the exhaust during scavenging.
The use of direct injection of petrol has often appeared as being particularly interesting for this type of engine. The injection is expensive, particularly in the form of direct injection. The field of two-stroke engines of the controlled ignition type is the one where direct injection appears technically to be the most desirable and, economically, the most difficult to apply. In fact, the engines are mainly of small and average cubic capacity for which it would be necessary to make very small and very accurate controls and for which the low cost price is a determining factor, the cost of a four-stroke engine of equivalent power being the limit not to be exceeded.
In an attempt to solve the problem raised by these engines, a double intake of the combustible mixture has been recommended, constituted by two valves at the top of the cylinder, one of the valves allowing a rich, or very rich mixture to enter, the other valve allowing a lean mixture, or pure air, to enter. This solution is not entirely satisfactory since there is interpenetration of the intake streams. Scavenging being in equicurrent, the path traversed is shorter and the reflection of these streams on the piston head accentuates their mixture. Carburetted mixture continues to be drawn through the exhaust port. For this type of motor, it has also be thought to create a double intake at the top and bottom of the cylinder, the intake of rich mixture being made at the top of the cylinder through an orifice with controlled opening and closure. This method is efficient but reduces the advantage of simplicity of the two-stroke engine with ports.
It is an object of the present invention to remedy these drawbacks by proposing a method of intake for a two-stroke engine carried out exclusively by ports, and two-stroke engines applying this method. The invention relates to a method and engines enabling the pollution and consumption of this type of engine to be very substantially reduced, in economical manner, and also enabling a higher specific power to be obtained, for the same consumption, than that of presently known engines.
SUMMARY OF THE INVENTION
To this end, the invention relates to a method for feeding the combustion chamber of a two-stroke reciprocating engine with controlled ignition, comprising at least one piston, a cylinder, a cylinder head defining said chamber and inlet and exhaust ports at the bottom of the cylinder, according to which the constituents of the combustible mixture are admitted into the chamber through two intake devices opening in the bottom of the cylinder, the one nearer the exhaust comprising two ports, the one more remote from the exhaust having at least one port. According to this method, air without fuel is admitted through the device nearer the exhaust, opening through two ports, symmetrically disposed with respect to the vertical plane of section of the exhaust port and the axes of which, intersecting inside the cylinder, are directed towards the wall opposite the exhaust, whilst the petrol-and-air mixture is admitted through the device more remote from the exhaust, comprising at least one port and the stream of which is directed towards the top of the cylinder.
In a preferred variant embodiment of this method, the cylinder head comprises a cavity for promoting the accumulation of mixture in said cavity, where the ignition member is located, and a flatter portion which, at top dead centre, creates the compression of the subjacent gaseous volume, and a turbulence towards this cavity. Said cavity advantageously opens on the combustion chamber along an oblong opening whose largest dimensions are contained in the median plane passing through the axis of the exhaust port.
Furthermore, the exhaust pipe is provided with an obturator intended to allow the closure of the exhaust at about bottom dead centre.
The invention also relates to an engine applying the above-mentioned method.
In a first embodiment, the two intake devices are connected to the same excess pressure system. Only the or each pipe most remote from the exhaust, which ensures intake of the mixture, is provided with a fuel-feed device, located downstream of the excess pressure system.
In the case of the excess pressure being solely effected by the crankcase acting as pump, and where the fuel feed downstream of said crankcase is effected by carburation or continuous indirect injection, known means are adopted to avoid a suction of the fuel in the crankcase-pump when the piston rises again; clack-valve, non-return valve or transfer port in the skirt of the piston or rotary distributor.
In other embodiments, one of the intake devices is connected to a first excess pressure system, provided with means for regulating its flow as a function of the engine speed; the second device then issues from another excess pressure system.
Finally, in a further embodiment, the cavity of the cylinder head intended to ensure the concentration of the mixture comprises two sparking plugs, the axes of which are located in the vertical median plane of the cavity and in the direction of the turbulence produced at top dead centre by the flattest part of the cylinder head.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B schematically illustrate a first embodiment of an engine according to the invention.
FIGS. 1C and 1D are schematic views of variant details of this first embodiment.
FIG. 2 is a diagram of a variant of this embodiment.
FIGS. 3A and 3B schematically illustrate a second embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, FIGS. 1A and 1B, show a combustion chamber 1 of an engine defined by a cylinder head 2, cylinder 3 and a piston 4 shown at bottom dead centre. This chamber 1 comprises, in known manner, an exhaust port 5 and a double intake system. This system comprises a first device constituted by two ports 6--only one of which is visible in FIG. 1A--symmetrical with respect to the vertical plane containing the exhaust port 5 and a second device constituted by a port 7 opening in the chamber 1 opposite the exhaust port 5.
These ports 6 and 7 are respectively connected to inlet pipes 8 and 9 issuing from a precompression system, known per se, which, in the case of the Figure, is a crankcase acting as pump 10, in which the lower face of the piston serves as member for forcing air drawn in the crankcase through port 11, through the transfer pipes 8 and 9.
On the pipe 8 opening in the combustion chamber 1 via port 7 opposite the exhaust 5, there has been arranged a fuel feed device 12, particularly a carburettor. Said latter being located downstream of the excess pressure system is provided in known manner with a device for connection with this latter system in order to be subjected to the pressure prevailing therein. Finally, the mixture inlet pipe 8 comprises, in its low part, between the fuel-feed device 12 and the inlet orifice of the pipe, a non-return valve 13. The exhaust pipe may be provided with an obturator (not shown).
With a feed by carburation or continuous indirect injection, placed on the pipe 8, located downstream of the crankcase-pump, one must avoid creating a partial vacuum in this pipe when the piston 4 rises again. To avoid this, other devices (not shown) may be used, apart from the non-return valve mentioned: non-return valve, port in the skirt of the piston ensuring the connection of the transfer pipe only during the time of the transfer towards the cylinder, rotary distributor disposed so as to establish a selective communication of the crankcase-pump with the atmosphere during the rise of the piston and with the mixture inlet pipe near the bottom dead centre.
FIG. 1C illustrates, on this subject, a rotary distributor 13a adapted to establish a communication between the precompression crankcase 10 and the pipe 8 around the bottom dead centre and a communication between said crankcase and a conduit 11a opening to the atmosphere when the piston rises again.
Finally, it will be noted that the cylinder head 2 comprises a slightly concave portion 2a, whose shape complements the convex shape of the piston head 4 and a portion of more accentuated concavity forming a cavity 2b in which the ignition member 14 is placed, in the present case a sparking plug.
The combustion of the mixture contained in the chamber at top dead centre by the sparking plug 14 pushes the piston back which firstly releases the exhaust port 5, this allowing the beginning of exhaust, then the inlet ports 6 and 7.
FIGS. 1A and 1B, said latter being a schematic horizontal section of FIG. 1A at the level of the ports 5, 6 and 7, show how the double intake of air without fuel (arrow A) and of carburetted mixture (arrow B) is effected. The air is admitted through the two ports 6 closest to the exhaust, located symmetrically with respect thereto and of which the axes directed towards the wall opposite the exhaust intersect inside the cylinder. In this way, they introduce a screen of air which ensures the scavenging, contributes to filling and isolates from the exhaust the mixture admitted through the port 7 opposite the exhaust.
FIG. 1A shows that the mixture directed towards the top of the chamber by the orientation of the pipe 8 (arrow B) and the pressure, and the direction of the air introduced (arrow A), is maintained isolated from the exhaust by this screen of air. In addition, the mixture is confined in portion 2b of the cylinder head by the dynamic effect of the gaseous currents produced by the pressure of intake and the partial vacuum of exhaust. Being given that, due to the invention, the direction of transfer is located in the plane of FIG. 1A (plane passing through ports 5 and 7), it is advantageous to provide a cavity 2b whose opening on the combustion chamber 1 is large in dimension in the direction of said plane. In the direction perpendicular to this plane, the opening of the cavity 2b may be more reduced, this moreover enabling a large surface of compression of the combustible mixture to be obtained and a considerable turbulence in said cavity to be produced. There can therefore not be any loss of mixture through the exhaust 5 and the rich mixture is concentrated in the cavity 2b of the cylinder head 2 where the sparking plug 14 is located.
It is known from VIOLET's studies that the scavenging is practically terminated around bottom dead centre. The obturator, known per se, which may be placed in the exhaust, will close, around the bottom dead centre, the exhaust pipe up to the moment of closure of the corresponding port by the piston rising, with a view to avoiding losses of air through the exhaust and to improve filling.
At the beginning of opening of the ports, there may be a delivery of burnt gases in the mixture inlet pipe, in this presenting the risk of disturbing the carburation. To avoid this risk, it has been provided to delay the opening of the mixture inlet port with respect to the opening of the air inlet ports, so that, at the beginning of intake of the mixture, the delivery pressure of the air by the crankcase-pump in the transfer pipe 8 has become higher than the pressure prevailing in the combustion chamber. This delay may be ensured simply by acting on the relative geometry (height) of the various inlet ports, or by having positioned an automatic valve opening the transfer conduit only when the lack of balance of the pressures is favourable to this transfer. FIG. 1D illustrates a particular embodiment of this valve 15b closing conduit 8 downstream of the carburation device 12 associated in a two-headed valve with the valve 15a fulfilling the role of non-return valve 13 of FIG. 1A.
It is obvious that, although this Figure shows a system of precompression using a crankcase acting as pump, it may, without departing from the scope of the invention, be conceived that the conduit issues from an auxiliary precompression system actuated by the rotation of the engine.
FIG. 2 shows an engine in which the two inlet devices are connected to two different excess pressure systems. Certain elements which have already been described with reference to the preceding Figures are shown again, with the same references.
The mixture inlet pipe 8 is equipped with an excess pressure system 16, upstream of which is disposed a fuel-feed system 17, for example a carburettor. The inlet ports for air without fuel, such as 6, are connected to a pipe (not shown) which may for example issue, as in the preceding Figures, from a precompression crankcase.
This Figure also schematically shows a device for obturating the exhaust 5 constituted by a rotary disc 18 driven by a shaft 19 rotating as a function of the rotation of the drive shaft 20.
In a variant (not shown), this exhaust obturating device could be constituted by an automatic device employing a valve.
The presence of a supercharger for supplying carburetted mixture to the chamber allows a very substantial increase in the rate of filling and therefore an increase in the specific power. It is to be noted, in this case, that the supercharger device must be such that it does not provoke, as a function of the speed of rotation, too high an increase in torque. This is the case in particular of the excess pressure devices with double-acting piston or volumetric devices with bosses. The engines thus equipped will be high performance engines. If, on the other hand, it is desired to produce a normal engine, i.e. to conserve a rate of filling of the same order of magnitude as that usually employed, centrifugal superchargers may be used which offer the advantage of being much less expensive and much simpler. A supercharger will then be chosen which ensures an excess pressure of less than 25% and of which the flow at low speed will be less than the stream of air without fuel admitted in the combustion chamber. However, it will be necessary to calculate the exhaust pipe so as to provoke a favourable reflection of the pressure wave at slow speed. Such an adjustment of the two intakes presents the advantage of displacing the maximum torque of the engine at a higher engine speed. In other words, at high speeds of rotation of the engine, a higher torque is obtained than that which is obtained by an ordinary two-stroke engine without supercharger. The favourable range of power as a function of the engine speed is therefore much more extensive and the vehicle provided with this engine is much more versatile. Finally, it is to be noted that, at high speed, is may happen that the combustible mixture enclosed in the combustion chamber is too rich. This drawback may be overcome by various devices: mention will be made particularly of the opening of several air intakes triggered by partial vacuum upstream of the throttle, the installation of a regulating carburettor or of an obturator manoeuvred as a function of the engine speed, or an electrical or mechanical device for driving the supercharger the power variation of which will be controlled in manner less than proportional to the increase of the engine speed.
In the particular case of engines capable of functioning at constant speed, a carburetted mixture feed may be envisaged by simple drawing of said latter in the cylinder, resulting on the one hand from the opening of the exhaust port and, on the other hand, from the effect of suction due to the intake of the air without fuel under pressure.
In FIGS. 3A and 3B, the pipes 9 for intake of air through ports 6 are connected to an excess pressure device 21 of the type as described previously. The axes of the ports 7a and 7b are directed towards the wall opposite the exhaust and form with the axes of the air inlet ports 6 angles C smaller than 90°. These pipes 8a and 8b are connected to the crankcase-pump, the inlet 22 of which is provided, in conventional manner, with a fuel feed device 23. This arrangement enables a "petroil" lubrication to be effected. In the case of the non-carburetted air supply supercharger being of the centrifugal type, to avoid too great an increase of its flow as a function of the increase of its speed of rotation, a member may be provided for obturating the air inlet pipe in the supercharger controlled by its speed of rotation or said supercharger may be driven by means of suitable mechanical or electrical devices, whilst, furthermore, ensuring a regulation of the carburation so that the richness of the carburetted mixture is increased as a function of the increase in speed.
It is to be noted that, in these Figures, the cavity 2b where the carburetted mixture is concentrated, comprises two sparking plugs 14a and 14b the axes of which are located in the vertical median plane of this cavity. One, 14a, of the two sparking plugs is close to the junction between the flattest portion 2a of the cylinder head and the cavity 2b. In this way, the turbulence provoked by the beginning of the combustion (sparking plug 14a) and the end of compression at dead centre of the volume located under the flattest part of the cylinder head, enables a projection of partially burnt gases to be obtained towards the second sparking plug, which are reactivated in a second ignition zone much larger than the first.
The advantages of the invention correspond to those obtained by a direct injection of petrol but much less expensively, much more simply, and with less difficult repairs. When it has to different feed systems, the invention offers the supplementary specific advantage of enabling the rate of filling to be increased.
Apart from their advantages of economy and increase in power, the engines forming the subject matter of the invention comprise devices enabling an overall lean mixture to be used, whilst respecting all the objectives of reducing pollution.
The most simple and most efficient means of reducing the proportion of carbon monoxide and nitrogen oxide is to use an overall lean mixture, due to the use of a heterogeneous mixture, comprising a rich portion in the zone adjacent the sparking plug, so as to have a rapid beginning of ignition. If this result can be obtained in good conditions fully loaded, under reduced load, the speed of combustion at the end of combustion is too slow and there is an increase in the unburnt products.
The following devices: cavity where the rich mixture concentrates, turbulence by compression of part of the volume of the chamber and double ignition in the axis of the turbulence, enable an excellent combustion to be made in all the operational conditions of the engine.
The rich mixture concentration cavity in which the sparking plug is located enables a rapid beginning of combustion to be obtained.
At top dead centre, the turbulence provoked by the compression of the adjacent zone of the flat portion avoids having too slow a final phase, which is the main danger of the combustion of the heterogeneous mixtures. Moreover, this turbulence also contributes to rendering the beginning of combustion moe rapid. Combustion is therefore constantly accelerated.
With this device, the mixture is heterogeneous at the beginning of combustion, enabling a rich mixture to be obtained near the sparking plug and a rapid initial combustion phase, and it is rendered homogeneous for the end of combustion by the turbulence provoked at top dead centre.
Finally, the device with tubulence and two sparking plugs placed in the axis of this turbulence has for its effect to create a second, larger zone of combustion than the first zone, without the reduction of the load being able to reduce the efficiency of this second zone. In fact, the increase in the combustion volume of this second zone is due to the products of decomposition coming from the first zone. These latter are provoked by an incomplete combustion. If the combustion of the first zone is slower, the proportion of decomposition products increases, promoting the combustion in the second zone. The reduction of the load increases the ratio between the volume of the second zone and that of the first combustion zone. One is therefore sure of a very considerable combustion under low load. Furthermore, the constitution of a rich mixture near the sparking plug due to the heterogeneity of the mixture ensures a regular combustion at all speeds and enables the irregularity of fonctioning of the two-stroke engines at low speed, caused by the unburnt products, to be avoided.
The invention finds advantageous application in the field of the construction of two-stroke internal combustion engines. | The present invention relates to a method for feeding the combustion chamber of a two-stroke engine, according to which the constituents of the combustible mixture are admitted into the combustion chamber via two intake devices at the bottom of the cylinder. Air without fuel is admitted through two ports, symmetrically disposed with respect to the vertical plane containing the axis of the exhaust port, directed towards the wall opposite the exhaust; the petrol-and-air mixture is admitted through at least one port remotest from the exhaust so that the stream of carburetted air is directed towards the cylinder head, the carburetted mixture thus being maintained towards the wall opposite the exhaust by the two streams of air without fuel until the ports are closed. The invention finds particular application in the field of automobile construction. | 5 |
CROSS REFERENCED TO RELATED APPLICATION
This application claims the benefit of U.S. provisional patent application No. 61/854,819 filed May 3, 2013 titled action reaction combustion engine.
BACKGROUND OF THE INVENTION
This invention has to do with internal combustible fuel burning reciprocating engines. There are several applicable types of U.S. patent classifications for this application, such as internal combustion engines where mechanical power is needed for various uses.
All internal combustion engines to date are very inefficient where a big portion of the heat energy is wasted and not effectively doing all the work that it could be doing (100% input with 20-30% output).
The wasted heat energy has to be carried away by a radiator or other means of cooling, the heat and pressure in a combustion chamber is the highest when the crank and piston's position is at top dead center. That is when the engine's piston and crank can do no work, driving the heat into the head and piston. The energy has no place to go.
As the crank moves down and starts to gain a mechanical advantage the pressure in that cylinder continuously drops off.
We have been making engines this way for about 150 years, and for most engines there is only one power stroke every forth cycle, every two revolutions of the crank, and very little change has been made in the design since the beginning of the internal combustion engine. We have used this same engine design for a long time.
BRIEF SUMMARY OF THE INVENTION
This invention uses the theory of action reaction. The energy and forces it takes to stop a mass in motion as well as the energy and forces it takes to accelerate it again and its ability to do work with those forces are the bases of my invention.
This invention uses the engine's reciprocating motion and the energy and forces that this motion produces by starting and stopping the mass of the pistons to turn a crank flywheel drive shaft pump or other type of drive mechanisms.
This technology is not new, but has never been used in the application for a combustion engine.
When the energy and forces that are applied to a crank are as close as possible to 90 degrees after top dead center is when the mechanical advantages are at their optimum. That is exactly what this engine will accomplish.
Not only does it gain a 90 degree mechanical advantage, but it also delivers four power events every reciprocating cycle or revolution of crank, two events when the mass stops on each opposite end and two when the mass reverses direction and starts the mass moving again on each opposite end.
The engine pushes and pulls the crank in both directions, but does so with a very simple design and few moving parts. It will burn most any kind of fuel and will be very efficient.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 depicts most of the descriptive parts of the main embodiment.
FIG. 2 depicts the valving and valving control for adjusting exhausting air and air inlet valving for controlling air intake for starting and or running on air.
FIG. 3 depicts the engine as a one-piston engine having separable cylinder.
FIG. 4 depicts the engine attached to a crank.
FIG. 5 depicts the engine supported by bearings and being fastened together with fasteners.
DESCRIPTION
An action reaction free piston combustion engine composed of one or more said engines connected to a crank or other drive mechanism consisting of one or more pistons and cylinders.
Said engines with three or more said pistons traveling together and being attached by rods and are allowed to reciprocate.
The two smaller said pistons on each end and the one large heavy said piston in the center are moveable and mated to their perspective said cylinders separated by two bulkheads. The said rods and said pistons are supported by lineal bearings.
The said lineal bearings being mounted in said bulkheads and said pistons having adequate mass to produce action reaction necessary to push and pull said engine and said engine is allowed to reciprocate on said lineal bearings against a workload like a crank to transmit energy, and that energy into work.
DETAILED DESCRIPTION OF THE INVENTION
I have numbered every part at least once with out numbering them twice where opposing parts are identical and obvious, the engine will always be referred to as the number 1. To begin in FIG. 1 the major parts for said engine 1 being an example of a three cylinder engine include one cylinder 2 in the center and two cylinders 3 on opposing ends of said engine 1 along with opposing cylinder heads 15 being fastened together with fastener means 20 in FIG. 5 .
The three said cylinders of said engine 1 in FIG. 1 being fitted with three pistons, one large center said piston 4 and two smaller end said pistons 5 and are movable in and mated to their perspective said cylinders 2 and 3 and are allowed to reciprocate freely in said cylinders 2 and 3 , compressing and firing on one end while the other end is exhausting.
The said pistons 4 and 5 are attached together by rods 6 if applicable running through bulkheads 14 for separating said pistons 4 and 5 and said cylinders 2 and 3 .
Said pistons 4 and 5 are supported by lineal bearing means 10 that are mounted in said bulkheads 14 .
Said pistons 4 and 5 are allowed to reciprocate in their perspective said cylinders 2 and 3 . Said pistons 5 are allowed to compress against the said cylinder heads 15 in turn pushing and pulling said engine 1 backward and forward while riding on said bearing means 21 as depicted in FIG. 5 and producing a work force.
The valving control rods 7 and valve adjusters 16 in FIG. 1 are for timing the exhaust valves 9 , letting the exhaust out through said valves 9 mounted in said cylinder heads 15 .
Plumbing means in FIG. 1 consisting of tubes 8 connected between said cylinders 2 and 3 with check valves 13 , located in said tubes 8 and taking out side air in through one way valves 12 where air is drawn in to said cylinder 2 and then compressed and sent through said tube 8 and past said check valve 13 into said cylinder 3 that is in position to exhaust and that said cylinder 3 is then purged out through said valve 9 for that end of said engine 1 .
As one end of said engine 1 in FIG. 1 is exhausting out through said valve 9 in said cylinder head 15 , the other end of said engine 1 is firing by means of a timed fuel injector 11 located in the end of said cylinder head 15 , and the cycle repeats firing on one end and exhausting on the other.
FIG. 2 drawing is a example of said engine 1 as the starter and an air engine where the air inlet valves 17 are properly timed to let high pressure air into said cylinder 2 and the air pressurizing said cylinder 2 , and applying high pressure air between said piston 4 and said bulkhead 14 , pushing said bulkhead 14 and said piston 4 apart, and pushing said bulkhead forward and said piston 4 backward causing said engine 1 to reciprocate producing a action reaction.
While said piston 4 is pressurizing and pushing one end of said engine 1 in FIG. 2 , exhausting is taking place simultaneously on opposite end of said cylinder 2 of said engine 1 and exhausts out through valve 9 A, and said valve 9 A, being timed by said valving control rod 7 and valve adjuster 16 a. So said piston 4 and said engine 1 now becomes a starter as well as air engine starting the said combustion engine 1 as well as to assist in the over all output of the said combustion engine 1 .
FIG. 3 is a drawing of said engine 1 having only one piston 4 a, and being of one piece with a larger center portion and having adequate mass and being movable and housed in cylinder 2 a and said cylinder 2 a being separable.
Each end of the said piston 4 a, FIG. 3 which is the two outboard ends of said piston 4 a and being housed in said cylinders 3 a which is the outboard end of said cylinder 2 a and said piston 4 a being slidable in lineal bearing means 10 a and said piston 4 a being allowed to reciprocate.
Said engine 1 in FIG. 3 having same parts including said valves 9 and said valve adjusters 16 , said cylinder heads 15 , and said plumbing means consisting of said tubes 8 with said check valves 13 and said fuel delivery injectors 11 as in said engine 1 in FIG. 1 except said lineal bearing means 10 a, being in drawing for said engine 1 FIG. 3 and as well as the same said engine starting means as in said engine 1 FIG. 2 , and having same said bearing means 21 as in FIG. 5 .
And said engine 1 of FIG. 3 being attached to same said crank 19 or other said drive mechanism as in said engine 1 FIG. 4 .
FIG. 4 is a drawing of said engine 1 in FIG. 1 , FIG. 2 , and FIG. 3 being connected to said crank 19 in FIG. 4 and said engine 1 is allowed to reciprocate on said bearing means 21 in FIG. 5 and turning said crank 19 in FIG. 4 , producing a force against a workload.
The drawing in FIG. 5 shows said engine 1 mounted on said bearing means 21 and allowed to reciprocate and is fastened together with said fastener means 20 . | An action reaction combustion engine comprising of one or more engines with one or more pistons having adequate mass being housed in mated cylinders and having two opposing heads also having valving plumbing fuel delivery and starting means and allowed to reciprocate on linear bearings delivering a workforce on each end of back and fourth stroke one force when the pistons compresses and stops and one force when fuel ignites or high pressure air pushes and drives the piston back producing four power events every one complete reciprocating cycle or revolution of the crank or other drive mechanism. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a jigsaw type electric-powered cutting machine having a blade holding mechanism.
[0003] 2. Background Art
[0004] A conventional electric-powered cutting machine will be described with reference to FIGS. 1 and 18, taking a jigsaw as an example.
[0005] As shown in FIG. 1, a jigsaw includes: a housing 2 which has a switch 4 and a handle 3 , in which a base 5 that serves as a guiding member during a cutting work is attached to a lower side, and which houses an electric motor that is not shown; and a plunger 1 which reciprocates in the vertical directions in the figure by a turning force of the electric motor. In the illustrated jigsaw, the plunger 1 is covered by a cover 6 which is formed by a transparent member. An upper portion of the plunger 1 is reciprocatively held inside the housing 2 , and a lower portion protrudes to the outside from the housing 2 . A blade 7 is detachably held by the lower portion of the plunger 1 .
[0006] As shown in FIG. 18, the conventional jigsaw has a configuration in which a locking screw 28 that presses a flat face of the blade 7 , and a support member 29 that supports a flat face of the blade 7 on the side opposite in the pressing direction are attached to the tip end of the plunger 1 . When the blade 7 is inserted into the plunger 1 , the blade 7 can be fixed to the plunger 1 by fastening the locking screw 28 .
[0007] However, the above-mentioned configuration has the inconvenience that it is necessary to use a tool for operating the locking screw 28 during a work of replacing the blade 7 . Apparently, the fastening force acting on the locking screw 28 is variously changed depending on the worker, thereby causing a problem in that, when the fastening force is excessively large, the blade 7 is deformed.
[0008] As a jigsaw for solving the problem, European Patent Nos. 722,802 and 855,239 disclose a configuration in which a work of replacing a blade can be conducted without using a tool or the like.
SUMMARY OF THE INVENTION
[0009] Among the conventional jigsaws, the jigsaw disclosed in European Patent No. 722,802 is configured in the following manner. When a lever disposed on the tip end of a plunger is operated without using a tool, two projections for preventing a blade from slipping off are engaged with a wall face which is perpendicular to a tip end face of the plunger, whereby the blade can be fixed easily and irrespective of a force exerted by the worker.
[0010] Since the lever having a relatively large size is disposed on the tip end of the plunger, the plunger is heavy. Therefore, the jigsaw has a disadvantage that, during a cutting work, the plunger largely vibrates. In the plunger, an opening for inserting a blade is not clearly formed. In a work of inserting a blade into the plunger, therefore, the blade may be erroneously inserted with being inclined. In this case, there is the possibility that the blade is fixed while maintaining the inclined state. Such an inclined blade greatly affects the cutting accuracy.
[0011] The jigsaw disclosed in European Patent No. 855,239 has a configuration which can solve the problem in the blade fixing method by screwing, in the same manner as that disclosed in European Patent No. 722,802, and in which the problem discussed with respect to that disclosed in European Patent No. 722,802 is solved by disposing a clear opening for inserting a blade, and by performing the fixation through a remote operation using a lever that is disposed in a place different from the plunger.
[0012] In the configuration, a spring pressing a moving member must be designed so that the spring can be placed in a gap formed between the moving member and an outer hull, while the gap is narrowed by the remote operation using the lever. When the lever is released and the moving member is moved to a position where the member presses the blade, the spring is stretched to some extent and the pressing force is lost. In order to compensate the pressing force, therefore, a number springs must be placed in the gap. As a result, the total weight of the plunger is increased. In a jigsaw in which a plunger reciprocates at a high speed, the increased weight tends to adversely affect vibrations of the main unit of the jigsaw.
[0013] It is an object of the invention to provide a jigsaw which can eliminate the above-discussed disadvantages, and in which, without increasing the weight of a plunger, vibrations during a cutting work can be suppressed and blade replacement can be conducted easily and in a short time.
[0014] The object can be attained by configuring a blade holding mechanism so as to comprise: a blade receiving face including a groove having a shape which is substantially identical with a shape of an attachment portion of a blade including projections; a swinging member having: one end which has a swing fulcrum that elongates in a direction substantially identical with a longitudinal direction of a plunger, and a blade pressing portion that can be placed in a place opposed to the groove; and another end which elongates to separate from the plunger; and a pressing member which presses the one end of the swinging member toward the groove of the plunger.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention may be more readily described with reference to the accompanying drawings:
[0016] [0016]FIG. 1 is a perspective view showing an embodiment of the electric-powered cutting machine of the invention.
[0017] [0017]FIG. 2 is an enlarged bottom view of main portions showing the embodiment of the electric-powered cutting machine of the invention.
[0018] [0018]FIG. 3 is a section view taken along the line A-A in FIG. 2.
[0019] [0019]FIG. 4 is a section view taken along the line B-B in FIG. 3.
[0020] [0020]FIG. 5 shows an enlarged front view of main portions and a side view showing an example of a blade.
[0021] [0021]FIG. 6 is a section view taken along the line C-C in FIG. 3.
[0022] [0022]FIG. 7 is an enlarged bottom view of main portions showing an operation state of the electric-powered cutting machine of the invention.
[0023] [0023]FIG. 8 is an enlarged bottom view of main portions showing an operation state of the electric-powered cutting machine of the invention.
[0024] [0024]FIG. 9 is an enlarged bottom view of main portions showing an operation state of the electric-powered cutting machine of the invention.
[0025] [0025]FIG. 10 is an enlarged bottom view of main portions showing an operation state of the electric-powered cutting machine of the invention.
[0026] [0026]FIG. 11 is an enlarged bottom view of main portions showing another embodiment of the electric-powered cutting machine of the invention.
[0027] [0027]FIG. 12 is an enlarged bottom view of main portions of FIG. 11 showing an operation state of the other embodiment of the electric-powered cutting machine of the invention.
[0028] [0028]FIG. 13 is an enlarged bottom view of main portions of FIG. 11 showing an operation state of the other embodiment of the electric-powered cutting machine of the invention.
[0029] [0029]FIG. 14 is an enlarged bottom view of main portions of FIG. 11 showing an operation state of the other embodiment of the electric-powered cutting machine of the invention.
[0030] [0030]FIG. 15 is a section view taken along the line D-D in FIG. 11 showing the other embodiment of the electric-powered cutting machine of the invention.
[0031] [0031]FIG. 16 is an enlarged bottom view of main portions of FIG. 15.
[0032] [0032]FIG. 17 is a section view taken along the line D-D in FIG. 11 showing an operation state of the other embodiment of the electric-powered cutting machine of the invention.
[0033] [0033]FIG. 18 shows an enlarged front view of main portions and a side view showing an example of a conventional electric-powered cutting machine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] An embodiment of the jigsaw of the invention will be described with reference to FIGS. 1 to 10 . FIG. 1 is a perspective view showing a state where the blade 7 is attached to a tip end portion of the plunger 1 , FIG. 2 is an enlarged bottom view of main portions showing a blade holding mechanism, FIG. 3 is a section view taken along the line A-A in FIG. 2, and FIG. 4 is a section view taken along the line B-B in FIG. 3.
[0035] As shown in FIG. 5, the blade 7 which can be attached to and detached from the jigsaw of the invention has an attachment portion 7 a including a pair of projections 7 b which elongate perpendicular to the longitudinal direction of the blade 7 .
[0036] A blade holding portion 8 is disposed in the tip end of the plunger 1 as shown in the Figures. A bottom face 9 which extends perpendicular to the longitudinal direction of the plunger 1 , and in which a hole 9 a is formed is disposed on the blade holding portion 8 on the side of the base 5 . The hole 9 a has a width t which is smaller than the width T of the attachment portion 7 a of the blade 7 , and a dimension L which is larger than a dimension V between the projections 7 b. The dimension V is the maximum width of the attachment portion 7 a of the blade 7 . The blade holding portion 8 has an upper face 10 which extends in parallel with the bottom face 9 , and which is positioned in the vicinity of the lower end face of the plunger 1 . A blade receiving face 11 which extends substantially parallel to the longitudinal direction of the plunger 1 is positioned between the bottom face 9 and the upper face 10 and in the vicinity of the middle of the plunger 1 .
[0037] As shown in FIG. 3, a groove 11 a having a shape which is substantially identical with that of the attachment portion 7 a of the blade 7 is formed in the blade receiving face 11 . The hole 9 a of the bottom face 9 communicates with the groove 11 a.
[0038] A pin 12 which is held by the upper face 10 and the bottom face 9 of the blade holding portion 8 is disposed between the upper face 10 and the bottom face 9 . A swinging member 13 which uses the pin 12 as a swing fulcrum is held by the blade holding portion 8 .
[0039] As shown in FIG. 4, the swinging member 13 has an approximately V-like shape, and is attached so that the pin 12 serving as a swing fulcrum is positioned in a substantially middle portion of the member. One end 13 a of the member is always pressed toward the blade receiving face 11 by a spring 14 which is a pressing member for pressing an end portion of the member. The one end 13 a of the swinging member 13 has a shape which can be placed substantially parallel to the blade receiving face 11 , and has a hemispherical convex portion 13 c in a place corresponding to the middle portion of the groove 11 a. The convex portion protrudes toward the groove 11 a to serve as a blade pressing portion. The center position of the pin 12 is located substantially on an extended line of the blade receiving face 11 , whereby the one end 13 a of the swinging member 13 is allowed to be easily placed substantially parallel to the blade receiving face 11 as described above.
[0040] Although the one end 13 a of the swinging member 13 is positioned between the upper face 10 and the bottom face 9 of the blade holding portion 8 , the other end 13 b is not positioned between the upper face 10 and the bottom face 9 , and has a shape which elongates so as to separate from the blade receiving face 11 or radially outward separate from the plunger 1 .
[0041] As shown in FIGS. 4 and 6, a hole la having an inner wall face which is substantially flush with the face of the groove 11 a is formed in the plunger 1 . When the blade 7 is attached, an end of the attachment portion 7 a of the blade is positioned in the hole 1 a of the plunger 1 .
[0042] In the housing 2 , a lever 15 which serves as an operation member, and which has a swing fulcrum 15 c that elongates in a direction substantially identical with the longitudinal direction of the plunger 1 is disposed on the housing 2 so as to cover the blade holding portion 8 . In the lever 15 , an abutting portion 15 b which can abut against the other end 13 b of the swinging member 13 is disposed at a position close to the swing fulcrum 15 c, and an operation portion 15 a is formed in a place which is remote from the abutting portion 15 b.
[0043] The lever 15 is pressed by a pressing member such as a torsion spring which is not shown, so as to be located at the position shown in FIG. 2. The lever can be swung with using the swing fulcrum 15 c as a fulcrum, by operating the operation portion 15 a.
[0044] When the lever 15 is swung, as shown in FIG. 7, the abutting portion abuts against the other end 13 b of the swinging member 13 . When the lever 15 is further swung, the shape of the abutting portion 15 b causes the swinging member 13 to be swung so that the other end 13 b of the swinging member 13 is moved toward the blade receiving face 11 against the pressing force of the spring 14 .
[0045] When the operation of swinging the lever 15 is cancelled in the state of FIG. 7, the lever 15 is returned to the state shown in FIG. 2 by the pressing member such as a torsion spring. In accordance with this returning operation, the swinging member 13 is swung by the urging force of the spring 14 so that the one end 13 a is moved toward the blade receiving face 11 , and the other end 13 b radially outward separate from the plunger 1 , with the result that also the swinging member 13 is returned to the state shown in FIG. 2.
[0046] Next, the operation to be performed when the blade 7 is attached to the blade holding portion 8 will be described.
[0047] First, the lever 15 is swung against the pressing member as described above to cause the swinging member 13 to swing against the pressing force of the spring 14 . The lever 15 is then held to the state shown in FIG. 7.
[0048] In this state, the attachment portion 7 a of the blade 7 is inserted into the blade holding portion 8 via the hole 1 a of the bottom face 9 of the blade holding portion 8 . The attachment portion 7 a of the blade 7 is then engaged with the groove 11 a of the blade receiving face 11 , and the holding of the lever 15 is cancelled. As shown in FIG. 8, therefore, the lever 15 is returned to the state shown in FIG. 2, and also the swinging member 13 is returned to the state shown in FIG. 2. This causes the convex portion 13 c on the one end 13 a of the swinging member 13 to press the flat face of the attachment portion 7 a of the blade 7 engaged with the groove 11 a. As a result, the work of attaching the blade 7 to the blade holding portion 8 is ended.
[0049] The blade 7 attached to the blade holding portion 8 is prevented from downward slipping off, by the projections 7 b of the blade 7 and the groove 11 a opposed to the projections 7 b. The upward movement of the blade 7 is restricted by butting of the upper faces of the projections 7 b of the blade 7 against the inner wall face of the upper face of the blade holding portion 8 .
[0050] In the jigsaw of the embodiment, as shown in FIG. 10, the abutting portion 15 b of the lever 15 has a shape which elongates in a direction substantially identical with the longitudinal direction of the plunger 1 . This configuration is employed because of the following reason. Even when the blade holding portion 8 , i.e., the other end 13 b of the swinging member 13 against which the abutting portion 15 b abuts is at any position in the reciprocal motion range of the plunger 1 , the abutting portion 15 b of the lever 15 can abut against the other end 13 b of the swinging member 13 to enable the blade 7 to be attached or detached.
[0051] The jigsaw of the embodiment is configured so that, as shown in FIG. 2, a through hole 11 b which communicates with the groove 11 a is formed in the blade receiving face 11 . A projecting portion 13 d is capable of being inserted into the through hole 11 b to protrude into the groove 11 a. The projecting portion 13 d is disposed on the other end 13 b of the swinging member 13 . According to the configuration, when the lever 15 is swung in the work of detaching the blade 7 , the projecting portion 13 d functions to cause the blade 7 to automatically slip off from the blade holding portion 8 , whereby the workability of the replacement of the blade 7 is improved.
[0052] The jigsaw of the embodiment is configured so that the plunger 1 is rockable in the cutting direction. The jigsaw has a roller 16 for abutting against a face of the blade 7 . The face is a rear face with respect to the cutting direction. The pin 12 which serves as the swing fulcrum of the swinging member 13 is positioned more rearward in the cutting direction than the center of the plunger 1 in order that, during an operation of attaching or detaching the blade 7 , the plunger 1 can rock in a direction along which the plunger separates from the roller 16 , i.e., toward the forward side in the cutting direction as shown in FIG. 10. When the abutting portion 15 b of the lever 15 abuts against the other end 13 b of the swinging member 13 , a moving force acts toward the forward side in the cutting direction. According to the configuration, the work of replacing the blade 7 can be conducted without being hindered by the roller 16 , whereby the workability can be improved.
[0053] As described above, the pressing force of the spring 14 serving as the pressing member acts on the vicinity of the end portion of the one end 13 a of the swinging member 13 having the swing fulcrum. According to the principle of the lever, therefore, a greater pressing force can be given to the blade 7 via the convex portion 13 c. In other words, it is not necessary to dispose plural springs 14 or the spring 14 of a larger size in order to obtain a pressing force which is required at minimum. Therefore, the weight of the blade holding portion 8 can be relatively reduced, so that vibrations which are caused during reciprocal motion of the plunger 1 can be suppressed. As shown in FIG. 2, the pin 12 which serves as the swing fulcrum of the swinging member 13 is placed at a position which is separated from the outer periphery of the plunger 1 , and the place where the spring 14 presses the one end of the swinging member 13 is set to the vicinity of the end portion of the one end 13 a, whereby the pressing force of the convex portion 13 c acting on the blade 7 can be further enhanced. A convex portion 13 e which is disposed on the one end 13 a of the swinging member 13 so as to protrude toward the spring 14 , and a pin 17 attached to the blade holding portion 8 prevent the spring 14 from slipping off from the blade holding portion 8 .
[0054] As described above, the convex portion 13 c is disposed on the one end 13 a of the swinging member 13 as a pressing member with a hemispherical shape. The convex portion 13 c presses the flat face of the blade 7 engaged with the groove 11 a of the blade receiving face 11 . Even when another blade 7 having a different width is inserted, therefore, the pressing force of the spring 14 acts on a substantially middle portion of the blade 7 via the convex portion 13 c.
[0055] In the jigsaw of the embodiment, after the blade 7 is inserted into the blade holding portion 8 through the hole 1 a of the bottom face 9 , the blade 7 must be moved in the direction perpendicular to the longitudinal direction to cause the attachment portion 7 a of the blade 7 to be engaged with the groove 11 a of the blade receiving face 11 . In the configuration of the embodiment, when the operation of the lever 15 is cancelled in the state where the blade 7 is inserted into the blade holding portion 8 , the blade is guided by the convex portion 13 c of the swinging member 13 to be engaged with the groove 11 a. At this time, because the convex portion 13 c has a hemispherical shape as described above, the convex portion 13 c presses a substantially middle portion of the blade 7 , and hence the blade 7 is stably guided into the groove 11 a.
[0056] As described above, in the blade holding portion 8 , the blade 7 must be moved in the direction perpendicular to the longitudinal direction. Therefore, the widths of the hole 1 a of the plunger 1 and the hole 9 a of the bottom face 9 of the blade holding portion 8 are set to have dimensions which enable the above-mentioned movement of the blade 7 .
[0057] In the embodiment, the upper face 10 of the blade holding portion 8 is positioned at the upper end of the groove 11 a. When the blade 7 is moved as described above in the state where the upper faces of the projections 7 b of the blade 7 abut against the inner wall face of the upper face 10 of the blade holding portion 8 , therefore, the attachment portion 7 a of the blade 7 is engaged with the groove 11 a. As a result, the movement of the blade 7 caused by the convex portion 13 c of the swinging member 13 is performed more stably, and the position of the blade 7 is set when the blade 7 is inserted into the blade holding portion 8 , so that the work of attaching the blade can be easily conducted.
[0058] In the embodiment, the blade holding portion 8 is formed as a member which is different from the plunger 1 . Alternatively, the blade holding portion may be formed integrally with the plunger 1 .
[0059] Next, another embodiment of the jigsaw of the invention will be described with reference to FIGS. 11 to 14 . The components similar to those of the above-described embodiment are denoted by the same reference numerals, and their description is omitted.
[0060] The embodiment has a feature in the shape of the convex portion 13 c which is disposed on the one end 13 a of the swinging member 13 to function as the blade pressing portion.
[0061] As shown in the figures, a convex portion 13 c ′ which is disposed on the one end 13 a of the swinging member 13 , and which presses the flat face of the blade 7 has a width which is slightly smaller than the illustrated width of the groove 11 a, and has a shape which can be placed substantially parallel to the groove 11 a, so that, when the blade 7 of a width which is more frequently used is engaged with the groove 11 a, the convex portion can substantially come into surface contact with the flat face of the blade 7 .
[0062] In the case of the hemispherical convex portion 13 c in the embodiment described above, the flat face of the blade 7 and the convex portion 13 c make a point contact, and there is the possibility that the blade 7 is inclined with using the convex portion 13 c as a fulcrum. By contrast, according to the above-mentioned configuration, even when the blade 7 of a different width is inserted and butting between the flat face of the blade 7 and the convex portion 13 c ′ is formed by a point contact, the face of a portion of the convex portion 13 c ′ which is not in contact with the flat face functions to suppress the inclination, with the result that the inclination of the blade 7 can be suppressed.
[0063] [0063]FIG. 12 is an enlarged view of main portions showing a state where the blade 7 of a thickness which is more frequently used is attached, FIG. 13 is an enlarged view of main portions showing a state where a blade 7 ′ of a thickness which is smaller than that of the blade 7 of FIG. 12 is attached, and FIG. 14 is an enlarged view of main portions showing a state where a blade 7 ″ of a thickness which is larger than that of the blade 7 of FIG. 12 is attached.
[0064] In the state shown in FIG. 12, the convex portion 13 c ′ and the flat face of the blade 7 are substantially in surface contact. The blade 7 can be almost completely prevented from being inclined to escape from the groove 11 a in the illustrated state. By contrast, in the state shown in FIG. 13 or 14 , the convex portion 13 c ′ and the flat face of the blade 7 ′ or 7 ″ make a point contact, but the allowable range of the inclination of the blade 7 ′ or 7 ″ is restricted by a portion other than the convex portion 13 c which is in contact with the flat face of the blade 7 ′ or 7 ″. Therefore, it can be seen that the inclination of the blade 7 ′ or 7 ″ can be suppressed to a small degree (approximately the degree of a or b shown in the figures).
[0065] Next, a further embodiment of the jigsaw of the invention will be described with reference to FIGS. 15 to 17 . The components similar to those of the above-described embodiments are denoted by the same reference numerals, and their description is omitted.
[0066] The embodiment has a feature in the shape of the hole 1 a formed in the plunger 1 , into which the end portion of the attachment portion 7 a of the blade 7 is to be inserted.
[0067] As shown in the figures, the hole 1 a of the plunger 1 has: a first inner wall face 1 b which is flush with the groove 11 a of the blade receiving face 11 ; a second inner wall face 1 c which is placed to be opposed to the first inner wall face 1 b; and a third inner wall face 1 d which is opposed to the end face of the blade 7 .
[0068] The width of the third inner wall face 1 d is substantially equal to the maximum width of the blade 7 which can be used. The second inner wall face 1 c is formed as an inclined face which is continuous with a portion (an upper portion in the figures) of the third inner wall face 1 d that is opposite to the first inner wall face 1 b, and which extends to the upper face 10 of the blade holding portion 8 .
[0069] As described above, to engage the attachment portion 7 a of the blade 7 with the groove 11 a, the attachment portion 7 a must be moved by a distance corresponding to the depth of the groove 11 a. Therefore, the hole 1 a of the plunger 1 must be formed so as to allow the movement of the blade 7 . Consequently, the width of the hole 1 a of the plunger 1 cannot be set to be substantially equal to that of the blade 7 . As a result, there is the possibility that, when a load is applied to the vicinity of the lower end of the blade 7 , the blade is inclined so as to rotate around the convex portion 13 c or 13 c ′ pressing the flat face of the blade 7 . The movement of the blade 7 is enabled by forming the second inner wall face 1 c as an inclined face. The inclination of the blade 7 can be suppressed by setting the width of the third inner wall face 1 d to be slightly larger than the thickness of the blade 7 .
[0070] [0070]FIGS. 16 and 17 are section views of main portions showing a state where the blade 7 of a width which is more frequently used is attached. As shown in FIG. 16, the width of the third inner wall face 1 d is slightly different from that of the blade 7 . As shown in FIG. 17, even when a load in the direction F shown in the figure is applied to the vicinity of the lower end (the left side in the figure) of the blade 7 , the end face of the blade 7 on the side of the attachment portion 7 a abuts against the second inner wall face 1 c, whereby the inclination of the blade 7 is restricted. Therefore, it can be seen that the inclination of the blade 7 can be suppressed to a small degree (approximately the degree of about c shown in the figure). In the embodiment, the work of attaching the blade 7 can be conducted in the following manner. When the blade 7 is to be inserted into the blade holding portion 8 , the blade 7 is inserted with being inclined with respect to the longitudinal direction of the plunger 1 . The blade 7 is inserted until the end face is substantially contacted with the third inner wall face 1 d of the hole 1 a of the plunger 1 . Thereafter, the attachment portion 7 a of the blade 7 is engaged with the groove 11 a by a manual operation or pressing by the convex portion 13 c or 13 c ′ of the swinging member 13 .
[0071] As described above, according to the invention, it is possible to provide a jigsaw in which, without increasing the weight of a plunger, vibrations during a cutting work can be suppressed and blade replacement can be conducted easily and in a short time. | An electric-powered cutting machine includes: an electric motor, a housing for the electric motor; a plunger driven by the electric motor to reciprocate; and a blade holding mechanism. The blade holding mechanism holds a blade at a tip end portion of the plunger. The blade holding mechanism includes: a blade receiving face including a groove, a swinging member and a pressing member. The groove is shaped substantially the same as an attachment portion of the blade. The swinging member has one and other ends and pivoted at a swing fulcrum. The one end has a blade pressing portion capable of being disposed to oppose to the groove. The other end elongates to separate from the plunger. The pressing member presses the one end toward the groove. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of the filing date of U.S. provisional patent application Ser. No. 60/616,254, filed Oct. 5, 2004; and Ser. No. 60/624,793, filed Nov. 2, 2004; both of which are incorporated herein by reference in their entireties. Furthermore, this application is a Continuation-In-Part of U.S. patent application Ser. No. 10/408,665, filed Apr. 8, 2003, which published as U.S. Patent Publication 2003/0216792 on Nov. 20, 2003, and issued as U.S. Pat. No. 7,162,303 on Jan. 9, 2007, and which claims the benefit of the filing dates of U.S. provisional patent application Ser. No. 60/370,190, filed Apr. 8, 2002; Ser. No. 60/415,575, filed Oct. 3, 2002; and Ser. No. 60/442,970, filed Jan. 29, 2003; all of which are incorporated herein by reference in their entireties.
INCORPORATION BY REFERENCE
All publications and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.
TECHNICAL FIELD
The present invention relates to methods and apparatus for renal neuromodulation. More particularly, the present invention relates to methods and apparatus for achieving renal neuromodulation via a pulsed electric field and/or electroporation or electrofusion.
BACKGROUND
Congestive Heart Failure (“CHF”) is a condition that occurs when the heart becomes damaged and reduces blood flow to the organs of the body. If blood flow decreases sufficiently, kidney function becomes impaired and results in fluid retention, abnormal hormone secretions and increased constriction of blood vessels. These results increase the workload of the heart and further decrease the capacity of the heart to pump blood through the kidney and circulatory system.
This reduced capacity further reduces blood flow to the kidney, which in turn further reduces the capacity of the heart. It is believed that progressively decreasing perfusion of the kidney is a principal non-cardiac cause perpetuating the downward spiral of CHF. Moreover, the fluid overload and associated clinical symptoms resulting from these physiologic changes are predominant causes for excessive hospital admissions, terrible quality of life and overwhelming costs to the health care system due to CHF.
While many different diseases may initially damage the heart, once present, CHF is split into two types: Chronic CHF and Acute (or Decompensated-Chronic) CHF. Chronic Congestive Heart Failure is a longer term, slowly progressive, degenerative disease. Over years, chronic congestive heart failure leads to cardiac insufficiency. Chronic CHF is clinically categorized by the patient's ability to exercise or perform normal activities of daily living (such as defined by the New York Heart Association Functional Class). Chronic CHF patients are usually managed on an outpatient basis, typically with drugs.
Chronic CHF patients may experience an abrupt, severe deterioration in heart function, termed Acute Congestive Heart Failure, resulting in the inability of the heart to maintain sufficient blood flow and pressure to keep vital organs of the body alive. These Acute CHF deteriorations can occur when extra stress (such as an infection or excessive fluid overload) significantly increases the workload on the heart in a stable chronic CHF patient. In contrast to the stepwise downward progression of chronic CHF, a patient suffering acute CHF may deteriorate from even the earliest stages of CHF to severe hemodynamic collapse. In addition, Acute CHF can occur within hours or days following an Acute Myocardial Infarction (“AMI”), which is a sudden, irreversible injury to the heart muscle, commonly referred to as a heart attack.
As mentioned, the kidneys play a significant role in the progression of CHF, as well as in Chronic Renal Failure (“CRF”), End-Stage Renal Disease (“ESRD”), hypertension (pathologically high blood pressure) and other cardio-renal diseases. The functions of the kidney can be summarized under three broad categories: filtering blood and excreting waste products generated by the body's metabolism; regulating salt, water, electrolyte and acid-base balance; and secreting hormones to maintain vital organ blood flow. Without properly functioning kidneys, a patient will suffer water retention, reduced urine flow and an accumulation of waste toxins in the blood and body. These conditions resulting from reduced renal function or renal failure (kidney failure) are believed to increase the workload of the heart. In a CHF patient, renal failure will cause the heart to further deteriorate as the water build-up and blood toxins accumulate due to the poorly functioning kidneys and, in turn, cause the heart further harm.
The primary functional unit of the kidneys that is involved in urine formation is called the “nephron”. Each kidney consists of about one million nephrons. The nephron is made up of a glomerulus and its tubules, which can be separated into a number of sections: the proximal tubule, the medullary loop (loop of Henle), and the distal tubule. Each nephron is surrounded by different types of cells that have the ability to secrete several substances and hormones (such as renin and erythropoietin). Urine is formed as a result of a complex process starting with the filtration of plasma water from blood into the glomerulus. The walls of the glomerulus are freely permeable to water and small molecules but almost impermeable to proteins and large molecules. Thus, in a healthy kidney, the filtrate is virtually free of protein and has no cellular elements. The filtered fluid that eventually becomes urine flows through the tubules. The final chemical composition of the urine is determined by the secretion into, and re-absorption of substances from, the urine required to maintain homeostasis.
Receiving about 20% of cardiac output, the two kidneys filter about 125 ml of plasma water per minute. Filtration occurs because of a pressure gradient across the glomerular membrane. The pressure in the arteries of the kidney pushes plasma water into the glomerulus causing filtration. To keep the Glomerulur Filtration Rate (“GFR”) relatively constant, pressure in the glomerulus is held constant by the constriction or dilatation of the afferent and efferent arterioles, the muscular walled vessels leading to and from each glomerulus.
In a CHF patient, the heart will progressively fail, and blood flow and pressure will drop in the patient's circulatory system. During acute heart failure, short-term compensations serve to maintain perfusion to critical organs, notably the brain and the heart that cannot survive prolonged reduction in blood flow. However, these same responses that initially aid survival during acute heart failure become deleterious during chronic heart failure.
A combination of complex mechanisms contribute to deleterious fluid overload in CHF. As the heart fails and blood pressure drops, the kidneys cannot function and become impaired due to insufficient blood pressure for perfusion. This impairment in renal function ultimately leads to the decrease in urine output. Without sufficient urine output, the body retains fluids, and the resulting fluid overload causes peripheral edema (swelling of the legs), shortness of breath (due to fluid in the lungs), and fluid retention in the abdomen, among other undesirable conditions in the patient.
In addition, the decrease in cardiac output leads to reduced renal blood flow, increased neurohormonal stimulus, and release of the hormone renin from the juxtaglomerular apparatus of the kidney. This results in avid retention of sodium and, thus, volume expansion. Increased renin results in the formation of angiotensin, a potent vasoconstrictor. Heart failure and the resulting reduction in blood pressure also reduce the blood flow and perfusion pressure through organs in the body other than the kidneys. As they suffer reduced blood pressure, these organs may become hypoxic, resulting in a metabolic acidosis that reduces the effectiveness of pharmacological therapy and increases a risk of sudden death.
This spiral of deterioration that physicians observe in heart failure patients is believed to be mediated, at least in part, by activation of a subtle interaction between heart function and kidney function, known as the renin-angiotensin system. Disturbances in the heart's pumping function results in decreased cardiac output and diminished blood flow. The kidneys respond to the diminished blood flow as though the total blood volume was decreased, when in fact the measured volume is normal or even increased. This leads to fluid retention by the kidneys and formation of edema, thereby causing the fluid overload and increased stress on the heart.
Systemically, CHF is associated with an abnormally elevated peripheral vascular resistance and is dominated by alterations of the circulation resulting from an intense disturbance of sympathetic nervous system function. Increased activity of the sympathetic nervous system promotes a downward vicious cycle of increased arterial vasoconstriction (increased resistance of vessels to blood flow) followed by a further reduction of cardiac output, causing even more diminished blood flow to the vital organs.
In CHF via the previously explained mechanism of vasoconstriction, the heart and circulatory system dramatically reduce blood flow to the kidneys. During CHF, the kidneys receive a command from higher neural centers via neural pathways and hormonal messengers to retain fluid and sodium in the body. In response to stress on the heart, the neural centers command the kidneys to reduce their filtering functions. While in the short term, these commands can be beneficial, if these commands continue over hours and days they can jeopardize the person's life or make the person dependent on artificial kidney for life by causing the kidneys to cease functioning.
When the kidneys do not fully filter the blood, a huge amount of fluid is retained in the body, which results in bloating (fluid retention in tissues) and increases the workload of the heart. Fluid can penetrate into the lungs, and the patient becomes short of breath. This odd and self-destructive phenomenon is most likely explained by the effects of normal compensatory mechanisms of the body that improperly perceive the chronically low blood pressure of CHF as a sign of temporary disturbance, such as bleeding.
In an acute situation, the body tries to protect its most vital organs, the brain and the heart, from the hazards of oxygen deprivation. Commands are issued via neural and hormonal pathways and messengers. These commands are directed toward the goal of maintaining blood pressure to the brain and heart, which are treated by the body as the most vital organs. The brain and heart cannot sustain low perfusion for any substantial period of time. A stroke or a cardiac arrest will result if the blood pressure to these organs is reduced to unacceptable levels. Other organs, such as the kidneys, can withstand somewhat longer periods of ischemia without suffering long-term damage. Accordingly, the body sacrifices blood supply to these other organs in favor of the brain and the heart.
The hemodynamic impairment resulting from CHF activates several neurohormonal systems, such as the renin-angiotensin and aldosterone system, sympatho-adrenal system and vasopressin release. As the kidneys suffer from increased renal vasoconstriction, the GFR drops, and the sodium load in the circulatory system increases. Simultaneously, more renin is liberated from the juxtaglomerular of the kidney. The combined effects of reduced kidney functioning include reduced glomerular sodium load, an aldosterone-mediated increase in tubular reabsorption of sodium, and retention in the body of sodium and water. These effects lead to several signs and symptoms of the CHF condition, including an enlarged heart, increased systolic wall stress, an increased myocardial oxygen demand, and the formation of edema on the basis of fluid and sodium retention in the kidney. Accordingly, sustained reduction in renal blood flow and vasoconstriction is directly responsible for causing the fluid retention associated with CHF.
CHF is progressive, and as of now, not curable. The limitations of drug therapy and its inability to reverse or even arrest the deterioration of CHF patients are clear. Surgical therapies are effective in some cases, but limited to the end-stage patient population because of the associated risk and cost. Furthermore, the dramatic role played by kidneys in the deterioration of CHF patients is not adequately addressed by current surgical therapies.
The autonomic nervous system is recognized as an important pathway for control signals that are responsible for the regulation of body functions critical for maintaining vascular fluid balance and blood pressure. The autonomic nervous system conducts information in the form of signals from the body's biologic sensors such as baroreceptors (responding to pressure and volume of blood) and chemoreceptors (responding to chemical composition of blood) to the central nervous system via its sensory fibers. It also conducts command signals from the central nervous system that control the various innervated components of the vascular system via its motor fibers.
Experience with human kidney transplantation provided early evidence of the role of the nervous system in kidney function. It was noted that after transplant, when all the kidney nerves were totally severed, the kidney increased the excretion of water and sodium. This phenomenon was also observed in animals when the renal nerves were cut or chemically destroyed. The phenomenon was called “denervation diuresis” since the denervation acted on a kidney similar to a diuretic medication. Later the “denervation diuresis” was found to be associated with vasodilatation of the renal arterial system that led to increased blood flow through the kidney. This observation was confirmed by the observation in animals that reducing blood pressure supplying the kidneys reversed the “denervation diuresis”.
It was also observed that after several months passed after the transplant surgery in successful cases, the “denervation diuresis” in transplant recipients stopped and the kidney function returned to normal. Originally, it was believed that the “renal diuresis” was a transient phenomenon and that the nerves conducting signals from the central nervous system to the kidney were not essential to kidney function. Later discoveries suggested that the renal nerves had a profound ability to regenerate and that the reversal of “denervation diuresis” could be attributed to the growth of new nerve fibers supplying the kidneys with necessary stimuli.
Another body of research focused on the role of the neural control of secretion of the hormone renin by the kidney. As was discussed previously, renin is a hormone responsible for the “vicious cycle” of vasoconstriction and water and sodium retention in heart failure patients. It was demonstrated that an increase or decrease in renal sympathetic nerve activity produced parallel increases and decreases in the renin secretion rate by the kidney, respectively.
In summary, it is known from clinical experience and the large body of animal research that an increase in renal sympathetic nerve activity leads to vasoconstriction of blood vessels supplying the kidney, decreased renal blood flow, decreased removal of water and sodium from the body, and increased renin secretion. It is also known that reduction of sympathetic renal nerve activity, e.g., via denervation, may reverse these processes.
It has been established in animal models that the heart failure condition results in abnormally high sympathetic stimulation of the kidney. This phenomenon was traced back to the sensory nerves conducting signals from baroreceptors to the central nervous system. Baroreceptors are present in the different locations of the vascular system. Powerful relationships exist between baroreceptors in the carotid arteries (supplying the brain with arterial blood) and sympathetic nervous stimulus to the kidneys. When arterial blood pressure was suddenly reduced in experimental animals with heart failure, sympathetic tone increased. Nevertheless, the normal baroreflex likely is not solely responsible for elevated renal nerve activity in chronic CHF patients. If exposed to a reduced level of arterial pressure for a prolonged time, baroreceptors normally “reset”, i.e., return to a baseline level of activity, until a new disturbance is introduced. Therefore, it is believed that in chronic CHF patients, the components of the autonomic-nervous system responsible for the control of blood pressure and the neural control of the kidney function become abnormal. The exact mechanisms that cause this abnormality are not fully understood, but its effects on the overall condition of the CHF patients are profoundly negative.
End-Stage Renal Disease is another condition at least partially controlled by renal neural activity. There has been a dramatic increase in patients with ESRD due to diabetic nephropathy, chronic glomerulonephritis and uncontrolled hypertension. Chronic Renal Failure slowly progresses to ESRD. CRF represents a critical period in the evolution of ESRD. The signs and symptoms of CRF are initially minor, but over the course of 2-5 years, become progressive and irreversible. While some progress has been made in combating the progression to, and complications of, ESRD, the clinical benefits of existing interventions remain limited.
It has been known for several decades that renal diseases of diverse etiology (hypotension, infection, trauma, autoimmune disease, etc.) can lead to the syndrome of CRF characterized by systemic hypertension, proteinuria (excess protein filtered from the blood into the urine) and a progressive decline in GFR ultimately resulting in ESRD. These observations suggest that CRF progresses via a common pathway of mechanisms and that therapeutic interventions inhibiting this common pathway may be successful in slowing the rate of progression of CRF irrespective of the initiating cause.
To start the vicious cycle of CRF, an initial insult to the kidney causes loss of some nephrons. To maintain normal GFR, there is an activation of compensatory renal and systemic mechanisms resulting in a state of hyperfiltration in the remaining nephrons. Eventually, however, the increasing numbers of nephrons “overworked” and damaged by hyperfiltration are lost. At some point, a sufficient number of nephrons are lost so that normal GFR can no longer be maintained. These pathologic changes of CRF produce worsening systemic hypertension, thus high glomerular pressure and increased hyperfiltration. Increased glomerular hyperfiltration and permeability in CRF pushes an increased amount of protein from the blood, across the glomerulus and into the renal tubules. This protein is directly toxic to the tubules and leads to further loss of nephrons, increasing the rate of progression of CRF. This vicious cycle of CRF continues as the GFR drops with loss of additional nephrons leading to further hyperfiltration and eventually to ESRD requiring dialysis. Clinically, hypertension and excess protein filtration have been shown to be two major determining factors in the rate of progression of CRF to ESRD.
Though previously clinically known, it was not until the 1980s that the physiologic link between hypertension, proteinuria, nephron loss and CRF was identified. In 1990s the role of sympathetic nervous system activity was elucidated. Afferent signals arising from the damaged kidneys due to the activation of mechanoreceptors and chemoreceptors stimulate areas of the brain responsible for blood pressure control. In response, the brain increases sympathetic stimulation on the systemic level, resulting in increased blood pressure primarily through vasoconstriction of blood vessels. When elevated sympathetic stimulation reaches the kidney via the efferent sympathetic nerve fibers, it produces major deleterious effects in two forms. The kidneys are damaged by direct renal toxicity from the release of sympathetic neurotransmitters (such as norepinephrine) in the kidneys independent of the hypertension. Furthermore, secretion of renin that activates Angiotensin II is increased, which increases systemic vasoconstriction and exacerbates hypertension.
Over time, damage to the kidneys leads to a further increase of afferent sympathetic signals from the kidney to the brain. Elevated Angiotensin II further facilitates internal renal release of neurotransmitters. The feedback loop is therefore closed, which accelerates deterioration of the kidneys.
In view of the foregoing, it would be desirable to provide methods and apparatus for the treatment of congestive heart failure, renal disease, hypertension and/or other cardio-renal diseases via renal neuromodulation and/or denervation.
SUMMARY
The present invention provides methods and apparatus for renal neuromodulation (e.g., denervation) using a pulsed electric field (PEF). Several aspects of the invention apply a pulsed electric field to effectuate electroporation and/or electrofusion in renal nerves, other neural fibers that contribute to renal neural function, or other neural features. Several embodiments of the invention are intravascular devices for inducing renal neuromodulation. The apparatus and methods described herein may utilize any suitable electrical signal or field parameters that achieve neuromodulation, including denervation, and/or otherwise create an electroporative and/or electrofusion effect. For example, the electrical signal may incorporate a nanosecond pulsed electric field (nsPEF) and/or a PEF for effectuating electroporation. One specific embodiment comprises applying a first course of PEF electroporation followed by a second course of nsPEF electroporation to induce apoptosis in any cells left intact after the PEF treatment, or vice versa. An alternative embodiment comprises fusing nerve cells by applying a PEF in a manner that is expected to reduce or eliminate the ability of the nerves to conduct electrical impulses. When the methods and apparatus are applied to renal nerves and/or other neural fibers that contribute to renal neural functions, this present inventors believe that urine output will increase and/or blood pressure will be controlled in a manner that will prevent or treat CHF, hypertension, renal system diseases, and other renal anomalies.
Several aspects of particular embodiments can achieve such results by selecting suitable parameters for the PEFs and/or nsPEFs. Pulsed electric field parameters can include, but are not limited to, field strength, pulse width, the shape of the pulse, the number of pulses and/or the interval between pulses (e.g., duty cycle). Suitable field strengths include, for example, strengths of up to about 10,000 V/cm. Suitable pulse widths include, for example, widths of up to about 1 second. Suitable shapes of the pulse waveform include, for example, AC waveforms, sinusoidal waves, cosine waves, combinations of sine and cosine waves, DC waveforms, DC-shifted AC waveforms, RF waveforms, square waves, trapezoidal waves, exponentially-decaying waves, combinations thereof, etc. Suitable numbers of pulses include, for example, at least one pulse. Suitable pulse intervals include, for example, intervals less than about 10 seconds. Any combination of these parameters may be utilized as desired. These parameters are provided for the sake of illustration and should in no way be considered limiting. Additional and alternative waveform parameters will be apparent.
Several embodiments are directed to percutaneous intravascular systems for providing long-lasting denervation to minimize acute myocardial infarct (“AMI”) expansion and for helping to prevent the onset of morphological changes that are affiliated with congestive heart failure. For example, one embodiment of the invention comprises treating a patient for an infarction, e.g., via coronary angioplasty and/or stenting, and performing an intra-arterial pulsed electric field renal denervation procedure under fluoroscopic guidance. Alternatively, PEF therapy could be delivered in a separate session soon after the AMI had been stabilized. Renal neuromodulation also may be used as an adjunctive therapy to renal surgical procedures. In these embodiments, the anticipated increase in urine output and/or control of blood pressure provided by the renal PEF therapy is expected to reduce the load on the heart to inhibit expansion of the infarct and prevent CHF.
Several embodiments of intravascular pulsed electric field systems described herein may denervate or reduce the activity of the renal nervous supply immediately post-infarct, or at any time thereafter, without leaving behind a permanent implant in the patient. These embodiments are expected to increase urine output and/or control blood pressure for a period of several months during which the patient's heart can heal. If it is determined that repeat and/or chronic neuromodulation would be beneficial after this period of healing, renal PEF treatment can be repeated as needed.
In addition to efficaciously treating AMI, several embodiments of systems described herein are also expected to treat CHF, hypertension, renal failure, and other renal or cardio-renal diseases influenced or affected by increased renal sympathetic nervous activity. For example, the systems may be used to treat CHF at any time by advancing the PEF system to a treatment site via a vascular structure and then delivering a PEF therapy to the treatment site. This may, for example, modify a level of fluid offload.
Embodiments of intravascular PEF systems described herein may be used similarly to angioplasty or electrophysiology catheters which are well known in the art. For example, arterial access may be gained through a standard Seldinger Technique, and an arterial sheath optionally may be placed to provide catheter access. A guidewire may be advanced through the vasculature and into the renal artery of the patient, and then an intravascular PEF may be advanced over the guidewire and/or through the sheath into the renal artery. The sheath optionally may be placed before inserting the PEF catheter or advanced along with the PEF catheter such that the sheath partially or completely covers the catheter. Alternatively, the PEF catheter may be advanced directly through the vasculature without the use of a guide wire and/or introduced and advanced into the vasculature without a sheath.
In addition to arterial placement, the PEF system may be placed within a vein. Venous access may, for example, be achieved via a jugular approach. PEF systems may be utilized, for example, within the renal artery, within the renal vein or within both the renal artery and the renal vein to facilitate more complete denervation.
After the PEF catheter is positioned within the vessel at a desired location with respect to the target neurons, it is stabilized within the vessel (e.g., braced against the vessel wall) and energy is delivered to the target nerve or neurons. In one variation, pulsed RF energy is delivered to the target to create a non-thermal nerve block, reduce neural signaling, or otherwise modulate neural activity. Alternatively or additionally, cooling, cryogenic, thermal RF, thermal or non-thermal microwave, focused or unfocused ultrasound, thermal or non-thermal DC, as well as any combination thereof, may be employed to reduce or otherwise control neural signaling.
In still other embodiments of the invention, other non-renal neural structures may be targeted from within arterial or venous conduits in addition to or in lieu of renal neural structures. For instance, a PEF catheter can be navigated through the aorta or the vena cava and brought into apposition with various neural structures to treat other conditions or augment the treatment of renal-cardiac conditions. For example, nerve bodies of the lumbar sympathetic chain may be accessed and modulated, blocked or ablated, etc., in this manner.
Several embodiments of the PEF systems may completely block or denervate the target neural structures, or the PEF systems may otherwise modulate the renal nervous activity. As opposed to a full neural blockade such as denervation, other neuromodulation produces a less-than-complete change in the level of renal nervous activity between the kidney(s) and the rest of the body. Accordingly, varying the pulsed electric field parameters will produce different effects on the nervous activity.
In one embodiment of an intravascular pulsed electric field system, the device includes one or more electrodes that are configured to physically contact a target region of a renal vasculature for delivery of a pulsed electric field. For example, the device can comprise a catheter having an expandable helical section and one or more electrodes at the helical section. The catheter may be positioned in the renal vasculature while in a low profile configuration. The expandable section can then be expanded to contact the inner surface of the vessel wall. Alternatively, the catheter can have one or more expandable helical electrodes. For example, first and second expandable electrodes may be positioned within the vessel at a desired distance from one another to provide an active electrode and a return electrode. The expandable electrodes may comprise shape-memory materials, inflatable balloons, expandable meshes, linkage systems and other types of devices that can expand in a controlled manner. Suitable expandable linkage systems include expandable baskets, having a plurality of shape-memory wires or slotted hypotubes, and/or expandable rings. Additionally, the expandable electrodes may be point contact electrodes arranged along a balloon portion of a catheter.
Other embodiments of pulsed electric field systems include electrodes that do not physically contact the vessel wall. RF energy, both traditional thermal energy and relatively non-thermal pulsed RF, are examples of pulsed electric fields that can be conducted into tissue to be treated from a short distance away from the tissue itself. Other types of pulsed electric fields can also be used in situations in which the electrodes do not physically contact the vessel wall. As such, the pulsed electric fields can be applied directly to the nerve via physical contact between the electrode contacts and the vessel wall or other tissue, or the pulsed electric fields can be applied indirectly to the nerve without physically contacting the electrode contacts with the vessel wall. The term “nerve contact” accordingly includes physical contact of a system element with the nerve and/or tissue proximate to the nerve, and also electrical contact alone without physically contacting the nerve or tissue. To indirectly apply the pulsed electrical field, the device has a centering element configured to position the electrodes in a central region of the vessel or otherwise space the electrodes apart from the vessel wall. The centering element may comprise, for example, a balloon or an expandable basket. One or more electrodes may be positioned on a central shaft of the centering element—either longitudinally aligned with the element or positioned on either side of the element. When utilizing a balloon catheter, the inflated balloon may act as an insulator of increased impedance for orienting or directing a pulsed electric field along a desired electric flow path. As will be apparent, alternative insulators may be utilized.
In another embodiment of the system, a combination apparatus includes an intravascular catheter having a first electrode configured to physically contact the vessel wall and a second electrode configured to be positioned within the vessel but spaced apart from the vessel wall. For example, an expandable helical electrode may be used in combination with a centrally-disposed electrode to provide such a bipolar electrode pair.
In yet another embodiment, a radial position of one or more electrodes relative to a vessel wall may be altered dynamically to focus the pulsed electric field delivered by the electrode(s). In still another variation, the electrodes may be configured for partial or complete passage across the vessel wall. For example, the electrode(s) may be positioned within the renal vein, then passed across the wall of the renal vein into the perivascular space such that they at least partially encircle the renal artery and/or vein prior to delivery of a pulsed electric field.
Bipolar embodiments of the present invention may be configured for dynamic movement or operation relative to a spacing between the active and ground electrodes to achieve treatment over a desired distance, volume or other dimension. For example, a plurality of electrodes may be arranged such that a bipolar pair of electrodes can move longitudinally relative to each other for adjusting the separation distance between the electrodes and/or for altering the location of treatment. One specific embodiment includes a first electrode coupled to a catheter and a moveable second electrode that can move through a lumen of the catheter. In alternative embodiments, a first electrode can be attached to a catheter and a second electrode can be attached to an endoluminally-delivered device such that the first and second electrodes may be repositioned relative to one another to alter a separation distance between the electrodes. Such embodiments may facilitate treatment of a variety of renal vasculature anatomies.
Any of the embodiments of the present invention described herein optionally may be configured for infusing agents into the treatment area before, during or after energy application. The infused agents can be selected to enhance or modify the neuromodulatory effect of the energy application. The agents can also protect or temporarily displace non-target cells, and/or facilitate visualization.
Several embodiments of the present invention may comprise detectors or other elements that facilitate identification of locations for treatment and/or that measure or confirm the success of treatment. For example, the system can be configured to also deliver stimulation waveforms and monitor physiological parameters known to respond to stimulation of the renal nerves. Based on the results of the monitored parameters, the system can determine the location of renal nerves and/or whether denervation has occurred. Detectors for monitoring of such physiological responses include, for example, Doppler elements, thermocouples, pressure sensors, and imaging modalities (e.g., fluoroscopy, intravascular ultrasound, etc.). Alternatively, electroporation may be monitored directly using, for example, Electrical Impedance Tomography (“EIT”) or other electrical impedance measurements. Additional monitoring techniques and elements will be apparent. Such detector(s) may be integrated with the PEF systems or they may be separate elements.
Still other specific embodiments include electrodes configured to align the electric field with the longer dimension of the target cells. For instance, nerve cells tend to be elongate structures with lengths that greatly exceed their lateral dimensions (e.g., diameter). By aligning an electric field so that the directionality of field propagation preferentially affects the longitudinal aspect of the cell rather than the lateral aspect of the cell, it is expected that lower field strengths can to be used to kill or disable target cells. This is expected to conserve the battery life of implantable devices, reduce collateral effects on adjacent structures, and otherwise enhance the ability to modulate the neural activity of target cells.
Other embodiments of the invention are directed to applications in which the longitudinal dimensions of cells in tissues overlying or underlying the nerve are transverse (e.g., orthogonal or otherwise at an angle) with respect to the longitudinal direction of the nerve cells. Another aspect of these embodiments is to align the directionality of the PEF such that the field aligns with the longer dimensions of the target cells and the shorter dimensions of the non-target cells. More specifically, arterial smooth muscle cells are typically elongate cells which surround the arterial circumference in a generally spiraling orientation so that their longer dimensions are circumferential rather than running longitudinally along the artery. Nerves of the renal plexus, on the other hand, run along the outside of the artery generally in the longitudinal direction of the artery. Therefore, applying a PEF which is generally aligned with the longitudinal direction of the artery is expected to preferentially cause electroporation in the target nerve cells without affecting at least some of the non-target arterial smooth muscle cells to the same degree. This may enable preferential denervation of nerve cells (target cells) in the adventitia or periarterial region from an intravascular device without affecting the smooth muscle cells of the vessel to an undesirable extent.
BRIEF DESCRIPTION OF THE DRAWINGS
Several embodiments of the present invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
FIG. 1 is a schematic view illustrating human renal anatomy.
FIG. 2 is a schematic detail view showing the location of the renal nerves relative to the renal artery.
FIGS. 3A and 3B are schematic side- and end-views, respectively, illustrating a direction of electrical current flow for selectively affecting renal nerves.
FIG. 4 is a schematic side-view, partially in section, of an intravascular catheter having a plurality of electrodes in accordance with one embodiment of the invention.
FIG. 5 is a schematic side-view, partially in section, of an intravascular device having a pair of expanding helical electrodes arranged at a desired distance from one another in accordance with another embodiment of the invention.
FIG. 6 is a schematic side-view, partially in section, of an intravascular device having a first electrode on an expandable balloon, and a second electrode on a catheter shaft in accordance with another embodiment of the invention.
FIG. 7 is a schematic side-view, partially in section, of an intravascular device having an expanding first electrode delivered through the lumen of a catheter and a complementary second electrode carried by the catheter in accordance with another embodiment of the invention.
FIG. 8 is a schematic side-view, partially in section, of an intravascular device having an expandable basket and a plurality of electrodes at the basket in accordance with another embodiment of the invention.
FIG. 9 is a schematic detail view of the apparatus of FIG. 8 illustrating one embodiment of the electrodes in accordance with another embodiment of the invention.
FIG. 10 is a schematic side-view, partially in section, of an intravascular device having expandable ring electrodes for contacting the vessel wall and an optional insulation element in accordance with another embodiment of the invention.
FIGS. 11A-11C are schematic detail views of embodiments of different windings for the ring electrodes of FIG. 10 .
FIG. 12 is a schematic side-view, partially in section, of an intravascular device having ring electrodes of FIG. 10 with the windings shown in FIGS. 11A-11C .
FIG. 13 is a schematic side-view, partially in section, of an intravascular device having a ring electrode and a luminally-delivered electrode in accordance with another embodiment of the invention.
FIG. 14 is a schematic side-view, partially in section, of an intravascular device having a balloon catheter and expandable point contact electrodes arranged proximally and distally of the balloon in accordance with another embodiment of the invention.
FIG. 15 is a schematic side-view of an intravascular device having a balloon catheter and electrodes arranged proximally and distally of the balloon in accordance with another embodiment of the invention.
FIGS. 16A and 16B are schematic side-views, partially in section, illustrating stages of a method of using the apparatus of FIG. 15 in accordance with an embodiment of the invention.
FIG. 17 is a schematic side-view of an intravascular device having a balloon catheter and a plurality of dynamically operable electrodes in accordance with another embodiment of the invention.
FIG. 18 is a schematic side-view of an intravascular device having a distal electrode deployed through a lumen of the balloon catheter in accordance with another embodiment of the invention.
FIGS. 19A and 19B are side-views, partially in section, illustrating methods of using the intravascular device shown in FIG. 18 to modulate renal neural activity in patients with various renal vasculatures.
FIG. 20 is a side view, partially in section, illustrating an intravascular device having a plurality of electrodes arranged along the shaft of, and in line with, a centering element in accordance with another embodiment of the invention.
FIG. 21 is a side-view, partially in section, illustrating an intravascular device having electrodes configured for dynamic radial repositioning to facilitate focusing of a pulsed electric field in accordance with another embodiment of the invention.
FIG. 22 is a side-view, partially in section, of an intravascular device having an infusion/aspiration catheter in accordance with another embodiment of the invention.
FIGS. 23A-23C are, respectively, a side-view, partially in section, and cross-sectional views along section line A-A of FIG. 23A , illustrating a method of using an intravascular device in accordance with an embodiment of the invention configured for passage of electrode(s) at least partially across the vessel wall.
FIGS. 24A and 24B are side-views, partially in section, illustrating an intravascular device having detectors for measuring or monitoring treatment efficacy in accordance with another embodiment of the invention.
DETAILED DESCRIPTION
A. Overview
The present invention relates to methods and apparatus for renal neuromodulation and/or other neuromodulation. More particularly, the present invention relates to methods and apparatus for renal neuromodulation using a pulsed electric field to effectuate electroporation or electrofusion. As used herein, electroporation and electropermeabilization are methods of manipulating the cell membrane or intracellular apparatus. For example, short high-energy pulses cause pores to open in cell membranes. The extent of porosity in the cell membrane (e.g., size and number of pores) and the duration of the pores (e.g., temporary or permanent) are a function of the field strength, pulse width, duty cycle, field orientation, cell type and other parameters. In general, pores will generally close spontaneously upon termination of lower strength fields or shorter pulse widths (herein defined as “reversible electroporation”). Each cell type has a critical threshold above which pores do not close such that pore formation is no longer reversible; this result is defined as “irreversible electroporation,” “irreversible breakdown” or “irreversible damage.” At this point, the cell membrane ruptures and/or irreversible chemical imbalances caused by the high porosity occur. Such high porosity can be the result of a single large hole and/or a plurality of smaller holes. Certain types of electroporation energy parameters also appropriate for use in renal neuromodulation are high voltage pulses with a duration in the sub-microsecond range (nanosecond pulsed electric fields, or nsPEF) which may leave the cellular membrane intact, but alter the intracellular apparatus or function of the cell in ways which cause cell death or disruption. Certain applications of nsPEF have been shown to cause cell death by inducing apoptosis, or programmed cell death, rather than acute cell death. Also, the term “comprising” is used throughout to mean including at least the recited feature such that any greater number of the same feature and/or additional types features are not precluded.
Several embodiments of the present invention provide intravascular devices for inducing renal neuromodulation, such as a temporary change in target nerves that dissipates over time, continuous control over neural function, and/or denervation. The apparatus and methods described herein may utilize any suitable electrical signal or field parameters, e.g., any electric field, that will achieve the desired neuromodulation (e.g., electroporative effect). To better understand the structures of the intravascular devices and the methods of using these devices for neuromodulation, it is useful to understand the renal anatomy in humans.
B. Selected Embodiments of Methods for Neuromodulation
With reference now to FIG. 1 , the human renal anatomy includes kidneys K that are supplied with oxygenated blood by renal arteries RA, which are connected to the heart by the abdominal aorta AA. Deoxygenated blood flows from the kidneys to the heart via renal veins RV and the inferior vena cava IVC. FIG. 2 illustrates a portion of the renal anatomy in greater detail. More specifically, the renal anatomy also includes renal nerves RN extending longitudinally along the lengthwise dimension L of renal artery RA generally within the adventitia of the artery. The renal artery RA has smooth muscle cells SMC that surround the arterial circumference spiral around the angular axis θ of the artery, i.e., around the circumference of the artery. The smooth muscle cells of the renal artery accordingly have a lengthwise or longer dimension extending transverse (i.e., non-parallel) to the lengthwise dimension of the renal artery. The misalignment of the lengthwise dimensions of the renal nerves and the smooth muscle cells is defined as “cellular misalignment.”
Referring to FIGS. 3A and 3B , the cellular misalignment of the renal nerves and the smooth muscle cells may be exploited to selectively affect renal nerve cells with reduced effect on smooth muscle cells. More specifically, because larger cells require less energy to exceed the irreversibility threshold of electroporation, several embodiments of electrodes of the present invention are configured to align at least a portion of an electric field generated by the electrodes with or near the longer dimensions of the cells to be affected. In specific embodiments, the intravascular device has electrodes configured to create an electrical field aligned with or near the lengthwise dimension of the renal artery RA to affect renal nerves RN. By aligning an electric field so that the field preferentially affects the lengthwise aspect of the cell rather than the diametric or radial aspect of the cell, lower field strengths may be used to necrose cells. As mentioned above, this is expected to reduce power consumption and mitigate effects on non-target cells in the electric field.
Similarly, the lengthwise or longer dimensions of tissues overlying or underlying the target nerve are orthogonal or otherwise off-axis (e.g., transverse) with respect to the longer dimensions of the nerve cells. Thus, in addition to aligning the PEF with the lengthwise or longer dimensions of the target cells, the PEF may propagate along the lateral or shorter dimensions of the non-target cells (i.e. such that the PEF propagates at least partially out of alignment with non-target smooth muscle cells SMC). Therefore, as seen in FIGS. 3A and 3B , applying a PEF with propagation lines Li generally aligned with the longitudinal dimension L of the renal artery RA is expected to preferentially cause electroporation, electrofusion, denervation or other neuromodulation in cells of the target renal nerves RN without unduly affecting the non-target arterial smooth muscle cells SMC. The pulsed electric field may propagate in a single plane along the longitudinal axis of the renal artery, or may propagate in the longitudinal direction along any angular segment θ through a range of 0°-360°.
Embodiments of the method shown in FIGS. 3A and 3B may have particular application with the intravascular methods and apparatus of the present invention. For instance, a PEF catheter placed within the renal artery may propagate an electric field having a longitudinal portion that is aligned to run with the longitudinal dimension of the artery in the region of the renal nerves RN and the smooth muscle cell SMC of the vessel wall so that the wall of the artery remains at least substantially intact while the outer nerve cells are destroyed.
C. Embodiments of Systems and Additional Methods for Neuromodulation
FIG. 4 shows one embodiment of an intravascular pulsed electric field apparatus 200 in accordance with the present invention that includes one or more electrodes configured to physically contact a target region within the renal vasculature and deliver a pulsed electric field across a wall of the vasculature. The apparatus 200 is shown within a patient's renal artery RA, but it can be positioned in other intravascular locations (e.g., the renal vein). This embodiment of the apparatus 200 comprises an intravascular catheter 210 having a proximal section 211 a , a distal section 211 b , and a plurality of distal electrodes 212 at the distal section 211 b , The proximal section 211 a generally has an electrical connector to couple the catheter 210 to a pulse generator, and the distal section 211 b in this embodiment has a helical configuration. The apparatus 200 is electrically coupled to a pulsed electric field generator 100 located proximal and external to the patient; the electrodes 212 are electrically coupled to the generator via catheter 210 . The generator 100 may be utilized with any embodiment of the present invention described hereinafter for delivery of a PEF with desired field parameters. It should be understood that electrodes of embodiments described hereinafter may be connected to the generator, even if the generator is not explicitly shown or described with each variation.
The helical distal section 211 b of catheter 210 is configured to appose the vessel wall and bring electrodes 212 into close proximity to extra-vascular neural structures. The pitch of the helix can be varied to provide a longer treatment zone, or to minimize circumferential overlap of adjacent treatments zones in order to reduce a risk of stenosis formation. This pitch change can be achieved by combining a plurality of catheters of different pitches to form catheter 210 , or by adjusting the pitch of catheter 210 through the use of internal pull wires, adjusting mandrels inserted into the catheter, shaping sheaths placed over the catheter, or by any other suitable means for changing the pitch either in-situ or before introduction into the body.
The electrodes 212 along the length of the pitch can be individual electrodes, a common but segmented electrode, or a common and continuous electrode. A common and continuous electrode may, for example, comprise a conductive coil formed into or placed over the helical portion of catheter 210 . A common but segmented electrode may, for example, be formed by providing a slotted tube fitted onto or into the helical portion of the catheter, or by electrically connecting a series of individual electrodes.
Individual electrodes or groups of electrodes 212 may be configured to provide a bipolar signal, or all or a subset of the electrodes may be used together in conjunction with a separate external patient ground for monopolar use (the ground pad may, for example, be placed on the patient's leg). Electrodes 212 may be dynamically assignable to facilitate monopolar and/or bipolar energy delivery between any of the electrodes and/or between any of the electrodes and an external ground.
Catheter 210 may be delivered to renal artery RA in a low profile delivery configuration within sheath 150 . Once positioned within the artery, the catheter may self-expand or may be expanded actively, e.g., via a pull wire or a balloon, into contact with an interior wall of the artery. A pulsed electric field then may be generated by the PEF generator 100 , transferred through catheter 210 to electrodes 212 , and delivered via the electrodes 212 across the wall of the artery. In many applications, the electrodes are arranged so that the pulsed electric field is aligned with the longitudinal dimension of the artery to modulate the neural activity along the renal nerves (e.g., denervation). This may be achieved, for example, via irreversible electroporation, electrofusion and/or inducement of apoptosis in the nerve cells.
FIG. 5 illustrates an apparatus 220 for neural modulation in accordance with another embodiment of the invention. The apparatus 220 includes a pair of catheters 222 a and 222 b having expandable distal sections 223 a and 223 b with helical electrodes 224 a and 224 b , respectively. The helical electrodes 224 a and 224 b are spaced apart from each other by a desired distance within a patient's renal vasculature. Electrodes 224 a - b may be actuated in a bipolar fashion such that one electrode is an active electrode and the other is a return electrode. The distance between the electrodes may be altered as desired to change the field strength and/or the length of nerve segment modulated by the electrodes. The expandable helical electrodes may comprise shape-memory properties that facilitate self-expansion, e.g., after passage through sheath 150 , or the electrodes may be actively expanded into contact with the vessel wall, e.g., via an inflatable balloon or via pull wires, etc. The catheters 222 a - b preferably are electrically insulated in areas other than the distal helices of electrodes 224 a - b.
FIG. 6 illustrates an apparatus 230 comprising a balloon catheter 232 having expandable balloon 234 , a helical electrode 236 arranged about the balloon 234 , and a shaft electrode 238 on the shaft of catheter 232 . The shaft electrode 238 can be located proximal of expandable balloon 234 as shown, or the shaft electrode 238 can be located distal of the expandable balloon 234 .
When the apparatus 230 is delivered to a target vessel, e.g., within renal artery RA, the expandable balloon 234 and the helical electrode 236 are arranged in a low profile delivery configuration. As seen in FIG. 6 , once the apparatus has been positioned as desired, expandable balloon 234 may be inflated to drive the helical electrode 236 into physical contact with the wall of the vessel. In this embodiment, the shaft electrode 238 does not physically contact the vessel wall.
It is well known in the art of both traditional thermal RF energy delivery and of relatively non-thermal pulsed RF energy delivery that energy may be conducted to tissue to be treated from a short distance away from the tissue itself. Thus, it may be appreciated that “nerve contact” comprises both physical contact of a system element with a nerve, as well as electrical contact alone without physical contact, or a combination of the two. A centering element optionally may be provided to place electrodes in a central region of the vessel. The centering element may comprise, for example, an expandable balloon, such as balloon 234 of apparatus 230 , or an expandable basket as described hereinafter. One or more electrodes may be positioned on a central shaft of the centering element—either longitudinally aligned with the element or positioned on one or both sides of the element—as is shaft electrode 238 of apparatus 230 . When utilizing a balloon catheter such as catheter 232 , the inflated balloon may act as an insulator of increased impedance for directing a pulsed electric field along a desired electric flow path. As will be apparent, alternative insulators may be utilized.
As seen in FIG. 6 , when the helical electrode 236 physically contacts the wall of renal artery RA, the generator 100 may generate a PEF such that current passes between the helical electrode 236 and the shaft electrode 238 in a bipolar fashion. The PEF travels between the electrodes along lines Li that generally extend along the longitudinal dimension of the artery. The balloon 234 locally insulates and/or increases the impedance within the patient's vessel such that the PEF travels through the wall of the vessel between the helical and shaft electrodes. This focuses the energy to enhance denervation and/or other neuromodulation of the patient's renal nerves, e.g., via irreversible electroporation.
FIG. 7 illustrates an apparatus 240 similar to those shown in FIGS. 4-6 in accordance with another embodiment of the invention. The apparatus 240 comprises a balloon catheter 242 having an expandable balloon 244 and a shaft electrode 246 located proximal of the expandable balloon 244 . The apparatus 240 further comprises an expandable helical electrode 248 configured for delivery through a guidewire lumen 243 of the catheter 242 . The helical electrode 248 shown in FIG. 7 is self-expanding.
As seen in FIG. 7 , after positioning the catheter 242 in a target vessel (e.g. renal artery RA), the balloon 244 is inflated until it contacts the wall of the vessel to hold the shaft electrode 246 at a desired location within the vessel and to insulate or increase the impedance of the interior of the vessel. The balloon 244 is generally configured to also center the shaft electrode 246 within the vessel or otherwise space the shaft electrode apart from the vessel wall by a desired distance. After inflating the balloon 244 , the helical electrode 248 is pushed through lumen 243 until the helical electrode 248 extends beyond the catheter shaft; the electrode 248 then expands or otherwise moves into the helical configuration to physically contact the vessel wall. A bipolar pulsed electric field may then be delivered between the helical electrode 248 and the shaft electrode 246 along lines Li. For example, the helical electrode 248 may comprise the active electrode and the shaft electrode 246 may comprise the return electrode, or vice versa.
With reference now to FIG. 8 , apparatus comprising an expandable basket having a plurality of electrodes that may be expanded into contact with the vessel wall is described. Apparatus 250 comprises catheter 252 having expandable distal basket 254 formed from a plurality of circumferential struts or members. A plurality of electrodes 256 are formed along the members of basket 254 . Each member of the basket illustratively comprises a bipolar electrode pair configured to contact a wall of renal artery RA or another desired blood vessel.
Basket 254 may be fabricated, for example, from a plurality of shape-memory wires or ribbons, such as Nitinol, spring steel or elgiloy wires or ribbons, that form basket members 253 . When the basket members comprise ribbons, the ribbons may be moved such that a surface area contacting the vessel wall is increased. Basket members 253 are coupled to catheter 252 at proximal and distal connections 255 a and 255 b , respectively. In such a configuration, the basket may be collapsed for delivery within sheath 150 , and may self-expand into contact with the wall of the artery upon removal from the sheath. Proximal and/or distal connection 255 a and 255 b optionally may be configured to translate along the shaft of catheter 252 for a specified or unspecified distance in order to facilitate expansion and collapse of the basket.
Basket 254 alternatively may be formed from a slotted and/or laser-cut hypotube. In such a configuration, catheter 252 may, for example, comprise inner and outer shafts that are moveable relative to one another. Distal connection 255 b of basket 254 may be coupled to the inner shaft and proximal connection 255 a of the basket may be coupled to the outer shaft. Basket 254 may be expanded from a collapsed delivery configuration to the deployed configuration of FIG. 8 by approximating the inner and outer shafts of catheter 252 , thereby approximating the proximal and distal connections 255 a and 255 b of the basket and expanding the basket. Likewise, the basket may be collapsed by separating the inner and outer shafts of the catheter.
As seen in FIG. 9 , individual electrodes may be arranged along a basket strut or member 253 . In one embodiment, the strut is formed from a conductive material coated with a dielectric material, and the electrodes 256 may be formed by removing regions of the dielectric coating. The insulation optionally may be removed only along a radially outer surface of the member such that electrodes 256 remain insulated on their radially interior surfaces; it is expected that this will direct the current flow outward into the vessel wall.
In addition, or as an alternative, to the fabrication technique of FIG. 9 , the electrodes may be affixed to the inside surface, outside surface or embedded within the struts or members of basket 254 . The electrodes placed along each strut or member may comprise individual electrodes, a common but segmented electrode, or a common and continuous electrode. Individual electrodes or groups of electrodes may be configured to provide a bipolar signal, or all or a subset of the electrodes may be actuated together in conjunction with an external patient ground for monopolar use.
One advantage of having electrodes 256 contact the vessel wall as shown in the embodiment of FIG. 8 is that it may reduce the need for an insulating element, such as an expandable balloon, to achieve renal denervation or other neuromodulation. However, it should be understood that such an insulating element may be provided and, for example, expanded within the basket. Furthermore, having the electrodes contact the wall may provide improved field geometry, i.e., may provide an electric field more aligned with the longitudinal axis of the vessel. Such contacting electrodes also may facilitate stimulation of the renal nerves before, during or after neuromodulation to better position the catheter 252 before treatment or for monitoring the effectiveness of treatment.
In a variation of apparatus 250 , electrodes 256 may be disposed along the central shaft of catheter 252 , and basket 254 may simply center the electrodes within the vessel to facilitate more precise delivery of energy across the vessel wall. This configuration may be well suited to precise targeting of vascular or extra-vascular tissue, such as the renal nerves surrounding the renal artery. Correctly sizing the basket or other centering element to the artery provides a known distance between the centered electrodes and the arterial wall that may be utilized to direct and/or focus the electric field as desired. This configuration may be utilized in high-intensity focused ultrasound or microwave applications, but also may be adapted for use with any other energy modality as desired.
Referring now to FIG. 10 , it is expected that electrodes forming a circumferential contact with the wall of the renal artery may provide for more complete renal denervation or renal neuromodulation. In FIG. 10 , a variation of the present invention comprising ring electrodes is described. Apparatus 260 comprises catheter 262 having expandable ring electrodes 264 a and 264 b configured to contact the wall of the vessel. The electrodes may be attached to the shaft of catheter 262 via struts 266 , and catheter 262 may be configured for delivery to renal artery RA through sheath 150 in a low profile configuration. Struts 266 may be self-expanding or may be actively or mechanically expanded. Catheter 262 comprises guidewire lumen 263 for advancement over a guidewire. Catheter 262 also comprises optional inflatable balloon 268 that may act as an insulating element of increased impedance for preferentially directing current flow that is traveling between electrodes 264 a and 264 b across the wall of the artery.
FIGS. 11A-11C illustrate various embodiments of windings for ring electrodes 264 . As shown, the ring electrodes may, for example, be wound in a coil ( FIG. 11A ), a zigzag ( FIG. 11B ) or a serpentine configuration ( FIG. 11C ). The periodicity of the winding may be specified, as desired. Furthermore, the type of winding, the periodicity, etc., may vary along the circumference of the electrodes.
With reference to FIG. 12 , a variation of apparatus 260 is described comprising ring electrodes 264 a ′ and 264 b ′ having a sinusoidal winding in one embodiment of the serpentine winding shown in FIG. 11C . Struts 266 illustratively are attached to apexes of the sinusoid. The winding of electrodes 264 a ′ and 264 b ′ may provide for greater contact area along the vessel wall than do electrodes 264 a and 264 b , while still facilitating sheathing of apparatus 260 within sheath 150 for delivery and retrieval.
FIG. 13 illustrates another variation of apparatus 260 comprising a proximal ring electrode 264 a , and further comprising a distal electrode 270 delivered through guidewire lumen 263 of catheter 262 . The distal electrode 270 is non-expanding and is centered within the vessel via catheter 262 . The distal electrode 270 may be a standard guide wire which is connected to the pulsed electric field generator and used as an electrode. However, it should be understood that electrode 270 alternatively may be configured for expansion into contact with the vessel wall, e.g., may comprise a ring or helical electrode.
Delivering the distal electrode through the lumen of catheter 262 may reduce a delivery profile of apparatus 260 and/or may improve flexibility of the device. Furthermore, delivery of the distal electrode through the guidewire lumen may serve as a safety feature that ensures that the medical practitioner removes any guidewire disposed within lumen 263 prior to delivery of a PEF. It also allows for customization of treatment length, as well as for treatment in side branches, as described hereinafter.
Ring electrodes 264 a and 264 b and 264 a ′ and 264 b ′ optionally may be electrically insulated along their radially inner surfaces, while their radially outer surfaces that contact the vessel wall are exposed. This may reduce a risk of thrombus formation and also may improve or enhance the directionality of the electric field along the longitudinal axis of the vessel. This also may facilitate a reduction of field voltage necessary to disrupt neural fibers. Materials utilized to at least partially insulate the ring electrodes may comprise, for example, PTFE, ePTFE, FEP, chronoprene, silicone, urethane, Pebax, etc. With reference to FIG. 14 , another variation of apparatus 260 is described, wherein the ring electrodes have been replaced with point electrodes 272 disposed at the ends of struts 266 . The point electrodes may be collapsed with struts 266 for delivery through sheath 150 and may self-expand with the struts into contact with the vessel wall. In FIG. 14 , catheter 262 illustratively comprises four point electrodes 272 on either side of balloon 268 . However, it should be understood that any desired number of struts and point electrodes may be provided around the circumference of catheter 262 .
In FIG. 14 , apparatus 260 illustratively comprises four struts 266 and four point electrodes 272 on either side of balloon 268 . By utilizing all of the distally disposed electrodes 272 b as active electrodes and all proximal electrodes 272 a as return electrodes, or vice versa, lines Li along which the electric field propagates may be aligned with the longitudinal axis of a vessel. A degree of line Li overlap along the rotational axis of the vessel may be specified by specifying the angular placement and density of point electrodes 272 about the circumference of the catheter, as well as by specifying parameters of the PEF.
With reference now to FIG. 15 , another variation of an intravascular PEF catheter is described. Apparatus 280 comprises catheter 282 having optional inflatable balloon or centering element 284 , shaft electrodes 286 a and 286 b disposed along the shaft of the catheter on either side of the balloon, as well as optional radiopaque markers 288 disposed along the shaft of the catheter, illustratively in line with the balloon. Balloon 284 serves as both a centering element for electrodes 286 and as an electrical insulator for directing the electric field, as described previously.
Apparatus 280 may be particularly well-suited for achieving precise targeting of desired arterial or extra-arterial tissue, since properly sizing balloon 284 to the target artery sets a known distance between centered electrodes 286 and the arterial wall that may be utilized when specifying parameters of the PEF. Electrodes 286 alternatively may be attached to balloon 284 rather than to the central shaft of catheter 282 such that they contact the wall of the artery. In such a variation, the electrodes may be affixed to the inside surface, outside surface or embedded within the wall of the balloon.
Electrodes 286 arranged along the length of catheter 282 can be individual electrodes, a common but segmented electrode, or a common and continuous electrode. Furthermore, electrodes 286 may be configured to provide a bipolar signal, or electrodes 286 may be used together or individually in conjunction with a separate patient ground for monopolar use.
Referring now to FIGS. 16A and 16B , a method of using apparatus 280 to achieve renal denervation is described. As seen in FIG. 16A , catheter 282 may be disposed at a desired location within renal artery RA, balloon or centering element 284 may be expanded to center electrodes 286 a and 286 b and to optionally provide electrical insulation, and a PEF may be delivered, e.g., in a bipolar fashion between the proximal and distal electrodes 286 a and 286 b . It is expected that the PEF will achieve renal denervation and/or neuromodulation along treatment zone one T 1 . If it is desired to modulate neural activity in other parts of the renal artery, balloon 284 may be at least partially deflated, and the catheter may be positioned at a second desired treatment zone T 2 , as in FIG. 16B . The medical practitioner optionally may utilize fluoroscopic imaging of radiopaque markers 288 to orient catheter 282 at desired locations for treatment. For example, the medical practitioner may use the markers to ensure a region of overlap O between treatment zones T 1 and T 2 , as shown.
With reference to FIG. 17 , a variation of apparatus 280 is described comprising a plurality of dynamically controllable electrodes 286 a and 286 b disposed on the proximal side of balloon 284 . In one variation, any one of proximal electrodes 286 a may be energized in a bipolar fashion with distal electrode 286 b to provide dynamic control of the longitudinal distance between the active and return electrodes. This alters the size and shape of the zone of treatment. In another variation, any subset of proximal electrodes 286 a may be energized together as the active or return electrodes of a bipolar electric field established between the proximal electrodes and distal electrode 286 b.
Although the apparatus 280 shown in FIG. 17 has three proximal electrodes 286 a 1 , 286 a 2 and 286 a 3 , it should be understood that the apparatus 280 can have any alternative number of proximal electrodes. Furthermore, the apparatus 280 can have a plurality of distal electrodes 286 b in addition, or as an alternative, to multiple proximal electrodes. Additionally, one electrode of a pair may be coupled to the catheter 282 , and the other electrode may be delivered through a lumen of the catheter, e.g., through a guidewire lumen. The catheter and endoluminally-delivered electrode may be repositioned relative to one another to alter a separation distance between the electrodes. Such a variation also may facilitate treatment of a variety of renal vasculature anatomies.
In the variations of apparatus 280 described thus far, distal electrode 286 b is coupled to the shaft of catheter 282 distal of balloon 284 . The distal electrode may utilize a lumen within catheter 282 , e.g., for routing of a lead wire that acts as ground. Additionally, the portion of catheter 282 distal of balloon 284 is long enough to accommodate the distal electrode.
Catheters commonly are delivered over metallic and/or conductive guidewires. In many interventional therapies involving catheters, guidewires are not removed during treatment. As apparatus 280 is configured for delivery of a pulsed electric field, if the guidewire is not removed, there may be a risk of electric shock to anyone in contact with the guidewire during energy delivery. This risk may be reduced by using polymer-coated guidewires.
With reference to FIG. 18 , another variation of apparatus 280 is described wherein distal electrode 286 b of FIGS. 16 and 17 has been replaced with a distal electrode 270 configured to be moved through a lumen of the catheter as described previously with respect to FIG. 13 . As will be apparent, proximal electrode 286 a alternatively may be replaced with the luminally-delivered electrode, such that electrodes 286 b and 270 form a bipolar electrode pair. Electrode 270 does not utilize an additional lumen within catheter 282 , which may reduce profile. Additionally, the length of the catheter distal of the balloon need not account for the length of the distal electrode, which may enhance flexibility. Furthermore, the guidewire must be exchanged for electrode 270 prior to treatment, which reduces a risk of inadvertent electrical shock. In one variation, electrode 270 optionally may be used as the guidewire over which catheter 282 is advanced into position prior to delivery of the PEF, thereby obviating a need for exchange of the guidewire for the electrode. Alternatively, a standard metallic guidewire may be used as the electrode 270 simply by connecting the standard guidewire to the pulsed electric field generator. The distal electrode 270 may be extended any desired distance beyond the distal end of catheter 282 . This may provide for dynamic alteration of the length of a treatment zone. Furthermore, this might facilitate treatment within distal vasculature of reduced diameter.
With reference to FIGS. 19A and 19B , it might be desirable to perform treatments within one or more vascular branches that extend from a main vessel, for example, to perform treatments within the branches of the renal artery in the vicinity of the renal hilum. Furthermore, it might be desirable to perform treatments within abnormal or less common branchings of the renal vasculature, which are observed in a minority of patients. As seen in FIG. 19A , distal electrode 270 may be placed in such a branch of renal artery RA, while catheter 282 is positioned within the main branch of the artery. As seen in FIG. 19B , multiple distal electrodes 270 might be provided and placed in various common or uncommon branches of the renal artery, while the catheter remains in the main arterial branch.
Referring to FIG. 20 , yet another variation of an intravascular PEF catheter is described. Apparatus 290 comprises catheter 292 having a plurality of shaft electrodes 294 disposed in line with centering element 296 . Centering element 296 illustratively comprises an expandable basket, such as previously described expandable basket 254 of FIG. 8 . However, it should be understood that the centering element alternatively may comprise a balloon or any other centering element. Electrodes 294 may be utilized in a bipolar or a monopolar fashion.
Referring now to FIG. 21 , another variation of the invention is described comprising electrodes configured for dynamic radial repositioning of one or more of the electrodes relative to a vessel wall, thereby facilitating focusing of a pulsed electric field delivered by the electrodes. Apparatus 300 comprises catheter 302 having electrodes 304 disposed in line with nested expandable elements. The nested expandable elements comprise an inner expandable element 306 and an outer expandable centering element 308 . Electrodes 304 are disposed along the inner expandable element, while the outer expandable centering element is configured to center and stabilize catheter 302 within the vessel. Inner element 306 may be expanded to varying degrees, as desired by a medical practitioner, to dynamically alter the radial positions of electrodes 304 . This dynamic radial repositioning may be utilized to focus energy delivered by electrodes 304 such that it is delivered to target tissue.
Nested elements 306 and 308 may comprise a balloon-in-balloon arrangement, a basket-in-basket arrangement, some combination of a balloon and a basket, or any other expandable nested structure. In FIG. 21 , inner expandable element 306 illustratively comprises an expandable basket, while outer expandable centering element 308 illustratively comprises an expandable balloon. Electrodes 302 are positioned along the surface of inner balloon 306 .
Any of the variations of the present invention described herein optionally may be configured for infusion of agents into the treatment area before, during or after energy application, for example, to enhance or modify the neurodestructive or neuromodulatory effect of the energy, to protect or temporarily displace non-target cells, and/or to facilitate visualization. Additional applications for infused agents will be apparent. If desired, uptake of infused agents by cells may be enhanced via initiation of reversible electroporation in the cells in the presence of the infused agents. Infusion may be especially desirable when a balloon centering element is utilized. The infusate may comprise, for example, saline or heparinized saline, protective agents, such as Poloxamer-188, or anti-proliferative agents. Variations of the present invention additionally or alternatively may be configured for aspiration. For example, infusion ports or outlets may be provided on a catheter shaft adjacent a centering device, the centering device may be porous (for instance, a “weeping” balloon), or basket struts may be made of hollow hypotubes and slotted or perforated to allow infusion or aspiration.
With reference to FIG. 22 , a variation of the present invention comprising an infusion/aspiration PEF catheter is described. Apparatus 310 comprises catheter 312 having proximal and distal inflatable balloons 314 a and 314 b , respectively. Proximal shaft electrode 316 a is disposed between the balloons along the shaft of catheter 312 , while distal electrode 316 b is disposed distal of the balloons along the catheter shaft. One or more infusion or aspiration holes 318 are disposed along the shaft of catheter 312 between the balloons in proximity to proximal electrode 316 a.
Apparatus 310 may be used in a variety of ways. In a first method of use, catheter 312 is disposed within the target vessel, such as renal artery RA, at a desired location. One or both balloons 314 are inflated, and a protective agent or other infusate is infused through hole(s) 318 between the balloons in proximity to electrode 316 a . A PEF suitable for initiation of reversible electroporation is delivered across electrodes 316 to facilitate uptake of the infusate by non-target cells within the vessel wall. Delivery of the protective agent may be enhanced by first inflating distal balloon 314 b , then infusing the protective agent, which displaces blood, then inflating proximal balloon 314 a.
Remaining infusate optionally may be aspirated such that it is unavailable during subsequent PEF application when irreversible electroporation of nerve cells is initiated. Aspiration may be achieved by at least partially deflating one balloon during aspiration. Alternatively, aspiration may be achieved with both balloons inflated, for example, by infusing saline in conjunction with the aspiration to flush out the vessel segment between the inflated balloons. Such blood flushing may reduce a risk of clot formation along proximal electrode 316 a during PEF application. Furthermore, flushing during energy application may cool the electrode and/or cells of the wall of the artery. Such cooling of the wall cells might protect the cells from irreversible electroporative damage, possibly reducing a need for infusion of a protective agent.
After infusion and optional aspiration, a PEF suitable for initiation of irreversible electroporation in target nerve cells may be delivered across electrodes 316 to denervate or to modulate neural activity. In an alternative method, infusion of a protective agent may be performed during or after initiation of irreversible electroporation in order to protect non-target cells. The protective agent may, for example, plug or fill pores formed in the non-target cells via the irreversible electroporation.
In another alternative method, a solution of chilled (i.e., less than body temperature) heparinized saline may be simultaneously infused and aspirated between the inflated balloons to flush the region between the balloons and decrease the sensitivity of vessel wall cells to electroporation. This is expected to further protect the cells during application of the PEF suitable for initiation of irreversible electroporation. Such flushing optionally may be continuous throughout application of the pulsed electric field. A thermocouple or other temperature sensor optionally may be positioned between the balloons such that a rate of chilled infusate infusion may be adjusted to maintain a desired temperature. The chilled infusate preferably does not cool the target tissue, e.g., the renal nerves. A protective agent, such as Poloxamer-188, optionally may be infused post-treatment as an added safety measure.
Infusion alternatively may be achieved via a weeping balloon catheter. Further still, a cryoballoon catheter having at least one electrode may be utilized. The cryoballoon may be inflated within a vessel segment to locally reduce the temperature of the vessel segment, for example, to protect the segment and/or to induce thermal apoptosis of the vessel wall during delivery of an electric field. The electric field may, for example, comprise a PEF or a thermal, non-pulsed electric field, such as a thermal RF field.
Referring now to FIGS. 23A , 23 B and 23 C, a variation of a PEF catheter configured for passage of electrode(s) at least partially across the vessel wall is described. For example, the electrode(s) may be positioned within the renal vein and then passed across the wall of the renal vein such that they are disposed in Gerota's or renal fascia and near or at least partially around the renal artery. In this manner, the electrode(s) may be positioned in close proximity to target renal nerve fibers prior to delivery of a pulsed electric field.
As seen in FIG. 23A , apparatus 320 comprises catheter 322 having needle ports 324 and centering element 326 , illustratively an inflatable balloon. Catheter 322 also optionally may comprise radiopaque markers 328 . Needle ports 324 are configured for passage of needles 330 therethrough, while needles 330 are configured for passage of electrodes 340 .
Renal vein RV runs parallel to renal artery RA. An imaging modality, such as intravascular ultrasound, may be used to identify the position of the renal artery relative to the renal vein. For example, intravascular ultrasound elements optionally may be integrated into catheter 322 . Catheter 322 may be positioned within renal vein RV using well-known percutaneous techniques, and centering element 326 may be expanded to stabilize the catheter within the vein. Needles 330 then may be passed through catheter 322 and out through needle ports 324 in a manner whereby the needles penetrate the wall of the renal vein and enter into Gerota's or renal fascia F. Radiopaque markers 328 may be visualized with fluoroscopy to properly orient needle ports 324 prior to deployment of needles 330 .
Electrodes 340 are deployed through needles 330 to at least partially encircle renal artery RA, as in FIGS. 23A and 23B . Continued advancement of the electrodes may further encircle the artery, as in FIG. 23C . With the electrodes deployed, stimulation and/or PEF electroporation waveforms may be applied to denervate or modulate the renal nerves. Needles 330 optionally may be partially or completely retracted prior to treatment such that electrodes 340 encircle a greater portion of the renal artery. Additionally, a single electrode 340 may be provided and/or actuated in order to provide a monopolar PEF.
Infusate optionally may be infused from needles 330 into fascia F to facilitate placement of electrodes 340 by creating a space for placement of the electrodes. The infusate may comprise, for example, fluids, heated or chilled fluids, air, CO 2 , saline, contrast agents, gels, conductive fluids or any other space-occupying material—be it gas, solid or liquid. Heparinized saline also may be injected. Saline or hypertonic saline may enhance conductivity between electrodes 340 . Additionally or alternatively, drugs and/or drug delivery elements may be infused or placed into the fascia through the needles:
After treatment, electrodes 340 may be retracted within needles 330 , and needles 330 may be retracted within catheter 322 via needle ports 324 . Needles 330 preferably are small enough that minimal bleeding occurs and hemostasis is achieved fairly quickly. Balloon centering element 326 optionally may remain inflated for some time after retrieval of needles 330 in order to block blood flow and facilitate the clotting process. Alternatively, a balloon catheter may be advanced into the renal vein and inflated after removal of apparatus 320 .
Referring to FIGS. 24A and 24B , variations of the invention comprising detectors or other elements for measuring or monitoring treatment efficacy are described. Variations of the invention may be configured to deliver stimulation electric fields, in addition to denervating or modulating PEFs. These stimulation fields may be utilized to properly position the apparatus for treatment and/or to monitor the effectiveness of treatment in modulating neural activity. This may be achieved by monitoring the responses of physiologic parameters known to be affected by stimulation of the renal nerves. Such parameters comprise, for example, renin levels, sodium levels, renal blood flow and blood pressure. Stimulation also may be used to challenge the denervation for monitoring of treatment efficacy: upon denervation of the renal nerves, the known physiologic responses to stimulation should no longer occur in response to such stimulation.
Efferent nerve stimulation waveforms may, for example, comprise frequencies of about 1-10 Hz, while afferent nerve stimulation waveforms may, for example, comprise frequencies of up to about 50 Hz. Waveform amplitudes may, for example, range up to about 50V, while pulse durations may, for example, range up to about 20 milliseconds. When the nerve stimulation waveforms are delivered intravascularly, as in several embodiments of the present invention, field parameters such as frequency, amplitude and pulse duration may be modulated to facilitate passage of the waveforms through the wall of the vessel for delivery to target nerves. Furthermore, although exemplary parameters for stimulation waveforms have been described, it should be understood that any alternative parameters may be utilized as desired.
The electrodes used to deliver PEFs in any of the previously described variations of the present invention also may be used to deliver stimulation waveforms to the renal vasculature. Alternatively, the variations may comprise independent electrodes configured for stimulation. As another alternative, a separate stimulation apparatus may be provided.
One way to use stimulation to identify renal nerves is to stimulate the nerves such that renal blood flow is affected—or would be affected if the renal nerves had not been denervated or modulated. Stimulation acts to reduce renal blood flow, and this response may be attenuated or abolished with denervation. Thus, stimulation prior to neural modulation would be expected to reduce blood flow, while stimulation after neural modulation would not be expected to reduce blood flow to the same degree when utilizing similar stimulation parameters and location(s) as prior to neural modulation. This phenomenon may be utilized to quantify an extent of renal neuromodulation. Variations of the present invention may comprise elements for monitoring renal blood flow or for monitoring any of the other physiological parameters known to be affected by renal stimulation.
In FIG. 24A , a variation of apparatus 280 of FIG. 16 is described having an element for monitoring of renal blood flow. Guidewire 350 having Doppler ultrasound sensor 352 has been advanced through the lumen of catheter 282 for monitoring blood flow within renal artery RA. Doppler ultrasound sensor 352 is configured to measure the velocity of flow through the artery. A flow rate then may be calculated according to the formula:
Q=VA (1)
where Q equals flow rate, V equals flow velocity and A equals cross-sectional area. A baseline of renal blood flow may be determined via measurements from sensor 352 prior to delivery of a stimulation waveform, then stimulation may be delivered between electrodes 286 a and 286 b , preferably with balloon 284 deflated. Alteration of renal blood flow from the baseline, or lack thereof, may be monitored with sensor 352 to identify optimal locations for neuromodulation and/or denervation of the renal nerves.
FIG. 24B illustrates a variation of the apparatus of FIG. 24A , wherein Doppler ultrasound sensor 352 is coupled to the shaft of catheter 282 . Sensor 352 illustratively is disposed proximal of balloon 284 , but it should be understood that the sensor alternatively may be disposed distal of the balloon.
In addition or as an alternative to intravascular monitoring of renal blood flow via Doppler ultrasound, such monitoring optionally may be performed from external to the patient whereby renal blood flow is visualized through the skin (e.g., using an ultrasound transducer). In another variation, one or more intravascular pressure transducers may be used to sense local changes in pressure that may be indicative of renal blood flow. As yet another alternative, blood velocity may be determined, for example, via thermodilution by measuring the time lag for an intravascular temperature input to travel between points of known separation distance.
For example, a thermocouple may be incorporated into, or provided in proximity to, each electrode 286 a and 286 b , and chilled (i.e., lower than body temperature) fluid or saline may be infused proximally of the thermocouple(s). A time lag for the temperature decrease to register between the thermocouple(s) may be used to quantify flow characteristic(s). A baseline estimate of the flow characteristic(s) of interest may be determined prior to stimulation of the renal nerves and may be compared with a second estimate of the characteristic(s) determined after stimulation.
Commercially available devices optionally may be utilized to monitor treatment. Such devices include, for example, the SmartWire™, FloWire™ and WaveWire™ devices available from Volcano™ Therapeutics Inc., of Rancho Cordova, Calif., as well as the PressureWire® device available from RADI Medical Systems AB of Uppsala, Sweden. Additional commercially available devices will be apparent. An extent of electroporation additionally or alternatively may be monitored directly using Electrical Impedance Tomography (“EIT”) or other electrical impedance measurements, such as an electrical impedance index.
Although preferred illustrative variations of the present invention are described above, it will be apparent to those skilled in the art that various changes and modifications may be made thereto without departing from the invention. For example, although the variations primarily have been described for use in combination with pulsed electric fields, it should be understood that any other electric field may be delivered as desired. It is intended in the appended claims to cover all such changes and modifications that fall within the true spirit and scope of the invention. | Methods and apparatus are provided for renal neuromodulation using a pulsed electric field to effectuate electroporation or electrofusion. It is expected that renal neuromodulation (e.g., denervation) may, among other things, reduce expansion of an acute myocardial infarction, reduce or prevent the onset of morphological changes that are affiliated with congestive heart failure, and/or be efficacious in the treatment of end stage renal disease. Embodiments of the present invention are configured for percutaneous intravascular delivery of pulsed electric fields to achieve such neuromodulation. | 0 |
BACKGROUND OF THE INVENTION
[0001] The subject matter disclosed herein relates to turbine engines and particularly to methods and apparatus involving shroud cooling in turbine engines.
[0002] The high pressure turbine section of a turbine engine includes rotor blades extending radially from a disk assembly mounted inside a casing. The turbine engine includes a shroud assembly mounted on the circumference of the casing surrounding the rotor blades. The rotor blades and shroud assembly are subjected to a high temperature gas flow that affects the rotation of the rotor blades. The rotor blades include a blade tip at a distal end of a rotor blade. A small gap is defined between the blade tips and the shroud assembly. The small gap is desirable for engine efficiency since gas flow passing through the gap does not efficiently affect the rotation of the rotor blades.
[0003] In practice, the shroud assembly often comprises a number of segments mounted to the casing to form a circumferential shroud assembly. The shroud assembly is subjected to high temperatures and the segments are often cooled with flowing pressurized air. The pressurized air contacts a surface of a shroud segment and may pass through internal passages of the shroud segment and into the gas flow path inside the casing. Once the pressurized air has cooled the shroud segment, the pressurized air entering the gas flow path may undesirably affect the gas flow path by changing a direction of flow. Thus, it is desirable to reduce the amount of pressurized air used to cool the shroud segment and to discharge the pressurized air into the gas flow path in a manner that lessens the effects to the gas flow path.
BRIEF DESCRIPTION OF THE INVENTION
[0004] According to one aspect of the invention, a turbine cooling component comprising, a circumferential leading edge, a circumferential trailing edge spaced from the leading edge, a first side panel connected to the leading and trailing edges, a second side panel connected to the leading and trailing edges, spaced and opposed to the first side panel, an arcuate base connected to the trailing ledge and the leading edge having a fore portion, a midsection portion, an aft portion, an opposed first side portion and second side portion, an outer surface partially defining a cavity operative to receive pressurized air, and an arcuate inner surface in contact with a gas flow path of a turbine engine moving in the direction from the leading edge to the trailing edge of the turbine component, a first side cooling air passage in the base extending along the first side portion from the fore portion to the aft portion, and a fore cooling air passage in the fore portion of the base communicative with the side cooling air passage and the cavity, operative to receive the pressurized air from the cavity.
[0005] According to another aspect of the invention, a method for manufacturing a turbine cooling component comprising, forming a first side cooling air passage in a base of a shroud segment having a circumferential leading edge, a circumferential trailing edge spaced from the leading edge, wherein the first side cooling air passage extends through the circumferential leading edge and the circumferential trailing edge, and forming a fore cooling air passage communicative with the first side cooling air passage, extending through a first side panel of the shroud segment connected to the leading and trailing edges and a second side panel connected to the leading and trailing edges, spaced and opposed to the first side panel.
[0006] According to yet another aspect of the invention, a method for forming a cooling air passage in a component comprising, forming a first portion of an air passage having a first inner diameter in the component with a probe, forming a second portion of the air passage having the first inner diameter in the component communicative with the first portion of the air passage with the probe, and varying a rate of travel of the probe such that the probe increases the inner diameter of the second portion of the air passage to a second inner diameter.
[0007] These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWING
[0008] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0009] FIG. 1 is a side partially-cutaway view of a turbine cooling subassembly in the form of a shroud assembly.
[0010] FIG. 2 is at top partially cut away view of an exemplary embodiment of the shroud segment of FIG. 1 .
[0011] FIG. 3 is at top partially cut away view of an alternate exemplary embodiment of the shroud segment of FIG. 1 .
[0012] FIG. 4 is at top partially cut away view of another alternate exemplary embodiment of the shroud segment of FIG. 1 .
[0013] FIG. 5 is at top partially cut away view of an exemplary method for manufacturing the shroud segment of FIG. 1 .
[0014] FIG. 6 is at front partially cut away view along the line A-A of FIG. 5 .
[0015] FIG. 7 is a top cut away view of a portion of an exemplary profiled inner surface of a passage.
[0016] FIG. 8 is a top cut away view of a portion of an exemplary method of forming the profiled inner surface of the passage of FIG. 7 .
[0017] The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0018] FIG. 1 illustrates a side partially-cutaway view of a turbine cooling subassembly in the form of a shroud assembly generally indicated at 100 disposed in a surrounding relation with turbine blades 112 . The turbine blades 112 are connected to a rotor (not shown) in a high pressure turbine section of a turbine engine. The gas flow path is shown in the direction of the arrows 101 . The shroud cooling assembly 100 includes a shroud having an annular array of arcuate shroud segments. A shroud segment is shown generally at 102 . The shroud segments 102 are held in position by an annular array of arcuate hanger sections. A hanger section is shown generally at 104 . The hanger sections 104 are supported by an engine outer case shown generally at 106 .
[0019] The shroud segment 102 includes a base 108 , a fore rail 110 radially and forwardly extending from the base 108 that defines a circumferential leading edge of the shroud segment 102 , an aft rail 114 that defines a circumferential trailing edge of the shroud segment 102 , and angularly spaced side rails 116 radially outwardly extending from the base 108 . The base 108 partially defines a shroud segment cavity 118 .
[0020] In operation, pressurized air 103 from, for example, the compressor section of the turbine engine enters an upper plenum cavity 120 defined by the hanger section 104 , and enters the shroud segment cavity 118 via holes 122 in the hanger section 104 . The pressurized air 103 in the shroud segment cavity 118 impinges on a radially outer surface 124 of the base 108 . Impingement air 105 cools the base 108 , and enters entrance holes 130 of passages 126 that extend from the outer surface 124 of the base 108 into the base 108 to provide convection cooling of the shroud segment 102 . The impingement air 105 exits the passages 126 via exit holes 128 located in the aft rail 114 of the shroud segment 102 . Once the impingement air 105 has exited the exit holes 128 , the impingement air 105 enters the gas flow path shown by the arrow 101 .
[0021] FIG. 2 illustrates at top partially cut away view of an exemplary embodiment of the shroud segment 102 . The shroud segment 102 includes a fore passage 202 communicative with the shroud segment cavity 118 via the entrance holes 130 . The fore passage 202 is communicative with side passages 204 that include the exit holes 128 . In operation, impingement air 105 (of FIG. 1 ) enters the entrance holes 130 and flows through the fore passage 202 and the side passages 204 , and exits into the gas flow path via the exit holes 128 . The illustrated embodiment includes supplemental pressure holes 206 that may be included to provide additional impingement air 105 to the side passages 204 . The supplemental pressure holes 206 compensate for a loss of impingement air 105 pressure in regions of the side passages 204 that are remote from the entrance holes 130 .
[0022] The location of the fore passage 202 and the side passages 204 increases convection cooling in the fore rail 110 and the side rail 116 regions of the shroud segment 102 . The fore rail 110 and the side rail 116 regions of the shroud segment 102 have been shown through experimentation to become relatively hotter than regions of the base 108 that are below to the shroud segment cavity 118 and are cooled by impingement air 105 that collects and cools the shroud segment cavity 118 .
[0023] Previous embodiments of shroud segments have included vent holes disposed along the side rails 116 , fore rail 110 , and aft rail 114 that receive impingement air 105 from the shroud segment cavity 118 and port the impingement air 105 along outer surfaces of the shroud segment cavity 118 into the gas flow path. The illustrated embodiment of FIG. 2 uses the fore passage 202 and side passages 204 to cool the fore rail 114 and side rail 116 regions and may not include such vent holes. One advantage of omitting the vent holes is that the shroud segment 102 may include a thermal coating along the radially inner surface 132 (of FIG. 1 ). In production, the coating may be applied after the vent holes are fabricated (cast or drilled into the shroud segment 102 ), or applied before the vent holes are fabricated. If the coating is applied after the vent holes are fabricated, the vent holes are covered to prevent the coating from fouling the vent holes. If the coating is applied before fabricating the vent holes, the coating is removed from the area of the vent holes prior to fabrication. Either of these production methods increases the production costs of the shroud segment 102 .
[0024] The increased cooling in the fore rail 114 and the side rail 116 provided by the location of the fore passage 202 and the side passages 204 may provide an opportunity to omit vent holes from the design of the shroud segment 102 , reducing production costs. Other benefits may include reducing the amount of impingement air 105 that exits the shroud segment 102 . The exiting impingement air 105 is often undesirable because the exiting impingement air 105 enters the high pressure section of the turbine engine and may negatively affect the gas flow path, thereby reducing the efficiency of the engine. The impingement air 105 is often ported from the air compressed in the compression section of the turbine engine (bleed air). Bleed air used for cooling is not used for combustion; thus reducing the bleed air used for cooling increases the efficiency of the turbine engine.
[0025] The illustrated embodiment of FIG. 2 is not limited to include two entrance holes 103 and exit holes 128 , but may include any number of entrance holes 130 and exit holes 128 , including a single entrance hole 130 or a plurality of entrance holes 130 , and a single exit hole 128 or a plurality of exit holes 128 .
[0026] FIG. 3 illustrates an alternate exemplary embodiment of the shroud segment 102 . The shroud segment 102 in FIG. 3 is similar to the shroud segment 102 of FIG. 2 and includes an aft passage 208 communicative with the side passages 204 . The aft passage 208 routs impingement air 105 for convection cooling of the aft rail 114 region of the shroud segment 102 .
[0027] FIG. 4 illustrates another alternate exemplary embodiment of the shroud segment 102 . The shroud segment 102 in FIG. 4 is similar to the shroud segment 102 of FIG. 2 and includes a plurality of vent holes 210 communicative with the side passages 204 and the outer surface of the side rails 116 . The vent holes 210 may be used to increase the cooling of the outer surface of the side rails 116 , though the vent holes 210 may increase production costs.
[0028] FIG. 5 illustrates at top partially cut away view of an exemplary method for manufacturing the shroud segment 102 . The fore passage 202 , the side passages 204 , and the aft passage 208 have been formed through the outer surfaces of the fore rail 110 , the side rails 116 , and the aft rail 114 . Once the passages have been drilled the undesirable drill holes may be sealed in the regions 501 . The forming of the passages may be performed using a variety of techniques including, for example, drilling, electrical discharge machining (EDM), and electro chemical machining (ECM).
[0029] FIG. 6 illustrates at front partially cut away view along the line A-A (of FIG. 5 ) of an exemplary method for manufacturing the shroud segment 102 . The radially inner surface 132 of the shroud segment 102 includes an annular profile. The annular profile may make drilling the fore passage 202 difficult. The drilling of the fore passage 202 may be more easily performed by drilling the fore passage 202 from each side rail 116 at an angle theta. For example, the drilling procedure may include drilling a first passage 601 from one of the side rails 116 at an angle theta to a mid point of the shroud segment 102 . A second passage 603 may then be drilled from the opposite side rail 116 at a similar angle with a drill depth that may intersect the first passage 601 approximately at the mid point of the shroud segment 102 . Alternate embodiments may include a first passage 601 and a second passage 603 that do not intersect. The drilling of the fore passage 202 at angles using from opposite side rails 116 accommodates the annular profile. The aft passage 208 (of FIG. 5 ) may be drilled in a similar manner. The side passages 204 may be drilled in one drilling procedure if desired and will intersect portions of the fore passage 202 and the aft passage 208 . Once the passages have been drilled, the portions of the passages that translate through the outer surfaces of the shroud segment may be sealed. The desired entrance holes 130 and exit holes 128 may be drilled in subsequent processes. Though the methods for fabricating the passages described above include drilling, the passages in the shroud segment 102 may be fabricated using other methods including, for example, casting processes.
[0030] An advantage of using a (EDM/ECM) processes for fabricating the passages described above is that the drilling process may be used to create a profiled inner surface of the passages. FIG. 7 illustrates a top, cut away view of a portion of an exemplary profiled inner surface of a passage. The profiled inner surface of the passage may be included as a feature of any of the passages described above, including the fore passage 202 , the aft passage 208 , and the side passage 204 . Referring to FIG. 7 , a passage 701 includes ridges 705 that decrease the inner diameter of the passage 701 . The ridges 705 may improve the convective cooling of the impingement air 105 that flows in the passage 701 , by disrupting the flow of the impingement air 105 (of FIG. 1 ). A desirable effect of the ridges 705 may include creating vortices in the flow of the impingement air 105 that increase the convective cooling effects of the impingement air 105 .
[0031] FIG. 8 illustrates an exemplary method for forming the ridges 705 . A EDM probe 801 is used to drill the passage 701 . While drilling, the probe 801 rotates, and is driven forward in the direction of the arrow 805 into the material 807 to drill the passage 701 . To form the ridges 705 , the forward drive of the probe 801 pauses momentarily while the probe 801 continues material removal in the region 803 increasing the inner diameter of the passage 701 in the region 803 . Pausing the forward drive of the probe 801 along portions of the passage 701 forms the ridges 705 .
[0032] While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims. | A turbine cooling component comprising a circumferential leading edge, a circumferential trailing edge, a pair of spaced and opposed side panels connected to the leading and trailing edges, an arcuate base connected to the trailing and leading edges having a fore portion, a midsection portion, an aft portion, opposed side portions, an outer surface partially defining a cavity operative to receive pressurized air, and an arcuate inner surface in contact with a gas flow path of a turbine engine, a first side cooling air passage in the base extending along the first side portion from the fore portion to the aft portion, and a fore cooling air passage in the fore portion of the base communicative with the side cooling air passage and the cavity, operative to receive the pressurized air from the cavity. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to devices facilitating the use of syringes and needles for injecting medication into a patient, and more specifically relates to a device enabling a single medical practitioner to hold a medication vial and draw medication therefrom with a syringe and needle using only one hand.
BACKGROUND OF THE INVENTION
[0002] Medical procedures performed in doctor offices and hospitals often require the injection of medication into a patient using a syringe and needle. For instance, it is frequently necessary, or at least desirable for the comfort of the patient, to inject a local anesthetic such as lidocaine into a part of the patient's body. It is standard procedure for a doctor or other medical practitioner to put on sterile gloves before touching or working on the patient to reduce the risk of introducing infectious microbes into the patient's body. It is also standard procedure for instruments that will be used upon the patient during a procedure, such as a needle and syringe used for injecting medications, to be sterilized before the procedure and to be laid out upon a sterile tray or the like. Proper protocol in order to preserve the sterile field calls for the doctor not to touch anything outside the sterile field once he or she has donned the sterile gloves and prior to touching the patient or any instrument that will be used on the patient.
[0003] The use of injectable medications complicates preservation of the sterile field because the outer surfaces of medication vials containing injectable medications are generally non-sterile. It is against protocol, therefore, for the medical practitioner to touch a medication vial with his or her gloved hands prior to working on a patient. Consequently, medical practitioners are forced to engage in all sorts of inefficient and/or potentially unsafe tactics simply to draw medication from a medication vial with a needle and syringe. The procedure cannot ordinarily be accomplished with one hand because the vial must be inverted (cap side down) while drawing medication into the syringe in order to prevent air from being drawn into the syringe, and the vial must be restrained to allow the needle to be pulled back out. One method that is commonly used is for the practitioner to call for an assistant to hold the medication vial while the practitioner inserts the needle into the vial and draws medication therefrom. If an assistant is not immediately available, the practitioner may be forced to wait until an assistant is free to come and assist. Thus, valuable time can be wasted, and meanwhile the patient may be in need of pain-relieving or other medication. Furthermore, it is possible for the practitioner to accidentally miss the vial and stick the assistant with the needle, which not only renders the needle non-sterile so that it must be discarded and replaced with a new sterile needle, but is also undesirable for the assistant, needless to say.
[0004] Another procedure that some medical practitioners use is to insert the needle into the vial while the vial is sitting upright on a table or the like, pick the vial up using only the inserted needle and syringe held in one hand, place the vial into the crook of the other arm, and grasp the vial between the upper arm and forearm. The practitioner then raises his or her arm to turn the vial cap side down so that medication can be drawn into the syringe, and then withdraws the needle from the vial. The practitioner then must put the vial back down on a table or other surface, using only his arm to maneuver the vial. If the vial is a multi-dose vial that is to be used again for the same patient, the vial must be set down on the table in an upright position so that the same procedure can be repeated when the practitioner needs to draw additional medication from the vial. It can be very difficult to set a vial down in an upright position using only one's arm holding the vial in the crook of the arm.
[0005] Thus, a need has long existed and continues to exist for a device enabling a medical practitioner to hold and maneuver medication vials and draw medication from the vials with a needle and syringe without having to touch or hold the vials with the hands.
SUMMARY OF THE INVENTION
[0006] The present invention addresses the above needs and achieves other advantages, by providing a wearable vial holder for securing at least one vial of medication on the person of a medical practitioner. The wearable vial holder comprises a body-engaging member structured and arranged to be secured to a part of the body of a medical practitioner, and a vial gripper affixed to the body-engaging member for releasably grasping and holding at least one vial so that the practitioner has access to the vial(s) for one-handed drawing of medication therefrom using a syringe with a needle.
[0007] In a preferred embodiment of the invention, the body-engaging member is configured to wrap securely about an arm of a medical practitioner so that it can be positioned, for example, on the forearm just below the elbow. However, the body-engaging member alternatively can be positioned on other parts of the body. The body-engaging member in preferred embodiments advantageously incorporates one or more elastic elements facilitating a secure, snug fit about the part of the body on which it is positioned, and preferably is also adjustable in size to fit people of varying sizes and proportions.
[0008] A preferred construction of the wearable vial holder employs a two-component releasable fastening system, such as a hook and loop (e.g., VELCRO®) system, providing releasable attachment between the body-engaging member and the vial gripper. In a preferred embodiment, the vial gripper comprises a strap or other gripping member that has one component of the releasable fastening system on a surface thereof, and the body-engaging member has the other component of the fastening system on its surface. Accordingly, the vial gripping member can be releasably attached to the body-engaging member such that a vial is gripped therebetween. The gripping member can be attached to the body-engaging member in various positions thereon, so as to accommodate various sizes and/or numbers of vials. If desired, one end of the gripping member can be permanently attached to the body-engaging member, such as by sewing or any other suitable technique.
[0009] The body-engaging member preferably incorporates a needle-puncture-resistant shield for covering the part of the body of the medical practitioner that is adjacent to a vial held in the vial gripper. In a preferred embodiment of the invention, the body-engaging member is a multi-layer construction including at least a shield layer and an outer layer whose outer surface has one component of the two-component releasable fastening system. For example, the outer surface of the outer layer can be formed by a loop component of a hook and loop fastening system. The body-engaging member can also include an inner layer that lies against the body part of the practitioner and that is breathable for comfort.
[0010] Preferably, a vial for use with the wearable vial holder has an attachment member affixed to it. The attachment member on the vial preferably comprises a component of the releasable two-component fastening system, which works in cooperation with the other component of the fastening system disposed on the outer surface of the body-engaging member, in order to releasably affix the vial to the body-engaging member. The attachment member on the vial allows the vial to be secured in place on the body-engaging member so that the practitioner's hand is then free to operate the vial gripper, which preferably comprises a strap or the like having the same component of the fastening system that is on the vial. In exemplary embodiments of the invention, the vial has a patch of hook material of a hook and loop fastening system attached to it, the vial gripper also has hook material, and the body-engaging member's outer surface has a loop component of the fastening system. However, various arrangements of the fastening system components can be used in accordance with the present invention, and furthermore other types of fastening systems besides hook and loop systems can alternatively be used. For instance, one or more vials can be releasably affixed to the body-engaging member by frictional grippers (e.g., resilient fingers that grip a vial snapped into place between the fingers) provided on the body-engaging member, or a movable clamp arrangement can be provided on the body-engaging member for releasably clamping a vial. Other vial-gripping devices are also possible within the scope of the present invention.
[0011] In accordance with the invention, a medical practitioner would don the wearable vial holder, and would install in the vial holder the vial or vials he or she anticipated using in a particular procedure. The practitioner would then put on sterile gloves. From that point on, the practitioner is able to draw medication from the vial(s) without having to pick up or touch the vial(s). Thus, the invention eliminates the requirement of an assistant to hold vials, along with the attendant risk of accidentally sticking the assistant with a needle. The invention thus facilitates a substantial savings in time (and, hence, expense), since the practitioner does not have to wait until an assistant becomes available in order to draw medication from a vial, and enables existing staff to be used in a safer and more-efficient manner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The above and other objects, features, and advantages of the invention will become more apparent from the following description of certain preferred embodiments thereof, when taken in conjunction with the accompanying drawings in which:
[0013] [0013]FIG. 1 is a perspective view showing a medical practitioner wearing a medication vial holder in accordance with the invention and placing a vial into the holder;
[0014] [0014]FIG. 2 is a view similar to FIG. 1, showing the vial secured in the holder and showing the medical practitioner inserting a needle into the vial in preparation for drawing medication from the vial into a syringe attached to the needle;
[0015] [0015]FIG. 3 is a perspective view of the vial holder in isolation;
[0016] [0016]FIG. 4 is a cross-sectional view taken along line 4 - 4 in FIG. 3; and
[0017] [0017]FIG. 5 is a perspective view showing two vials secured in the vial holder and showing a medical practitioner drawing medication from one of the vials.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
[0019] With reference to the drawings, a wearable medication vial holder 10 in accordance with a preferred embodiment of the invention is illustrated. The vial holder 10 includes a body-engaging member 12 for encircling an arm of a medical practitioner. More particularly, the body-engaging member 12 includes a base 14 sized to only partially encircle an average-sized arm just below the elbow, a first elastic member 16 having its opposite ends affixed to opposite edges of the base 14 , and a second elastic member 18 having one end affixed to one edge of the base 14 . The base 14 and first elastic member 16 together form a band or sleeve for encircling the arm, and the elastic member 16 can elastically stretch to accommodate various arm sizes and remain snug about the arm. The second elastic member 18 provides further size adjustment capability and additional gripping strength about the arm, as further described below.
[0020] The outward-facing or outer surface of the base 14 is formed in whole or in part of a first component 20 of a two-component releasable fastening system. A preferred fastening system comprises any of the various hook and loop fastening systems available from Velcro USA Inc. of Manchester, N.H. under the trademark VELCRO®, or the hook and loop fastening systems available from Velcro USA Inc. that employ hook components sold under the trademark ULTRA-MATE®. However, other types of releasable fastening systems can be used instead. The first component 20 preferably comprises a loop component of the hook and loop fastening system. A loop component generally comprises a fabric formed to have a large number of thread loops exposed at its surface for engaging hooks of the hook component of the system. Preferably, substantially the entire outer surface of the base 14 of the vial holder is formed of the loop component 20 . Additionally, it is preferred to have loop material on the outer surface of the first elastic member 16 as well, for reasons explained below.
[0021] The second elastic member 18 at its free end has a region of its inner surface covered by the second component of the releasable fastening system. Thus, in the preferred embodiment comprising hook and loop fasteners, the second elastic member 18 has a piece of hook material 22 attached to the inner surface of the elastic member at the free end thereof. Accordingly, the free end of the elastic member 18 can be releasably attached to the outer surface of the base 14 by engaging the hook material 22 on the member with the loop material 20 on the base 14 , as shown in FIG. 1. The hook material 22 can extend as far along the length of the elastic member 18 toward the fixed end thereof as needed to provide a secure releasable attachment of the free end of the member to the outer surface of the base 14 . The snugness of the fit of the vial holder 10 about one's arm can be adjusted by attaching the second elastic member 18 in various locations on the outer surface of the base 14 to make the relaxed circumference of the vial holder larger or smaller; to this end, as noted above, it is advantageous to have loop material 20 covering most or all of the outer surface of the base 14 . Additionally, it is advantageous but not essential to have loop material 20 on the outer surface of the first elastic member 16 so that the second elastic member can be attached to it, if desired.
[0022] To secure a vial 24 in the vial holder 10 , preferably the vial has a patch of hook material 26 affixed to it. Thus, the vial 24 can be releasably attached to the outer surface of the base 14 by engaging the hook patch 26 with the loop material 20 on the outer surface of the base 14 . However, the attachment force provided by the hook patch 26 on the vial is insufficient to withstand the types of forces exerted on the vial during use without the vial becoming detached from the vial holder; rather, the hook patch 26 is provided so that the vial can be fixed in place on the base 14 to allow the practitioner to then operate a vial gripping strap 28 for securing the vial in the vial holder. The vial gripping strap 28 has one end affixed to the base 14 such as by stitching or other substantially permanent attachment method. The strap 28 has hook material 30 forming its inner surface such that the strap is releasably attachable to the outer surface of the base 14 . To secure the vial 24 , the strap 28 is drawn over the top of the vial and attached to the base 14 so that the vial is clamped between the strap 28 and the base 14 , as shown in FIG. 2. The strap 28 can be formed of a material that has hooks on one side for engaging the loop material on the base 14 , and loops on the opposite side. An end portion of the strap can be folded over and stitched or otherwise secured, as shown in FIG. 4, so as to form a tab portion on the end of the strap that will not adhere to the loop material on the base 14 . This facilitates getting a grasp on the strap to detach it from the base 14 .
[0023] Once the vial is secured in the vial holder, the medical practitioner can put on sterile gloves and use one hand to insert a needle into the vial as shown in FIG. 2, and draw medication from the vial. The vial can easily be inverted by raising the arm having the vial holder so that medication can be drawn without drawing air into the syringe. The practitioner can then inject the patient and carry on with other activities and procedures, while the vial 24 is still held in the vial holder 10 . If the patient requires a second injection of medication from the same vial 24 , the practitioner can draw further medication from the vial when the vial is a multi-dose vial.
[0024] In some cases, the practitioner may anticipate requiring more than one type of injectable medication for a particular patient or procedure. The vial holder 10 thus is preferably sized and configured to hold more than one vial 24 , 24 ′, as shown in FIG. 5. Various sizes of vials can be held in the vial holder. In a preferred embodiment of the invention, the vial holder is sized and configured to hold vials containing from about 10 to 50 ml of liquid medication, which are commonly available. However, the vial holder can be sized and configured to hold larger vials, if desired.
[0025] It is possible that when attempting to insert a needle into a vial held in the vial holder 10 , the practitioner may accidentally miss the vial and stick the base 14 of the vial holder. Accordingly, the base 14 preferably includes a needle-puncture-resistant shield 32 to prevent a needle from piercing entirely through the base 14 into the practitioner's arm. The shield 32 may comprise, for example, a flexible sheet of plastic or other material that is puncture-resistant but sufficiently flexible to enable the vial holder to be wrapped about an arm. In the preferred embodiment, the base 14 of the vial holder comprises a multi-layer structure, including the shield 32 , an outer layer 34 whose outer surface has the loop material 20 , and an inner layer 36 , as shown in FIG. 4. The outer layer 34 preferably comprises a non-woven fabric of synthetic fibers having many thread loops on its surface. The shield 32 is sandwiched between the outer layer 34 and inner layer 36 , and the outer and inner layers are secured together such as by stitching along their perimeters. The inner layer 36 preferably comprises a fabric that is breathable and comfortable against the arm. For instance, the inner layer 36 can comprise a tricot fabric or the like. The inner layer preferably has sufficient thickness to provide padding between the arm and the shield 32 .
[0026] Based on the foregoing, it will be appreciated that the invention enables a medical practitioner to draw medication from one or more vials without having to touch the non-sterile outside surfaces of the vial(s) with his or her gloved hands. In this manner, the sterility of the practitioner's gloves is not compromised, and no assistant is required for holding the vial as is the current practice in many cases.
[0027] Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. | A wearable vial holder for securing at least one vial of medication on the person of a medical practitioner comprises a body-engaging member structured and arranged to be secured to a part of the body of a medical practitioner, and a vial gripper affixed to the body-engaging member for releasably grasping and holding at least one vial so that the practitioner has access to the vial(s) for one-handed drawing of medication therefrom using a syringe with a needle. The vial holder includes a needle-puncture-resistant shield to protect the practitioner against accidental needle sticks. | 0 |
RELATED APPLICATIONS
[0001] This application is a continuation-in-part application Ser. No. 09/851,685, filed May 8, 2001 and of Ser. No. 09/653,646, filed Sep. 1, 2000, which is a continuation application of Ser. No. 09/226,322, filed Jan. 6, 1999, now U.S. Pat. No. 6,190,018, issued Feb. 20, 2001.
BACKGROUND OF INVENTION
[0002] 1. Field of Invention
[0003] This invention is directed generally to flashlights, and more particularly to a miniature flashlight using a light emitting diode (“LED”) as a light source that is useful for law enforcement personnel and civilians alike.
[0004] 2. Background of the Invention
[0005] Conventional general purpose flashlights are well known in the prior art and have often been used by law enforcement personnel in the execution of their duties and by them and civilians in emergency situations. Flashlights are used for a wide variety of purposes. For example, they are often used during traffic stops to illuminate the interior of a stopped vehicle or to complete a police report in the dark. They are also used to facilitate searches of poorly lit areas and may be used to illuminate dark alleys or stairwells. Also, they are used to check or adjust equipment when positioned in a darkened area or at night time, and can be used to send coded signals to one another. Generally, small incandescent lightbulbs and LED flashlights were not dependable when needed.
[0006] However, the size and weight of conventional flashlights add to the inconvenience and reduce the mobility of law enforcement personnel required to carry such flashlights along with the other law enforcement equipment. Sometimes the flashlight is purposefully or inadvertently left behind. This presents a problem when the need for a flashlight arises and the flashlight is not located on the person, or otherwise readily available In addition to the use of flashlights by law enforcement personnel, civilians also use flashlights for a number of different reasons. Besides the traditional, home uses of flashlights, smaller flashlights are used in today's society for various security purposes. For example, when going to one's car late in the evening, it is not uncommon for an individual, especially a female, to carry a small flashlight with her. She can use the flashlight to assist in getting the key in the keyhole in the dark. Additionally, she can use the flashlight to check whether someone is hiding in the back seat before getting into the car. Even small conventional flashlights, however, are generally cumbersome and inconvenient to carry for this purpose.
[0007] Thus, there is a need for a compact, lightweight flashlight that may easily be carried on the person of a law enforcement officer or civilian and conveniently attached to one's keychain or carried on one's clothing to help insure that the flashlight remains in possession of the user and can be quickly and easily retrieved and removed when needed.
DESCRIPTION OF THE PRIOR ART
[0008] Although not having been proven useful to law enforcement personnel, there exists in the prior art a small flashlight known as the Photon Micro Light. The Micro Light consists of two flat, circular 3 volt batteries, a light emitting diode (“LED”) and an outer shell that encloses the batteries and leads of the LED. The Micro Light uses a slide switch or pressure switch that activates the light by moving the leads of the LED into direct engagement with the batteries. The outer shell consists of two hard plastic parts opposite either side of the batteries and may be held together with four threaded screws.
[0009] The Micro Light, however, has a number of disadvantages. The Micro Light lacks the durability required for a miniature flashlight. It lacks an internal structure for protecting and securing the batteries and LED. Only the hard plastic outer shell protects the internal components of the flashlight. Thus, little protection is provided for the internal components of the flashlight and the Micro Light may be adversely affected when subjected to shock.
[0010] The Micro Light operates by using either a slide switch or pressure switch which upon activation brings both the leads of the LED into direct engagement with the batteries. This results in increased fatigue on the leads of the flashlight and undesirable wear that affects the reliability of the switch. Moreover, because of its external shape and hard plastic outer shell construction, the Micro Light is not suitable for receiving markings or engravings on the outside surfaces thereof, cannot have a medallion installed thereon, have a die struck panel, or disclose using a translucent housing. In many instances it is desirable to color code the exterior of the flashlight, or to provide medallions, die struck panels, engravings, markings, or other indicia on the exterior surface. However, the construction of the Micro Light is not well suited or adapted to allow for any such color coding or desired markings or engravings.
SUMMARY OF THE INVENTION
[0011] The subject invention is specifically directed to a small, compact LED flashlight useful to both law enforcement personnel and civilians. One embodiment of the invention may include an LED flashlight wherein the LED has first and second leads extending therefrom; a power source; a power source frame enclosing at least a portion of the power source; a power source frame housing containing the power source frame, light source and power source; a switch located adjacent the power source and operable to close a circuit including the light source and the power source; a keyring extension extending from the power source frame, said keyring extension having an opening whereby an article can be attached to the keyring extension, and the keyring extension further includes a keyring lock connected to the power source frame or power source frame housing wherein upon exerting a force against the keyring lock, the keyring lock is opened to permit the article to be attached to the keyring extension.
[0012] The power source frame is non-conductive and has a cavity adapted to house the power source. The power source frame may also have a receptacle for receiving and housing a connector end of the light source. The power source frame therefore serves as a fitted compartment for holding in place and protecting the various internal components of the flashlight. The power source frame provides significant protection to the power source and the light source and serves to cushion these elements from the adverse affects of any shock the flashlight might receive. The power source frame housing encases the power source frame, and provides further protection to the internal components of the flashlight, in addition to that provided by the power source frame. The power source frame housing thus serves to provide an additional level of protection to the light source and the power source and enhances the durability of the flashlight.
[0013] Another embodiment of the invention may include an LED flashlight wherein the LED has first and second leads extending therefrom; a power source having a first side and a second side, the second side being opposite the first side; a housing enclosing the leads of the LED and the power source, wherein the housing is comprised of translucent material; and a switch operable to close a circuit including the LED and the power source.
[0014] Still a further embodiment of the invention may include an LED flashlight wherein the LED has first and second leads extending therefrom; a power source; a housing containing the LED and the power source; the housing includes at least one side cover which is not integral with the housing; the at least one side cover being selected from anodized metal, anodized metal which includes indicia, die struck metal, laser engraved metal, and a side cover having a separate medallion attached thereto; and a switch located adjacent the power source and operable to close a circuit including the light source and the power source.
[0015] The LED is preferably an LED that has a high luminous intensity. Manufacturers of LEDs grade the LED according to its quality. The highest quality LEDs are given an “E” grade. The next highest quality is a “D” grade. LEDs with a “D” grade can be equipped with a lens to approximate the quality of an “E” grade LED. LEDs of this quality were initially used in medical applications and are sometimes referred to as having medical grade application. Although the flashlight of the present invention can be used with any conventional LED, in a preferred embodiment, the light source is an “E” grade LED or lensed “D” grade LED. Such a high intensity LED may be obtained from Hiyoshi Electric, Co., Ltd. located in Tokyo, Japan, having Part No. E1L533BL. The high intensity LED herein described has from three to five times the luminous intensity of a conventional LED. The LED preferably emits blue light, although the present invention may be used with any color LED. Blue light helps to preserve a user's night vision compared with conventional flashlights emitting white light. For other applications bluegreen LEDs can be used, for example, in situations where compatibility with night vision equipment is desired. Other colored LEDs can also be used. Red LEDs can be used in applications where the preservation of night vision is desired or for use with pilots and photographers, and even infrared LEDs can be used where certain signalling capabilities are required or for use with equipment that senses infrared light. The LED includes first and second leads extending from a connector end of the LED. The LED leads may be provided with extensions that can be soldered onto the leads of the LED.
[0016] The power source may be any battery having sufficient power to energize an LED. The power source is preferably round and has oppositely disposed generally flat sides, sometimes referred to as coin cells. A pair of stacked 3 volt batteries of this type may be used as the power source. Three-volt lithium batteries are preferably used to provide for longer life, and greater shelf life.
[0017] The power source frame may be made of nonconductive plastic and preferably has generally flat oppositely disposed first and second sides. The power source frame may be adapted to receive and house a power source, and includes a power source cavity for this purpose. The power source frame also includes a receptacle at a front end to receive and house a connector end of an LED. The leads of the LED are preferably positioned so that one lead extends over the first side of the power source and another lead extends over the second side of the power source. The power source frame protects and secures the internal components of the flashlight. The power source frame also provides resistance to shock and safeguards the light source and power, source within its frame. The power source frame may include a power source cavity cover that serves to further enclose the power source, and may include a bottom support beneath the cavity for further supporting the power source.
[0018] A switch element is preferably located on the side opposite of the power source cavity. The side of the power frame opposite the side having the power source cavity may include a counterbore having a terminus in the power source frame that houses a switch element. The counterbore may be included in the power source cavity cover as well. The switch element is preferably a dome plate that is located between one of the leads of the LED and the power source, but out of contact with the power source. The dome plate is sometimes referred to as a tactile dome plate or a snap dome plate. The switch is activated by applying pressure to the dome plate, thereby completing a circuit that includes the leads of the LED and the power source. With this switch arrangement, a switch button is depressed forcing one lead of the LED into contact with the dome plate which in turn contacts the power source. Thus, in this embodiment, one lead of the LED never comes into direct contact with the power source. Once pressure is removed from the button, the contact between the dome plate and power source is broken and the flashlight returns to its normal “off” position. Thus, the switching arrangement reduces the wear on the leads of the LED and increases the overall reliability.
[0019] The power source frame may be adapted to receive a weight, which is preferably round and has opposite ends coplanar with the opposite sides of the power source frame. The weight may be press fit into a cavity or tapered hole in the power source frame specifically adapted to receive the weight. The weight provides for a heavier flashlight and improved balance. In addition, the weight provides the flashlight with greater substance and as a result a higher perceived value in the hands of the user. With the additional weight added to the flashlight, the flashlight appears more substantial and of a higher quality than a lighter weight flashlight.
[0020] The power source frame housing is preferably of a two piece construction, with each piece disposed on either side of the power source frame. The power source frame housing includes a first housing side disposed about the first side of the power source frame and a second housing side disposed about the second side of the power source frame, the two sides conforming to the periphery of the power source frame. The housing is preferably constructed of plastic. In one embodiment, the housing may be translucent. In this manner, the light from the LED may be dispersed throughout the housing to effectively illuminate the light. In one embodiment, the entire housing may be translucent. It may also be colored to match the color of the LED. For example, a red translucent housing may be used with a red LED, a blue translucent housing may be used with a blue LED, etc.
[0021] The power source frame may have a plurality of pegholes located about the periphery of either side thereof. In addition, the first and second housing sides of the power source frame housing may be provided with a plurality of pegs extending from an inner periphery thereof. The pegs are positioned to engage in a mating relationship with the plurality of pegholes located about the periphery of the sides of the power source frame such that the housing sides can be engaged with the power source frame. The mating of the pegs and the pegholes facilitates assembly of the flashlight by allowing the parts to be precisely aligned during their assembly. It has been found that gluing the power source frame housing to the power source frame provides for a suitable adhesion of the parts. Alternately, ultrasonic welding can be used to attach the parts. Unlike the prior art, separate screws are not needed to attach the parts of the flashlight together and thus assembly is facilitated. In this manner, the housing sides may include notches that mate with corresponding notch receptacles on the power source frame. The housing sides may thus be advantageously ultrasonically welded to the power source frame.
[0022] The flashlight housing may be provided with at least one separate side cover and preferably be provided with first and second side covers that are positioned between the first and second housing sides of the power source frame housing and with the housing sides sandwiches the power source frame. The side covers preferably lie in parallel planes and may have flat outer surfaces that are capable of receiving engravings or markings. It is often desirable to engrave or imprint the side covers with surface indicia. For example, a company logo or name of a product could be located on either of the side covers. The use of engraving or printing on the side covers can be used for promotional or advertising purposes. In addition, a flashlight bearing certain markings on the side covers could serve as a prize or be used to commemorate an important event. In one embodiment, a die struck medallion could be inset in the side cover.
[0023] The side covers can be made of a variety of materials, such as metal, plastic, or other protective materials. The side covers are preferably made of anodized aluminum. Aluminum provides the desired strength to the side covers and is easily anodized aluminum engraved or imprinted. Indicia may be laser engraved, silk screened, inked, pad printed, or marked in any known manner. In the embodiment where the housing is translucent, the side covers may also be made of a translucent plastic material, or they may be made of non-translucent plastic or metal. Thus, a flashlight may be provided with a translucent housing, and translucent side covers, or a translucent housing and opaque side covers. Where both the housing and side covers are translucent, they may of different colors, to present a two, or even three, tone flashlight. Further, the flashlight may include a translucent power source frame as well. Where translucent side covers are used, indicia may be engraved or printed on the inside surface of the side cover. Thus, the side cover protects the indicia from being marred by normal wear and tear, and also by virtue of being translucent, may provide an attractive gloss finish highlighting the indicia.
[0024] In another embodiment, the side covers are a die struck, or coined metal, preferably brass, in which physical indicia may be formed in the metal side cover. Most preferably, both sides of a side cover are struck to provide finer detail in the physical indicia, which may include a company logo, name, or other suitable information.
[0025] In another embodiment, a side cover can have a medallion therein. One way of doing this is to cut a hole the size of the medallion in the side cover. An appropriate support and single faced adhesive is attached to the inside of the side cover so that the adhesive can be used to attach the medallion too the side cover.
[0026] The side covers provide additional protection to the internal components of the flashlight. The sturdy aluminum construction serves to guard the light source and power source from external forces. Moreover, there is an insulated pocket located between the power source frame and the side covers that provides an air cushion that serves to further protect the light source and power source within the power source frame housing. The side covers may be manufactured as separate components of the flashlight from the power source frame housing. Thus, side covers of varying colors may used to assemble flashlights of varying and contrasting colors. For example, flashlights having side covers bearing corporate colors can be easily assembled. Similarly, flashlights having side covers bearing the colors of a favorite team can be provided. For example, a flashlight having a green side cover on one side and a yellow side cover on the other side could be used to represent the colors of the Green Bay Packers. In addition, a Green Bay Packers logo could be included on one or both side covers of the flashlight.
[0027] One of the side covers is adapted to receive a switch button that is secured to the side cover. The button may be made of rubber, and is preferably made of Kraton, the trade name of a thermoplastic rubber made by the Shell Oil Company, and located adjacent the power source. When the button is pushed, a circuit including the leads of the LED and the power source is completed.
[0028] The power source frame or power source frame housing may be provided with a keyring extension. The keyring extension may directly extend from the housing or power source frame. The keyring extension includes a keyring lock that opens and closes the keyring extension when a force is exerted against the keyring lock. The keyring extension is opened to permit an item such as a keyring to be attached to the keyring extension. The keyring lock is preferably springbiased and may be attached to the power source frame. The keyring lock may pivot about a circular post positioned on the power source frame. Alternatively, the keyring lock may extend from the interior of the housing, or if a power source frame is used, extend from the power source frame. The keyring extension may be easily attached and detached from any number of items, such as the zipper of a coat or backpack, the handle of a purse or briefcase, a beltloop, or any other handle or case.
[0029] The flashlight of the present invention is small, compact and easy to operate. The flashlight may easily be carried in the pocket, on the clothing, or on the keychain of law enforcement personnel or civilians. The flashlight may also be quickly and easily retrieved and operated.
[0030] In another embodiment of the invention, a magnet may be provided on the flashlight. It may be internal, external, or coextensive with the housing sides or side covers. Preferably, the magnet is internally positioned within the flashlight. It may be positioned within the interior of the housing, or if a power source frame is used may be positioned on the power source frame or within a cavity on the power source frame. An internal magnet allows for indicia to be marked, printed, or engraved on the housing or side covers of the flashlight. When internally positioned, the magnet is protected from chipping or scratching that could occur if the magnet were externally mounted to the flashlight. Moreover, the magnet itself does not scratch the surface to which it may be mounted as the magnet is protected by the housing or side covers. The magnet may be of sufficient strength to allow the flashlight to be mounted to metal objects. In a preferred embodiment using a magnet, the magnet is of sufficient strength to allow the magnet to attach to metal objects even when using side covers that are made of aluminum or other metals.
[0031] It will be understood by those of skill in the art that the various aspects of the disclosed embodiments may be used alone or in connection with the other aspects of the disclosed embodiments. For example, the various disclosed keyring extensions may be used with a housing, with a power source frame and power source frame housing together, with or without side covers, with a translucent housing, with a magnet, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] Further advantages of the present invention will become apparent to those skilled in the art with the benefit of the following detailed description of the preferred embodiments and upon reference to the accompanying drawings in which:
[0033] FIG. 1 is a perspective view of an embodiment of the flashlight of the present invention.
[0034] FIG. 2 is a side view of the flashlight depicted in FIG. 1 .
[0035] FIG. 3 is a side view of a first side of the power source frame.
[0036] FIG. 4 is a side view of a second side of the power source frame opposite the first side.
[0037] FIG. 5 is a side view of a power source consisting of two circular batteries having generally flat sides.
[0038] FIG. 6 is a side view of alight emitting diode (LED).
[0039] FIG. 7 is a perspective view of a weight.
[0040] FIG. 8 is a side view of a first side of the power source frame including a power source, an LED, a keyring lock, and a spring.
[0041] FIG. 9 is a side view of a second side of the power source frame including an LED, a weight, a keyring lock, a spring, and a switch element.
[0042] FIG. 10 is a cross-sectional view of the power source frame of FIG. 4 taken along plane 11 .
[0043] FIG. 11 is a side view of the exterior of a first side of the power source frame housing.
[0044] FIG. 12 is a side view of the interior of a first side of the power source frame housing.
[0045] FIG. 13 is a side view of the exterior of a second side of the power source frame housing.
[0046] FIG. 14 is a side view of the interior of a second side of the power source frame housing.
[0047] FIG. 15 is a side view of a first side cover.
[0048] FIG. 16 is a side view of a second side cover.
[0049] FIG. 17 is a cross-sectional view of a switch button.
[0050] FIG. 18 is a partial cross-sectional view of the flashlight of FIG. 2 taken along the plane 22 .
[0051] FIG. 19 is a side view of an alternate embodiment of the power source frame.
[0052] FIG. 20 is the opposite side view of the power source frame shown in FIG. 19 .
[0053] FIG. 21 is a side view of a power source cavity cover.
[0054] FIG. 22 is an opposite side view of the power source cavity cover shown in FIG. 21 .
[0055] FIG. 23 is a perspective view showing the power source cavity cover of FIGS. 21 and 22 used in connection with the power source frame of FIGS. 19 and 20 .
[0056] FIG. 24 is atop view of an alternate embodiment of a keyring extension and keyring lock in a connecting relationship.
[0057] FIG. 25 is a top view of the keyring lock of FIG. 24 .
[0058] FIG. 26 a is a top view of another alternate embodiment of a keyring lock showing a latch receptacle in dotted lines.
[0059] FIG. 26 b is a bottom view of the keyring lock of FIG. 26 a.
[0060] FIG. 27 is a side view of an alternate embodiment of a power source frame having a cavity for a magnet.
[0061] FIG. 28 is an opposite view of the power source frame of FIG. 27 .
[0062] FIG. 29 is a view of the power source frame of FIG. 28 along line 2929 showing a magnet and magnet cavity in dotted lines.
[0063] FIG. 30 is side view of an alternate embodiment of the present invention showing a flashlight with a translucent housing.
[0064] FIG. 31 is an opposite side view of the flashlight of FIG. 30 .
[0065] FIG. 32 is a side view of a flashlight having an alternate embodiment of a keyring lock.
[0066] FIG. 33 is a side view of the inside of a die struck cover according to the present invention.
[0067] FIG. 34 is a side view of the outside of the die struck panel of FIG. 33 .
[0068] FIG. 35 is a front side view of a cover having a medallion pocket.
[0069] FIG. 36 is FIG. 35 with the medallion in the pocket.
[0070] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereof are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0071] A handheld flashlight 10 made in accordance with the principles of the subject invention is depicted in FIG. 118 . As shown in FIG. 2 , flashlight 10 preferably includes a side cover 12 , a power source frame housing 14 , a keyring extension 16 , a keyring lock 80 , a switch button 18 , and a light source 20 , extending from a front end of the flashlight.
[0072] As depicted in FIGS. 3 and 4 , the flashlight of the subject invention further includes a power source frame 22 . The power source frame 22 has oppositely disposed first and second sides 26 , 33 that are generally flat and lie in parallel planes. The power source frame 22 further includes a cavity 24 located on the first side 26 of the power source frame adapted to receive a power source, such as that depicted in FIG. 5 . The frame 22 also is provided with a receptacle 28 at a front end 30 thereof, adapted to receive a light source, such as that depicted in FIG. 6 . The first side 26 further includes a light source lead channel 29 extending from receptacle 28 to cavity 24 to allow a lead from the light source 20 to extend over cavity 24 .
[0073] As depicted in FIG. 3 , the power source frame 22 may also include an area 32 adapted to receive a weight. In the embodiment shown in the figures, although not required, the area 32 is a throughhole extending from the first side 22 of the frame to the second side 33 of the frame. Area 32 is tapered at a slight angle to allow the weight to be friction fit within area 32 . The power source: frame 22 is further provided with a plurality of pegholes 100 positioned about an outer periphery of the first side 26 of the power source frame. The pegholes 100 are adapted to receive a corresponding set of pegs located on the power source frame housing 14 . The mating of the pegs with the pegholes positions the power source frame housing 14 in proper alignment with the power source frame 22 . The power source frame housing may be ultrasonically welded to the power source frame and/or glued thereto. Thus, there is no need to use threaded screws or other fastening means to hold the frame and the housing together. As a result, the flashlight of the invention is assembled without difficulty.
[0074] The power source frame 22 is preferably made of a nonconductive material. Preferably, the power source frame 22 is comprised of Acrylonitrile Butadiene Styrene “ABS” which provides for exceptional durability and toughness. However, any nonconductive material may be employed to construct the frame 22 . Polycarbonate is preferred where the power source frame is translucent.
[0075] FIG. 4 depicts a side view of the second side 33 of power source frame 22 . The second side 33 is provided with a counterbore 34 having a terminus 36 within the power source frame 22 . As shown in FIG. 4 , the counterbore 34 is adapted to receive a switch element. The counterbore 34 is preferably located opposite the power source cavity 24 and includes a throughhole 38 extending into cavity 24 that is located on the first side 26 of the power source frame 22 .
[0076] As with the first side 26 , the second side 33 preferably includes a light source lead channel 39 extending from receptacle 28 to counterbore 34 to allow a lead from the light source 20 to extend over counterbore 34 . The second side 33 of power source frame 22 may preferably further include a post 40 about which an element of the keyring lock 80 may pivot. Power source frame 22 is also provided with a hub 42 located on a rear side 44 of the frame 20 that is adapted to secure one end of a spring element associated with the keyring lock 80 . As with the first side, the second side 33 of the power source frame may be provided with a plurality of pegholes 110 positioned about its outer periphery to mate with a corresponding set of pegs located on the power source frame housing 14 .
[0077] The power source may be any type of battery with sufficient power to energize the light source. As shown in FIG. 5 , the power source is preferably one or more circular batteries 50 having generally flat oppositely disposed first and second sides 52 and 54 . In a preferred embodiment, the power source consists of two 3 volt lithium coin cell batteries available from Panasonic bearing the CR2016 marking. These lithium batteries provide for exceptionally long life and durability. In addition, they operate at a low temperature, are leakproof, and vibration resistant.
[0078] The light emitting diode light source may be of any type suitable for flashlight use. As shown in FIG. 6 , the light emitting diode (“LED”) 60 has first and second leads 62 and 64 extending therefrom. An LED provides great advantages over conventional neon or incandescent light sources, since it requires much less energy, is smaller in size, and more resistant to shock than conventional light sources. It also generates less heat and is more durable than a conventional light source. LEDs are widely available, inexpensive, and can be replaced easily and quickly. In a preferred embodiment, the light source is a high intensity LED having a high luminous intensity emitting blue light. The LED may be a “E” grade LED or a tensed “D” grade LED.
[0079] The flashlight may include a weight 70 positioned in area 32 on the power frame housing 14 . The weight provides for a heavier flashlight and for improved balance. It also provides a more substantial feel to the flashlight resulting in a higher perceived value. In a preferred embodiment shown in FIG. 7 , the weight 70 has a cylindrical shape and has oppositely disposed first and second faces that are generally flat and lie in parallel planes. The weight 70 preferably has a thickness equal to the thickness of the power source frame 14 . It is preferably made of a dense metal material, preferably stainless steel, and preferably weighs approximately eleven grams. The weight is friction fit or press fit into the corresponding portion of the power source frame housing.
[0080] FIG. 8 is a side view of the first side 26 of the power source frame 22 and depicts power source 50 , LED 60 , keyring lock 80 , and spring 82 . The power source frame 22 preferably has a thickness in the range of approximately 0.15 and 0.25 inch, and preferably 018 inches, which is approximately equal to the diameter of LED 60 . As shown in FIG. 8 , the LED 60 is positioned in receptacle 28 of the power source frame 22 , and the power source SO is positioned in the cavity 24 of the power source frame 22 .
[0081] A first lead 62 of the LED 60 preferably extends over the first side 52 of the power source 50 , which is preferably coplanar with the first side 26 of the power source frame 22 . A lead extension 75 may be attached to the first lead 62 of the LED to extend the length of the lead. The lead extension 75 may be soldered to the first lead 62 . The weight 70 may be positioned within the power source frame 22 , and preferably has a first side 72 that is coplanar with the first side 26 of the power source frame. The weight 70 is preferably press fit or friction fit within the power source frame 22 .
[0082] FIG. 9 is a side view of the second side 33 of the power source frame 22 and depicts LED 60 , weight 70 , keyring lock 80 , spring 82 and switch element 90 . As shown in FIG. 9 , the switch element 90 is positioned in the counterbore 34 . The switch element 90 has an outer periphery that contacts the terminus 36 of the counterbore 34 , but is out of contact with the power source 50 . The second lead 64 of LED 60 preferably extends over the switch element 90 . A lead extension may be attached to the second lead 64 , as required.
[0083] The switch element 90 is preferably a dome plate 92 or a convex conductor that is positioned in the counterbore 34 , but out of contact with the power source 50 . The dome plate is preferably made of a thin, flexible conductive metal stamping. The lead 64 of the LED contacts the dome plate. To ensure contact, the lead may be taped to the dome plate using, for example, 1.5 millimeter thick tape manufactured by 3M. The dome plate preferably has an engaging element 91 located at the center of its inner surface.
[0084] When pressure is applied to the dome plate, the dome plate flexes from a convex to a concave configuration, thereby completing the circuit through the first and second leads of the LED, the engaging element of the dome plate, and the power source. When the pressure is removed, the dome plate returns to its convex position breaking contact with the power source and returning the flashlight to its normal “off” position. In this manner, the lead does not come into direct contact with the power source. It should be noted that a number of alternative push button switch arrangements could be used. For example, the power source frame could include a flexible tongue adjacent to the power source. A lead of the LED could be wrapped around the tongue such that depression of the tongue would bring the lead of the LED into contact with another switch element or into direct contact with the power source to complete the circuit. Alternatively, the lead of the LED could be connected to a flexible tongue having a split metal eyelet adjacent the power source, such that depression of the tongue would complete the circuit. In addition, a number of other mechanical or electrical switches could be utilized, such as slide switches and pressure switches.
[0085] As shown in FIG. 9 , the keyring lock 80 includes hub 84 operatively connected to a coil spring 82 which is in turn operatively connected to hub 42 of power source frame 22 . It should be understood that many types of springs can be used to bias the keyring lock including coil springs, leaf springs, and U-shaped or plastic springs to name a few. The coil spring may be a separate component, or may be made integral with the power source frame. Spring 82 exerts a force to bias keyring lock 80 to pivot outwardly and about post 40 . The keyring lock 80 is preferably adapted to pivot about post 40 for only a limited distance. Keyring lock 80 further includes a stop 86 that abuts the power source frame 22 to limit the travel of the keyring lock 80 . Preferably, the stop 86 prevents an outer edge 88 of the keyring lock to travel beyond the position where the edge 88 is parallel to an edge 89 of the power source frame. Other keyring locking mechanisms could be used having other forms of springs or resistance to bias the keyring lock. Alternately, the keyring lock could be externally or internally hinged.
[0086] The keyring extension 16 and keyring lock 80 of the present invention provide a user with significant versatility in attaching the flashlight to the user's person. For example, the keyring lock 80 may be moved to its open position to allow the flashlight to be easily attached to the zipper of a coat or backpack, the handle of a purse or briefcase, a beltloop, or any other handle or case. In addition, because the keyring lock 80 is normally biased into its closed position, the keyring extension and keyring lock 80 can serve as a clip to easily fasten the flashlight to a shirt pocket or directly to one's clothing. In this manner the shirt pocket or portion of clothing is pinched between an outer end 134 of keyring lock 80 and an outer end 132 of keyring extension 16 . (See FIG. 2 ). The ability to easily clip the flashlight to one's clothing provides the user with great flexibility in carrying the flashlight on one's person.
[0087] FIG. 10 is a cross-sectional view of the power source frame 22 of FIG. 4 taken along line 11 . Cavity 24 on side 26 preferably has a depth equal to the thickness of the power source 50 and encloses all but an outer surface of the power source. Counterbore 34 on side 33 is located opposite the cavity 24 and has a terminus 36 in the power source frame and throughhole 38 extending therethrough into cavity 24 . The diameter of the counterbore 34 is preferably slightly larger than throughhole 38 .
[0088] FIGS. 3-10 depict the inner workings of an embodiment of the present invention. However, the invention is not intended to be limited by the particular geometry, locations, and components depicted herein, which are illustrative.
[0089] FIG. 11 is a side view of the exterior of a first housing side 150 of the power source frame housing 14 depicted in FIG. 1 . First housing side 150 is adapted to fit over and enclose the first side 26 of the power source frame 22 .
[0090] FIG. 12 is a side view of the interior 156 of first housing side 150 . A plurality of pegs 158 are preferably positioned about an inner periphery of the first housing side 150 . As mentioned above, the pegs 158 are adapted to engage in a mating relationship a corresponding plurality of pegholes 100 located on an outer periphery of the first side 26 of the power source frame 22 .
[0091] FIG. 13 is a side view of an exterior 142 of a second housing side 140 of power source frame housing 14 depicted in FIG. 2 . The second housing side 140 is adapted to fit over and enclose the second side 33 of the power source frame 22 . With reference to FIGS. 2 and 13 , the exterior 142 includes a keyring extension 16 extending from a rear side 144 thereof. An outer end 132 of keyring extension 16 engages an outer end 134 of keyring lock 80 (as shown in FIG. 2 ). Alternatively, the keyring extension could be attached to, or integral with, the power source frame, such that the power source frame housing could fit over and enclose the power source frame, except for the keyring extension. In such an alternate embodiment, the second housing side 140 will be identical to the first housing side 150 , shown in FIG. 12 .
[0092] FIG. 14 is a side view of an interior 146 of second housing side 140 . A plurality of pegs 148 are preferably positioned about an inner periphery of second housing side 140 . The pegs 148 are adapted to engage in a mating relationship a corresponding plurality of pegholes 110 located on an outer periphery of the second side 33 of the power source frame 22 .
[0093] FIGS. 11-14 show first and second power source frame housing sides having an opening therein to accommodate the side covers shown in FIGS. 15 and 16 . It should be understood, however, that the power source frame housing sides are not limited to accommodating the particular side covers shown in FIGS. 15 and 16 . They could be modified to be used with side covers of any geometry. In addition, the housing sides could be made without any openings and used without side covers, such that the power source frame housing sides would completely enclose the power source frame housing. Also, the power source frame housing can be made from any suitable material, and is preferably strong and durable. In a preferred embodiment, the power source frame housing is made of ABS.
[0094] FIGS. 15 and 16 are side views of first and second side covers 160 and 170 . The first and second side covers are preferably positioned between the power source frame 22 and the power source frame housing 14 . First and second side covers 160 and 170 are generally flat and adapted to conform to the outer surfaces of the power source frame 22 such that the side covers preferably lie in parallel planes when positioned between the power source frame 22 and the power source frame housing 14 . The power source frame housing 14 conceals the edges of the side covers when they are positioned between the power source frame 22 and the power source frame housing 14 . The side covers may be of any suitable material including metals, rubbers, and plastics. Preferably the side covers are made of stamped aluminum, preferably anodized 6061 aluminum, and have surfaces suitable for marking or engraving. As noted above, it is often desirable to engrave or imprint the side covers with surface indicia. For example, a company logo or name of a product could be located on either of the side covers. The use of engraving or printing on the side covers can be used for promotional or advertising purposes. In addition, a flashlight bearing certain markings on the side covers could serve as a prize or be used to commemorate an important event.
[0095] FIGS. 35 and 36 illustrate a die struck medallion 161 inset in one of the side covers 162 . A hole 163 is cut in the side cover 162 the size of the medallion 161 . The medallion is shown as cylindrical, but could be any shape, i.e., box, oval, etc. A piece of adhesive 164 is placed inside of the cover so that an adhesive portion 165 faces the outside of the side cover and forms a medallion pocket that permits the medallion to be attached to the side cover. Other mechanisms can be used to attach the medallion to the side cover such as adhering a support piece within the side cover to form the base of the medallion pocket and using an appropriate adhesive to attach the medallion to the side cover. Also, although the medallion is generally metal, it can be any suitable material, i.e., plastic.
[0096] A further embodiment is shown in FIGS. 33 and 34 wherein the side cover 166 is die struck metal, i.e., brass, aluminum, wherein the entire side cover 166 is die struck metal, i.e., brass, aluminum having the desired depiction 167 (positive), 167 a (negative) die struck on both sides 168 and 169 for greater detail. This provides a special flashlight for a designated group of people.
[0097] The side covers can be made of a variety of materials, such as metal, plastic, or other protective materials. Generally, the side covers are preferably made of anodized aluminum. Aluminum provides the desired strength to the side covers and is easily engraved or imprinted. Indicia may be laser engraved, silk screened, inked, pad printed, or marked in any known manner.
[0098] The side covers are on both sides of the power source frame and are held by the power source frame housing. The side covers provide additional protection to the internal components of the flashlight. The sturdy aluminum construction serves to guard the light source and power source from external forces. Moreover, there is an insulated pocket located between the power source frame and the side covers that provides an air cushion that serves to further protect the light source and power source within the power source frame housing. As noted above, in applications where no side covers are used, it is desirable to similarly provide a spaced pocket of air between the power source and the power source frame housing sides to further protect the light source and power source.
[0099] As shown in FIG. 15 , the second side cover 170 has a hole 172 therethrough adapted to receive a switch button 18 (shown in FIG. 17 ). When the side cover 170 is positioned between the power source frame 22 and the power source frame housing 14 , hole 172 is located adjacent the switch element 90 . In a preferred embodiment, a thin piece of foam (not shown) is attached to the inner surface of the first side cover 160 . When the flashlight is assembled, the piece of foam serves to compress the first lead 62 of the light source 20 into engagement with power source 50 . The piece of foam also serves to keep the elements of the power source frame 22 tightly enclosed therein, and prevents the internal components from rattling or making noise when in use.
[0100] FIG. 17 is a side view of switch button 18 . Switch button 18 is preferably circular with a circular recess 182 about its periphery. The recess 182 is adapted to secure the switch button 18 to the second side cover 170 . Switch button 18 is preferably made of a resilient material, such as rubber, to allow the button to deform when a force is exerted thereon. In a preferred embodiment, the switch button 18 is made of Kraton, the trade name of a thermoplastic rubber made by the Shell Oil Company.
[0101] The switch button 18 further includes an engaging element 184 on an interior surface thereof. When a force is exerted on the button, the engaging element 184 contacts the switch element 90 located in the power source frame 22 . When not engaged, the engaging element 184 is preferably out of contact with the switch element 90 .
[0102] FIG. 18 is a partial cross-sectional view of the flashlight 10 taken along the line 22 of FIG. 2 . As shown in FIG. 18 , switch button 18 is secured to second side cover 170 , which is positioned between the second housing side 140 of power source frame housing 14 and the power source frame 22 . The engaging element 184 of switch button 18 is preferably positioned adjacent to, but out of contact with, dome plate 92 . An outer periphery 186 of the interior surface of switch button 18 engages an outer periphery of dome plate 92 . As a force is exerted on switch button 18 , the engaging element 184 contacts dome plate 92 . The dome plate 92 then moves in a direction towards the power source 50 until it comes in contact with power source 50 . Once contact is made, a circuit including the leads of the light source 60 , the dome plate 92 , and the power source 50 is completed.
[0103] Typically, a flashlight pressure switch makes noise upon its engagement. With the switch button configuration shown herein, the noise created by the dome plate 92 coming in contact with the power source 50 is muffled because the switch button 18 completely encloses the dome plate 92 in the power source frame. Moreover, a raised annular portion 190 of the power source frame partially encloses the outer diameter of the switch button to further enclose the switch button and muffle any sound from the operation of the dome plate. In addition, 1.5 millimeter thick 3M tape may be placed over the lead and dome plate to further muffle the sound of the switch operation. In addition, a small notch is placed in the outer periphery 186 of the interior surface of switch button to allow air to escape through the notch when the button is depressed.
[0104] Thus, any noise created is muffled within the switch button 18 . In addition, with the disclosed switch button configuration, when a force is exerted on the dome plate 92 , the user is able to feel the flexure of the dome plate as it moves into contact with the power source 50 . Thus, the switch button configuration provides tactile feedback to the user so that the user is able to feel when the dome plate has come into contact with the power source, and when it is released. This tactile feedback is particularly useful where the flashlight is being operated out of the direct sight of the user, and it is not possible to tell by sight whether the flashlight is on or off.
[0105] FIGS. 19-23 depict an alternate embodiment of a miniature LED flashlight. As shown in FIGS. 19 and 20 , power source frame 222 has oppositely disposed first and second sides 226 , 233 that are generally flat and lie in parallel planes. The power source frame 222 further includes a cavity 224 located on the second side 233 of the power source frame adapted to receive a power source, such as that depicted in FIG. 5 . The frame 222 also is provided with a receptacle 228 at a front end 230 thereof, adapted to receive a light source, such as that depicted in FIG. 6 . The first side 226 further includes a light source lead channel 229 extending to cavity 224 from receptacle 228 to allow a lead from the light source 220 to extend into cavity 224 .
[0106] As depicted in FIG. 20 , the power source frame 222 may also include a cavity 232 adapted to receive a weight. In the embodiment shown in the FIGS. 19 and 20 , although not required, the power source cavity 224 and the weight cavity 232 have a bottom support 235 positioned on side 226 of the power source frame 222 . The bottom support 235 may be separate from, but is preferably molded integrally with, the power source frame 222 . In addition, the bottom support 235 is shown supporting both the power source cavity 224 and the weight cavity 232 , but also could be limited to support only one or the other.
[0107] As shown in FIGS. 21 and 22 , a power source cavity cover 240 may be used in connection with the power source frame 222 shown in FIGS. 19 and 20 . Power source cavity cover 240 may include pegs 242 that mate in pegholes 244 located on side 233 of power source frame 222 . While such pegs are preferred for proper alignment of the power source cavity cover, any number of known conventions, such as notches, tabs, etc. could be used to properly position and secure the power source cavity cover to the power source frame. The power source cavity cover may be provided with a counterbore 250 having a terminus 252 within the power source cavity cover 240 . As shown in FIGS. 21 and 22 , the counterbore 250 is adapted to receive a switch element. Preferably, the switch element is a dome plate, such as that shown as element 92 in. FIG. 18 . Of course, other types of flexible switch plates can be suitably used. As shown in FIG. 23 , when the power source cavity cover 240 is positioned on the power source frame 222 , the counterbore 250 is preferably located opposite the power source cavity 224 and includes a throughhole 254 extending into cavity 224 that is located on the side 233 of the power source frame 222 .
[0108] Referring back to FIGS. 19 and 20 , keyring extension 260 extends from power source frame 222 . Keyring extension 260 includes an outer end 262 adapted to engage and connect to an outer end of a keyring lock of the type shown in FIG. 2 . In an embodiment shown in FIGS. 24 and 25 , the outer end 262 includes a latch 264 that connects to a latch receptacle 266 of the keyring lock 268 . This configuration provides for a positive lock between the outer end 262 of the keyring extension 260 and the keyring lock 268 . The keyring lock may be attached to the interior of the housing, or to the power source frame, using any suitable means of attachment. Preferably, the keyring lock is springbiased and may pivot about a circular post 270 (shown in FIG. 20 ) in the same manner as shown in FIG. 9 .
[0109] Alternatively, as shown in FIGS. 26 a and 26 b , the keyring lock may include a receptacle hood 270 that extends over the receptacle 272 , such that the receptacle hood 270 abuts the keyring extension latch 264 , thus preventing an over-extension of the keyring lock 268 . Preferably, the keyring extension is made of ABS, Acrylonitrile Butadiene Styrene, along with the power source frame, although any suitable nonconductive material may be used. The keyring lock is preferably made of a different material, such as nylon, so that it does not become welded to the keyring extension during ultrasonic welding of the power source frame housing sides.
[0110] In yet an additional embodiment, shown in FIGS. 27 through 29 , a power source frame 322 may include a magnet cavity 370 positioned in bottom support 335 that is adapted to receive a magnet 372 . The magnet attracts both the power source and the weight, if used, to further maintain the placement of the internal components. In the absence of a power source frame, the magnet is preferably positioned within the housing. In a preferred embodiment, the internal magnet 372 is approximately 0.060 inches thick and a half inch in diameter. The magnet is advantageously made of Neodymium alloyed with iron and boron. Most preferably it is a NEP3042NP Neodymium 30 magnet having a Rockwell C scale hardness of 55 available from Bunting Magnets. It is also preferably nickel plated to protect against corrosion. The magnet weighs only 0.003 pounds and has a holding force of three pounds. The use of an internal magnet allows the outer surfaces of the light to maintain their distinctive smooth lines and allows for engravings or other indicia to be placed on the outer surfaces of the light. With this magnet, the light can be attached to refrigerators, toolboxes, or any metal surface. An adhesive steel disc may be provided that may be mounted on any surface in any location to provide a place to attach the light. For example, the steel disc can be mounted to the interior dashboard of a car to provide a resting place for the light and allow for quick retrieval when needed.
[0111] A further alternative embodiment is shown in FIGS. 30 and 31 . This embodiment includes a translucent housing 400 . The translucent housing may be made of polycarbonate. The flashlight may be constructed using any of the various embodiments disclosed herein. Preferably it includes a power source frame 410 that may also be made of translucent material. In a preferred embodiment, the flashlight includes a translucent power source frame housing 420 having integral side covers that together completely enclose the power source frame. The housing is preferably made of a colored translucent material that may include a matching colored LED 430 . For example, a flashlight having a red colored translucent housing may be used with a red LED. With the translucent housing, the light emitted from the LED is dispersed throughout the housing to provide an illuminated housing. Alternatively, the housing may be provided with separate side covers that are either translucent or opaque. Different colored LEDs may be used with a different colored housing, as well as different colored side covers to provide a rainbow, or kaleidoscope of colors. Or, if the side covers are opaque, the light is only dispersed throughout the translucent portion of the housing.
[0112] In an further alternative embodiment, shown in FIG. 32 , flashlight 500 may include a keyring extension 510 extending from the housing, or power source frame if used, and may further include a keyring lock 520 extending from the interior of the housing, or the power source frame if used. The keyring lock 520 is preferably springbiased, or most preferably internally hinged, as shown in FIG. 32 . The keyring lock 520 includes an outer end 530 that is biased towards and abuts an outer end 540 of keyring extension 510 . The keyring lock operates to allow a keyring to be slipped between the outer end 530 of the keyring lock and the outer end 540 of the keyring extension 510 . This embodiment also may include side covers 550 that are made of santoprene.
[0113] While certain features and embodiments of the invention have been described herein, it will be readily understood that the invention encompasses all modifications and enhancements within the scope and spirit of the present invention. | A flashlight having a light-emitting diode light source with first and second leads extending therefrom, a power source, a power source frame enclosing at least a portion of the power source; a housing containing the light source and power source, a switch located adjacent the power source and operable to close a circuit including the light source and the power source, and wherein one or all of the following may be included 1) a keyring extension extending from a power source frame or the housing with the keyring extension having an opening whereby an article can be attached to the keyring extension and includes a keyring lock wherein upon exerting a force against the keyring lock, the keyring lock is opened to permit the article to be attached to the keyring extension; 2) the housing is comprised of translucent material; and 3) the housing includes at least one side cover which is not integral with the housing and the at least one side cover being selected from anodized aluminum, anodized metal, anodized metal which includes indicia, die struck metal, laser engraved metal, and a side cover having a separate medallion attached thereto. | 5 |
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