description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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GOVERNMENT RIGHTS
This invention was made with Government support under Contract No. F33657-98-C-3008. The Government has certain rights in this invention.
RELATED APPLICATION
The present application is based on the Applicants' U.S. Provisional Patent Application Ser. No. 60/072,693, entitled "Control System for Oscillating Structures," filed on Jan. 27, 1998.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of control systems. More specifically, the present invention discloses a control system for counter-oscillating masses, such as found in a light detection and ranging (LIDAR) spacecraft, to provide overall controller and system structural modal stability.
2. Statement of the Problem
Spacecraft have been used for a number of years for remote sensing of earth environmental concerns. Some of these spacecraft have employed small oscillating mirrors to optically scan earth features. An application of this type, using a large mirror, has been proposed for a LIDAR payload. A large oscillating inertia on a spacecraft, even when a counterbalance is used, can couple through the scanning controller with flexible spacecraft structure to cause structural modal instability of the overall system. The requirement to stabilize the overall spacecraft structural system including the controller is the primary motivation behind this invention.
Active remote sensing techniques using lasers such as LIDAR and laser altimetry, have proven useful for many years. While such methods from ground-based and airborne platforms are fairly mature, active remote sensing from space-based platforms is still very much in its infancy. However, the global reach of space-based methods make them highly attractive for a wide range of active remote sensing activities such as detection of atmospheric pollution, global wind measurement, topological, chlorophyll and mineral mapping, and global climate monitoring. An important requirement for space-based LIDAR-type systems is the ability to accurately scan a laser spot and collect the scattered return signal. In general, this translates to the ability to precisely scan a large aperture mirror system. Throughout the remainder of the present application, the word "system" should be construed as including, but not being limited to a LIDAR or similar space-based system.
FIG. 1 is a simplified schematic diagram of the scanning device, including a mirror 12, a counterbalance 16, and an actuator 14 for rotating the mirror 12 and counterbalance 16 about a common axis. The mirror 12 oscillates in a sinusoidal scanning motion with an amplitude of plus and minus a certain number of desired degrees. The oscillation is about a center position which could be nadir or any other commanded center position. The counterbalance 16 is driven oppositely to the mirror 12 to produce, in the ideal case, zero net angular momentum. A closed-loop controller commands and stabilizes the oscillating motion of the mirror 12 and counterbalance 16.
Research into controller designs uncovered an unexpected result in which the actuator 14, closed-loop controller, and flexible spacecraft structure 18 couple to create an unstable condition. The instability was unexpected because the actuator is designed, with the mirror 12 and counterbalance 16 oscillating in opposite directions, to produce very little net force and torque on the mounting structure. The actuator 14 is attached to a flexible mounting structure 18 that is in turn attached to a spacecraft bus 19 that hosts the system payload. Other possible flexible elements of this system are the bus 19 itself and appendages such as solar arrays and booms supporting antenna and other instrument packages. All such flexible elements can contribute to the observed instability. Straight forward application of a conventional PID (proportional, integral, differential) controller was found not to be sufficient to stabilize this phenomenon. Therefore, a need exists for a control system capable of preventing such instability in this type of system.
3. Solution to the Problem
The present invention provides a control system for a highly precise and efficient mechanical scanning device suitable for use in this type of system. In particular, the present invention employs feedback control with a high bandwidth channel for the mirror and a low-bandwidth channel for the counterbalance. The counterbalance control channel includes torque cross-feed from the mirror control channel, and a notch filter to remove the commanded oscillation frequency.
SUMMARY OF THE INVENTION
This invention provides a new controller design that is capable of stabilizing the flexible body bending modes of the system containing the controller and its actuating mechanism, while providing angular position control of an oscillating mass connected to a counter-oscillating counterbalance. The actuating mechanism uses two drive motors to exert torques on the mass and counterbalance, respectively, under the control of a feedback controller. The controller has a first control channel generating a first torque command signal for the first drive based on the angular position of the mass, and a second control channel generating a second torque command signal for the second drive based on the angular position of the counterbalance and a torque cross-feed signal from the first control channel. The second control channel includes a notch filter for removing input frequencies in a predetermined bandwidth about the frequency of the first torque command signal. Removal of frequencies at and about the first torque command signal allows just enough of the counterbalance controller error signal through the counterbalance channel to keep the oscillation of the counterbalance centered about its desired center of oscillation, and it allows essentially equal and opposite torques to be commanded to the mass and counterbalance. These features contribute significantly to the capability of this new design to stabilize the system flexible body structural modes. The present invention provides a control system for a highly precise and efficient mechanical scanning device suitable for use in a space-based LIDAR application or other similar airborne or ground-based systems. These and other advantages, features, and objects of the present invention will be more readily understood in view of the following detailed description and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention can be more readily understood in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic diagram of a LIDAR scanning device with a mirror 12 and counterbalance 16.
FIGS. 2(a) and 2(b) are schematic diagrams of two examples of prior art actuators. FIG. 2(a) uses a reaction wheel to cancel the torque and momentum imparted to a vehicle or mounting structure by a rotating mirror in a LIDAR system or by any rotating mass in a similar system. FIG. 2(b) uses a counter-rotating mass for this purpose. However, neither example is known to employ the unique controller described in this invention.
FIG. 3 is a schematic diagram of a LIDAR non-reactive drive system using a first drive for the mirror and a second drive for the counterbalance.
FIG. 4 is a block diagram of the LIDAR flexible body plant model.
FIG. 5(a) is a block diagram of a controller using matched high-gain mirror and counterbalance control channels.
FIG. 5(b) is a block diagram of a controller using an open-loop counterbalance control channel. In contrast to FIG. 5(a), the counterbalance channel is entirely absent in this figure.
FIG. 5(c) is a block diagram of a controller using torque cross-feed with a low-bandwidth counterbalance channel.
FIG. 6 is a Nichols plot of the system with the controller shown in FIG. 5(a).
FIG. 7 is a block diagram of a controller similar to FIG. 5(c), but including a notch filter in the counterbalance control channel.
FIG. 8 is a Nichols plot of the system with the controller shown in FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
Actuator Selection
The actuators described herein, by themselves, are not the heart of this invention. However, the description of the candidate actuators helps define the environment of intended use for the present control system.
One of the concerns with a large oscillating mirror 12 is the disturbances it imparts to the spacecraft bus 19, as shown in FIG. 1. For a one-meter mirror, a significant disturbance torque would arise beyond the capability of standard reaction wheel systems. The oscillating mirror 12 will impart a disturbance to the spacecraft unless some type of cancellation technique is used. FIGS. 2(a), 2(b), and 3 show three candidate schemes to incorporate a reactionless drive.
As shown in FIGS. 2(a) and 2(b), traditional approaches use a reaction wheel or a counter-rotating inertia to cancel the torque and momentum imparted to the vehicle. The counter-rotating inertia is not powered by a separate motor as in FIG. 3. These approaches have significant shortcomings in that they require additional power and would be hard pressed to meet the torque required to cancel the effect of a large oscillating mirror. In the drive shown in FIG. 2(a), a specially designed high-torque wheel 22 would be required. The second traditional option shown in FIG. 2(b) uses a counter-rotating inertia 25 driven a gear train 23. This technique will supply the required torque but is highly inefficient in terms of power.
The reactionless drive shown in FIG. 3, which is the actuator used in the preferred embodiment of this invention, uses a torsion spring 35 to connect the mirror 12 to a counterbalance mass 16. The ends of the torsion spring 35 are attached only to the mirror 12 and counterbalance 16. The spring 35 allows potential energy to swap back and forth between the mirror 12 and counterbalance 16 thus minimizing the torque capability required of the drive motors 31, 32 and 33, 34. This configuration results in basically a second-order resonant spring-mass system. Minimum power consumption is achieved when the oscillatory scanning motion is driven at the resonant frequency of the system. As a variation, two torsion springs could be used, one for the mirror and one for the counterbalance, where one end of each spring is rigidly attached to a non-rotating structure such as the case of the drive motors. However, this variation would preclude large-angle repositioning of the mirror. It should also be understood that the torsion spring 35 need not be a separate element, but rather could result from the torsional spring constant of the shaft connecting the mirror 12 and counterbalance 16. In contrast to the embodiments shown in FIGS. 2(a) and 2(b), this approach is not only reactionless but also energy efficient.
Two DC torque motors 31, 32 and 33, 34 are shown in FIG. 3, one on each mass 12, 16. It may seem possible that only one motor would be sufficient to excite a resonant system; however, the characteristics of this particular system might preclude the use of just one motor. In this system the inertias of the mirror 12 and counterbalance 16 are large, and this system is very lightly damped because it is built with extremely low friction to minimize power consumption. With only one motor, an excessively long time of uneven oscillatory motion is observed before accurate steady-state scanning is achieved. In the oscillatory or scanning mode, the two motors drive the mirror 12 and counterbalance 16 in opposite directions. As a result, steady-state oscillatory motion is quickly achieved. In the repositioning mode, the mirror 12 can be positioned to scan about any center position. Repositioning requires that the mirror and counterbalance motor be slewed in the same direction. Again, two drives are best for repositioning large inertias in a lightly damped system. The actuator used in the preferred embodiment of this invention implies a dual-channel controller.
Two highly-precise absolute encoders 36 and 37, one on the counterbalance motor shaft and one on the mirror motor shaft, furnish the positions of the shafts to the closed-loop controller and may be used to commutate the motors.
This actuator design meets all requirements for this scanning application and it seems fairly straightforward. However, as mentioned in the Statement of the Problem, when this system is mounted on a flexible spacecraft, unexpected coupling occurs with the spacecraft structure that gives rise to system instability. The controller designs that are needed to stabilize this system are discussed next.
Controller Design
This section develops the system plant model and then discusses several candidate control schemes for stabilizing the plant while meeting high positioning accuracy requirements and minimizing disturbances on the spacecraft.
System Plant Model
FIG. 4 is a block diagram of the flexible body spacecraft plant model. The controller generates the torque commands T cmd .sbsb.-- m and T cmd .sbsb.-- cb to the mirror and counterbalance drive motors. In FIG. 4, Kt m and Kt cb are the torque constants for the mirror and counterbalance motors. T m and T cb are the torques generated by the motors. T s is the spring torque acting on the mirror and counterbalance. B s is the damping constant of the spring and K s is the spring constant.
In the flexible body state space plant model, B is the system input matrix, C is the output matrix, and A is the system or plant matrix. The A matrix contains bending modes and the mirror and counterbalance inertia effects. The outputs of the C matrix contain the effects of the bending modes.
The input to the B matrix has four elements. For the mirror, the torque from the mirror motor plus the spring torque is applied to the mirror inertia. The motor torque, T m , is applied with a negative sign to the motor case and thus is the reaction torque resulting from motor action that is felt by the mounting structure. Torques are applied similarly in the counterbalance control channel.
Referring ahead to FIG. 7, one example is shown of how the LIDAR plant model 40 (from FIG. 4) is integrated into an overall closed-loop controller scheme. In FIG. 7, two control channels are shown, one for the mirror channel containing a PID controller and a bending filter 73, and one for the counterbalance channel also containing a PID controller and a bending filter 74. These bending filters remove input frequencies corresponding to the bending modes of the mirror 12 and counterbalance 16, respectively. Thus, the bending filters serve to stabilize the local bending modes of the mirror and counterbalance, and they may or may not contribute to stabilizing the system stability problem which involves flexibility of the entire spacecraft or mounting structure.
A PID controller allows any combination of proportional, integral, and differential functions to be generated by the input to generate the controller output. However, proportional-differential controllers may be sufficient in the present invention.
Of note in FIG. 7 is the θ mcmd variable. It is the sinusoidal position command for the mirror. The gain factor (G cf ) 76 is nominally -1. It inverts θ mcmd to drive the counterbalance oppositely to the mirror. G cf is always negative for the oscillatory mode. It is equal to the inertia ratio of the mirror to the counterbalance, and thus may be somewhat greater than or less than exactly -1. In the reposition mode, where the mirror and counterbalance move together in the same direction, G cf is set to +1. FIG. 7 also shows a notch filter 75 and a torque cross feed gain (K cf ) 77. These items are unique and crucial to solution of the system stability problem and are discussed in the next section.
Candidate Controller Designs
FIGS. 5(a) through 5(c) show three candidate controller designs. The bandwidth and thus the gain of the mirror channel always has to be high to meet the precision pointing requirements for the mirror. Each design is discussed in the following subsections:
Matched High-Gain Mirror and Counterbalance Control Channels
The first attempt at a controller design, shown in FIG. 5(a), has equal high-bandwidth channels for both the mirror and counterbalance. This configuration easily meets positioning requirements for the mirror but results in an unstable system as shown in the Nichols plot of FIG. 6. Instability in FIG. 6 is indicated by the curve passing above the -180 degree, 0 dB point on the plot. This instability is caused, as mentioned previously, by coupling between the controller, the drive actuator, and spacecraft flexible elements.
To resolve this system instability, the key observation is that if equal but opposite torque is applied to the mirror and counterbalance, then there should be no net reaction torque applied back on the flexible spacecraft. With dual high-gain position channels this is impossible to do in a practical sense because of parameter variations. One specific problem is the need to exactly calibrate the command cross feed gain, G cf , which as mentioned earlier, is the ratio of the mirror to counterbalance inertia. The effective inertias of the mirror and counterbalance depend on their bending characteristics and are therefore difficult to predict precisely. A straightforward solution is to feed the commanded torque, T cmd .sbsb.-- m , with a negative sign, to the counterbalance and open the counterbalance control loop. Thus we have equal and opposite torques applied to the mirror and counterbalance. This configuration is shown in FIG. 5(b).
Open-Loop Counterbalance Controller
The open-loop counterbalance controller in FIG. 5(b) appears to be an ideal solution to the control problem as it eliminates the need to cross feed the commanded mirror angle so that the inertia ratio need not be known accurately, and it eliminates the possibility of the counterbalance exciting system flexible body modes. Unfortunately, it has the downfall of all open-loop schemes in that it is very sensitive to parameter differences in the plant. In fact, this configuration is unstable. The counterbalance will slowly drift away from its center point due to plant differences between the mirror and the counterbalance. Obviously, a closed-loop control channel for the counterbalance is still needed.
Torque Cross Feed with Low Bandwidth Counterbalance Channel
The low bandwidth counterbalance controller, shown in FIG. 5(c), removes many of the sensitivity problems. However the bandwidth of the controller must be kept high enough to at least keep the counterbalance centered about its center of oscillation and to remain insensitive to variations in the motor torque constants, K tm and K tcb , as shown in FIG. 4. This creates two problems: First, since the command frequency of θ mcmd is coming through the counterbalance PID controller, too much torque, T cmd .sbsb.-- cb , is commanded. In fact T cmd .sbsb.-- cb can be almost double since it is the sum of the torque cross feed through K cf and the torque command from the counterbalance PID controller. The only way to avoid T cb becoming excessively large is to lower the gain of the counterbalance PID controller further to the point where the counterbalance channel is almost open loop. Thus we are back to the problems of the open-loop controller. Secondly, the position command θ mcmd must still be cross-fed to the counterbalance, so the inertia ratio must be known. Further, this approach only very slightly reduces the susceptibility to system modal instability. The ideal controller would not excite system modes, would be insensitive to plant variations, and would not require knowledge of the inertia ratio. The following controller meets these requirements.
Torque Cross Feed with Command Signal Notch Filter
By adding a notch filter as shown in FIG. 7, set at the frequency of θ mcmd , to the low bandwidth counterbalance control loop, the torque commanded at the command frequency is removed. (Recall that the frequency of θ mcmd is constant, equal to the resonant frequency of the spring-mass actuator system.) This solves the excessive torque problem and other problems mentioned above with the low bandwidth counterbalance channel. Because the notch filter is designed to remove the command frequency, the closed-loop counterbalance loop can focus on centering the counterbalance while allowing the torque cross feed through K cf to take care of the torque cancellation. The parameter, K cf , is also used to compensate for any differences in torque constants, K tm and K tcb , between the mirror and counterbalance motors, and therefore in practice may not be exactly 1.0. Because the command signal frequency is removed, the notch filter makes the counterbalance controller insensitive to the inertia ratio. With the notch filter included, the counterbalance bandwidth may not exceed the command frequency. Inclusion of the notch filter in this system is a large part of what makes this invention a significant improvement over the prior art.
Returning to FIG. 7, a schematic diagram is provided of the controller. The mirror encoder 71 outputs the angular position of the mirror, θ m and the counterbalance encoder 72 outputs the angular position of the counterbalance, θ cb . The controller receives a command signal for the desired angular position of the mirror, θ mcmd , as an input. In the mirror control channel, θ m is subtracted from θ mcmd to output θ m .sbsb.-- err to the mirror bending filter and PID 73. The PID generates a mirror torque command signal, T cmd .sbsb.-- cb , as a proportional, integral, and differential function of θ m .sbsb.-- err .
In the counterbalance control channel, θ mcmd is multiplied by a predetermined cross-feed gain factor, G cf , to output θ cb .sbsb.-- cmd . θ is then subtracted from θ cb .sbsb.-- cmd to output θ cb .sbsb.-- err to a notch filter 75, which removes or attenuates frequencies from θ cb .sbsb.-- err in a predetermined bandwidth about the frequency of the command signal, θ mcmd . The filtered θ cb .sbsb.-- err is processed by the counterbalance bending filter and PID 74, which generates a counterbalance torque command signal, T cmd .sbsb.-- cb , as a proportional, integral, and differential function of the filtered θ cb .sbsb.-- err .
The mirror torque command signal, T cmd .sbsb.-- m , for the mirror control channel is multiplied by a predetermined torque cross-feed factor, K cf , to output T cf . T cf is subtracted from T cmd .sbsb.-- cb before T cmd .sbsb.-- cb is output to the counterbalance drive.
FIG. 8 shows the Nichols plot for the torque-cross-feed-with-notch system illustrated in FIG. 7. In comparison with FIG. 6, FIG. 8 shows almost no response to the system bending modes and FIG. 8 shows that the previous stability concern no longer exists.
The discussion above describes the main mode of operation of this system, namely the scanning or oscillatory mode. The system is also required to reposition the mirror 12. The presence of the notch filter is compatible with the reposition mode of operation. When the mirror 12 and counterbalance 16 are commanded to reposition, the commanded reposition signal is not significantly affected by the notch filter because the frequency content of the reposition signal is not concentrated about the commanded resonant oscillation frequency. The reposition signal is simply a constant value or ramp that commands the mirror 12 and counterbalance 16 to move together from one angular position to another. When the mirror 12 and counterbalance 16 are commanded to reposition, the cross feed gain, K cf , is set to zero as shown in FIGS. 5(a)-5(c) and 7.
For example, the mirror 12 and counterbalance 16 could be commanded to reposition from 0 degrees to 30 degrees. The mirror 12 and counterbalance 16 then move in unison from the initial position of 0 degrees to the final position of 30 degrees. After the final position is reached, oscillation about the 30-degree center point can be commanded. As described above, there is sufficient counterbalance error signal to keep the counterbalance oscillation centered about the 30-degree center point.
In summary, the present invention provides a scanning controller for the LIDAR mission based on the reactionless drive shown in FIG. 3. The reactionless drive provides the desired minimum energy solution to the actuation problem, but it creates challenging control problems. Control of the mirror and counterbalance system presented behaviors that required a unique solution. Excitation of system structural modes, that occurred with the high bandwidth position controllers, was an unexpected problem. Several conventional low bandwidth position controller designs were tried. However, they provide only limited isolation from the system structural modes. When the control problem was viewed as one of torque canceling rather than one of accurately controlling the counterbalance position with high bandwidth to achieve torque cancellation, the system stability problem was minimized. One controller was found to provide system mode isolation. This unique controller uses a notch filter in the counterbalance channel to remove the commanded frequency, making it insensitive to inertia differences between the mirror and the counterbalance. The resulting low bandwidth in the counterbalance channel along with cross-fed torque provides minimum excitation of system modes. A major advantage of this controller, since it stabilizes bending modes of the entire system, is that it can eliminate a possible need for modal testing of the entire assembled spacecraft or system. Thus, the cost of this type of modal testing, which can run beyond six figures, is avoided. It is believed that this design is the best controller for the reactionless drive system shown in FIG. 3.
Although the preceding discussion has focused on use of the present control system in the context of a LIDAR payload having a oscillating mirror and counterbalance, it should be understood that the present invention could be applied in many other fields of use. In particular, the present control system can be employed in any system of counter-rotating masses. For example, the present invention can be used in compressors, rotating machinery, instrumentation, radars, antennas, telescopes, scanning devices, and other types of balloon-mounted or satellite-mounted imaging systems. Therefore, the mirror 12 described above can be viewed generally as any rotating mass, and should not necessarily be limited to an optical structure.
The above disclosure sets forth a number of embodiments of the present invention. Other arrangements or embodiments, not precisely set forth, could be practiced under the teachings of the present invention and as set forth in the following claims. | A control system stabilizes the flexible body bending modes of a space, airborne, or ground-based system, while providing angular position control of an oscillating mass connected to a counter-oscillating counterbalance. The actuating mechanism uses two drive motors to exert torques on the mass and counterbalance, respectively, under the control of a feedback controller. The controller has a first control channel generating a first torque command signal for the first drive based on the angular position of the mass, and a second control channel generating a second torque command signal for the second drive based on the angular position of the counterbalance and a torque cross-feed signal from the first control channel. The second control channel includes a notch filter for removing input frequencies in a predetermined bandwidth about the frequency of the first torque command signal. The same controller can be used to control the system in oscillation and for large angle repositioning of the mass and counterbalance. The present invention provides a control system for a highly precise and efficient mechanical scanning device suitable for use in a space-based LIDAR system or other similar systems. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to drip irrigation and more particularly to drip irrigation pipes which are biodegradable in situ.
BACKGROUND OF THE INVENTION
[0002] The following patent publications are believed to represent the current state of the art:
U.S. Pat. No. 4,474,330; U.S. Patent Publications 2008/0191464 and 2008/0072480.
SUMMARY OF THE INVENTION
[0005] The present invention seeks to provide drip irrigation pipes having desired biodegradable characteristics.
[0006] There is thus provided in accordance with a preferred embodiment of the present invention a delayed degradability drip irrigation pipe including a water conduit at a water conduit pressure and a plurality of drip irrigation outlets, each communicating with the water conduit and providing a water output at a pressure below the water conduit pressure, at least the water conduit being formed at least partially of a degradable material and also including a degradability delayer which provides a desired delay prior to failure of the water conduit but permits eventual degradation of the degradable material under predetermined conditions.
[0007] In accordance with a preferred embodiment of the present invention, the degradable material includes biodegradable material.
[0008] Preferably, the degradability delayer includes a bacterial growth delayer.
[0009] In accordance with a preferred embodiment of the present invention, the degradability delayer includes a generally non-biodegradable material which is mixed with the biodegradable material.
[0010] In accordance with a preferred embodiment of the present invention, the degradability delayer is mixed with the biodegradable material.
[0011] Preferably, the degradability delayer is formed as a co-extruded layer alongside the biodegradable material. Additionally, the degradability delayer is formed as a co-extruded inner layer of the drip irrigation pipe. Alternatively or additionally, the degradability delayer is formed as a co-extruded outer layer of the drip irrigation pipe.
[0012] In accordance with a preferred embodiment of the present invention the degradability delayer is formed as strips along the length of the drip irrigation pipe.
[0013] In accordance with a preferred embodiment of the present invention the water conduit includes at least one first layer formed of a biodegradable material, the biodegradable material being mixed with a biodegradability delayer and at least one second layer formed of a non-biodegradable, UV degradable material. Additionally, the at least one second layer also includes an oxo-biodegradable material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:
[0015] FIG. 1 is a simplified illustration of part of a delayed degradability drip irrigation pipe constructed and operative in accordance with a preferred embodiment of the present invention;
[0016] FIG. 2 is a simplified comparative illustration of the relative degradability characteristics of a biodegradable drip irrigation pipe and of the delayed degradability drip irrigation pipe, constructed and operative in accordance with a preferred embodiment of the present invention, illustrated in FIG. 1 ;
[0017] FIG. 3 is a simplified illustration of part of a delayed degradability drip irrigation pipe constructed and operative in accordance with another preferred embodiment of the present invention;
[0018] FIG. 4 is a simplified comparative illustration of the relative degradability characteristics of a biodegradable drip irrigation pipe and of the delayed degradability drip irrigation pipe, constructed and operative in accordance with another preferred embodiment of the present invention, illustrated in FIG. 3 ;
[0019] FIG. 5 is a simplified illustration of part of a delayed degradability drip irrigation pipe constructed and operative in accordance with a further preferred embodiment of the present invention;
[0020] FIG. 6 is a simplified comparative illustration of the relative degradability characteristics of a biodegradable drip irrigation pipe and of the delayed degradability drip irrigation pipe, constructed and operative in accordance with a further preferred embodiment of the present invention, illustrated in FIG. 5 ;
[0021] FIG. 7 is a simplified illustration of part of a delayed degradability drip irrigation pipe constructed and operative in accordance with yet another preferred embodiment of the present invention;
[0022] FIG. 8 is a simplified comparative illustration of the relative degradability characteristics of a biodegradable drip irrigation pipe and of the delayed degradability drip irrigation pipe, constructed and operative in accordance with yet another preferred embodiment of the present invention, illustrated in FIG. 7 ;
[0023] FIG. 9 is a simplified illustration of part of a delayed degradability drip irrigation pipe constructed and operative in accordance with still another preferred embodiment of the present invention;
[0024] FIG. 10 is a simplified comparative illustration of the relative degradability characteristics of a biodegradable drip irrigation pipe and of the delayed degradability drip irrigation pipe, constructed and operative in accordance with yet another preferred embodiment of the present invention, illustrated in FIG. 9 ;
[0025] FIG. 11 is a simplified illustration of part of a delayed degradability drip irrigation pipe constructed and operative in accordance with still a further another preferred embodiment of the present invention; and
[0026] FIG. 12 is a simplified comparative illustration of the relative degradability characteristics of a biodegradable drip irrigation pipe and of the delayed degradability drip irrigation pipe, constructed and operative in accordance with yet another preferred embodiment of the present invention, illustrated in FIG. 11 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0027] Reference is now made to FIG. 1 , which is a simplified illustration of part of a delayed degradability drip irrigation pipe, constructed and operative in accordance with a preferred embodiment of the present invention, and to FIG. 2 , which is a simplified comparative illustration of the relative degradability characteristics of a biodegradable drip irrigation pipe and of the delayed degradability drip irrigation pipe constructed and operative in accordance with the preferred embodiment of the present invention illustrated in FIG. 1 .
[0028] FIG. 1 illustrates part of a delayed degradability drip irrigation pipe 100 which includes discrete emitter units 102 distributed along the length thereof in communication with the interior thereof. It is appreciated that the present invention is not limited in its applicability to this type of drip irrigation pipe and also applies to other types of drip irrigation pipes wherein the emitters are fully or partially defined by the pipe. The present invention applies to drip irrigation pipes which are formed by extrusion and equally to drip irrigation pipes that are formed by welding of elongate sheets.
[0029] The term “biodegradable” is used throughout to refer to degradation as the result of biological activity. When applied to irrigation pipes, it is not limited to pipes which do not leave any residue whatsoever in the ground.
[0030] The irrigation pipe 100 is preferably formed of a biodegradable plastic material, such as PBAT (polybutylene adipate/teraphthalate), PTMAT (polymethylene adipate/teraphthalate), naturally produced polyester, such as PHA polyesters (polyhydroxyalkanoates), PHBH polyesters (poly-hydroxybutyrate-co-polyhydroxy hexanoates) and PLA polyesters (polylactic acid), which is biodegradable by bacterial and/or fungal action.
[0031] In accordance with a preferred embodiment of the present invention delayed degradability functionality is provided by the addition of an active anti-bacterial and anti-fungal agent which demonstrates activity against a wide range of bacteria, mold and yeast, such as CIBA® IRGAGUARD® B-1000, B-5000 or B-7000, HYGATE® 4000 or 9000 and ALPHASAN®.
[0032] Preferably, the active anti-bacterial and anti-fungal agent is mixed with the biodegradable plastic material prior to formation of the pipe, for example, prior to extrusion of the pipe or of a sheet from which the pipe is formed. Alternatively, the active anti-bacterial and anti-fungal agent is co-extruded onto one or more surface of the pipe or sheet or coated thereon.
[0033] As seen in FIG. 1 , the active anti-bacterial and anti-fungal agent may appear throughout the thickness of the pipe 100 .
[0034] Turning to FIG. 2 , degradable plastic drip irrigation pipes 100 , which include an active anti-bacterial and anti-fungal agent, are shown alongside biodegradable plastic drip irrigation pipes 110 , which do not include an active anti-bacterial and anti-fungal agent, at the same point in time.
[0035] It is seen that at a given point in time, typically six months following installation, biodegradable plastic drip irrigation pipes 110 , which do not include an active anti-bacterial and anti-fungal agent, are in the process of biodegradation, typically under bacterial and fungal action. In contrast, in accordance with a preferred embodiment of the present invention, delayed degradability drip irrigation pipes 100 , constructed and operative in accordance with a preferred embodiment of the present invention, include active anti-bacterial and anti-fungal agents, thereby delaying biodegradation under bacterial and fungal action, for a time duration, until such agents are no longer released or they become ineffective.
[0036] Reference is now made to FIG. 3 , which is a simplified illustration of part of a delayed degradability drip irrigation pipe, constructed and operative in accordance with another preferred embodiment of the present invention, and to FIG. 4 , which is a simplified comparative illustration of the relative degradability characteristics of a biodegradable drip irrigation pipe and of the delayed degradability drip irrigation pipe constructed and operative in accordance with the preferred embodiment of the present invention illustrated in FIG. 3 .
[0037] FIG. 3 illustrates part of a delayed degradability drip irrigation pipe 200 which includes discrete emitter units (not shown) distributed along the length thereof in communication with the interior thereof. It is appreciated that the present invention is not limited in its applicability to this type of drip irrigation pipe and also applies to other types of drip irrigation pipes wherein the emitters are fully or partially defined by the pipe. The present invention applies to drip irrigation pipes which are formed by extrusion and equally to drip irrigation pipes that are formed by welding of elongate sheets.
[0038] The irrigation pipe 200 is preferably formed of a biodegradable plastic material, such as PBAT (polybutylene adipate/teraphthalate), PTMAT (polymethylene adipate/teraphthalate), naturally produced polyester, such as PHA polyesters (polyhydroxyalkanoates), PHBH polyesters (poly-hydroxybutyrate-co-polyhydroxy hexanoates) and PLA polyesters (polylactic acid), which is biodegradable by bacterial and/or fungal action.
[0039] In accordance with a preferred embodiment of the present invention, delayed degradability functionality is provided by provision of an active anti-bacterial and anti-fungal agent, which demonstrates activity against a wide range of bacteria, mold and yeast, such as CIBA® IRGAGUARD® B-1000, B-5000 or B-7000.
[0040] Preferably, the active anti-bacterial and anti-fungal agent is coextruded with the biodegradable plastic material during formation of the pipe or of a sheet from which the pipe is formed. Alternatively, the active anti-bacterial and anti-fungal agent is coated onto one or more surface of the pipe or sheet.
[0041] As seen in FIG. 3 , the active anti-bacterial and anti-fungal agent may appear as strips 204 along the length of the pipe 200 .
[0042] Turning to FIG. 4 , biodegradable plastic drip irrigation pipes 200 , which include an active anti-bacterial and anti-fungal agent, are shown alongside biodegradable plastic drip irrigation pipes 210 , which do not include an active anti-bacterial and anti-fungal agent, at the same point in time.
[0043] It is seen that at a given point in time, typically six months following installation, biodegradable plastic drip irrigation pipes 210 , which do not include an active anti-bacterial and anti-fungal agent, are in the process of biodegradation, typically under bacterial and fungal action. In contrast, in accordance with a preferred embodiment of the present invention, delayed degradability drip irrigation pipes 200 , constructed and operative in accordance with a preferred embodiment of the present invention, include active anti-bacterial and anti-fungal agents, thereby delaying biodegradation under bacterial and fungal action, for a time duration, until either such agents are no longer released or they become ineffective.
[0044] Reference is now made to FIG. 5 , which is a simplified illustration of part of a delayed degradability drip irrigation pipe, constructed and operative in accordance with yet another preferred embodiment of the present invention, and to FIG. 6 , which is a simplified comparative illustration of the relative degradability characteristics of a biodegradable drip irrigation pipe and of the delayed degradability drip irrigation pipe constructed and operative in accordance with the embodiment of the present invention illustrated in FIG. 5 .
[0045] FIG. 5 illustrates part of a delayed degradability drip irrigation pipe 300 which includes discrete emitter units (not shown) distributed along the length thereof in communication with the interior thereof. It is appreciated that the present invention is not limited in its applicability to this type of drip irrigation pipe and also applies to other types of drip irrigation pipes wherein the emitters are fully or partially defined by the pipe. The present invention applies to drip irrigation pipes which are formed by extrusion and equally to drip irrigation pipes that are formed by welding of elongate sheets.
[0046] The irrigation pipe 300 is preferably formed of a biodegradable plastic material, such as PBAT (polybutylene adipate/teraphthalate), PTMAT (polymethylene adipate/teraphthalate), naturally produced polyester, such as PHA polyesters (polyhydroxyalkanoates), PHBH polyesters (poly-hydroxybutyrate-co-polyhydroxy hexanoates) and PLA polyesters (polylactic acid), which is biodegradable by bacterial and/or fungal action.
[0047] In accordance with a preferred embodiment of the present invention, delayed degradability functionality is provided by the addition of a generally non-biodegradable material, such as polyethylene, to the biodegradable plastic material.
[0048] Additionally, in accordance with a preferred embodiment of the present invention, delayed degradability functionality may be enhanced by the addition of an active anti-bacterial and anti-fungal agent which demonstrates activity against a wide range of bacteria, mold and yeast, such as CIBA® IRGAGUARD® B-1000, B-5000 or B-7000, HYGATE® 4000 or 9000 and ALPHASAN®. Preferably, the active anti-bacterial and anti-fungal agent is mixed with the biodegradable plastic material prior to formation of the pipe, for example, prior to extrusion of the pipe or of a sheet from which the pipe is formed.
[0049] Preferably, the generally non-biodegradable material is mixed with the biodegradable plastic material prior to formation of the pipe, for example, prior to extrusion of the pipe or of a sheet from which the pipe is formed. The resulting pipe or sheet includes relatively long linked plastic molecules which define a net or screen type structure 302 , which resists and delays degradation, such as failure due to bursting of the drip irrigation pipe 300 , notwithstanding early stage biodegradation of the biodegradable plastic material thereof.
[0050] As seen in FIG. 5 , the generally non-biodegradable material preferably is distributed generally throughout the thickness of the pipe 300 .
[0051] Turning to FIG. 6 , biodegradable plastic drip irrigation pipes 300 , which include an internal net or screen type structure 302 formed of a generally non-biodegradable material, are shown alongside biodegradable plastic drip irrigation pipes 310 , which do not include an internal net or screen type structure formed of a generally non-biodegradable material, at the same point in time.
[0052] It is seen that at a given point in time, typically six months following installation, biodegradable plastic drip irrigation pipes 310 , which do not include an internal net or screen type structure formed of a generally non-biodegradable material, are in the process of biodegradation, typically under bacterial and fungal action. In contrast, in accordance with a preferred embodiment of the present invention, delayed degradability drip irrigation pipes 300 , constructed and operative in accordance with a preferred embodiment of the present invention, are mechanically strengthened against bursting by net or screen type structure 302 , thereby delaying degradation under bacterial and fungal action for a desired time duration.
[0053] Reference is now made to FIG. 7 , which is a simplified illustration of part of a delayed degradability drip irrigation pipe, constructed and operative in accordance with still another preferred embodiment of the present invention, and to FIG. 8 , which is a simplified comparative illustration of the relative degradability characteristics of a biodegradable drip irrigation pipe and of the delayed degradability drip irrigation pipe constructed and operative in accordance with the preferred embodiment of the present invention illustrated in FIG. 7 .
[0054] FIG. 7 illustrates part of a delayed degradability drip irrigation pipe 400 which includes discrete emitter units 402 distributed along the length thereof in communication with the interior thereof. It is appreciated that the present invention is not limited in its applicability to this type of drip irrigation pipe and also applies to other types of drip irrigation pipes wherein the emitters are fully or partially defined by the pipe. The present invention applies to drip irrigation pipes which are formed by extrusion and equally to drip irrigation pipes that are formed by welding of elongate sheets.
[0055] The irrigation pipe 400 is preferably formed of a biodegradable plastic material, such as PBAT (polybutylene adipate/teraphthalate), PTMAT (polymethylene adipate/teraphthalate), naturally produced polyester such as PHA polyesters (polyhydroxyalkanoates), PHBH polyesters (poly-hydroxybutyrate-co-polyhydroxy hexanoates) and PLA polyesters (polylactic acid), which is biodegradable by bacterial and/or fungal action.
[0056] In accordance with a preferred embodiment of the present invention, delayed degradability functionality is provided by the addition of an active anti-bacterial and anti-fungal agent, which demonstrates activity against a wide range of bacteria, mold and yeast, such as CIBA® IRGAGUARD® B-1000, B-5000 or B-7000, HYGATE® 4000 or 9000 and ALPHASAN®, to at least one of, and preferably all of, an outer coextruded biodegradable plastic layer 404 , an innermost coextruded biodegradable plastic layer 405 and a middle biodegradable plastic layer 406 of pipe 400 .
[0057] Preferably, the active anti-bacterial and anti-fungal agent is mixed with the biodegradable plastic material used to form layer 404 , layer 405 and/or layer 406 , prior to coextrusion of the pipe or of a sheet from which the pipe is formed.
[0058] As seen in FIG. 7 , the active anti-bacterial and anti-fungal agent may appear throughout the thickness of the outer layer 404 , innermost layer 405 and/or middle layer 406 of pipe 400 . It is appreciated that the active anti-bacterial and anti-fungal agents included in outer layer 404 , innermost layer 405 and middle layer 406 may be the same for each layer or may be different for each layer to provide different time delays for the delayed degradability functionality of delayed degradability drip irrigation pipe 400 .
[0059] Turning to FIG. 8 , biodegradable plastic drip irrigation pipes 400 , in which at least one of outer layer 404 , innermost layer 405 and/or middle layer 406 include an active anti-bacterial and anti-fungal agent, are shown alongside biodegradable plastic drip irrigation pipes 410 , which do not include an active anti-bacterial and anti-fungal agent, at the same point in time.
[0060] It is seen that at a given point in time, typically six months following installation, biodegradable plastic drip irrigation pipes 410 , which do not include at least one layer including an active anti-bacterial and anti-fungal agent, are in the process of biodegradation, typically under bacterial and fungal action. In contrast, in accordance with a preferred embodiment of the present invention, delayed degradability drip irrigation pipes 400 , constructed and operative in accordance with the preferred embodiment of the present invention of FIG. 7 include active anti-bacterial and anti-fungal agents, thereby delaying biodegradation under bacterial and fungal action for a time duration until either such agents are no longer released or they become ineffective.
[0061] It is appreciated that, although in the illustrated embodiment shown in FIG. 7 , pipes 400 include three layers 404 , 405 and 406 , in accordance with the present invention pipes 400 may include any number of layers, including two or more layers, of which at least one layer includes active anti-bacterial and anti-fungal agents. In a most preferred embodiment of the present invention, at least the outermost layer of pipes 400 includes active anti-bacterial and anti-fungal agents.
[0062] Reference is now made to FIG. 9 , which is a simplified illustration of part of a delayed degradability drip irrigation pipe, constructed and operative in accordance with still another preferred embodiment of the present invention, and to FIG. 10 , which is a simplified comparative illustration of the relative degradability characteristics of a biodegradable drip irrigation pipe and of the delayed degradability drip irrigation pipe constructed and operative in accordance with the preferred embodiment of the present invention illustrated in FIG. 9 .
[0063] FIG. 9 illustrates part of a delayed degradability drip irrigation pipe 500 which includes discrete emitter units 502 distributed along the length thereof in communication with the interior thereof. It is appreciated that the present invention is not limited in its applicability to this type of drip irrigation pipe and also applies to other types of drip irrigation pipes wherein the emitters are fully or partially defined by the pipe. The present invention applies to drip irrigation pipes which are formed by extrusion and equally to drip irrigation pipes that are formed by welding of elongate sheets.
[0064] The irrigation pipe 500 is preferably formed of a biodegradable plastic material, such as PBAT (polybutylene adipate/teraphthalate), PTMAT (polymethylene adipate/teraphthalate), naturally produced polyester such as PHA polyesters (polyhydroxyalkanoates), PHBH polyesters (poly-hydroxybutyrate-co-polyhydroxy hexanoates) and PLA polyesters (polylactic acid), which is biodegradable by bacterial and/or fungal action.
[0065] In accordance with a preferred embodiment of the present invention, delayed degradability functionality is provided by the addition of at least one of an outer coextruded biodegradable plastic layer 504 and an innermost coextruded biodegradable plastic layer 505 , containing an active anti-bacterial and anti-fungal agent which demonstrates activity against a wide range of bacteria, mold and yeast, such as CIBA® IRGAGUARD® B-1000, B-5000 or B-7000, HYGATE® 4000 or 9000 and ALPHASAN®.
[0066] Preferably, the active anti-bacterial and anti-fungal agent is mixed with the biodegradable plastic material used to form layer 504 and/or layer 505 , prior to coextrusion of the pipe or of a sheet from which the pipe is formed.
[0067] It is appreciated that the active anti-bacterial and anti-fungal agent may appear throughout the thickness of the outer layer 504 and/or innermost layer 505 of pipe 500 .
[0068] Turning to FIG. 10 , biodegradable plastic drip irrigation pipes 500 , which include a coextruded outer layer 504 and/or inner layer 505 , including an active anti-bacterial and anti-fungal agent, are shown alongside biodegradable plastic drip irrigation pipes 510 , which do not include an active anti-bacterial and anti-fungal agent, at the same point in time.
[0069] It is seen that at a given point in time, typically six months following installation, biodegradable plastic drip irrigation pipes 510 , which do not include a coextruded outer layer including an active anti-bacterial and anti-fungal agent, are in the process of biodegradation, typically under bacterial and fungal action. In contrast, in accordance with a preferred embodiment of the present invention, delayed degradability drip irrigation pipes 500 , constructed and operative in accordance with the preferred embodiment of the present invention of FIG. 9 include active anti-bacterial and anti-fungal agents, thereby delaying biodegradation under bacterial and fungal action for a time duration until either such agents are no longer released or they become ineffective.
[0070] Reference is now made to FIG. 11 , which is a simplified illustration of part of a delayed degradability drip irrigation pipe, constructed and operative in accordance with still a further preferred embodiment of the present invention, and to FIG. 12 , which is a simplified comparative illustration of the relative degradability characteristics of a biodegradable drip irrigation pipe and of the delayed degradability drip irrigation pipe constructed and operative in accordance with the preferred embodiment of the present invention illustrated in FIG. 11 .
[0071] FIG. 11 illustrates part of a delayed degradability drip irrigation pipe 600 which includes discrete emitter units 602 distributed along the length thereof in communication with the interior thereof. It is appreciated that the present invention is not limited in its applicability to this type of drip irrigation pipe and also applies to other types of drip irrigation pipes wherein the emitters are fully or partially defined by the pipe. The present invention applies to drip irrigation pipes which are formed by extrusion and equally to drip irrigation pipes that are formed by welding of elongate sheets.
[0072] The irrigation pipe 600 is preferably formed with an outer layer 604 of a biodegradable plastic material, such as PBAT (polybutylene adipate/teraphthalate), PTMAT (polymethylene adipate/teraphthalate), naturally produced polyester such as PHA polyesters (polyhydroxyalkanoates), PHBH polyesters (poly-hydroxybutyrate-co-polyhydroxy hexanoates) and PLA polyesters (polylactic acid), which is biodegradable by bacterial and/or fungal action.
[0073] In accordance with a preferred embodiment of the present invention, delayed degradability functionality is provided by the addition to the outer layer 604 of an active anti-bacterial and anti-fungal agent which demonstrates activity against a wide range of bacteria, mold and yeast, such as CIBA® IRGAGUARD® B-1000, B-5000 or B-7000, HYGATE® 4000 or 9000 and ALPHASAN®.
[0074] In accordance with a preferred embodiment of the present invention, additional delayed degradability functionality is provided by the provision of an inner layer 606 formed of a plastic material which is not-biodegradable but is degradable in response to exposure to another degradability initiator, such as UV. A suitable UV degradable plastic material is polyethylene. Layers 604 and 606 are preferably co-extruded.
[0075] Additionally, inner layer 406 may also include an oxo-biodegradable material, such as EPIcor™ 2058, commercially available from EPI Environmental Products, Inc., of Vancouver, B.C., Canada, which enhances breakdown of inner layer 606 .
[0076] Preferably, the active anti-bacterial and anti-fungal agent is mixed with the biodegradable plastic material used to form layer 604 , prior to co-extrusion of the pipe or of a sheet from which the pipe is formed.
[0077] It is appreciated that the active anti-bacterial and anti-fungal agent may appear throughout the thickness of the outer layer 604 .
[0078] Turning to FIG. 12 , biodegradable plastic drip irrigation pipes 600 , which include a coextruded outer layer 604 and inner layer 606 as described hereinabove, are shown alongside biodegradable plastic drip irrigation pipes 610 , which do not include an active anti-bacterial and anti-fungal agent, at the same point in time.
[0079] It is seen that at a given point in time, typically six months following installation, biodegradable plastic drip irrigation pipes 610 , which do not include a coextruded outer layer including an active anti-bacterial and anti-fungal agent, are in the process of biodegradation, typically under bacterial and fungal action. In contrast, in accordance with a preferred embodiment of the present invention, delayed degradability drip irrigation pipes 600 , constructed and operative in accordance with the preferred embodiment of the present invention of FIG. 11 , remain intact and functional for a predetermined, desired duration.
[0080] It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes combinations and subcombinations of the features described above as well as modifications and variations which would occur to persons skilled in the art upon reading the foregoing description and which are not in the prior art. | A delayed degradability drip irrigation pipe including a water conduit at a water conduit pressure and a plurality of drip irrigation outlets, each communicating with the water conduit and providing a water output at a pressure below the water conduit pressure, at least the water conduit being formed at least partially of a degradable material and also including a degradability delayer which provides a desired delay prior to failure of the water conduit but permits eventual degradation of the degradable material under predetermined conditions. | 8 |
BACKGROUND OF THE INVENTION
The invention relates in general to rotary electric machines, in particular electric machines in which an axial spring element is arranged between the rotor body and the bearing of the rotor shaft.
In electric machines having an internal rotor, a rotor body which bears a rotor armature is generally arranged on a rotor shaft. The rotor shaft is mounted in a housing of the electric machine by means of corresponding ball bearings.
Document JP 2000 30 8305 A also discloses that arranged between a ball bearing and the rotor body on the rotor shaft is a washer which supports the rotor axially with respect to the ball bearing. In this context, the washer is embodied as a spring element with a ring part on which radially protruding spring parts are integrally formed, said spring parts being supported in a sprung fashion on the rotor armature. Document DE 2004 041 074 A1 discloses an electric machine in which the axial spring element is fixedly attached to the rotor armature.
SUMMARY OF THE INVENTION
According to the invention, an axial spring element for a rotary electric machine and an electric machine and a method for assembling the electric machine are provided.
According to a first aspect, an axial spring element is provided with two peripheral ring elements which are spaced apart from one another in the axial direction and are connected to one another in a spring-elastic fashion, wherein at least one of the ring elements comprises one or more retaining elements in order to brace the spring element with a rotor and thereby retain the spring element on the rotor.
An idea of the axial spring element above is to ensure secure and at the same time simple and robust mounting of the spring element when an electric machine is constructed. In the known prior art, it was necessary to make structural interventions into the design of the rotor, in particular of the rotor body, in order to secure the axial spring element fixedly on the rotor body. This lead to expenditure incurred for the change and/or to increases in the expenditure for the design of the components relating to the rotor, in particular the rotor body. The above axial spring element therefore provides that it can be connected to the rotor without structural interventions into rotor bodies or the rotor shaft being necessary. However, at the same time it is ensured that the axial spring element can also be applied to the vertical rotor shaft and connected to the rotor in such a way that it cannot become detached from the rotor.
For this purpose, the axial spring element provides, on its outer part, sprung retaining elements which are secured by a press fit to the rotor, in particular to an insulating lamination of the rotor body or of the rotor shaft. As a result, the spring element can be secured axially without having to change rotor components. Furthermore, the elastic retaining elements have the advantage that tolerances due to manufacture and mounting can be compensated. As a result of the clamping connection between the retaining elements of the spring element and the rotor, acceleration forces of the rotor can be transmitted directly to the spring element, with the result that a relative movement in the form of a slip between the rotor and the spring element is no longer possible during the operation of the motor.
It is also possible to provide that the one or more retaining elements is/are each embodied with a retaining claw which protrudes outward in the radial direction from the respective ring element.
Furthermore, the one or more retaining elements can each be embodied with a retaining claw which protrudes inward in the radial direction from the respective ring element.
According to a further embodiment, the ring element on which the one or more retaining elements is/are arranged can be larger than a further ring element of the ring elements, and wherein the corresponding retaining claws protrude obliquely in the direction of the further ring element.
According to a further aspect, an electric machine is provided, in particular for use in a motor vehicle, comprising:
a rotor with a rotor shaft and a rotor body arranged thereon; a housing part with a bearing for accommodating the rotor shaft of the rotor; an elastic spring element according to the invention, and which is arranged between the bearing and the rotor body on the rotor shaft;
wherein the spring element comprises, at its end facing the rotor body, one or more retaining elements in the axial direction, with which one or more retaining elements the end facing the rotor body can be braced in such a way that the spring element is held on the rotor body.
Furthermore, the rotor body can be provided with a cylindrical internal recess into which the spring element is inserted.
It is also possible to provide that the internal recess is formed by a hollow cylindrical insulating lamination on which an armature packet composed of armature laminations is applied.
According to a further aspect, a method for mounting an electric machine is provided, wherein before a rotor is inserted into a housing part the above spring element is fitted onto a rotor shaft of the rotor, at least until the retaining element or elements secures/secure the spring element against dropping out, and wherein the rotor is subsequently inserted with the spring element into the housing part, with the result that the rotor shaft is retained by the bearing.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention are explained in more detail below with reference to the appended drawings, in which:
FIG. 1 shows an exploded illustration of an electric machine;
FIGS. 2A to 2C show views of the axial spring element according to one embodiment;
FIG. 3 shows a perspective illustration of a rotor with an inserted spring element;
FIG. 4 shows a plan view in an axial direction of the rotor with an inserted spring element; and
FIG. 5 shows a view of the axial spring element according to a further embodiment.
DETAILED DESCRIPTION
FIG. 1 illustrates a perspective exploded illustration of a part of an electric machine 1 . In the present exemplary embodiment, the electric machine 1 corresponds to an internal rotor electric motor. The electric machine 1 comprises a housing part 2 , which is embodied as a pole pot. The pole pot can be embodied in one piece from a metallic material, for example by deep drawing or comparable manufacturing methods.
The housing part 2 has at its front-side end a circular-cylindrical recess 3 in which a bearing 4 in the form of a ball bearing or roller bearing can be accommodated. In the mounted state, the bearing 4 is accommodated completely or partially in the recess 3 and retained against slipping at least in the radial direction by the peripheral wall of the recess 3 . The bearing 4 is embodied in a conventional way with an internal part 41 and an external part 42 which are arranged in a rotational fashion with respect to one another by means of rollers or balls (not shown). The internal part 41 has a through-opening 43 which is concentric with respect to the external circumference of the bearing 4 .
A rotor 5 is also provided which has a rotor body 52 on a rotor shaft 51 . The rotor body 52 also comprises a rotor armature 55 which is attached to the rotor shaft 51 . An essentially cylindrical insulating part 53 , which defines an essentially circular-cylindrical internal recess 54 , can be provided between the rotor shaft 51 and the rotor armature 52 . The rotor armature 52 is embodied, for example, as a lamination packet which is fitted onto the insulating part 53 .
An elastic spring element 6 is arranged between the bearing 4 and the rotor 5 in order to brace the rotor shaft 51 axially with respect to the bearing 4 . The spring element 6 is supported, on the one hand, on the internal part 41 of the bearing 4 and, on the other hand, on the rotor body 52 .
As is shown in the views in FIGS. 2 a to 2 c , the spring element 6 has an internal ring 61 and an external ring 62 which are embodied concentrically with respect to the receptacle of the rotor shaft 51 and are offset axially with respect to one another. The internal ring 61 and the external ring 62 are connected to one another by means of webs 63 which are helical or at least arranged obliquely with respect to the radial direction. The webs 63 are embodied in such a way that they enable an axially sprung displacement of the internal ring 61 and of the external ring 62 with respect to one another in order to make available spring travel in the axial direction. In the exemplary embodiment shown, three webs 63 are provided, but the number of webs 63 is essentially random, provided that the axial spring mounting between the internal ring 61 and the external ring 62 is ensured.
The axial spring element 6 is manufactured, for example, as a punched bend part composed of spring steel and can have depressions in a suitable form in order to prevent bending of the internal ring 61 or of the external ring 62 .
In the embodiment shown in FIGS. 2 a to 2 c , the external ring 62 has retaining claws 64 , protruding on its outer circumference, as elastic retaining elements with which the spring element 6 can be pressed into the internal recess 54 , with the result that the retaining claws 64 press against a peripheral internal wall of the internal recess 54 and thereby secure the spring element 6 against dropping out from the internal recess 54 . In the non-mounted state, the external ends of the retaining claws 64 define a diameter which is larger than the diameter of the rotor shaft 51 .
The retaining claws 64 are preferably arranged distributed around the circumferential direction of the external ring 62 . The number of the retaining claws 64 is preferably three, but it is also possible to provide only two or more than three retaining claws 64 .
The retaining claws 64 preferably protrude outward in the radial direction and obliquely in the direction of the internal ring 61 , i.e. in the direction of the bearing 4 . In this way, during the mounting of the electric machine 1 it is easily possible to fit the spring element 6 into the rotor recess 54 until the retaining claw 64 is braced with the internal surface of the insulating part 53 and thereby ensures the reliable seat of the spring element 6 .
Various views of a spring element 6 which has been introduced into the internal recess 54 of the rotor 5 are illustrated in FIGS. 3 and 4 . It is clear that the external ends of the retaining claw 64 rest on the internal wall of the internal recess 54 and thereby retain the spring element 6 concentrically with respect to the rotor shaft 51 .
In order to mount the electric machine 1 , the axial spring element 6 is secured at least axially on the pre-mounted rotor 5 by pushing it into the internal recess 54 . The spring element 6 is reliably retained on the rotor 5 by the retaining claws 64 , with the result that the rotor 5 can also be inserted upside down by means of what is referred to as blind mounting into the bearing 4 which has been mounted in the housing part 2 . The axial prestress of the spring element 6 can be adjusted on the basis of the axial mounting force. When thermal expansion occurs during operation, the rotor body 52 can be displaced with respect to the housing part 2 while maintaining an axial clamping force, without the spring element 6 being able to become tilted on the rotor shaft 51 .
According to a further embodiment which is illustrated in FIG. 5 , the retaining elements can also be embodied in the form of retaining claws 65 which extend inward in the radial direction and which are arranged on the external ring 62 . In this embodiment the retaining claws are also preferably embodied running obliquely in the direction of the internal ring 61 . In the non-mounted state, the internal ends of the retaining claws 65 define a diameter which is smaller than the diameter of the rotor shaft 51 . In this case, during mounting the retaining claws 65 may brace with the rotor shaft 51 . | The invention relates to an axial spring element ( 6 ) having two peripheral ring elements ( 61, 62 ) that are spaced from one another in the axial direction and are connected to one another in a spring-elastic manner, wherein at least one of the ring elements ( 61 ) comprises one or more retaining elements ( 64 ) in order to brace the spring element with a rotor ( 5 ) and thereby hold the spring element on the rotor ( 5 ). | 5 |
BACKGROUND OF THE INVENTION
This invention is broadly in the field of latch devices and is more specifically directed to latching means that is resistant to undesired opening movement caused by vibration of the members on which the latching means is mounted.
Latch means for enabling retention of closures, cabinet doors and the like are employed in a wide variety of devices and embody a similar large number of structural designs. All such latch devices should desirably provide a reliable, easy to use latching function. Unfortunately, many of the prior known devices, while satisfactory for use on rigid, firm support members, have not provided satisfactory performance when mounted on access doors or the like of equipment such as washing machines in which the latch members are subjected to substantial continuous vibration. More specifically, many prior known latching devices employing slide bolt means mounted for movement between a locking position and an unlocked position tend to move toward the unlocked position under the influence of the vibrational forces to which they are subjected. The foregoing is true even in the case of slide-bolt members in which spring means are provided for biassing the slide-bolt toward a locked position.
While it is possible to solve the foregoing problem by the provision of relatively complex structures such as over-center toggle linkages and the like, no simple, inexpensive and easy to use solution to the problem has been proposed prior to the subject invention.
Therefore, it is the primary object of this invention to provide a new and improved latch means.
A more specific object of the invention is the provision of new and improved latch means having latch locking capability resistant to vibrational forces imparted to the latch means by the members on which the latch means is mounted.
A still further object of the invention is the provision of new and improved latch means that is economical to fabricate, easy to use and reliable in operation.
Achievement of the foregoing objects is enabled by the preferred embodiments of the invention through the provision of a rotary latch lock mounted in association with a slide-bolt component of the latch device. The rotary latch lock is supported on a stub shaft for rotation with a compressible washer also being mounted on the stub shaft and biassed against one side of the rotary latch lock to provide a frictional resistance to rotation of the latch lock member. The engagement of the compressible washer with the rotary latch lock serves to maintain the rotary latch lock in any desired position of rotation but permits the latch lock to be manually rotated to such a desired position without undue effort. The rotary latch lock comprises a disc member having a cylindrical outer surface portion about a substantial portion of its periphery and having a chordal surface defining the remaining portion of its periphery. The chordal surface is spaced closer to the axis of the rotary member.
Positioning of the rotary latch lock so that the chordal surface faces means extending from the slide-bolt enables the slide-bolt to move toward the rotary latch lock to an unlocking position. However, the rotary latch lock can be rotated to a second position in which the cylindrical surface faces the slide-bolt when the slide-bolt is in its locked position. Engagement of the cylindrical surface with the slide-bolt when the slide-bolt is in the locked position serves to prevent movement of the slide-bolt toward the unlocked position. Moreover, the friction washer engageable with the rotary latch lock serves to maintain the latch lock in any position of rotation so that vibration will not result in movement of the latch lock to permit the slide bolt to become unlocked under the influence of such vibrations.
In another embodiment of the invention, the rotary latch lock is mounted on the slide-bolt in a position adjacent a fixed bracket lug for rotation about a stub shaft. In this embodiment, an identical compressible friction washer engages the rotary latch lock to maintain the latch lock in any given position of rotation while permitting manual adjustment of the latch lock without undue effort. The outer surface of the rotary latch lock of the last-mentioned embodiment is cylindrical for the most part, but is interrupted by a radial slot of a width greater than the width of the stop lug. Rotation of the latch lock to a position in which the radial slot is aligned with the stop lug enables movement of the latch lock and the slide-bolt to an unlocked position. However, movement of the slide-bolt to a locked position and positioning of the rotary latch lock with the cylindrical surface facing the stop lug prevents movement of the slide-bolt to the unlocked position. The members will remain in the foregoing position due to the operation of the compressible washer engaging the rotary latch lock.
A better understanding of the manner in which the preferred embodiments of the invention achieve the objects of the invention will be enabled when the following written description is considered in conjunction with the appended drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the preferred embodiment of the invention illustrating the latch member components in a locked condition;
FIG. 2 is a perspective view of the latch members of FIG. 1 illustrating the latch member components in an unlocked condition;
FIG. 3 is a sectional view taken along lines 3--3 of FIG. 1;
FIG. 4 is a sectional view taken along the same lines as FIG. 3 but illustrating the parts in an unlocked condition as in FIG. 2;
FIG. 5 is an exploded perspective view of the latch lock components of the preferred embodiment;
FIG. 6 is a perspective view of another embodiment of the invention illustrating the component parts in a locked condition;
FIG. 7 is a perspective view of the embodiment of FIG. 6 illustrating the component parts in an unlocked condition;
FIG. 8 is a front elevation view of the embodiment of FIG. 6;
FIG. 9 is a sectional view taken along lines 9--9 of FIG. 8;
FIG. 10 is a perspective view of another embodiment of the invention illustrating the component parts in a locked condition;
FIG. 11 is a perspective view of the embodiment of FIG. 10 illustrating the component parts in an unlocked condition;
FIG. 12 is an elevational view of the embodiment of FIG. 10 illustrating the parts in a locked condition;
FIG. 13 is a sectional view taken along lines 13--13 of FIG. 12;
FIG. 14 is a front elevation view of another embodiment of the invention illustrating the component parts in a locked condition;
FIG. 15 is a front elevation view of the embodiment of FIG. 14 illustrating the component parts in an unlocked condition; and
FIG. 16 is an exploded perspective view of the slide-bolt and latch lock components of the embodiment of FIG. 14.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Attention is initially invited to FIG. 1 of the drawings which illustrates the preferred embodiment of the invention, generally designated 10, mounted on a door or panel member 20 supported by a hinge 22 on a housing 24. A keeper 26 is fixedly attached to an upper portion 28 of the housing and a slide-bolt guide means 30 is fixedly attached to the door or panel 20.
A slide-bolt 32 is mounted for axial reciprocation in the slide-bolt guide means 30 with a slide-bolt actuator 34 being fixedly connected to the lower end of the slide-bolt 32 as best shown in FIG. 2. Slide-bolt actuator 34 is larger than the opening in the slide-bolt guide 30 and the upper surface 36 consequently serves as a stop for limiting the extent of upward movement which the slide-bolt 32 is capable of achieving. Additionally, it should be noted that the slide-bolt actuator 34 also includes a forwardly facing open slot S as shown in FIG. 2 which is provided for receipt of an actuator rod or the like employed on doors or panels using latch members of this type.
Slide-bolt 32 is capable of movement between an extended or locking position illustrated in FIG. 1 and a retracted or unlocking position illustrated in FIG. 2. In the extended position, the upper end of the slide-bolt is received within the keeper 26 in a well-known manner while in the retracted position, the slide-bolt end is fully enclosed and received within the slide-bolt guide 30 as shown in FIG. 2.
Latch lock means for maintaining the slide-bolt in a locked or extended position is provided below the slide-bolt actuator 34 and comprises a rotary latch lock 40 mounted on a stub shaft 42 for rotation in a manner to be discussed. Stub shaft 42 is supported by a U-shaped bracket member 44 including a spanner portion 46 and mounted on the door or panel member 20 as best shown in FIG. 1. A compressible vibration damping means consisting of a compressible washer 48 formed of material such as neoprene having a hardness of approximately 60 durometer is mounted on the stub shaft 42 and received in a cylindrical recess 50 on the outer face of the rotary latch lock member 40 as shown in FIG. 3. A metal washer 52 engages the outer face of the compressible washer 48 under the influence of a retainer nut 54 so that the washer 48 is slightly compressed and serves to provide resistance to rotation of the rotary latch lock 40 in an obvious manner. However, the rotary latch lock 40 is capable of manual rotation as desired.
Rotary latch lock 40 has a first outer peripheral surface 56 concentric about the axis of stub shaft 42 and the opening in the latch lock through which the stub shaft passes and which comprises a cylindrical surface. The remainder of the peripheral surface of the rotary latch lock 40 comprises a second peripheral surface 58 which is a planar chordal surface with respect to the cylindrical surface 56 and which is obviously more closely spaced to the axis of stub shaft 42 than is the cylindrical surface 56. Two manually engageable actuator protrusions 59 for enabling rotation of latch lock 40 extend outwardly from the front face of member 40.
When the rotary latch lock 40 is positioned with the cylindrical surface 56 engaging the lower face 37 of the slide-bolt actuator 34, it is impossible for the slide-bolt 32 to move from the locked position as illustrated in FIGS. 1 and 3. On the other hand, when the rotary latch lock 40 is positioned with the chordal surface 58 facing the lower face 37 of actuator 34, the slide-bolt 32 can move to its retracted or unlocking position illustrated in FIGS. 2 and 4. When the slide-bolt is held in the locking position of FIGS. 1 and 3, vibrational forces do not have any rotational effect on the latch lock 40 and the slide-bolt consequently remains locked regardless of the influence of such vibrational forces. However, the latch lock 40 can be easily rotated by manual gripping of protrusions 59 to enable an unlocking movement of the latch bolt to the position illustrated in FIGS. 2 and 4.
The embodiment illustrated in FIGS. 6-9 is similar to the embodiment of FIGS. 1-5 with the latch components comprising a keeper 60 mounted on a fixed panel component 62, a slide-bolt guide 64 supporting a slide-bolt 66 for axial reciprocation. The slide-bolt guide 64 has a slot 68 in its outer face through which a lug 69 extends. The lug 69 is in facing relation to a rotary latch lock 40 identical to the rotary latch lock of the first embodiment. The rotary latch lock 40 is mounted on a U-shaped bracket 44 identical to the first bracket 44 extending transversely across the slide-bolt guide 64 and supporting the rotary latch lock 40 in exactly the same manner. It will be apparent that positioning of the rotary latch lock 40 with its cylindrical surface 56 facing the lug 69 as in FIGS. 6 and 8 will serve to retain the slide-bolt 66 in a locked position as thus illustrated in said figures. The rotary latch lock is held in position by a compressible washer in exactly the same manner and employing exactly the same construction as that illustrated in FIG. 5.
FIG. 7 illustrates the rotary latch lock in a position permitting the slide-bolt 66 to be moved to its unlocked position.
Turning now to FIGS. 10-13, it will be noted that these figures illustrate another embodiment of the invention including a keeper 72 mounted on a fixed panel 73 for receiving the outer end of a slide-bolt 74 mounted for reciprocation in a slide-bolt guide means 75 fixed to the face of a movable door or panel 76. A slot is provided in the outer face of the slide-bolt guide 75 in a manner essentially identical to the slot provided in the slide-bolt guide 64 of the last-discussed embodiment, and a support lug 78 extends outwardly from the slide-bolt 74 for providing support on its outer end for an actuator knob 80. A rotary latch lock 40 identical to the previously discussed latch lock is supported on an identical U-shaped bracket and is mounted below the actuator knob 80 and can be rotated to the position illustrated in FIG. 12 for holding the slide-bolt 74 in a locked condition. Alternatively, the latch lock 40 can be rotated to the position illustrated in FIG. 11 for permitting the slide-bolt 74 to move to its unlocked position. Since the rotary latch lock 40 of the embodiment of FIGS. 10-13 is mounted in an identical manner to the previously discussed latch locks, the compressible washer associated therewith serves to retain the latch lock in any position of rotation in which it is occupying.
Turning now to FIGS. 14-16, it will be noted that these figures illustrate another embodiment of the invention which constitutes a modification of the device illustrated in FIGS. 10-13. The last embodiment employs a keeper 72 mounted on a fixed panel 73 in conjunction with a movable door or closure 76 on which a slide-bolt guide 75 containing a slide-bolt 74 is mounted. The parts of the last embodiment discussed in the preceeding sentence having the same reference numerals as the parts in the last-discussed embodiment are identical to the like numbered parts of the last-discussed embodiment of FIGS. 10, etc.
However, the embodiment of FIGS. 14-16 employs a latch lock member 84 mounted for positionable rotation on a stub shaft bolt 86 extending through the slot in the outer face of the slide-bolt guide 75. A slot 88 extends inwardly radially from the outer periphery of the latch lock 84 and is of a sufficient width to be received over a stop lug 90 extending outwardly from a spanner portion 100 of a U-shaped bracket plate 102 fixedly connected to the movable door or panel member 76. When the latch lock 84 is in the position illustrated in FIG. 14, its outer cylindrical peripheral portion 85 engages the stop lug 90 to prevent the slide-bolt from moving to the unlocking position. However, rotation of the latch lock 84 to the position illustrated in FIG. 15 in which the slot 88 is aligned with the stop lug 90 permits the movement of the slide-bolt to the unopened position. The latch lock 84 is mounted as shown in FIG. 16 with a spacer 104 engaging a washer 49 and a washer 52 engaging a compressible washer 48 which is identical to the previously discussed washer member bearing the same designator. Consequently, the rotary latch lock 84 tends to remain in any given position in which it is rotationally positioned, but can be manually rotated for enabling an unopening of the slide-bolt 74. Latch lock 84 can also be provided with protrusions like members 59 if desired.
While numerous modifications of the subject invention will undoubtedly occur to those of skill in the art, it should be understood that the spirit and scope of the invention is to be limited solely by the appended claims. | A slide-bolt type latch locking means is disclosed including a rotary member mounted on a shaft for engagement with a latch bolt to hold the latch bolt in locked condition; a rubber washer is compressed by the rotary latch lock and prevents rotation of the latch lock by vibration of the supporting member to maintain the latch lock in position but permitting manual rotation of the latch lock to permit unlocking of the latch-bolt. Another embodiment employs a rotary latch lock mounted on a slide bolt with a radial slot alignable with a fixed lug to permit movement of the slide bolt to an opened condition, a movement not possible when the slot is not aligned with the fixed lug; a compressible washer maintains the latch lock in any given position of rotation. | 4 |
The present invention relates to a process for lining wellbores and to a tool for producing downhole coatings for a wellbore.
BACKGROUND TO THE INVENTION
As a general method of forming a wellbore, e.g. for extraction of oil or gas from a formation, a drilling operation typically involves mounting a drill bit on a drilling assembly (the “bottom hole assembly”) at the lower end of a drill string and rotating the drill bit against the bottom of a hole to penetrate the formation, thereby creating a wellbore.
A drilling fluid, such as a “drilling mud”, typically circulates down through the drill string, passes via the drill bit, and returns back to the surface, usually in the annular portion between the drill string and the wall of the wellbore. The drilling fluid serves a number of purposes, including lubricating the drill bit and cooling the drilling assembly. However, the drilling fluid can also be suitably pressurized to provide sufficient hydrostatic pressure at the wellbore wall to prevent the flow of fluids into the wellbore from the surrounding formation.
Such relatively high pressure can produce undesirable mechanical forces on the formation, which may lead to wellbore damage. In particular, as the wellbore deepens the hydrostatic pressure at the lower end of the wellbore can be significantly higher than the pressure near the entrance aperture of the wellbore.
Accordingly, in the past, it has been necessary periodically to halt the drilling operation and to provide a casing within the wellbore to provide structural support, the casing typically being cemented in place to the wall of the wellbore. U.S. Pat. Nos. 4,760,882, 4,547,298 and 4,768,593 describe such a process in more detail.
In particular, in the method disclosed in these patents a cement mixture is located in the annular region between the casing and the wall of the wellbore and is set (solidified) in situ by exposure to gamma-radiation produced by e.g. a Co-60 source lowered down the encased wellbore on a probe.
However, to be able to drill a deep wellbore or a wellbore in a relatively unstable formation (e.g. a shale or clay formation), the drilling operation must be halted repeatedly to allow the wellbore to be so encased. This has disadvantages in that it delays the extraction of valuable oil and/or gas from the well and consequently has a negative economic impact.
GB Patent No. 2 363810 recognizes this disadvantage and discloses a method of lining a wellbore during the drilling operation. The method allows a material to form a layer supported by a wall of the wellbore, where the material is selected so that the shear modulus of the layer is smaller than the shear modulus of the formation forming the wall of the wellbore. When the wellbore is sufficiently deep, a casing can be cemented in place in the wellbore in the usual way.
GB Patent No. 2420572 discloses a process of forming a layer on the wall of a wellbore when drilling through a shale and/or clay formation. The interaction of water with a shale and/or clay wellbore wall can cause the shale and/or clay to swell, thereby contracting the wellbore and possibly leading to softening and disintegration of the wall of the wellbore. The lining disclosed in GB Patent No. 2420572 is intended to prevent absorption of water into the shale and/or clay, rather than to provide the wellbore wall with mechanical support.
The process of GB2420572 includes the steps of bringing a drilling fluid which includes a graft polymer into contact with the clay or shale wall of the wellbore and letting the graft polymer form a layer on the wall. The graft polymer is a copolymer, formed by the reaction of an oligomeric or polymeric substrate with at least one ethylenically unsaturated monomer. The reaction to form the graft polymer, e.g. performed in a reaction chamber, is conducted in the presence of a type II photo initiator and by the action of actinic radiation. The resulting graft polymer being suitable for adding to a drilling mud for use as described above.
However, the use of such a process has its disadvantages. The extent of mechanical support offered by a layer of graft polymer is likely to be small. The graft polymer is relatively indiscriminate, and it is therefore likely to be difficult to control accurately the thickness or location of the layer which it forms on the wall of the wellbore.
SUMMARY OF THE INVENTION
Embodiments of the present invention provide a controllable process for lining a wellbore or coating downhole components of a wellbore, wherein a chemical reaction can be initiated downhole, by actinic radiation, to create a solid or gel, from a suitable fluid composition, for coating a surface.
In a first aspect, the present invention provides a process for lining a wellbore comprising: providing a fluid composition in an open-hole (i.e. uncased) wellbore, the fluid composition being solidifiable or gellable on exposure to actinic radiation of a predetermined wavelength; and providing actinic radiation of said predetermined wavelength at the wall of the wellbore, whereby the composition solidifies or gels to line said wall.
By providing the actinic radiation for solidifying or gelling the fluid composition in situ in the wellbore proximate to the region in which the solidified or gelled fluid composition is desired, more control over the lining of the wellbore is achievable. Thus, in accordance with an embodiment of the present invention, specific regions of a wellbore, e.g. cracked or fissured regions, can be lined or re-lined. Advantageously, the present invention also allows a wellbore, such as an open-hole wellbore, to be lined without the need to halt the drilling, or with the need to complete the drilling before lining the wellbore.
The predetermined wavelength of the actinic radiation may be in the range 1 nm to 1500 nm, 10 nm to 1500 nm, 100 nm to 1200 nm, or 200 nm to 1200 nm. On certain aspects, the actinic radiation is in the range of from 250 nm to 800 nm. Sources of actinic radiation in this wavelength range are readily available and are safe to use, and they do not carry the inherent risks associated with the use of ionizing radiation such as gamma-radiation etc.
In another aspect, the present invention provides a process for producing coatings on downhole components of a wellbore, the process comprising: providing a fluid composition at a surface of a downhole component of a wellbore, the fluid composition being solidifiable or gellable on exposure to actinic radiation of a wavelength in the range of from 250 nm to 800 nm; and providing actinic radiation of said wavelength at said surface, whereby the composition solidifies or gels to coat said surface.
The following preferred features are applicable to all aspects of the present invention.
The fluid composition may contain a pre-polymer and photoinitiator, the pre-polymer and photoinitiator taking part in a downhole reaction to form the solidified or gelled composition when irradiated with a sufficient dose of the actinic radiation. The solidified or gelled composition is preferably impermeable to wellbore and/or reservoir fluids.
The fluid composition may be formed downhole in the wellbore. Indeed, the fluid composition may be formed downhole and proximate to a predetermined region of the wall to be lined or to the surface to be coated.
One or more of the components of the fluid composition may be injected into the wellbore at the surface. If a drilling mud is injected to the wellbore at the surface, then the components of the fluid composition may be carried, e.g. downhole, by the drilling mud.
In another aspect, the present invention provides a tool for producing downhole coatings, the tool being configured to operate downhole, and comprising a source of actinic radiation of a wavelength in the range of from 250 nm to 800 nm.
The tool may further comprise a reservoir for holding one or more components of a fluid composition which is solidifiable or gellable on exposure to actinic radiation of such a wavelength, the reservoir being configured such that the components are controllably releasable from the reservoir to be delivered to a surface to be coated, e.g. for lining a wall of the wellbore.
In another aspect, the present invention provides a tool for producing downhole coatings, the tool being configured to operate downhole, wherein the tool comprises a source of actinic radiation of a predetermined wavelength, and a reservoir for holding one or more components of a fluid composition which is solidifiable or gellable on exposure to actinic radiation of said predetermined wavelength, the reservoir being configured such that the components are controllably releasable from the reservoir to be delivered to a surface to be coated, e.g. for lining a wall of the wellbore.
A tool according to the present invention may be attachable to a wireline and be operable when so attached. A tool according to the present invention may be attachable to a drill string or a coiled tubing, and may be operable when so attached. Therefore, the lining of the wellbore can take place during the drilling process. Indeed, a tool according to the present invention may be an element of a bottom hole assembly. The bottom hole assembly may carry the source of actinic radiation.
A tool according to the present invention could be an element of a drill string stabiliser. Advantageously, drill string stabilisers are generally in contact with a portion of the wellbore wall, and so a tool according to the present invention which is an element of such a stabiliser should also be located close to the wellbore wall, thereby allowing the wellbore to be lined progressively as the drill string is lowered downhole.
A tool according to the present invention may comprise one or more movable members which are deployable to irradiate the surface to be coated, e.g. the wall of the wellbore, with actinic radiation produced by said source. The movable members may carry the source of actinic radiation. The movable members may carry the light-emitting ends of one or more lights guides which extend from the source of actinic radiation.
The source of actinic radiation may include one or more light emitting diodes, one or more laser diodes, and/or one or more organic light emitting diodes, such as a polymer light emitting diode.
Further aspects and embodiments of the present invention will be apparent to those skilled in the art. For the avoidance of doubt, it is stated here that all documents mentioned in this text are incorporated herein by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
Aspects and embodiments of the present invention will now be illustrated, by way of example, with reference to the accompanying figures, in which:
FIG. 1 shows the shape of a mould used to produce solidified or gelled compositions for subsequent tensile testing;
FIG. 2 shows the results of tensile tests on acrylate resins, series A, for the compositions in Table 1;
FIG. 3 shows the curing Kinetics for acrylate resin Ad mixed with clay, for the composition in Table 1;
FIG. 4 shows the results of tensile tests on acrylate resin Ba with added clay, for the composition in Table 1;
FIG. 5 shows the results of tensile tests on divinyl ether resins, for the compositions in Table 2;
FIG. 6 shows the results of tensile strength tests on vinyloxybutylbenzoate type resins A:B ratio 2:1; and
FIG. 7 shows a tool according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Radiation curing is the technique of using electromagnetic (EM) or actinic radiation to cause physical changes in materials. The curing process can involve one or more of polymerisation, cross-linking, grafting, and, in certain cases, depolymerisation.
Frequently used sources of EM radiation for curing include electron beam (EB), ultraviolet light (UV) and gamma radiation. However, the field has recently expanded to include the use of deep UV (<200 nm), visible light, near infra-red radiation, and microwaves.
The EM radiation can be used to generate radicals, carbocations and bases, to initiate cycloaddition reactions, and in the case of microwave radiation, to bring about thermal reactions.
In the present invention, actinic radiation, preferably EM actinic radiation is used to gel or solidify a fluid composition which is solidifiable or gellable on exposure to the actinic radiation.
Examples of typically water-soluble chemicals which exhibit photo-initiated polymerization and are therefore suitable for implementing the present invention are acrylate and methacrylate monomers, such as:
Bis phenol A ethoxylate diacrylate; Ethylene glycol diacrylate (varying molecular weight); Hexanediol diacrylate; and Trimethyolpropane triacrylate.
Examples of water-soluble and oil-soluble chemicals which exhibit photo-initiated polymerization and are therefore suitable for implementing the present invention are vinyl ethers, such as:
Vectomers™: vinyloxybutyl benzoate and bis and tris variants; Urethane divinyl ethers; and Ethylene glycol divinyl ethers (varying molecular weight).
Merely by way of example, other examples of suitable chemicals are vinyl functionalized polymers and oligomers such as polybutadienes or polyisoprenes, block copolymers such as styrene-butadiene, styrene-butadiene-styrene and styrene-isoprene-styrene such as those manufactured by Kraton Polymer LLC. They are primarily solvated in nonaqueous base fluids and would be especially useful for use with oil based muds.
Thus, the prepolymer may be optionally substituted alkenyl, preferably optionally substituted C 2-5 alkenyl, most preferably optionally substituted C 2-3 alkenyl. The alkenyl may be substituted with one or more groups independently selected from C 1-10 alkyl, C 1-10 aryl and C 3-20 heterocyclyl, C 1-10 alkoxy, halo, hydroxyl and ester. Each of the substituents may be independently further substituted where appropriate. The alkenyl may be substituted with one or more groups independently selected from —R, —OR and —C(═O)OR, where R is halo or hydroxyl, or an optionally substituted group selected from: C 1-10 alkyl, C 1-10 aryl and C 3-20 heterocyclyl. The further substituents may be selected from C 1-10 alkyl, C 1-10 aryl and C 3-20 heterocyclyl, C 1-10 alkoxy, hydroxyl, halo and ester.
The optionally substituted C 2-5 alkenyl may be optionally substituted C 2-5 alk-1-enyl (also known as C 2-5 1-alkenyl). Preferably, the C 2-5 alk-1-enyl includes a vinyl functionality.
The prepolymer may contain one or more polyalkoxy (or polyether) moieties. Preferably, a polyalkoxy moiety is a polyethylene glycol.
Preferably, the molecular weight of a prepolymer is at most 700, at most 600, or at most 350.
A prepolymer may be selected from an acrylate prepolymer, a divinyl ether prepolymer, an alkenyl prepolymer, a styrene prepolymer and a vinyloxy)alkyl prepolymer.
In a preferred embodiment, an alkenyl substituent, including a substituent of an alkenyl substituent, comprises one or more alkenyl groups. The compound may be referred to as a bisalkenyl prepolymer where two alkenyl groups are present in the prepolymer, or a trisalkenyl prepolymer where three alkenyl groups are present in the prepolymer.
The prepolymer may be symmetrical.
In another embodiment the prepolymer is optionally substituted epoxidyl (oxirane). Preferably, the optionally substituted epoxidyl is optionally substituted glycidyl ether. Preferably, the glycidyl ether is substituted with optionally substituted C 1-10 alkyl, C 1-10 aryl or C 3-20 heterocyclyl. The optional substituents may be selected from hydroxyl, alkoxy and heterocyclyl, aryl.
Preferably the composition comprises two or more prepolymers. Each prepolymer may be independently selected from the vinyl prepolymers and the epoxidyl prepolymers described above. The preferred compositions include at least one vinyl prepolymer. The preferred compositions include one or two prepolymers.
Each prepolymer may be independently selected from the group of prepolymers listed above.
Where the polymer is made from two or more prepolymers, the polymer may be an alternating, block or random polymer.
The polymer may be linear or branched.
The composition may include a photoinitiator. The photoinitiator is a compound that is capable of converting absorbed light, visible or UV light preferably light in the range about 250 to about 800 nm, into chemical energy in the form of a reactive initiating species. The initiating species may be a cation or a free radical. The photoinitiator may therefore be referred to as a cation photoinitiator or a free radical photoinitiator respectively.
The radical photoinitiator may be a type I (cleavage type) or a type II (H-abstraction and electron donor) initiator. The type I initiator undergoes a unimolecular bond cleavage (α-cleavage) upon irradiation to yield the free radical. The type II initiator undergoes a bimolecular reaction where the triplet excited state of the photoinitiator interacts with either a second molecule, which may be another initiator molecule, to generate a free radical. Typically, the second molecule is a hydrogen donor. Where the second molecule is not another initiator molecule, it may be referred to as coinitiator. The coinitiator may be an amine, alcohol or ether. Preferably, the coinitiator is an amine, most preferably a tertiary amine. Where the second molecule is another initiator molecule, the initiator may contain amine, alcohol or ether functionality.
Preferably, the cation initiator is a photoacid generator.
Suitable photoinitiators for use in implementing the present invention include (a) Free radical type and (b) Cationic photo-initiation type.
(a) Free radical type. For Type I cleavable photo-initators, benzoin ethers, dialkoxy acetophenones, phosphine oxide derivatives, amino ketones, e.g. 2-dimethyl, 2-hydroxyacetophenone, bis(2,4,6-trimethyl benzoyl)phenyl phosphine oxide, can be used.
If Type II hydrogen abstraction or electron transfer (photo-initiator and synergist) are preferred, then typically aromatic ketones e.g. camphorquinone, thioxanthone, anthraquinone, 1-phenyl 1,2 propanedione, combined with H donors such as alcohols, or electron donors such as amines, can be used.
(b) Cationic photo-initiation type. Photoacid generators typically Diazonium or Onium salts e.g. diaryliodonium or triarylsulphonium hexafluorophosphate, can be used.
A laboratory experiment has been setup to demonstrate the effectiveness of the present invention, the experiment employed a standard 6 W UV lamp and viewing/curing chamber manufactured by UVproducts, and purchased from Fisher Scientic UK. The lamp was dual wavelength, emitting UVA (254 nm) or UVC (365 nm).
The liquid resin was placed in an I-shaped plastic mould 1 in the curing chamber and exposed to UV radiation for several minutes. Typical curing times ranged between 2-10 minutes. The shape of the mould 1 is shown in FIG. 1 .
The cast resin samples, approximately 1 mm thick, were tested for tensile strength using the TXAT texture analyzer (Stable Microsystems Inc.) in extension mode. Coarse abrasive paper was glued to the face of the sample grips to prevent slippage of the smooth resins.
Curing kinetics were followed using a Nicolet FTIR (Fourier Transform Infra-Red) spectrometer with a ZnSe ATR (attenuated total reflection) plate. The UV lamp was placed in the access port on the spectrometer, and the plate was irradiated during spectral acquisition.
The evolution of the height of the 1634 or 1610 cm −1 peaks were followed, these being the C═C stretch of the acrylate and vinyl ether groups respectively. As the polymerization reaction proceeded the C═C bonds were eliminated and the peak height dropped.
EXAMPLE 1
Acrylate Type Resins
In this example the liquid composition includes components A, B, C and D:
A) bisphenol A ethoxylate diacrylate (BAED) B) trimethylolpropane triacrylate (TPT) C)
i. poly(ethylene glycol) diacrylate (PEGD) molecular weight 260; ii. poly(ethylene glycol) diacrylate (PEGD) m wt. 700; iii. poly(ethylene glycol) diacrylate (PEGD) m wt. 575; iv. 1,6-hexanedioldiacrylate (HDD); v. poly(ethylene glycol) dimethacrylate m wt. 330 (PEGDM)
D) may be a photoinitiator ˜10 drops 2-hydroxy-2-methyl-propiophenone.
TABLE 1
Acrylate based resins compositions
Component A
Product B
Component C
Formulation
(15 g)
(0.5 g)
(5 g)
Aa
BAED
TPT
PEGD 260
Ab
BAED
TPT
HDD
Ac
BAED
TPT
PEGD 700
Ad
BAED
TPT
PEGDM 330
Ae
BAED
TPT
PEGD 575
Ba
BAED
TPTM
PEGD 260
These compositions produced hard, strong, quite brittle resins. FIG. 2 depicts tensile test data for Series Aa:Ae.
If desired, the resins can be reinforced with fillers such as clay, two examples were used: clay 1, Bentone 42, an organophilic clay from Elementis Specialities Inc.; and clay 2, Bentopharm, a natural montmorillonite from Wilfred Smith Ltd. The clays were added at 1%, 5%, 10% or 20% to the base resins and rolled overnight to ensure dispersion.
FIG. 3 shows the effect of the two clays on the photo-polymerisation kinetics of acrylate blend Ad. Little or no change in the kinetics were seen. FIG. 4 shows the effect of clay 1 concentration on the tensile strength of resin blend Ba. The resin increases the breaking load but at high concentrations the breaking strain decreases sharply.
EXAMPLE 2
Divinyl Ether Type Resins
In this example, the compositions include component A, component B (cf. table 2) and C photoinitiator.
A. TEGDVE: tri(ethylene glycol) divinyl ether 98% B.
a. DEGDGE: di(ethylene glycol) diglycidyl ether b. GDGE: Glycerol diglycidyl ether c. NGDGE: Neopentyl glycol diglycidyl ether d. PPGDGE: Polypropylene glycol diglycidyl ether e. BDGE: 1,4-butanediol diglycidyl ether
C. Photoinitiator: triarylsulfonium hexafluorophosphate salts, mixed 50% in propylene carbonate. 5:10 drops
TABLE 2
Divinyl ether based resins formulations
Formulation
Component A
Component B
B2a
TEGDVE
GDGE
B2b
B3a
TEGDVE
NGDGE
B3b
B4b
TEGDVE
PPGDGE
B5a
TEGDVE
BDGE
These formulations produced resins that ranged quite widely in softness and elasticity. Resin B1 was too soft to test in tensile mode. FIG. 5 shows tensile tests on samples of the other formulations, some in duplicate (B2, B3.).
EXAMPLE 3
Vinyloxybutylbenzoate Type Resins
In this example the compositions include the photoinitiator C, component A and one of the components listed in B.
A. 4-vinyloxybutylbenzoate B. di or trivinyl ether, such as:
a. bis[4(vinyloxy)butyl]succinate b. bis[4(vinyloxy)butyl]isophtalate c. tris[4(vinyloxy)butyl]trimellitate
C. photoinitiator: triarylsulfonium hexafluorophosphate salts, mixed 50% in propylene carbonate (5-10 drops).
The component concentrations A and B were varied in ratio 2:1, 5:1, 10:1. Softer more elastic gels, with more rapid curing than acrylate type resins were obtained. FIG. 6 summarises test data for 2:1 ratios.
Other examples Other examples include Styrene-polybutadiene-styrene block copolymer dispersed in xylene at approximately 4 g/l, the reaction being initiated by 2-hydroxy-2-methyl-propiophenone or the triarylsulfonium hexafluorophosphate salts (50% in propylene carbonate). Both achieved a cure of a sticky gel, in 24 hours.
Conveyance Downhole To implement the present invention, the one or more components of the fluid composition can be delivered downhole according to various methods as follows.
The one or more components of the fluid composition can be delivered passively as part of the drilling fluid as soluble (solvated) components (either water or oil) to be crosslinked into a gel as they invade the formation or form part of the filtercake.
The one or more components of the fluid composition can be delivered as encapsulated chemicals to be passively captured in the filtercake, e.g. emulsified polymers, resins and/or polymers not soluble in the drilling fluid (water or oil).
Optionally, they can be concentrated at the treatment surface by some active mechanism. For example, resin particles filled with magnetic particles could be harvested from the circulating fluid by an electromagnet.
Although electrophoresis or dielectrophoreisis could be used, such methods are considered likely to be too slow for use in commercial wellbores.
In a preferred method, a tool 10 is provided, for example as shown in FIG. 7 , which is configured to operate downhole. The tool 10 is configured to implement the present invention.
The tool 10 shown in FIG. 7( b ) is attachable, e.g. by threaded portion 12 , to a drill string, a bottom hole assembly (BHA) or a wire line, generally represented by the body 100 in FIG. 7( a ).
The tool 10 may be attachable to a flow line for conveying one or more of the components of the fluid composition to the tool downhole, e.g. from outside the wellbore. The flow line may include a plurality of conduits for conveying respective components of the fluid composition.
The tool 10 may have an onboard reservoir for holding one or more of the components of the fluid composition to be delivered into the wellbore, e.g. to the wellbore wall. The reservoir may be in fluid communication with the flow line, or the reservoir may be self contained. The respective components of the fluid composition, or the fluid composition itself, in the reservoir may be concentrated to reduce the storage volume required of the reservoir.
The reservoir could be adapted to be refillable by dropping degradable balls of the fluid composition into the wellbore (or down a conduit which is in communication with the tool) to be captured by the tool, or to be captured by another assembly and conveyed to the reservoir.
The reservoir may be multi-chambered coil tubing (CT) with one or more chambers respectively filled with the components of the fluid composition (however, the one or more chambers may each be filled with a mixture of the one or more components of the fluid composition).
The tool 10 may include a main conduit which is reserved for the circulation of drilling mud. Bypass valves, or some other assembly, may be provided in the tool to direct the fluid composition to the surface which is to be coated.
A downhole curing tool. A tool according to the present invention may include one or more injectors 14 for directing the fluid composition (or one or more components thereof) to the surface which is to be coated.
A plurality of injectors 14 may be in fluid communication with respective chambers (or flow line conduits), thereby allowing two or more of the components of the fluid composition to be mixed together in the wellbore after injection by the tool.
The or each injector 14 may be in fluid communication with the reservoir (or the flow line) such that the components of the fluid composition are mixed in the reservoir (or in an intermediate mixing chamber located upstream of the or each injector but downstream of the reservoir) prior to injection into the wellbore.
The tool 10 includes a source of actinic radiation, which preferable includes an emitter element 16 and a radiation generator. The generator may include a light emitting diode (LED). The generator preferably emits actinic radiation of a wavelength in the range of 250 nm to 800 nm.
Reaction Initiation. The actinic radiation for initiating the reaction is preferably delivered at an intensity of 0.1-1 mW/cm2.
Light sources such as halogen or mercury lamps which are fragile are not expected to be applicable in the downhole environment. However, an assembly including light guides, such as optical fibre waveguides, which can convey the actinic radiation from such light sources retained in a safe environment to the tool may be feasible.
Also, microwave and eximer lamps delivering high intensity radiation are available, and a source including such generators and a suitable waveguide is also feasible.
High powered laser light sources are available but are bulky, whilst compact lasers are relatively lower powered (mW). Therefore, it is preferred to use UV and/or blue/white LEDs which are now becoming widely available and are used in other industrial applications. LEDs are the preferred option for implementing the present invention.
The light source could be protected from the wellbore environment with an appropriate window, e.g of sapphire or diamond.
To minimize the attenuation path length between the emitter 16 and the surface to be coated, the emitter 16 may be included in a deployable movable member 18 which may be adapted to be pushed into contact with the surface to be coated.
A suitable deployment assembly already exists in the form of Schlumberger's Power-Drive technology—although for the present invention, steering the tool is not required and the contact force is envisaged to be significantly lower.
The portion of the tool which includes the emitter 16 may be a member movable relative to a main body of the tool. The movable member 18 is preferably deployable to irradiate a surface to be coated by the actinic radiation produced by the radiation generator. Additionally, wave guides and fibre optics could be used to transmit the light from the protected source to windows in the movable member 18 .
The movable member 18 may also include one or more of the injectors 14 . Therefore, the movable member 18 is preferably deployable both to deliver the fluid composition locally to the surface to be coated and to irradiate the fluid composition locally to the surface to be coated.
The or each injector 14 and the or each emitter 16 may be provided on respective movable members 18 .
The components of the fluid composition may be mixed externally to the wellbore, and subsequently pumped downhole, e.g. to form a resin plug and squeezed into the formation to be plugged or coated whilst initiating the curing reaction downhole by photo-initiation.
The components for the radiation cured system could be carried in an emulsion (or multiple emulsion) and intimately mixed at the drill bit.
Another method for delivering the fluid composition may involve the components of the fluid composition being delivered by the main fluid flow, e.g. by the drilling mud, with the initiator being stored in a reservoir in the tool (or conveyed to the tool via the previously mentioned flow line) to be delivered into the wellbore by the tool.
While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the scope of the invention. | Embodiments of the present invention provide systems and methods for lining a wellbore. In certain aspects, the systems and methods comprise providing a fluid composition that is solidifiable or gellable on exposure to actinic radiation of a predetermined wavelength at the wall of open-hole wellbore and providing actinic radiation at the predetermined wavelength to solidify or gel the composition. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to electrical connectors, and, in particular, to such connectors designed to reduce crosstalk between adjacent conductors of different transmission paths.
2. Description of the Related Art
Near-end crosstalk refers to unwanted signals induced in one transmission path due to signals that are transmitted over one or more other transmission paths appearing at the end nearest to where the transmitted signals are injected. Near-end crosstalk often occurs when the wires and/or other conductors that form the various transmission paths are in close proximity to one another. Classic examples of near-end crosstalk are the signals induced during some voice transmissions that result in parties to one telephone call hearing the conversation of parties to another call. An example that would benefit from this invention is when high-speed data transmission is impaired due to coupling of unwanted signals from one path to another.
In a conventional telephony or data application, a signal is transmitted over a transmission path consisting of a pair of conductors, neither of which is grounded. To achieve a balanced signal, one voltage is applied to one of the conductors and another voltage having the same magnitude but opposite sign is applied to the other conductor. The difference between these two voltages is referred to as the differential voltage and their sum divided by two is referred to as the common mode voltage. When the two voltages are exactly equal in magnitude and opposite in sign, only a differential voltage will exist. A balanced signal is also referred to a differential signal. When such a differential signal is transmitted over one pair of conductors, two different types of crosstalk can be induced in an adjacent pair of conductors: differential crosstalk and common-mode crosstalk. Differential crosstalk refers to a differential or balanced signal that is induced in the adjacent pair, while common-mode crosstalk refers to a common-mode or an unbalanced signal that is induced in the adjacent pair.
Existing crosstalk compensation schemes for adjacent pairs of conductors in electrical connectors are designed to compensate for differential crosstalk on an idle pair induced (i.e., coupled) from an adjacent driven pair. In so doing, however, these schemes do not provide compensation for the differential-to-common-mode crosstalk between the driven pair and the idle pair.
FIG. 1 is a schematic drawing representing an example of an existing crosstalk compensation scheme designed to compensate for differential crosstalk between Pairs 2 and 3 in a four-pair modular mated plug/jack combination, such as those typically used for telephony or data applications (e.g., conforming to the T568-B wiring convention of the Telecommunications Industry Association (TIA) 568-A Standard). If, for example, Pair 3 is driven differentially, any coupled differential signal on Pair 2 is canceled out. Unfortunately, coupled common-mode signals on Pair 2 are not addressed by the compensation scheme of FIG. 1. The presence of this common-mode signal on Pair 2 degrades the crosstalk performance of the connector when it is deployed in a short link (known in the industry as short-link resonance). It also results in unacceptable levels of ingress and egress of electromagnetic interference. One way to compensate for this differential-to-common-mode coupling is to crossover both pairs of conductors, as shown in FIG. 2
FIG. 2 is a schematic drawing representing an example of a crosstalk compensation scheme designed to compensate for differential-to-common-mode coupling. While the compensation scheme of FIG. 2 effectively cancels out any coupled common-mode signals, it does not address differential-to-differential crosstalk.
What is needed is a crosstalk compensation scheme for connectors that addresses both differential-to-differential crosstalk as well as differential-to-common-mode crosstalk.
SUMMARY OF THE INVENTION
The present invention is directed to an electrical connector comprising two or more pairs of conductors, each adapted to carry a differential signal, wherein one or more coupling devices (e.g., capacitors) are connected between the conductors of different pairs to compensate for crosstalk between the different pairs.
BRIEF DESCRIPTION OF THE DRAWINGS
Other aspects, features, and advantages of the present invention will become more fully apparent from the following detailed description, the appended claims, and the accompanying drawings in which:
FIG. 1 is a schematic drawing representing an example of an existing crosstalk compensation scheme designed to compensate for differential-to-differential coupling;
FIG. 2 is a schematic drawing representing an example of a crosstalk compensation scheme designed to compensate for differential-to-common-mode coupling; and
FIG. 3 is a schematic drawing representing a crosstalk compensation scheme, according to one embodiment of the present invention.
DETAILED DESCRIPTION
The present invention is directed to a crosstalk compensation scheme for connectors that addresses both differential-to-differential crosstalk as well as differential-to-common-mode crosstalk. According to the present invention, a connector having two or more pairs of conductors has coupling devices (e.g., capacitors) that are connected between conductors of different pairs. Values are selected for the coupling devices to provide compensation for differential-to-differential crosstalk as well as differential-to-common-mode crosstalk.
FIG. 3 is a schematic drawing representing a crosstalk compensation scheme for a modular plug/jack combination, according to one embodiment of the present invention. FIG. 3 shows the crosstalk compensation scheme between Pair 2 and Pair 3 of a four-pair connector. According to the present invention, capacitors are connected between conductors to form a compensation region for the connector. In particular, in the embodiment of FIG. 3, capacitor Cc1 is connected between T2 (the tip line of Pair 2) and T3 (the tip line of Pair 3), capacitor Cc2 is connected between R2 (the ring line of Pair 2) and R3 (the ring line of Pair 3), and capacitor Cc3 is connected between T2 and R3. In one possible implementation of the crosstalk compensation scheme of FIG. 3, capacitors Cc1, Cc2, and Cc3 are implemented by routing of traces of a printed wire board that is part of the jack of the plug/jack combination.
As represented in FIG. 3, the crosstalk coupling between Pair 2 and Pair 3, whether caused by capacitive or inductive mechanisms, can be characterized by four inherent capacitances Cs1, Cs2, Cs3, and Cs4 in a crosstalking region of the connector, the values of which are determined by the geometries of the conductors and the electrical properties of the medium material in the crosstalking region. These four capacitance values can be measured directly or inferred from measurements of actual crosstalk levels.
If the values of capacitors Cc1, Cc2, and Cc3 are chosen correctly, all differential-to-differential and differential-to-common-mode couplings between Pairs 2 and 3 will be canceled, regardless which of the two pairs is driven and which is idle.
The following analysis shows how to calculate the capacitor values for Pairs 2 and 3 of the modular plug/jack combination of FIG. 3 in order to achieve both differential and common-mode crosstalk compensation. The differential-to-differential and differential-to-common-mode crosstalk coupling effects in the crosstalking region can be represented by Equations (1)-(3) as follows:
Csu=--Cs1-Cs2+Cs3+Cs4 (1)
Csb23=--Cs1+Cs2-Cs3 +Cs4 (2)
Csb32=Cs1-Cs2-Cs3+Cs4 (3)
where:
Csu is the capacitive unbalance in the crosstalking region, responsible for differential-to-differential crosstalk between the two pairs;
Csb23 is the capacitive balance in the crosstalking region, responsible for differential-to-common-mode crosstalk when Pair 2 is driven and Pair 3 is idle; and
Csb32 is the capacitive balance in the crosstalking region, responsible for differential-to-common-mode crosstalk when Pair 3 is driven and Pair 2 is idle.
The term "capacitive unbalance" describes the total capacitive coupling between two pairs contributing to differential-to-differential crosstalk, and the term "capacitive balance" describes the total capacitive coupling between two pairs contributing to differential-to-common-mode crosstalk. For total differential-to-differential and differential-to-common mode crosstalk cancellation, the three capacitors Ccl, Cc2, and Cc3 should be chosen to produce capacitive unbalances and balances equal to and opposite in polarity to those in the crosstalking region, as expressed in Equations (4)-(6) as follows:
--Cc1-Cc2+Cc3=--Csu (4)
--Cc1+Cc2-Cc3=--Csb23 (5)
Cc1-Cc2-Cc3=--Csb32 (6)
Solving Equations (4)-(6) for Cc1, Cc2, and Cc3 yields Equations (7)-(9) as follows: ##EQU1## Substituting for Csu, Csb23, and Csb32 from Equations (1)-(3) into Equations (7)-(9) yields Equations (10)-(12) as follows:
Cc1=Cs4-Cs1 (10)
Cc2=Cs4-Cs2 (11)
Cc3=Cs4-Cs3 (12)
As indicated by Equations (10)-(12), knowing Cs1, Cs2, Cs3, and Cs4, the values of Cc1, Cc2, and Cc3 that will produce total cancellation of all differential-to-differential and differential-to-common-mode crosstalk in the combined plug/jack combination of FIG. 3 can be calculated. The same can be achieved by inferring Csu, Csb23, and Csb32 from differential-to-differential and differential-to-common-mode crosstalk measurements performed for the crosstalking region.
When three capacitors are used to provide crosstalk compensation, there is a unique solution for a given set of inherent connector capacitances. In an alternative embodiment, four capacitors can be used (e.g., adding a capacitor Cc4 between R2 and T3). In this case, a degree of freedom is added to the selection of capacitor values that will achieve the desired result of crosstalk compensation. It will also be understood that, in theory, the present invention can be implemented using any type of coupling device (i.e., either capacitors or inductive transformers or both). Furthermore, these devices may be discrete or integral parts of printed wiring boards, lead-frames, or stamped metal conductors.
The above derivation for the values for capacitors Cc1, Cc2, and Cc3 is based on the crosstalk between only Pairs 2 and 3 of a four-pair connector. Those skilled in the art will understand that the same principles can be extended to derive capacitor values that will compensate for crosstalk between all pairs of any multi-pair plug/jack combination. In general, the problem is one of solving multiple linear equations of multiple unknowns.
One of the advantages of the present invention is that it eliminates the need for crossover of conductors. This may reduce costs of manufacturing at least those portions of plug/jack combinations of the present invention when compared with combinations that employ conventional crossover compensation schemes, such as those of FIGS. 1 and 2. Nevertheless, the present invention can be implemented in situations in which one or more pairs of conductors do crossover. In such situations, one or more of the equations in the above derivation will be changed to reflect the different types of capacitive coupling between pairs of conductors. In FIG. 3, the present invention is implemented in the context of a modular plug/jack combination, such as may be implemented with jack shown in FIG. 4 having printed wire board 402. It will be understood that the present invention can be generalized to apply to crosstalk compensation for any two balanced signal pairs that are adjacent to one another in any type of mating connector.
The use of figure reference labels in the claims is intended to identify one or more possible embodiments of the claimed subject matter in order to facilitate the interpretation of the claims. Such labeling is not to be construed as necessarily limiting the scope of those claims to the embodiments shown in the corresponding figures.
It will be further understood that various changes in the details, materials, and arrangements of the parts which have been described and illustrated in order to explain the nature of this invention may be made by those skilled in the art without departing from the principle and scope of the invention as expressed in the following claims. | Crosstalk compensation is achieved by connecting coupling devices (e.g., capacitors) between different pairs of conductors of a multi-pair connector. The coupling devices are selected to offset both differential-to-differential coupling as well as differential-to-common-mode coupling that would otherwise occur between pairs of conductors when one of the conductor pair is driven with a differential signal. The present invention can be used to achieve both differential and common-mode crosstalk compensation without relying on conductor crossover techniques. | 8 |
BACKGROUND OF THE INVENTION
The subject matter of the present invention relates to an apparatus for sealing a well casing, and more particularly, to a multiple cup stuffer through tubing bridge plug for sealing a perforated well casing when hydrocarbon well fluids cease to flow from the perforated casing.
When a well casing is perforated, hydrocarbon fluids flow from the perforated casing. Frequently, a particular formation, from which hydrocarbon fluids had previously been flowing, ceases to flow the desired hydrocarbons, but rather undesired fluids, such as water, begin to flow into the casing. If another formation exists adjacent the casing, such formation being located above the first formation which is now flowing the undesired fluids, the casing is sealed above the first group of perforations. Thereafter, the casing is again perforated along its length adjacent the second formation from which hydrocarbon fluids are desired to be produced. A sealing apparatus is normally suspended by wireline, the sealing apparatus sealing the casing above the first group of perforations. One such sealing apparatus is disclosed in U.S. Pat. No. 4,554,973 to Shonrock, et al, assigned to the same assignee as that of the present invention. The Shonrock sealing apparatus is an elastomeric sealing element for a bridge plug; however, due to its appearance, it is commonly known as a "football". The shonrock football sealing apparatus possessed a low temperature rating relative to the current needs of the logging industry. In addition, the football is expensive to manufacture. Furthermore, if it is necessary to seal a well casing, it is desirable to use the same sealing apparatus for different sized well casings. However, it is very difficult if not impossible to manufacture the football sealing apparatus in larger sizes Therefore, it is very difficult if not impossible to use the Shonrock football sealing apparatus for different sized well casings.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide a new and novel sealing apparatus for sealing a well casing which has a high temperature rating, is inexpensive to manufacture, may selectively and easily be constructed in different sizes using present manufacturing technology and may therefore be used to seal different sized well casings.
It is a further object of the present invention to provide a new multiple cup sealing apparatus which comprises a plurality of successively sized cups of different diameters, each cup being adapted to fit inside a successively larger cup, the size of the multiple cup sealing apparatus depending upon the number of successively sized cups interfit together to form the multiple cup sealing apparatus.
It is a further object of the present invention to apply a first compressive load to one side of the multiple cup sealing apparatus and to apply a second compressive load to the other side of the multiple cup sealing apparatus, the first and second compressive loads forcing the number of successively sized cups to deploy then interfit together thereby forming the multiple cup sealing apparatus of the present invention.
It is a further object of the present invention to provide a novel platform means disposed on both sides of the multiple cup sealing apparatus for applying the compressive force to both sides of the multiple cup sealing apparatus in response to the application thereto of the compressive force, each of the platform means including a petal and buttress backup which deploys in response to the application thereto of the compressive force.
It is a further object of the present invention to provide a novel anchor apparatus disposed behind each of the petal and buttress backups for anchoring each of the petal and buttress backups to a casing when the backups are disposed in a selected position in the wellbore.
It is a further object of the present invention to provide novel designs for the petal and buttress backups and for the novel anchor apparatus.
In accordance with these and other objects of the present invention, a novel sealing apparatus comprises a plurality of cups, each cup being slightly larger in size or diameter than its immediately preceeding successively sized cup, a first back-up disposed on one side of the plurality of cups, a second back-up disposed on the other side of the plurality of cups, and a means for applying a first and second compressive load to the first and second back-up, respectively, the first back-up and the second back-up compressing the plurality of cups until a single plug is created, the single plug sealing a perforated well casing when the plug is disposed adjacent the perforated well casing in a wellbore. The first and second back-ups each include a petal backup for applying a compressive force to each side of the plug when the petal backup is deployed, and a buttress backup for applying a compressive force to each side of the petal backup when the buttress backup is deployed, the petal and buttress backups contacting the well casing when deployed thereby functioning to provide strength and extrusion prevention. A multitooth anchor arm is disposed behind each buttress backup for anchoring the plug to the wellbore casing and maintaining the plug in its deployed and sealing condition regardless of the condition of the casing. In addition, the anchor arms ensure uniform deployment and centralization in the borehole. Since the deployment force of each multi-arm anchor is lower than the deployment force required to deploy the buttress and petal backups and the cup elements, the anchor deploys before the buttress backup, the petal backup, and the cup elements deploy.
Further scope of applicability of the present invention will become apparent from the detailed description presented hereinafter. It should be understood, however, that the detailed description and the specific examples, while representing a preferred embodiment of the present invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become obvious to one skilled in the art from a reading of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
A full understanding of the present invention will be obtained from the detailed description of the preferred embodiment presented hereinbelow, and the accompanying drawings, which are given by way of illustration only and are not intended to be limitative of the present invention, and wherein:
FIGS. 1 and 2 are partial cross sectional views along the longitudinal axis of a well bore schematically illustrating the intended use of the method and apparatus in providing a plug or seal in the borehole in accordance with the present invention;
FIGS. 3 and 4 illustrate the method by which the plug or seal is first disposed in the borehole by wireline;
FIGS. 5 through 7 a prior art sealing apparatus representing the plug or seal of FIGS. 1-4;
FIGS. 8a-8b illustrate a novel sealing apparatus representing the plug or seal of FIGS. 1-4 in accordance with the present invention when the multi-cup plug is not deployed and is ready to be inserted into a well tubing and when the multi-cup plug has entered the wellbore casing, the anchors and petals have deployed, the cups have broken out of their sleeves, and the multi-cup plug has partially deployed;
FIGS. 9a-9b illustrate the novel sealing apparatus of FIGS. 8a-8b when the multi-cup plug is being successively deployed in the wellbore casing;
FIG. 10 illustrates a construction of the petal and buttress backups of FIGS. 8 and 9;
FIG. 11 illustrates a top view showing the petal backup of FIG. 10 when the petal backup is in its deployed condition;
FIG. 12 illustrates a cross sectional view of the buttress backup of FIG. 10 when disposed in its non-deployed condition;
FIG. 13 illustrates a side view of the buttress backup assembly of FIG. 10 when the buttress petals are deployed; and
FIGS. 14 and 15 illustrate detailed constructions of the anchor arms of FIGS. 8 and 9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1 and 2, a borehole 170 is disposed in the earth's surface 171, which borehole 170 has been provided with a conventional well casing 172. As shown in FIG. 1, a first set of perforations 173 have been provided in well casing 172 adjacent a hydrocarbon producing formation 174. Conventional production tubing 175 having a diameter less than the diameter of the well casing 172, is disposed within well casing 172 and is sealed about its end in a conventional manner as by a packer 176. The hydrocarbons, as illustrated by arrows 177, flow upwardly to the earth's surface 171 via production tubing 175. Upon the formation 174 producing undesired fluids, such as water, it becomes necessary to seal well casing 172 at a depth disposed above the first set of perforations 173. With reference to FIG. 2, a seal, or plug, shown schematically as 178, is disposed within well casing 172 above the first set of perforations 173 adjacent formation 174, which now has water 179 and/or other undesired fluids flowing through perforations 173. After seal, or plug, 178 has been disposed within well casing 172, perforations 180 are provided in a conventional manner in well casing 172 adjacent another hydrocarbon producing formation 181, through which hydrocarbons 182 may flow upwardly through production tubing 175, as previously described. In order to most efficiently, expeditiously, and economically provide seal 178 in well casing 172, it is necessary to utilize a device capable of passing through the reduced diameter production tubing 175.
Referring to FIGS. 3 and 4, the method by which plug 178 is placed in borehole 170 is illustrated.
In FIG. 3, plug 178 and a setting tool 195 are suspended by wireline or coil tubing 190 within production tubing 175, the plug 178 being compressed to a size which is smaller than the inside diameter of the production tubing 175 around packer 176, or any other restrictions. The plug 178 of FIG. 3 is lowered through production tubing 175 until it passes completely through the tubing 175 and is disposed immediately above perforations 173 of hydrocarbon producing formation 174.
In FIG. 4, the plug 178 is expanded in size until it presses firmly against the casing 172, thereby functioning as a plug or seal for sealing off the borehole adjacent formation 174 below the plug from the remaining portion of borehole 170. As a result, the undesirable fluids, such as water, flowing from perforations 173 cannot access the production tubing 175 and mix with the other desirable hydrocarbon well fluids being produced from perforations 180. If desired, a cement layer 192 may be disposed over the plug 178 for increasing the pressure rating and assisting the plug 178 in sealing off the borehole adjacent formation 174 below the plug 178 from the remaining portion of the borehole 170 above plug 178.
Referring to FIGS. 5 through 7, a prior art plug 178, set forth in U.S. Pat. No. 4,554,973 and Re 32,831, is illustrated.
In FIG. 5, the plug 178, suspended by wireline or coiled tubing, has elements pulled into sleeves 178c during manufacturing. When the plug elements exit the sleeves 178c, they are deployed by a setting tool to football shapes, as shown in FIG. 6, by applying a compressive load to both ends. When it is desired to plug the perforations 173 which are producing the unwanted fluid, such as water, instead of the wanted hydrocarbon material, the two ends 178a and 178b of two or more football shaped plugs 178 of FIG. 6 are compressed tightly together to produce the plug of FIG. 7. However, as noted in the background section of this specification, the football shaped plug of FIGS. 5-7 is virtually impossible to manufacture in larger sizes. Since it is desirable to use the plug 178 for different sized cased boreholes, the plug of FIGS. 5-7 could not be used for the larger sized cased boreholes, since it was virtually impossible to manufacture the plug of FIGS. 5-7 in larger sizes.
Referring to FIGS. 8a-8b, a novel plug or sealing apparatus 178A in accordance with the present invention is illustrated in FIG. 8a in its pre-deployment condition and includes a plurality of cup seal elements, the cup elements being disposed within sleeves for transport within the production tubing 175, and in FIG. 8b in its deployed condition prior to the final application thereto of the compressive force on both sides of the sealing apparatus.
In FIG. 8a, the novel plug or sealing apparatus 178A in accordance with the present invention is illustrated in its pre-deployment condition. The plug 178A cup seal elements A1 are disposed within a sleeve A5. The sleeve A5 is manufactured with a seam A5-1 running longitudinally along its length. The seam A5-1 allows the sleeve A5 to split apart longitudinally along its length when a compressive load is applied to both ends of the plug 178A and an internal radially directed force is applied to an inner wall surface of the sleeve A5. Undeployed petal backups A2 are disposed on both sides of the sleeve A5, and an undeployed buttress backup A3 is disposed adjacent each undeployed petal backup A2. An undeployed anchor element A4 is disposed adjacent each undeployed buttress backup A3. A mandrel lock A6 is disposed adjacent each undeployed anchor element. Each of these structural components of the sealing apparatus of the present invention will be described in further detail in this specification.
In FIG. 8b, the novel plug or sealing apparatus 178A is shown in its deployed condition prior to the final application thereto of a compressive force. The sealing apparatus 178A includes a plurality of stuffer cup seal elements A1 which are inserted into sleeve A5 during manufacturing, deployed petal backups A2 disposed on both sides of the cup elements A1, deployed buttress backups A3 disposed on both sides of the petal backups A2, and deployed anchors A4 disposed on both sides of the buttress backups A3. Each of the petal backups A2 are shown in a deployed condition; when deployed, each of the petal backups A2 contact the well casing 172; this prevents an extrusion of the cup elements A1 from their location between the deployed petal backups A2 when a compressive force is applied to both petal backups A2. The compressive force nests the cups together and squeezes them against the casing wall, thereby affecting the seal. Each of these elements will be shown and described in more detail in the following paragraphs.
In FIG. 8a, when the sealing apparatus 178A is disposed in a well casing 172, a compressive force is applied to both ends of the sealing apparatus 178A. In response to this compressive force, the anchors A4 are first to deploy. The petal backups A2 are next to deploy, and the buttress backups A3 are the last to deploy. Following deployment of the buttress and petal backups A3 and A2, the compressive force creates an internal radially directed force within the sleeve A5. The force is radially directed, the sleeve A5 splits apart along its seam A5-1. When the sleeve splits apart along seam A5-1, the plug 178A assumes the deployed condition shown in FIG. 8b. However, the final compressive load to nest and seal the stuffer cup elements A1 has not yet been applied to the plug 178A of FIG. 8b.
In FIG. 8b, each of the plurality of cup seal elements A1 is made of rubber and is shaped in the form of a cup, a smaller cup being sized to fit within a next larger sized cup. For example, smaller cup 1a fits within the next larger sized cup 1b, cup 1b fitting within next larger sized cup 1c, cup 1c fitting within next larger sized cup 1d, etc. When deployed, a petal back-up assembly A2 is disposed on both sides of the plurality of cup elements A1. When deployed, each petal back-up A2 contacts a wall of the well casing 172 and functions as a platform for transmitting a compressive force to the plurality of cup elements A1 when the compressive load is applied to the back-ups A2.
Since the deployed petal back-ups A2 contact the well casing 172 wall, the cup elements A1 cannot extrude from within the interspace located between adjacent petal backups A1 when the compressive force is applied to the back-ups A2. A buttress back-up assembly A3, which includes a plurality of buttress legs A3-1 of FIG. 10, is disposed behind each petal back-up assembly A2 and is adapted to deploy when a compressive load is applied thereto. An anchor element A4 is disposed behind each buttress backup A3 for anchoring the deployed plug to the casing 172 thereby holding the plug in the deployed and sealing position within the wellbore in response to the application thereto of the compressive force. A mandrel lock A6 is also used to lock the components in the compressed state. Therefore, if the anchors A4 slide in response to a differential pressure, the whole plug assembly will move without relieving the compressive load on the elements. Anchor teeth A4-1 on the anchor elements A4 firmly grip the well casing 172 thereby holding the buttress backup A3, the petal backup A2 and the plurality of cups A1 in their respective deployed and/or compressed positions within the wellbore.
The plug 178A in FIG. 8b is shown in its deployed condition prior to the application thereto of the final compressive force on both sides of the sealing apparatus 178A. In this condition, the cup seal elements A1 have not yet been compressed tightly together to form a single sealing plug, such as the single plug 178 illustrated in FIGS. 2 and 4.
Referring to FIGS. 9a-9b, the novel plug or sealing apparatus 178A in accordance with the present invention is illustrated in its deployed and partially compressed condition (FIG. 9a) and in its deployed and totally compressed condition (FIG. 9b). As shown in FIG. 9b, when totally compressed, the cup seal elements A1 are compressed together to form a single sealing plug, such as the single plug 178 shown in FIGS. 2 and 4.
Since an outer periphery of the deployed petal backups A2 contact a surface of the well casing 172, the compressed cup seal elements A1 cannot extrude from within the interspace located between the deployed petal backups A2.
A functional operation of the present invention will be set forth in the following paragraphs with reference to FIGS. 8a-8b and 9a-9b of the drawings.
A pressure or electrical signal is transmitted to the setting tool 195 of FIG. 3, the setting tool 195 applying a longitudinal compressive load to the plug assembly 178A. Starting with the sealing apparatus 178A of FIG. 8a, (1) the compressive load first deploys the upper anchor thereby preventing the plug from moving upward in the casing 172; teeth A4-1 of anchor A4 grip the casing 172. When the anchor elements A4 are completely deployed; (2) second, the compressive load then deploys the back up petal A2 and buttress A3 backups disposed on the upper side of the cup elements A1, which prevents extrusion of the elastomeric cups Al from differential pressure and form a platform by which a uniform compressive load is applied to the deployed cups A1 for affecting a complete footprint and seal on the well casing 172 wall; FIG. 9a shows the anchor elements A4, buttress backup A3 and petal backup A2 in their respective deployed condition; the lower petal and backup may deploy here or as part of step (6); (3) third, when the compressive load is further increased, the sleeve A5 splits along its seam A5-1; (4) fourth, the cups A1 deploy in roughly decending order from their respective sleeves thereby resulting in the sealing apparatus shown in FIG. 8b of the drawings; (5) fifthly, the cups A1 are "stuffed" together to form a partial mass of rubber, as shown in FIG. 9a; (6) sixth, the lower anchor A4 deploys at this point or sooner thereby firmly affixing the plug of FIGS. 8 and 9 to the casing 172 and preventing any movement; and (7) seventh, the cups A1 are further "stuffed" together to form a solid mass of rubber, in an artful manner, as shown in FIG. 9b of the drawings. In particular, when it is desired to plug the well, similar to the plug 178 shown in FIG. 2, the anchors, buttress back-ups A3 and petal back-ups A2 approach one another. As they approach one another, the cup elements A1 compress tightly together, sealing the well casing 172. As a result, cup 1a fits within cup 1b, cup 1b fitting within cup 1c, and cup 1c fitting with cup 1d, etc. The final resultant plug or sealing apparatus 178A of the present invention is shown in FIG. 9b.
Referring to FIGS. 10 through 13, a construction of the petal back-ups A2 and the buttress backups A3 of FIGS. 8a-8b and FIGS. 9a-9b is illustrated.
In FIG. 10, the petal and buttress backup assemblies A2 and A3 are shown in their pre-deployment positions. The petal back-up assembly A2 includes a first plurality of petal assembly petals A2-1 and a second plurality of petal assembly petals A2-2 hinged to the first plurality of petal assembly petals A2-1 via the hinge or joint A2-3, and a third plurality of petal assembly petals A2-4 connected to the second plurality of petal assembly petals A2-2. The hinge A2-3 is intended to include any structure which will allow a first petal assembly petal A2-1 to rotate with respect to a second petal assembly petal A2-2 along a point interconnecting the two petals herein designated as a "hinge" A2-3. The buttress assembly A3 includes a first plurality of buttress assembly legs A3-1 hinged to the third plurality of petal assembly petals A2-4 via another hinge A3-2. The hinge A3-2 is defined in the same terms as hinge A2-3.
In FIG. 11, a top view of the petal back-up A2 assembly of FIG. 10 is illustrated in its deployed position, the top view illustrating the petal assembly petal A2-1 on top of petal assembly petal A2-2, the combined petal assembly petals A2-1/A2-2 being interleaved in the figure with the petals A2-4. The buttress legs A3-1 are not shown in the top view of FIG. 11, since the legs A3-1 are disposed below the petals A2-1/A2-2/A2-4 in the figure.
FIG. 12 is a cross sectional view of the buttress assembly A3 buttress legs A3-1 taken along section lines 12--12 of FIG. 10.
In FIG. 13, the buttress assembly A3 is shown in its deployed condition; that is, the petal assembly petals A2-4 have rotated approximately 90 degrees to a deployed position, the buttress legs A3-1 being hinged to the petals A2-4 via hinge A3-2 and deploying to the position shown in the figure in response to rotation of the petals A2-4 as shown. When the petal assembly petals A2-4 have finished rotating, the petals A2-4 are disposed approximately perpendicular to a rod 4f running through the longitudinal center of the plug, the buttress legs A3-1 and a spacer A3-3 supporting the petal assembly petals A2-4 in their deployed position.
Referring to FIGS. 14 and 15, a construction of the anchor elements A4 of FIGS. 8a-8b and 9a-9b is illustrated.
In FIG. 14, an anchor element A4 is shown in its non-deployed condition; whereas, in FIG. 15, the anchor element A4 is shown in its deployed condition. The anchor element A4 includes a center rod 4f, a body 4a slidable with respect to the rod 4f, a slide 4b adapted to slide over the end of the body 4a, a backup arm 4d having one end pinned to the slide 4b and the other end pinned to an anchor arm 4c, the anchor arm 4c having one end pinned to the other end of the backup arm 4d and one end pinned to the body 4a at location 4g. A cam 4e is slidable with respect to rod 4f. In FIG. 14, the cam 4e includes an angled surface 4e1 and a flat surface 4e2; and the anchor arm 4c includes an intermediate plate 4c1 disposed between two outer plates 4c2. The outer plates 4c2 each include teeth A4-1 disposed on an outer end for gripping the casing in the borehole. The intermediate plate 4c1 also includes an angled surface 4c1a which coincides with the angled surface 4e1 of the cam 4e and a flat surface 4c1b (see FIG. 15) which lies along the longitudinal axis of the anchor arm 4c.
A functional operation of the anchor elements A4 will be set forth in the following paragraph with reference to FIGS. 14 and 15 of the drawings. Further, a functional description of the petal assembly A2 and the buttress assembly A3 will be set forth in subsequent paragraphs with reference to FIGS. 8-13, and in particular, FIGS. 10-13.
When the cam 4e slides along rod 4f and travels downwardly in FIG. 14, the angled surface 4e1 of cam 4e slides with respect to the angled surface 4c1a of the intermediate plate 4c1 of anchor arm 4c; and the flat surface 4e2 of cam 4e slides with respect to flat surface 4c1b thereby forcing the anchor arm 4c to rotate with respect to the rod 4f. Since the anchor arm 4c is pinned at location 4g, the anchor arm 4c rotates with respect to the location 4g. Since the backup arm 4d is pinned to the anchor arm 4c on one end and to the slide 4b on the other end, rotation of the anchor arm 4c about the location 4g forces the backup arm 4d to move the slide 4b downwardly in FIGS. 14 and 15. When the anchor arms 4c rotate, they rotate outwardly relative to the body 4a and in unison. The teeth A4-1 of outer plates 4c2 of anchor arms 4c grip the well casing 172 of FIGS. 8a-8b an 9a-9b when the arms 4c are disposed in the deployed position of FIG. 15 but fail to grip the well casing 172 when disposed in the nondeployed position of FIG. 14. The anchor teeth A4-1 can grip the casing 172 at intermediate positions of the slide 4b relative to rod 4f thus making the anchor A4 itself useful for gripping various diameters and conditions of the well casing 172. However, rotation or deployment of anchor arm 4c stops when the slide 4b, moving downwardly in FIG. 15, abuts against the buttress assembly A3 of FIG. 8b. Anchor arms 4c are thus prevented from rotating beyond their maximum radial extent by the action of the backup arms 4d and slide 4b when abutment against buttress assembly A3 occurs.
Referring to FIGS. 10-13, the petal and buttress back-up assemblies A2 and A3 of FIG. 10 deploy after the anchor elements A4 deploy in the manner described above and when a further force is applied to both opposite ends of the petal and buttress back-up assemblies A2 and A3 so as to compress the assemblies. During deployment, the first plurality of petal assembly petals A2-1 rotate via hinge A2-3 with respect to the second plurality of petal assembly petals A2-2 until the first and second petal assembly petals A2-1 and A2-2 nearly touch each other and therefore assume the configuration shown by numerals A2 and A3 in FIGS. 8a, 9a-9b of the drawings; simultaneously, however, the third plurality of petal assembly petals A2-4 rotate with respect to the plurality of buttress legs A3-1, along hinge A3-2, until the third plurality of petal assembly petals A2-4 and the buttress legs A3-1 assume the configuration shown in FIG. 13 of the drawings. When these rotations occur, the petal back up assembly A2 of FIG. 10 appears to assume a "flat plate" shape, roughly the configuration of the petal backup A2 assembly shown in the side views of FIGS. 8a-8b and FIGS. 9a-9b. Alternatively, when these rotations occur, a top view of the petal assembly petals A2-1, A2-2, and A2-4, shown in their deployed positions, is illustrated in FIG. 11 of the drawings.
The invention being thus described, it will be obvious 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 obvious to one skilled in the art are intended to be included within the scope of the following claims. | A bridge plug for sealing a well casing comprises a plurality of cups which tightly interfit together when a compressive load is applied to both opposite ends of the plurality of cups. Application of the compressive load to both opposite ends of the cups forces a first cup to fit into a second cup, the second cup to fit into a third cup, and the third cup to fit into a fourth cup, etc., thereby producing a single unitary plug which includes a plurality of tightly interfit cups. Further application of the compressive load to both opposite ends causes transverse expansion of the plurality of interfit cups to occur. When the cups contact the well casing wall, a permanent seal is achieved between the cups and the well casing wall. Anchor elements on both sides of the cups contact the well casing wall and permanently hold the interfitting cups in their compressed condition. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] A claim for priority under 35 U.S.C. §119 is made to Korean Patent Application No. 10-2014-0145403 filed Oct. 24, 2014, in the Korean Intellectual Property Office, the entire contents of which are hereby incorporated by reference.
BACKGROUND
[0002] Embodiments of the inventive concepts described herein relate to a substrate treating apparatus and a substrate cleaning method using the same.
[0003] Various processes such as photolithography, etching, ashing, ion implantation, and film deposition are performed on a substrate so as to manufacture a semiconductor device or a liquid crystal display. A substrate cleaning process for removing various contamination materials and particles attached to a substrate surface may be performed before and after each unit process for fabricating a semiconductor device.
[0004] Various methods such as spraying a chemical, a treating solution including a gas, or a treating solution with a vibration may be used as a cleaning process to remove various contamination materials and particles remaining on the substrate surface.
SUMMARY
[0005] Embodiments of the inventive concepts provide a substrate treating apparatus capable of improving cleaning efficiency.
[0006] Embodiments of the inventive concepts provide a substrate treating apparatus.
[0007] One aspect of embodiments of the inventive concept is directed to provide a substrate treating apparatus. The substrate treating apparatus includes a housing defining a space for treating a substrate therein, a spin head supporting and rotating the substrate in the housing, a spray unit including a first nozzle member for spraying a first treating solution on the substrate placed on the spin head, and a controller controlling the spray unit, wherein the controller sprays the first treating solution while moving the first nozzle member between edge and center regions of the substrate and above the substrate, and wherein the controller differently adjusts a first height at which the first treating solution is sprayed on the edge region of the substrate and a second height at which the first treating solution is sprayed on the center region of the substrate.
[0008] The second height may be higher than the first height.
[0009] The controller may control the first nozzle member such that a height of the first nozzle member is progressively increased as the first nozzle member moves from the edge region of the substrate to the center region thereof.
[0010] The controller may control the first nozzle member such that a height of the first nozzle member is continuously increased as the first nozzle member moves from the edge region of the substrate to the center region thereof.
[0011] The first nozzle member may include a body including an injection flow path and a first discharge hole therein, the first treating solution flowing through the injection flow path and the first discharge hole connected with the injection flow path and spraying the first treating solution on the substrate, and a vibrator installed in the body and providing a vibration to the first treating solution flowing into the injection flow path.
[0012] The first nozzle member may include a body including an injection flow path and first micro-holes therein, the first treating solution flowing through the injection flow path and the first micro-holes connected with the injection flow path and spraying the first treating solution on the substrate.
[0013] The first nozzle member may include a body including an injection flow path and a first discharge hole therein, the first treating solution flowing through the injection flow path and the first discharge hole connected with the injection flow path and spraying the first treating solution on the substrate, and a gas supply unit installed in the body and spraying a gas together with the first treating solution sprayed through the first discharge hole.
[0014] The injection flow path may include a first region and a second region each having a ring shape when viewed from the top, and a radius of the first region is greater than that of the second region.
[0015] When viewed from the top, the first discharge holes of the first region may be provided in a line along the first region, and the first discharge holes of the second region are provided in two lines along the second region.
[0016] The inventive concept, however, may be embodied in various different forms, and should not be construed as being limited only to the illustrated embodiments. Embodiments of the inventive concept are provided to illustrate more fully the scope of the inventive concept to those skilled in the art.
BRIEF DESCRIPTION OF THE FIGURES
[0017] The above and other objects and features will become apparent from the following description with reference to the following figures, wherein like reference numerals refer to like parts throughout the various figures unless otherwise specified, and wherein:
[0018] FIG. 1 is a top plan view schematically illustrating a substrate treating apparatus;
[0019] FIG. 2 is a cross-sectional view illustrating a substrate treating apparatus of FIG. 1 ;
[0020] FIG. 3 is a cross-sectional view illustrating a first nozzle member of FIG. 2 ;
[0021] FIG. 4 is a bottom view illustrating a first nozzle member of FIG. 3 ;
[0022] FIG. 5 is a diagram illustrating a conventional substrate cleaning method;
[0023] FIG. 6 is a diagram illustrating a region where a first treating solution is supplied when the first treating solution is sprayed using a substrate cleaning method of FIG. 5 ;
[0024] FIG. 7 is a diagram illustrating a substrate cleaning method for supplying a first treating solution on a substrate using a first nozzle member according to an embodiment of the inventive concept;
[0025] FIG. 8 is a diagram illustrating a substrate cleaning method for supplying a first treating solution on a substrate using a first nozzle member according to another embodiment of the inventive concept;
[0026] FIG. 9 is a diagram illustrating a surface velocity at which a first treating solution reaches a substrate, varied according to a spray height of the first nozzle member;
[0027] FIG. 10 is a diagram illustrating a first nozzle member according to other embodiment of the inventive concept; and
[0028] FIG. 11 is a diagram illustrating a first nozzle member according to another embodiment of the inventive concept.
DETAILED DESCRIPTION
[0029] Embodiments will be described in detail with reference to the accompanying drawings. The inventive concept, however, may be embodied in various different forms, and should not be construed as being limited only to the illustrated embodiments. Embodiments of the inventive concept are provided to illustrate more fully the scope of the inventive concept to those skilled in the art. Therefore, the shapes of the components in the drawings may be exaggerated to emphasize a more clear description.
[0030] Below, an example of the inventive concept will be described with reference to FIGS. 1 to 11 .
[0031] FIG. 1 is a top plan view schematically illustrating a substrate treating apparatus according to an embodiment of the inventive concept. Referring to FIG. 1 , a substrate treating apparatus 1 may have an index module 10 and a process treating module 20 . The index module 100 may contain a load port 120 and a transfer frame 140 . The load port 120 , the transfer frame 140 , and the process treating module 20 may be arranged in a line. Below, a direction where the load port 120 , the transfer frame 140 , and the process treating module 20 are arranged may be referred to as “first direction” 12 . When viewed from the top, a direction perpendicular to the first direction 12 may be referred to as “second direction” 14 , and a direction perpendicular to a plane defined by the first direction 12 and the second direction 14 may be referred to as “third direction” 16 .
[0032] A carrier 130 where a substrate W is received may be safely put on the load port 120 . The load port 120 may be in plurality, and the plurality of load ports 120 may be arranged in a line along the second direction 14 . The number of load ports 120 may increase or decrease according to conditions such as process efficiency, footprint, and the like in the process treating module 20 . A plurality of slots (not illustrated) may be formed in the carrier 130 so as to receive the substrates W in a state where they are placed in a horizontal position on the ground surface. A Front Opening Unified Pod (FOUP) may be used as the carrier 130 .
[0033] The process treating module 20 may contain a buffer unit 220 , a transfer chamber 240 , and process chambers 260 . The transfer chamber 240 may be arranged such that its length direction is parallel with the first direction 12 . The process chambers 260 may be arranged at opposite sides of the transfer chamber 240 along the second direction 14 . The process chambers 260 may be arranged at one side and the other side of the transfer chamber 240 so as to be arranged symmetrically with respect to the transfer chamber 240 . The plurality of process chambers 260 may be provided at one side of the transfer chamber 240 . A portion of the process chambers 260 may be arranged along a length direction of the transfer chamber 240 . Furthermore, a portion of the process chambers 260 may be arranged to be stacked. That is, the process chambers 260 may be arranged in an A-by-B matrix at the one side of the transfer chamber 240 . In this case, “A” may indicate the number of process chambers 260 arranged in a line along the first direction 12 , and “B” may indicate the number of process chambers 260 arranged in line along the third direction 16 . When four or six process chambers 260 are arranged at the one side of the transfer chamber 240 , the process chambers 260 may be arranged in a 2-by-2 or 3-by-2 matrix. The number of process chambers 260 may increase or decrease. Unlikely, the process chambers 260 may be provided at any one side of the transfer chamber 240 . In addition, the process chambers 260 may be arranged at one side and opposite sides of the transfer chamber 240 to form a single layer.
[0034] The buffer unit 220 may be disposed between the transfer frame 140 and the transfer chamber 240 . The buffer unit 220 may provide a space where a substrate W stays before transferred between the transfer chamber 240 and the transfer frame 140 . A slot(s) (not illustrated) where a substrate W is placed may be provided in the buffer unit 220 . A plurality of slots may be provided to be spaced apart from each other along the third direction 16 . The buffer unit 220 may have an opened surface that faces the transfer frame 140 and an opened surface that faces the transfer chamber 240 .
[0035] The transfer frame 140 may transfer a wafer W between the buffer unit 220 and the carrier 130 safely put on the load port 120 . An index rail 142 and an index robot 144 may be provided at the transfer frame 140 . The index rail 142 may be provided such that its length direction is parallel with the second direction 14 . The index robot 144 may be mounted on the index rail 142 and may move in a straight line toward the second direction 14 along the index rail 142 . The index robot 144 may contain a base 144 a, a body 144 b, and an index arm 144 c. The base 144 a may be installed to be movable along the index rail 142 . The body 144 b may be joined to the base 144 a. The body 144 b may be provided to be movable on the base 144 a along the third direction 16 . Furthermore, the body 144 b may be provided to be rotatable on the base 144 a. The index arm 144 c may be joined to the body 144 b such that it is forward and backward movable with respect to the body 144 b. The index arm 144 c may be in plurality, and the plurality of index arms 144 c may be driven independently of each other. The index arms 144 c may be arranged to be stacked on each other under the condition that index arms 144 c are spaced apart from each other along the third direction 16 . A portion of the index arms 144 c may be used to transfer a substrate W from the process treating module 20 to the carrier 130 , and a portion of remaining index arms 144 c may be used to transfer the substrate W from the process treating module 20 to the carrier 130 , thereby preventing particles, generated from a substrate W not experiencing process treating when the substrate W is carried into or taken out of by the index robot 144 , from being attached to the substrate W.
[0036] The transfer chamber 240 may transfer a substrate W between the buffer unit 220 and the process chamber 260 and between the process chambers 260 . A guide rail 242 and a main robot 244 may be provided at the transfer chamber 240 . The guide rail 242 may be arranged such that its length direction is parallel with the first direction 12 . The main robot 244 may be installed on the guide rail 242 and may move in a straight line along the first direction 12 on the guide rail 242 . The main robot 244 may contain a base 244 a, a body 244 b, and a main arm 244 c. The base 244 a may be installed to be movable along the guide rail 242 . The body 244 b may be joined to the base 244 a. The body 244 b may be provided to be movable on the base 244 a along the third direction 16 . Furthermore, the body 244 b may be provided to be rotatable on the base 244 a. The main arm 244 c may be joined to the body 244 b such that it is forward and backward movable with respect to the body 144 b. The main arm 244 c may be in plurality, and the plurality of main arms 244 c may be driven independently of each other. The main arms 244 c may be arranged to be stacked on each other in a state where the main arms 244 c are spaced apart from each other along the third direction 16 .
[0037] A substrate treating apparatus 300 performing a cleaning process for cleaning a substrate W may be provided in the process chamber 260 . The substrate treating apparatus 300 may have different structures according to types of cleaning processes. In contrast, the substrate treating apparatuses 300 of the process chambers 260 may have the same structure. Selectively, the process chambers 260 may be divided into a plurality of groups. The substrate treating apparatuses 300 in the same groups may have the same structure, and the substrate treating apparatuses 300 in different groups may have different structures.
[0038] FIG. 2 is a cross-sectional view illustrating a substrate treating apparatus of FIG. 1 . Referring to FIG. 2 , the substrate treating apparatus 300 may include a housing 320 , a spin head 340 , an elevation unit 360 , a spray unit 380 , and a controller 500 . The housing 320 may contain a space where the substrate treating process is performed and an upper end portion of the housing 320 may be opened. The housing 320 may contain an internal collection barrel 322 and an external collection barrel 326 . The internal and external collection barrels 322 and 326 may collect different treating solutions among treating solutions used in a process, respectively. The internal collection barrel 322 may be provided in the form of a ring surrounding the spin head 340 , and the external collection barrel 326 may be provided in the form of a ring surrounding the internal collection barrel 322 . An internal space 322 a of the internal collection barrel 322 and a space 326 a between the internal collection barrel 322 and the external collection barrel 326 may serve as inlets that allow the treating solutions to flow into the internal collection barrel 322 and the external collection barrel 326 , respectively. Collection lines 322 b and 326 b which extend vertically and downwardly toward the bottom may be connected to the respective collection barrels 322 and 326 . The collection lines 322 b and 326 b may discharge treating solutions collected by the collection barrels 322 and 326 . The discharged treating solutions may be recycled through an external treating solution recycling system (not illustrated).
[0039] The spin head 340 may support and rotate a substrate W during a process. The spin head 340 may include a body 342 , a support pin 344 , a chuck pin 346 , and a support shaft 348 . The body 342 may have an upper surface provided in the form of a circle when viewed from the top. The support shaft 348 rotated by a motor 349 may be fixedly mounted on a lower surface of the body 342 .
[0040] The support pin 344 may be provided in plurality. The support pins 344 may be disposed to be spaced apart by a predetermined gap from an edge of the upper surface of the body 342 and may protrude upwardly from the body 342 . The support pins 344 may be disposed to have the form of a ring as a whole through a combination thereof. The support pins 344 may support an edge of a rear surface of the substrate W to allow the substrate W to be spaced apart by a predetermined distance from the upper surface of the body 342 .
[0041] The chunk pin 346 may be provided in plurality. The chuck pins 346 may be disposed such that it is further away from the center of the body 342 than the support pin 344 . The chuck pin 346 may be provided to protrude upwardly from the body 342 . The chuck pin 346 may support a side portion of the substrate W to prevent the substrate W from deviating from a given position to a lateral direction when the spin head 340 rotates. The chuck pin 346 may be provided to move in a straight line between a waiting position and a support position along a radius direction of the body 342 . The waiting position may be a position such that it is further away from the center of the body 342 than the support pin 344 . When the substrate W is loaded on or unloaded from the body 342 , the chuck pin 346 may be placed at the waiting position; when a substrate treating process is performed, the chuck pin 346 may be placed at the support position. The chuck pin 346 may be contacted with a side portion of the substrate W at the support position.
[0042] The elevation unit 360 may upwardly or downwardly move the housing 320 in a straight line. A height relative to the spin head 340 may be changed as the housing 320 moves upwardly or downwardly. The elevation unit 360 may include a bracket 362 , a moving shaft 364 , and a driver 366 . The bracket 362 may be fixedly installed on an outer wall of the housing 320 and the moving shaft 364 which moves upwardly or downwardly by the driver 366 may be fixedly jointed with the bracket 362 . When the substrate W is loaded on or lifted from the spin head 340 , the housing 320 may descend such that the spin head 340 protrudes upwardly from an upper portion of the housing 320 . Furthermore, when the process is performed, a height of the housing 320 may be adjusted such that the treating solution flows into a predetermined collection barrel 360 depending on a type of the treating solution supplied to the substrate W. Selectively, the elevation unit 360 may move the spin head 340 upwardly or downwardly.
[0043] The spray unit 380 may spray the treating solution on the substrate W. The spray unit 380 may be provided in plurality to spray various kinds of treating solutions or to spray the same kind of treating solutions in various ways. The spray unit 380 may include a support shaft 386 , a nozzle arm 382 , a first nozzle member 400 , a cleaning member, and a second nozzle member 480 . The support shaft 386 may be disposed at one side of the housing 320 . The support shaft 386 may have a rod form where its length direction is a vertical direction. The support shaft 386 may be rotated, ascended and descended by a driver member 388 . In contrast, the support shaft 386 may be moved and ascended and descended in a straight line along a horizontal direction by the driver member 388 . The nozzle arm 382 may be fixedly jointed at a top end of the support shaft 386 . The nozzle arm 382 may support a first nozzle member 400 and a second nozzle member 480 . The first nozzle member 400 and the second nozzle member 480 may be disposed at an end portion of the nozzle arm 382 . For example, the second nozzle member 480 may be located closer to the end portion relative to the first nozzle member 400 . A cleaning member may clean the first nozzle member 400 . The cleaning member may be provided at one side in the housing 320 . When a first treating solution is discharged on the substrate through the first nozzle member 400 , the controller 500 may place the first nozzle member 400 at a discharging position above the substrate. In contrast, when the discharging of the first treating solution is completed, the controller 500 may place the first nozzle member 400 at a cleaning position in a liquid bath.
[0044] FIG. 3 is a cross-sectional view illustrating a first nozzle member 400 according to an embodiment of the inventive concept. FIG. 4 is a bottom view illustrating the first nozzle member 400 of FIG. 3 . The first nozzle member 400 may spray the first treating solution in a spray manner. When viewed from the top, the first nozzle member 400 may be provided in the form of a ring. Referring to FIGS. 3 and 4 , the first nozzle member 400 may spray the first treating solution in an inkjet manner. The first nozzle member 400 may include a body 410 and 430 , a vibrator 436 , a treating solution supply line 450 , and a treating solution collection line 460 . The body 410 and 430 may contain a lower plate 410 and an upper plate 430 . The lower plate 410 may have a cylinder form. An injection flow path 412 through which the first treating solution flows may be formed in the lower plate 410 . A plurality of first discharge holes 414 may be formed at a lower surface of the lower plate 410 to spray the first treating solution, and each of the first discharge holes 414 may be connected with the injection flow path 412 . The first discharge holes 414 may be microscopic holes. The injection flow path 412 may include a first region 412 b, a second region 412 c, and a third region 412 a. When viewed from the top, the first region 412 b and the second region 412 c may be provided in the form of a ring. In this case, a radius of the first region 412 b may be greater than that of the second region 412 c. The first discharge holes 414 of the first region 412 b may be provided in a line along the first region 412 b. The first discharge holes 414 of the second region 412 c may be provided in tow lines along the second region 412 c. The third region 412 a may connect the first region 412 b and the second region 412 c to an inflow path 432 . The third region 412 a may connect the first region 412 b and the second region 412 c to a collection flow path 434 . For example, as illustrated in FIG. 4 , the third region 412 a may connect the inflow path 432 or the collection flow path 434 to the third region 412 a. The upper plate 430 may be provided in the form of a cylinder having the same diameter as the lower plate 410 . The upper plate 430 may be fixedly jointed on a top surface of the lower plate 410 . The inflow path 432 and the collection flow path 434 may be formed at an inside of the upper plate 430 . The inflow path 432 and the collection flow path 434 may be provided to pass through the second region 412 b of the injection flow path 412 . The inflow path 432 may function as an inlet into which the first treating solution flows, and the collection flow path 434 may function as an outlet through which the first treating solution is collected from the injection flow path 412 . The inflow path 432 and the collection flow path 434 may be disposed to face each other with the first nozzle member 400 as the center
[0045] The vibrator 436 may be placed in the upper plate 430 . When viewed from the top, the vibrator 436 may be provided to have a ring shape. For example, the vibrator 436 may be provided to have the same diameter as the first region 412 b . Selectively, the diameter of the vibrator 436 may be greater than that of the first region 412 b and may be smaller than that of the upper plate 430 . The vibrator 436 may be electrically connected to a power 438 placed at an outside. The vibrator 436 may provide a vibration to the first treating solution to be sprayed and may adjust a particle size and a flow velocity of the first treating solution. For example, the first treating solution may be electrolytic ionized water. The first treating solution may include any one of hydrogen water, oxygen water, and ozone water or all thereof. Selectively, the first treating solution may be pure water.
[0046] A treating solution supply line 450 may provide the first treating solution to the inflow path 432 , and a treating solution collection line 460 may collect the first treating solution from the collection flow path 434 . The treating solution supply line 450 may be connected to the inflow path 432 and the treating solution collection line 460 may be connected to the collection flow path 434 . A pump 452 and a supply valve 454 may be installed on the treating solution supply line 450 . A collection valve 462 may be installed on the treating solution collection line 460 . The pump 452 may pressurize the first treating solution supplied from the treating solution supply line 450 into the inflow path 432 . The supply valve 454 may open and close the treating solution supply line 450 . According to an example, the collection valve 462 may open the treating collection line 460 before a process, and thus, the first treating solution may collect the first treating solution via the treating solution collection line 460 and may not be injected via a first injection hole 414 . In contrast, the collection valve 462 may close the treating collection line 460 during a process. In this case, since the first treating solution may be filled in the injection flow path 412 , an internal pressure of the injection flow path 412 may be increased. When a voltage is applied to the vibrator 436 , the first treating solution may be injected via first injection hole 414 .
[0047] Referring again to FIG. 2 , the second nozzle member 480 may provide a second treating solution on the substrate. The second nozzle member 480 may supply the second treating solution simultaneously when the first nozzle member 400 supplies the first treating solution. In this case, the second nozzle member 480 may supply the second treating solution ahead before the first nozzle member 400 starts supplying the first treating solution. For example, the second nozzle member 480 may inject the second treating solution in a dropping manner. The second nozzle member 480 may be provided to surround a part of the first nozzle member 400 . The second nozzle member 480 may be more adjacent to one end of the nozzle arm 382 than the first nozzle member 400 . The second nozzle member 480 may have a second discharge hole vertically discharging the second treating solution on the substrate. When viewed from the top, the second nozzle member 480 may be provided in the form of an arc surrounding the first nozzle member 400 . A straight-line distance from one end of the second nozzle member 480 to the other end thereof may be greater than a diameter of the first nozzle member 400 . In this case, the first nozzle member 400 and the second nozzle member 480 may have the same center. The second treating solution may be provided as a protective liquid. For example, the second treating solution may be a solution including ammonia and hydrogen peroxide. The second treating solution may form a liquid film on the substrate W and the liquid film may relax influence of the treating solution on the substrate W. Accordingly, it may be possible to prevent a pattern on the substrate W from falling due to the second treating solution. The second treating solution may be pure water. The second discharge hole may be provided in the form of a single slit. Selectively, the second discharge hole may include in a plurality of circular discharge holes. The second nozzle member 480 may spray the second treating solution into a region adjacent to a region in which the first treating solution is sprayed on the substrate W. A region where the second treating solution sprayed may be closer to a center region of the substrate W than that where the first treating solution is sprayed. Selectively, the second nozzle member 480 may be provided in a bar shape, not an arc shape.
[0048] The controller 500 may control the spray unit 380 . For example, the controller 500 may control spray position, spray point in time, and spray amount of the spray unit 380 . For example, the controller 500 may control spray position, spray point in time, and spray amount of the first treating solution of the first nozzle member 400 .
[0049] FIG. 5 is a diagram illustrating a conventional substrate cleaning method. FIG. 6 is a diagram illustrating a region where a first treating solution is supplied when the first treating solution is sprayed using the substrate cleaning method of FIG. 5 . Referring to FIGS. 5 and 6 , the conventional substrate treating apparatus may supply the first treating solution while the first nozzle member 400 reciprocates from an edge region of the substrate to the center region thereof. In this case, the first nozzle member 400 may move under the condition that a spray height at which the first treating solution is applied over a substrate using the first nozzle member 400 is maintained constantly. In this case, due to the same angular velocity, sizes of areas where the first treating solutions are supplied on the substrate during the same time may be different from each other. That is, when a treating solution is sprayed during the same time, a spray region E 2 at the edge region of the substrate may be greater in size than a spray region E 1 at the center of the substrate. For this reason, the amount of droplets colliding with the center of the substrate W per unit area may be greater than that colliding with the edge region thereof, and thus, the center region of the substrate W may be damaged.
[0050] FIG. 7 is a diagram illustrating a substrate cleaning method for supplying the first treating solution on a substrate using the first nozzle member 400 according to an embodiment of the inventive concept. FIG. 8 is a diagram illustrating a substrate cleaning method for supplying the first treating solution on a substrate using the first nozzle member 400 according to another embodiment of the inventive concept. FIG. 9 is a diagram illustrating a surface velocity Vs at which the first treating solution reaches the substrate W, varied according to a spray height of the first nozzle member 400 . Below, a substrate treating method will be described with reference to FIGS. 7 to 9 . The controller 500 may spray the first treating solution while the first nozzle member 400 moves above the substrate W and between the edge region and the center region of the substrate. In this case, the controller 500 may differently adjust a first height h 1 where the first nozzle member 400 sprays the first treating solution at the edge region of the substrate W and a second height h 2 where the first nozzle member 400 sprays the first treating solution at the center of the substrate W. In this case, the second height h 2 may be higher than the first height h 1 . The surface velocity Vs at which the first treating solution reaches the substrate W may be variable according to a discharge height at which the first nozzle member 400 discharges the first treating solution. That is, as the height of the first nozzle member 400 becomes higher, the velocity of droplets discharged may become slower due to air resistance, thereby reducing influence of the droplet on the substrate W. For example, a surface velocity Vs at which the first nozzle member 400 discharges a treating solution at a height of 10 mm may become slower by about 2.4 m/s than a surface velocity Vs at which the first nozzle member 400 discharges a treating solution at a height of 5 mm. Accordingly, since impact on the center region on the substrate W is reduced as much as about 12%, it may be possible to prevent the center region of the substrate W from being damaged. The controller 500 may adjust a height of the first nozzle member 400 such that a height of the first nozzle member 400 is continuously increased as the first nozzle member 400 moves from the edge region of the substrate W to the center region thereof. For example, the controller 500 may linearly increase the height of the first nozzle member 400 . Selectively, The controller 500 may adjust a height of the first nozzle member 400 such that a height of the first nozzle member 400 is progressively increased as the first nozzle member 400 moves from the edge region of the substrate W to the center region thereof. For example, the controller 500 may stepwise increase the height of the first nozzle member 400 .
[0051] FIG. 10 is a diagram illustrating a first nozzle member 400 a according to another embodiment of the inventive concept. FIG. 11 is a diagram illustrating a first nozzle member 400 b according to another embodiment of the inventive concept. As illustrated in FIG. 10 , the first nozzle member 400 a may have micro-holes 430 a in the body 410 a. The first nozzle member 400 a may pressurize the first treating solution sprayed via the micro-holes 430 a to spray the first treating solution with mist. Furthermore, selectively, as illustrated in FIG. 11 , the first nozzle member 400 b may further include a gas supply unit 430 b at a body 410 b. The gas supply unit 430 b may be provided to be inclined downwardly toward a first discharge hole 420 b spraying the first treating solution. Accordingly, gas and the first treating solution may be sprayed respectively through the gas supply unit 430 b and the first discharge hole 420 b and may supply the first treating solution in a spray manner. In contrast, selectively, the first nozzle member may have another type of spray manner. Furthermore, selectively, the first nozzle member may supply the first treating solution in any other manners, not the spray manner.
[0052] The substrate treating apparatus described above may be used for various processes as well as the substrate cleaning process. For example, the substrate treating apparatus may be used for a substrate etching process. In addition, the substrate treating apparatus may include a rinse liquid member.
[0053] According to an exemplary embodiment of the inventive concept, it may be possible to improve cleaning efficiency.
[0054] The inventive concept, however, may be embodied in various different forms, and should not be construed as being limited only to the illustrated embodiments. Embodiments of the inventive concept are provided to illustrate more fully the scope of the inventive concept to those skilled in the art.
[0055] While the inventive concepts have been described with reference to example embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the spirits and scopes of the inventive concepts. Therefore, it should be understood that the above embodiments are not limiting, but illustrative. Thus, the scopes of the inventive concepts are to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing description. | Disclosed is a substrate treating apparatus. The substrate treating apparatus includes a housing defining a space for treating a substrate therein, a spin head supporting and rotating the substrate in the housing, a spray unit including a first nozzle member for spraying a first treating solution on the substrate placed on the spin head, and a controller controlling the spray unit. The controller sprays the first treating solution while moving the first nozzle member between edge and center regions of the substrate and above the substrate. The controller differently adjusts a first height at which the first treating solution is sprayed on the edge region of the substrate and a second height at which the first treating solution is sprayed on the center region of the substrate. | 7 |
PRIORITY CLAIM
[0001] This application claims priority under 35 U.S.C. 119 (e) to U.S. Provisional Application No. 60/691,380, filed Jun. 17, 2005, entitled METHODS AND INTERFACES FOR EVENT TIMELINES AND LOGS OF VIDEO STREAMS, and to U.S. Provisional Application No. 60/691,983, filed Jun. 17, 2005, entitled METHODS AND INTERFACES FOR VISUALIZING ACTIVITY ACROSS VIDEO FRAMES IN AN ACTION KEYFRAME, and to U.S. Provisional Application No. 60/691,899, filed Jun. 17, 2005, entitled METHOD AND SYSTEM FOR ANALYZING FIXED-CAMERA VIDEO VIA THE SELECTION, VISUALIZATION, AND INTERACTION WITH STORYBOARD KEYFRAMES, each of which is incorporated herein by reference.
CROSS REFERENCE TO RELATED APPLICATIONS
[0002] This application is related to the following applications, which were filed of even date herewith:
[0003] (1) “Method and System for Analyzing Fixed-Camera Video via the Selection, Visualization, and Interaction with Storyboard Keyframes,” by Andreas Girgensohn, et al. (Attorney Docket No. FXPL-01119US1 MCF/AGC); and
[0004] (2) “Methods and Interfaces for Visualizing Activity across Video Frames in an Action Keyframe,” by Andreas Girgensohn, et al. (Attorney Docket No. FXPL-01121US1 MCF/AGC).
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] Techniques for generating timelines and event logs from one or more fixed-position cameras based on the identification of activity in the video, an assessment of the importance of the activity, the creation of a timeline identifying events of interest, and interaction techniques for seeing more details of an event or alternate views of the video are identified.
[0007] 2. Description of the Related Art
[0008] Identifying events of interest within a set of synchronized video streams, such as video from a set of security cameras, is difficult due to the quantity of video and the lack of authored metadata or indexing. Yet, security personnel need to identify, either in real time or after the fact, activities of interest and determine interrelationships between activities in different video streams. They must develop an understanding of the sequence of actions that led to or happened after a particular incident.
[0009] Timelines have been explored by a variety of researchers. Plaisant et al. use timelines to visualize events in people's lives (e.g., criminal or medical records), Plaisant C., Milash B., Rose A., Widoff S., Shneiderman B., LifeLines: Visualizing Personal Histories. Proceedings of the SIGCHI conference on Human factors in computing systems, pp. 221-227, 1996. Kumar et al. visualize data from digital libraries such as information about music composers in timelines. Kumar V., Furuta R., Allen R. B., Metadata Visualization for Digital Libraries: Interactive Timeline Editing and Review. Proceedings of the third ACM conference on Digital libraries, pp. 126-133, 1998.
[0010] Other approaches are given in Chueng, S.-C. S. and Kamath C. Robust Techniques for Background Subtraction in Urban Traffic Video. Video Communications and Image Processing, SPIE Electronic Imaging, San Jose, 2004.
[0011] U.S. Pat. No. 6,366,296 discloses a timeline view for a single camera. U.S. patent application Ser. No. 10/126,555 Publication Number 20030197731 shows a related map technique where keyframes of events fade in and out while the user moves along the timeline.
SUMMARY OF THE INVENTION
[0012] A timeline interface for presenting events of interest within a set of video streams has been developed. The timeline interface includes techniques for locating periods of interesting activity within a video stream, methods for grouping activity into events, methods for presenting events, and interface elements for selecting periods of interest and playing through events in a map.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Preferred embodiments of the present invention will be described in detail based on the following figures, wherein:
[0014] FIG. 1 shows an artists impression of FIG. 8 where a graph of the importance determined from activity close to hot spots versus time is plotted where horizontal lines are used to indicate the time at which the important event was first present in the video stream and extend to the time the event was last present in the video stream and keyframes representative of the activity are displayed, in FIG. 1 the symbols (□, Δ, ⋄, O) corresponding to colors (green, red, yellow, blue) are used to indicate the source camera ( 1 , 2 , 3 , 4 ) and different hatched line drawings of the characters in FIG. 1 are used to better distinguish the different actors present in FIG. 8 ;
[0015] FIG. 2 shows an artists impression of FIG. 9 where a timeline with events from a single source camera ( 2 ) indicated in FIG. 2 using the triangle symbol (Δ) to exemplify that the horizontal box and the keyframe outlines in FIG. 9 are shaded red and different hatched line drawings of the characters in FIG. 2 are used to better distinguish the different actors present in FIG. 9 ;
[0016] FIG. 3 shows an artists impression of FIG. 10 where a timeline with events from multiple cameras is displayed and keyframes are outlined in FIG. 3 with symbols (□, Δ, ⋄, O) corresponding to colors (green, red, yellow, blue) in FIG. 10 to indicate the source camera ( 1 , 2 , 3 , 4 ) and different hatched line drawing of the characters in FIG. 3 are used to better distinguish the different actors present in FIG. 10 ;
[0017] FIG. 4 shows an artists impression of FIG. 11 where a quad representation of keyframes from four cameras is displayed with keyframes cropped to the center of activity and sized proportional to their importance and different hatched line drawings of the characters in FIG. 4 are used to better distinguish the different actors present in FIG. 11 ;
[0018] FIG. 5 shows an artists impression of FIG. 12 where an event list and keyframes with activity close to the hotspot and time-lapse visualization of the whole event are displayed, where the intensity of the object in the time lapse visualization in FIG. 5 is indicated using the code (continuous line, dashed line, dotted line) to indicate intense, weak and faint figures and different hatched line drawings of the characters in FIG. 5 are used to better distinguish the different actors present in FIG. 12 ;
[0019] FIG. 6 shows an artists impression of FIG. 13 which illustrates a map showing camera positions identified in FIG. 6 using symbols (□, Δ, ⋄, O) corresponding to colors (green, red, yellow, blue) in FIG. 13 to indicate the camera ( 1 , 2 , 3 , 4 ) respectively, where keyframes of events fade in and out while the user moves along the timeline (not shown) and different hatched line drawings of the characters in FIG. 6 are used to better distinguish the different actors present in FIG. 13 ;
[0020] FIG. 7 shows a block diagram of the steps involved in identifying events in a video streams to generate a timeline;
[0021] FIG. 8 shows a graph of the importance determined from activity close to hot spots versus time;
[0022] FIG. 9 shows a timeline with events from a single source camera ( 2 );
[0023] FIG. 10 shows a timeline with events from multiple cameras and keyframes;
[0024] FIG. 11 shows a quad representation of keyframes from four cameras with keyframes cropped to the center of activity and sized proportional to their importance;
[0025] FIG. 12 shows an event list and keyframes with activity close to the hotspot and time-lapse visualization of the whole event; and
[0026] FIG. 13 illustrates a map showing camera positions, where keyframes of events fade in and out while the user moves along the timeline (not shown).
DETAILED DESCRIPTION OF THE INVENTION
[0000] Identifying Activity in Video
[0027] Two different approaches for determining activity are proposed. The first approach compares successive video frames and determines the pixels that change. The second approach models the background of the camera view and determines foreground pixels in every video frame. Both approaches look at the changed or foreground pixels and count them or determine the direction and speed of the overall motion. Frames with sufficient activity are grouped into video segments with activity. Thresholds for the minimum fraction of changed pixels to be considered activity, for the minimum pause in activity to start a new segment, and the minimum length of an activity segment to ignore video noise are experimentally determined.
[0000] Turning Activity into Events
[0028] Events are identified by determining periods of activity which are considered of interest based on the amount of activity in the video, distance to points of interest in the space being videotaped, detected features such as people's faces, and events from other sensors, e.g., Radio Frequency Identification (RFID). If multiple cameras have the same point of interest in view, the distance measure to the point of interest can be improved by considering all cameras.
[0029] Once the measure of interest has been computed for each frame in the video, frames are combined into event sequences by first smoothing the importance score with a moving average, and then selecting sequences where the moving average is above a threshold. This is illustrated in FIG. 1 and FIG. 8 , where a graph of the importance, determined from activity close to hot spot, is plotted versus time. In FIGS. 1 and 8 , sequences with the moving average above a threshold are grouped into events and events with short gaps are merged. Another threshold determines the maximum duration for gaps for merging events. FIGS. 1 and 8 also depict keyframes with high importance associated with the events.
[0000] Visualizing Events on a Timeline
[0030] Rather than simply providing a list of events, the events are visualized using a timeline and keyframes. FIG. 2 and FIG. 9 show a timeline with events from a single (# 2 ) camera. In FIG. 2 the triangle symbol (Δ) is used to exemplify that the horizontal bar/line and the keyframe outlines are shaded red in FIG. 9 to indicate that the video comes from the camera associated with that color. The horizontal bar/lines indicate the duration of the event, and a keyframe is used to visualize the content of each event. Users can adjust the endpoints of the timeline to obtain the time interval of interest. FIG. 7 shows a block diagram of the steps involved in identifying events in video streams to generate a timeline. For multiple cameras, a single timeline is still used, but horizontal bars of different colors indicate events for different cameras. FIG. 3 and FIG. 10 show a timeline with events from multiple cameras. In FIG. 3 keyframe outlines are coded symbols (□, Δ, ⋄, O) corresponding to colors (green, red, yellow, blue) in FIG. 10 to indicate the source camera ( 1 , 2 , 3 , 4 ). Composite keyframes or activity keyframes are provided to give a sense of the different views of an event and the activity in an event. FIG. 4 and FIG. 11 illustrate a quad representation of keyframes from four cameras with keyframes cropped to the center of activity and sized proportional to their importance.
[0000] Interaction with Timeline
[0031] Users such as security personnel need to be able to select video streams for inclusion in the timeline. A map interface component has been designed and developed for this purpose. The map and timeline interact to provide the user with the information necessary to locate video segments of interest.
[0000] The Map Shows the Geographic Position
[0032] The map shows the geographic position of the cameras and is used for selecting video streams to include in the timeline. Cameras are identified using both color-coding and textual camera identifiers. When a user selects a set of cameras with the mouse, the timeline is recreated.
[0000] Playback of Events in Map
[0033] Users can choose to play through a portion of the timeline. During timeline playback, keyframes indicating interesting activity fade into view on the map near the camera showing the activity and fade out after the time of the activity has passed. FIG. 6 and FIG. 13 illustrate a map showing camera positions where keyframes of events fade in and out while the user moves along the timeline (not shown in Figures).
[0000] Visualizing Activity in Keyframes
[0034] Action Keyframes. To visualize a period of activity in a video stream via a single keyframe, foreground objects appearing in different frames in the video segment are alpha-blended to show motion. FIG. 5 and FIG. 12 illustrate an event list and keyframes with activity close to the hotspot and time-lapse visualization of the whole event, where in FIG. 5 the intensity of the object in the time lapse visualization is indicated using a code (continuous line, dashed line, dotted line) to indicate intense, weak and faint figures.
[0035] Keyframe Compositions. An approach to presenting simultaneous action in multiple video streams can be to create a composition from areas of interest in keyframes from multiple cameras. The size of the regions taken from the source keyframes is used to indicate the relative importance of activity in those video streams (see FIGS. 4 and 11 ).
[0036] Various embodiments of the invention may be implemented using a processor(s) programmed according to the teachings of the present disclosure, as will be apparent to those skilled in the computer art. Appropriate software coding can readily be prepared by skilled programmers based on the teachings of the present disclosure, as will be apparent to those skilled in the software art. The invention may also be implemented by the preparation of integrated circuits and/or by interconnecting an appropriate network of component circuits, as will be readily apparent to those skilled in the art.
[0037] Various embodiments include a computer program product which can be a storage medium (media) having instructions and/or information stored thereon/in which can be used to program a general purpose or specialized computing processor(s)/device(s) to perform any of the features presented herein. The storage medium can include, but is not limited to, one or more of the following: any type of physical media including floppy disks, optical discs, DVDs, CD-ROMs, micro drives, magneto-optical disks, holographic storage devices, ROMs, RAMs, EPROMs, EEPROMs, DRAMs, PRAMS, VRAMs, flash memory devices, magnetic or optical cards, nano-systems (including molecular memory ICs); paper or paper-based media; and any type of media or device suitable for storing instructions and/or information. Various embodiments include a computer program product that can be transmitted in whole or in parts and over one or more public and/or private networks wherein the transmission includes instructions and/or information, which can be used by one or more processors to perform any of the features, presented herein. In various embodiments, the transmission may include a plurality of separate transmissions.
[0038] Stored on one or more computer readable media, the present disclosure includes software for controlling the hardware of the processor(s), and for enabling the computer(s) and/or processor(s) to interact with a human user or other device utilizing the results of the present invention. Such software may include, but is not limited to, device drivers, interface drivers, operating systems, execution environments/containers, user interfaces and applications.
[0039] The execution of code can be direct or indirect. The code can include compiled, interpreted and other types of languages. Unless otherwise limited by claim language, the execution and/or transmission of code and/or code segments for a function can include invocations or calls to other software or devices, local or remote, to do the function. The invocations or calls can include invocations or calls to library modules, device drivers, interface drivers and remote software to do the function. The invocations or calls can include invocations or calls in distributed and client/server systems.
[0040] In one embodiment of the invention, a method of identifying events in one or more video streams is envisaged comprising the steps of: (a) determining a measure of interest; (b) generating an importance score for each video frame based on the measure of interest; (c) computing one or more threshold values; and (d) selecting video frames identifying events based on the threshold values.
[0041] In another embodiment of the invention, the measure of interest is based on criteria selected from the group consisting of the amount of activity in the video, points of interest in the video, distance to points of interest from the camera, detected features in the video, facial features in the video, if the activity is of interest, if the feature is of interest, activities detected by other sensors and events detected by other sensors.
[0042] In another embodiment of the invention, determining the measure of interest further comprises the steps of: (e) determining one or more points of interest in the video stream; (f) determining one or more distances from the one or more video camera positions to the one or more points of interest in the video stream; and (g) determining the measure of interest based on the distances to the points of interest.
[0043] In another embodiment of the invention, generating the importance score further comprises the step of smoothing. In another embodiment of the invention, the smoothed importance score is generated by applying a moving average to the importance score.
[0044] In another embodiment of the invention, one or more threshold values are computed for measures selected from the group consisting of the minimum measure of interest, the minimum fraction of changed pixels to be considered activity, the minimum pause in activity to start a new video segment and the minimum length of the activity segment to ignore noise.
[0045] In another embodiment of the invention, selecting video frames further comprises the steps of: (h) including video frames in the event if the smoothed importance score is above a minimum measure of interest threshold; and (i) merging selected consecutive video frames into a single event if the gap between the selected consecutive video frames is below the minimum pause in activity to start a new video segment threshold value.
[0046] Another embodiment of the invention further comprises generating a timeline of at least one of the events in the video stream.
[0047] In another embodiment of the invention, the duration of events in the timeline are identified using a horizontal line where the line begins at the time the event was first present in the video stream and ends at the time the event was last present in the video stream; and wherein a keyframe is used to visualize the content of each event; wherein the keyframe is associated with the duration of events.
[0048] In another embodiment of the invention, where two or more video streams simultaneously recorded with two or more cameras are represented on a single timeline; where the duration of the event present in each video stream is represented with a horizontal line using a code to indicate the camera used to record the stream; wherein the same code is used for different events present in the video from the same camera; wherein the same code is used to frame the keyframe for each event from the same camera.
[0049] In another embodiment of the invention, the code uses different colors to indicate an event shot with a different camera; wherein the same color is used for different events present in the video from the same camera; wherein the same color is used to frame the keyframe for each event from the same camera.
[0050] In another embodiment of the invention, a map is used to show the geographic position of two or more cameras used to film the two or more video streams; where a code is used to indicate a camera; where a keyframes is used to show the video stream observed from the camera and is framed in that code; where a different code is used to indicate a different camera; where different keyframes used to show the video stream observed from the different cameras are framed with the different code associated with the different cameras; where the keyframes vary as a cursor moves along the timeline.
[0051] In another embodiment of the invention, the code uses different colors to show the geographic position of two or more cameras used to film the two or more video streams; where a color is used to indicate a camera; where the keyframes is framed in that color; where a different color is used to indicate a different camera; where the different keyframes are framed with the different colors associated with the different cameras; where the keyframes vary as a cursor moves along the timeline.
[0052] In another embodiment of the invention, keyframes of the identified event are presented; where the keyframes are numbered according to the timeline. In another embodiment of the invention, the keyframes are selected from the group consisting of single action keyframes representative of the period of activity and/or time-lapse visualization of the period of activity. In another embodiment of the invention, keyframes are used to visualize a composition in a video stream; where the keyframes are numbered according to the single timeline.
[0053] In another embodiment of the invention, an event-log is used with keyframes on a map to visualize the event.
[0054] In another embodiment of the invention, the event is represented using a medium selected from the group consisting of a map, an event-log and a timeline.
[0055] In an embodiment of the invention, a program of instructions executable by a computer to generate a timeline of events in a video stream, comprising the steps of: determining a measure of interest; generating an importance score for each video frame based on the measure of interest; computing one or more threshold values; electing video frames identifying events based on the threshold values; and generating a timeline of the one or more events in the video stream.
[0056] In another embodiment of the invention, a system or apparatus for generating a timeline of events in a video stream, wherein generating a timeline comprises: a) one or more processors capable of specifying one or more sets of parameters; capable of transferring the one or more sets of parameters to a source code; capable of compiling the source code into a series of tasks for visualizing an event in a video stream; and b) a machine readable medium including operations stored thereon that when processed by one or more processors cause a system to perform the steps of specifying one or more sets of parameters; transferring one or more sets of parameters to a source code; compiling the source code into a series of tasks for generating a timeline of events in a video stream.
[0057] In another embodiment of the invention, a machine-readable medium having instructions stored thereon to cause a system to: determine a measure of interest; generate an importance score for each video frame based on the measure of interest; compute one or more threshold values; select video frames identifying events based on the threshold values; and generate a timeline of the one or more events in the video stream. | Techniques for generating timelines and event logs from one or more fixed-position cameras based on the identification of activity in the video are presented. Various embodiments of the invention include an assessment of the importance of the activity, the creation of a timeline identifying events of interest, and interaction techniques for seeing more details of an event or alternate views of the video. In one embodiment, motion detection is used to determine activity in one or more synchronized video streams. In another embodiment, events are determined based on periods of activity and assigned importance assessments based on the activity, important locations in the video streams, and events from other sensors. In different embodiments, the interface consists of a timeline, event log, and map. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to a piezoelectric filter having an improved group delay time characteristic (hereinafter referred to as the G.D.T. characteristic).
There has heretofore been known a ladder type filter constituted by a plurality of piezoelectric resonators each utilizing a face vibration mode or a radial vibration mode, an example of which is shown in FIG. 1 of the accompanying drawings in side elevational view. Referring to FIG. 1, the prior art ladder type filter comprises a plurality of, for example, five, piezoelectric resonators 1a, 1b, 1c, 1d and 1e. Of these piezoelectric resonators, the piezoelectric resonators 1a, 1c and 1e are series resonance elements while the piezoelectric resonators 1b and 1d are parallel resonance elements, these piezoelectric resonators being so arranged that a parallel resonance element is positioned between each two adjacent series resonance elements. These piezoelectric resonators 1a to 1e are of identical construction and each piezoelectric resonator 1a, 1b, 1c, 1d and 1e includes a piezoelectric substrate of a plate-like configuration of any desired shape, for example, a square shape, having its opposing major surfaces coated or deposited with electrode layers of known fabrication, and first and second electroconductive terminal plates 2a and 3a, 2b and 3b, 2c and 3c, 2d and 3d, or 2e and 3e. Each of these first and second terminal plates contacts and is, therefore, electrically connected to a corresponding face of the piezoelectric substrate through an electroconductive protuberance 4a rigidly secured to or integrally formed with the terminal plates, the point of contact of the protuberance 4a with the corresponding face of the piezoelectric substrate of the associated resonator corresponding to a node of vibration of that piezoelectric substrate. The protuberances 4a are kept at a certain position and are urged against the corresponding face of the piezoelectric substrate of the associated resonator by application of a small pressure, such as 250˜300 g/cm 2 by means of a spring having a known construction. While the terminal plates 2a and 3e serve as input and output terminal elements, respectively, the terminal plates 3a and 2c are electrically connected to each other by means of a bridge element 5 and the terminal plates 3c and 2e are electrically connected to each other by means of a bridge element 6. Electrically insulating sheets 7 and 8 are positioned respectively between the terminal plates 3b and 2c and between the terminal plates 3d and 2e. In use, the terminal plates 3b and 3d are electrically grounded.
The selective filtering characteristic and the G.D.T. characteristic of the prior art ladder type filter are shown in a graph of FIG. 2. An improvement of such a ladder type filter as described above has long been desired to improve the G.D.T. characteristic in order to suppress the phase distortion. One conventional method for improving the G.D.T. characteristic is to decrease the mechanical quality factor Q to a value of from several tens to hundreds. However, it has been found that the conventional method for improving the G.D.T. characteristic entails various difficulties. In particular, depending upon the particular value of the mechanical quality factor Q chosen, the ratio of materials to be mixed together has to be adjusted and, consequently, the filter having a desired temperature characteristic TC, electromechanical coupling coefficient K and dielectric constant can no longer be obtained without difficulty.
Moreover, as the mechanical quality factor Q is lowered, the frequency constant (Fol) is correspondingly reduced. By way of example, when a filter utilizing resonators having a relatively low mechanical quality factor Q is incorporated in a casing in which resonators having a mechanical quality factor Q of about 1,000 are incorporated, the resistance to impact tends to be intolerably low, and the attentuation level varies considerably, because the resonators employed are small in size.
SUMMARY OF THE INVENTION
Accordingly, the present invention has been made with a view to substantially eliminating the above described disadvantages and inconveniences inherent in the prior art piezoelectric filter, and has for its essential object to provide an improved piezoelectric filter having an improved G.D.T. characteristic and comprising at least one piezoelectric resonator with a relatively high mechanical quality factor Q.
Another important object of the present invention is to provide an improved piezoelectric filter of the type referred to above, wherein the piezoelectric resonator is of a construction having a relatively high resistance to vibration and impact and is supported in an electrically and mechanically stable manner.
A further object of the present invention is to provide an improved piezoelectric filter of the type referred to above utilizing conventional component parts to improve the G.D.T. characteristic.
A still further object of the present invention is to provide an improved piezoelectric filter of the type referred to above that can be manufactured simply and without any increase in manufacturing cost.
For accomplishing these and other objects of the present invention, there is provided a piezoelectric filter comprising at least one piezolectric resonator including a piezoelectric substrate and first and second electroconductive terminal members disposed on and in electrical contact with the first and second major opposing sides of the piezoelectric substrate respectively. At least one electroconductive pliable sheet is positioned between the first electroconductive terminal member and the associated face of the piezoelectric substrate.
According to the present invention, unlike each of the terminal plates employed in the prior art filter of the construction shown in FIG. 1, the terminal members employed in the present invention have no protuberances and are instead held flat against the corresponding face of the piezoelectric substrate or against the interposed electroconductive pliable sheet.
In the assembled condition and in use, the filter according to the present invention is subjected to pressure applied in a direction perpendicular to any one of the opposed major faces of the piezoelectric substrate so that the G.D.T. characteristic can be improved.
The electroconductive pliable sheet employed in the present invention is currently commercially available in three types. The first of them is an electroconductive plastic sheet having electroconductivity in all directions; the second type is an electroconductive plastic sheet having substantial electroconductivity only across its thickness; the third is an electroconductive plastic sheet having substantial electroconductivity only across its thickness and only when external pressure is applied. The second type of the direction-oriented electroconductive plastic sheet is generally made of a sheet of silicone rubber containing electroconductive material, for example, metallic particles, carbon particles or metallic fibers, dispersed therein in a predetermined arrangement. The second type is similar in character to the third type, but differs from the latter in that the third type requires the application of the pressure to establish the electroconductivity. The last two types are a fairly recent development and are generally termed "aniso-tropically electroconductive plastic sheet" and "pressure-conductive sheet" by those skilled in the art, respectively. In view of these recently developed electroconductive plastic sheets, the term "total-conductive plastic sheet" is employed herein to denote the first-mentioned type and also to render the first mentioned type distinct from either the second or the third type.
In any event, not only the total-conductive plastic sheet, but also either the anisotropically electroconductive plastic sheet or the pressure-conductive plastic sheet can be utilized in the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the present invention will become apparent from the following description of a preferred embodiment thereof with reference to the accompanying drawings, in which:
FIG. 1 is a side elevational view of the prior art ladder-type filter, reference to which has already been made;
FIG. 2 is a graph showing the A.M.P. and G.D.T. characteristics of the prior art filter shown in FIG. 1;
FIG. 3 is a side elevational view of a piezoelectric resonator forming a part of a filter according to the present invention;
FIG. 4 is a side elevational view, showing the details of the internal structure of a ladder-type filter according to the present invention;
FIG. 5 is a graph showing the relationship between variation in pressure applied to the resonator and variation in band width of the filter of the present invention;
FIG. 6 is a graph showing the relationship between variation in pressure applied to the resonator and the insertion loss of the filter of the present invention;
FIG. 7 is a graph showing the relationship between variation in applied pressure and the resonance frequency of the filter of the present invention;
FIG. 8 is a graph showing the relationship between variation in applied pressure and the antiresonance frequency of the filter of the present invention;
FIG. 9 is a graph showing the relationship between variation in applied pressure and the resonant resistance of the filter of the present invention;
FIG. 10 is a graph showing the relationship between variation in applied pressure and the antiresonant resistance of the filter of the present invention; and
FIG. 11 is a graph showing the A.M.P. and G.D.T. characteristics of the filter of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Before the description of the present invention proceeds, it is to be noted that like parts are designated by like reference numerals throughout the accompanying drawings.
Referring first to FIG. 3, there is shown a piezoelectric resonator forming a part of a filter according to the present invention. The piezoelectric resonator comprises a piezoelectric substrate 11 of a plate-like configuration having, for example, a square shape and having its opposing major surfaces coated or deposited with electrode layers 11a, 11b of known construction in association with first and second electroconductive terminal plates 2 and 3, the first terminal plate 2 facing one of the major faces of the piezoelectric substrate 11 and the second terminal plate 3 facing its other major face. These first and second terminal plates 2 and 3 are electrically connected to the piezoelectric substrate 11 through respective electroconductive pliable sheets 9 and 10.
Where the ladder-type filter is desired, a plurality of, for example, five, piezoelectric resonators each being of the construction which has been described with reference to and shown in FIG. 3, are assembled in the manner shown in FIG. 4. In FIG. 4, the five piezoelectric resonators are respectively identified by I, II, III, IV and V and are arranged in face-to-face relation to each other in a manner substantially similar to that shown in FIG. 1.
However, because the terminal plates 2 and 3 are not provided with such electroconductive protuberances as are required in the prior art arrangement shown in FIG. 1, either the second terminal plate 3 of either the first or the third resonators I and III or the first terminal plate 2 of either the second or the fourth resonators II and IV can be omitted, as shown.
As is the case with the filter shown in FIG. 1, the first terminal plate 2 of the first resonator I and the second terminal plate 3 of the fifth resonator V respectively serve as input and output terminal elements, while the second terminal plate 3 of the second resonator II and the second terminal plate 3 of the fourth resonator IV are adapted to be electrically grounded.
In practice, the assembly shown in FIG. 4 is housed in a casing and is subjected to a relatively great pressure, for instance, 600 gf/cm 2 , so as to compress the resonators I to V together. This pressure may be exerted by one or more spring elements positioned between a wall of the casing and either the first terminal plate 2 of the first resonator I or the second terminal plate 3 of the fifth resonator V.
As this pressure increases beyond that used in the conventional design shown in FIG. 1, no substantial variation takes place in resonance or antiresonance frequency, but the resonant resistance increases and the antiresonant resistance decreases, with the mechanical quality factor Q consequently being lowered substantially. FIG. 5 shows the relationship between applied pressure and variation in band width for the filter of the invention. FIG. 6 shows the relationship between applied pressure and the insertion loss. FIG. 7 shows the relationship between applied pressure and resonance frequency. FIG. 8 shows the relationship between applied pressure and antiresonance frequency. FIG. 9 shows the relationship between applied pressure and resonant resistance. FIG. 10 shows the relationship between applied pressure and antiresonant resistance.
It is to be noted that, in the graphs shown in FIGS. 7 to 10, the solid line is obtained with the filter wherein each of the electroconductive pliable sheets 9 and 10 is of a circular shape while the broken line is obtained with the filter wherein each of the electroconductive pliable sheets 9 and 10 is of a square shape, both of the sheets 9 and 10 having, in either case, substantial electroconductivity only across their thickness.
As can readily be understood from the graphs of FIGS. 5 to 10, by suitably selecting the amount of pressure to be applied, a desired G.D.T. characteristic can readily be achieved. By way of example, as compared with the prior art filter having a mechanical quality factor of 1,000, the mechanical quality factor of the filter assembled according to the present invention and wherein the resonators I to V are compressed together by the application of the pressure has been found to be only about 100. FIG. 10 shows the selective filtering characteristic and the G.D.T. characteristic of the ladder-type filter according to the present invention.
It is to be noted that the electroconductive pliable sheets 9 and 10 may be of any desired shape, for example, square, circular, rectangular, hexagonal, octagonal or oval, and of any desired size. Furthermore, the electroconductive pliable sheets 9 and 10 may be of different shape and/or size. In addition, a resonator could have only one pliable sheet rather than two as shown, and in a ladder-type filter such as that shown in FIG. 4, at least one of the component resonators I to V may be provided with only one electroconductive pliable sheet.
According to the present invention, because of the provision of an electroconductive pliable sheet between the terminal plate and the corresponding face of the resonator, the following advantages can be gained. The G.D.T. characteristic can be improved even if a piezoelectric substrate of high mechanical quality factor is employed.
Moreover, the prior art ladder-type filter of the construction shown in FIG. 1 is susceptible to change in performance characteristic, particularly, at an attenuation level of -90 dB to -110 dB, when the filter itself receives an impact or is dropped. The prior art ladder-type filter is such that its performance curves at high and lower frequency components of the frequency at which maximum attenuation is attained exhibit a considerable fluctuation.
While the prior art ladder-type filter exhibits a maximum attenuation of -80 to -90 dB, the ladder-type filter of the present invention has in practice exhibited a maximum attenuation of about -120 dB with its performance curve exhibiting no fluctuation.
As regards the resistance to vibration and impact, while the prior art filter can withstand a vibration of 20 cycles per second, the present invention is such that its performance can be stabilized under vibration of up to at least 100 cycles per second. This means that the filter according to the present invention can withstand any possible vibration or impact which it may receive during ordinary handling and, therefore, even if the filter of the present invention is handled more roughly than the prior art filter, it will not generate shock noises. Furthermore, as compared with variation in level within the band width occurring from 0.5 to 1.0 dB in the prior art filter, the filter of the present invention has shown variation in level within the band width within the range of 0 to 0.2 dB.
In particular, in the prior art filter shown in FIG. 1, there is a direct contact of each protuberance to the electrode layer on the corresponding face of the piezoelectric substrate. Therefore, when an impact or vibration is applied to the prior art filter, the protuberance rubs the electrode to such an extent that the electrode is ultimately stripped off. The piezoelectric substrate used in the prior art filter is particularly susceptible to damage when a strong impact is applied to it. However, according to the present invention, this possibility is advantageously eliminated by the provision of the electroconductive pliable sheet.
Furthermore, the employment of the electroconductive pliable sheet enables the employment of a relatively thin piezoelectric substrate, which in turn permits the manufacture of a filter of a relatively small size. Since the conventional piezoelectric substrate of a high mechanical quality factor can be employed in the present invention, a conventional casing can be employed without causing any variation in attenuation level. Use of the conventional casing permits the manufacture of the filter of the present invention at reduced cost.
As compared with the conventional method of manufacturing the piezoelectric filter, the present invention requires only the extra step of providing the electroconductive pliable sheet. Even though the extra manufacturing step is required in the manufacture of the piezoelectric filter of the present invention, the method is believed to be simpler than the prior art method, as disclosed in the Japanese Laid-open Utility Model Publication No. 52-60278, laid open to public inspection in 1977. This last mentioned publication discloses the use of an electroconductive polymer compound as a material for the protuberance, which must be subsequently bonded to the associated terminal plate. This publication also discloses coating the electroconductive polymer compound on the metallic terminal element to develop an elastic and electroconductive connection between the piezoelectric substrate and the corresponding terminal element.
In the manufacture of the prior art filter of the construction shown in FIG. 1, care is required in positioning each terminal plate relative to the corresponding piezoelectric substrate so that the associated protuberance 4a is aligned with the node of vibration of the piezoelectric substrate. However, in the present invention, such care is not required and, therefore, the manufacture of the filter according to the present invention can be automated with high yield, and the manufacturing cost of the filter according to the present invention can be reduced.
It should be noted that the concept of the present invention is applicable not only to the ladder-type filter such as described above, but also to any other type of filter utilizing a piezoelectric resonator.
Although the present invention has fully been described in connection with a preferred embodiment thereof with reference to the accompanying drawings, many variations and modifications therefor will now be apparent to those skilled in the art, and the scope of the present invention is to be limited, not by the details of the preferred embodiment described herein, but only by the terms of the appended claims. | A piezoelectric filter comprises at least one piezoelectric resonator comprising a piezoelectric substrate and first and second electroconductive terminal members deposed one on each side of the piezoelectric substrate, with which they are in electrical contact. At least one electroconductive pliable sheet is disposed between the first terminal member and the associated face of the piezoelectric substrate, and pressure is applied across the thickness of the combination of electrodes, pliable sheet and substrate. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a digital convergence apparatus for use in a color television receiver, a RGB three-tube type color projector, etc., and more particularly to an apparatus of this type capable of performing convergence correction in response to various kinds of television signals.
2. Description of the Related Art
Large screens are now demanded. To meet this demand, large color television receivers or projection tube type color projectors are widely spread. In the projection tube type color projectors, image signals indicative of three elementary colors RGB are supplied to R-, G- and B-projection tubes, respectively, and images projected from the projection tubes are superposed upon each other on a screen, thereby creating a color image. However, since the projection tubes are positioned at different angles relative to the screen, misconvergence may well occur in the color image. To avoid this, a coil is provided for each projection tube, and a correction signal is supplied to the coil to make it generate a magnetic field for correcting the misconvergence and thereby to control the direction of deflection of electron beams emitted from the tube.
A digital convergence apparatus is now used as an apparatus for generating the correction signal. This apparatus stores, in its memory, convergence adjusting data corresponding to a plurality of adjusting points, which respectively correspond to a plurality of points on the screen. In synchronism with scanning, the convergence adjusting data is read from the memory, and converted to a convergence correction signal by digital/analog conversion. A convergence correction signal corresponding to a point on the screen interposed between adjacent adjusting points is created by obtaining interpolation convergence adjusting data as a result of interpolating convergence adjusting data corresponding to the adjacent points, and subjecting the interpolation convergence adjusting data to digital/analog conversion.
The interpolation convergence adjusting data includes data concerning the horizontal direction and data concerning the vertical direction.
In the conventional digital convergence apparatus, interpolation convergence adjusting data is created in both odd and even fields, using the same interpolation convergence adjusting data. Accordingly, an error will occur between an ideal scanning position and the actual scanning position corrected by convergence correction. For example, where convergence adjusting data is created concerning the odd field, an error will occur, in the even field, between an ideal scanning position and the actual scanning position corrected by convergence correction. This error will make it impossible to situate a scanning line, which is included in the even field, in the center position of adjacent scanning lines which are included in the odd field. In other words, the scanning lines will not be arranged at regular intervals because of the error. This phenomenon is called a pairing phenomenon, which will degrade the quality of an image. In the case of an apparatus with a screen size of 40 inches or less, the interval between adjacent scanning lines is not so large, and hence the degree of degradation in image quality due to the pairing phenomenon falls within an allowable range. However, as the screen is enlarged, the scanning-line interval increases, and accordingly the quality degradation due to the pairing phenomenon becomes conspicuous. Furthermore, in the recent projectors, the distance between the projection tubes and the screen is more and more shortened, and the size of the screen is more and more increased. In these projectors, the amount of convergence correction using the adjusting data much more increases, and the amount of the aforementioned error accordingly increases. As a result, image quality degradation due to the pairing phenomenon becomes unallowable.
SUMMARY OF THE INVENTION
It is the object of the invention to provide a digital convergence apparatus free from image quality degradation due to the pairing phenomenon.
According to an aspect of the invention, there is provided a digital convergence apparatus characterized by comprising:
adjusting data memory means storing convergence adjusting data for convergence adjustment, which corresponds to each of adjusting points corresponding to points on a display screen;
calculation means for calculating interpolation convergence adjusting data corresponding to correction points located between at least two adjacent ones of the adjusting points, using convergence data corresponding to the at least two adjacent adjusting points;
conversion means for converting a digital signal output from the calculation means, to an analog signal, thereby obtaining a convergence correction signal;
supply means for supplying the convergence correction signal from the conversion means to a convergence correction coil;
discrimination means for discriminating whether an image signal to be displayed on the display screen indicates a point included in a first field or in a second field; and
coefficient supply means for setting, in the calculation means, a coefficient for the first field or for the second field on the basis of the discrimination result of the discrimination means.
Since the convergence adjusting data which has different values between the first (odd) field and the second (even) field is calculated, a convergence correction signal optimal to each field can be obtained, thereby eliminating image degradation.
According to another aspect of the invention, there is provided a digital convergence apparatus characterized by comprising:
adjusting data memory means storing convergence adjusting data for convergence adjustment, which corresponds to each of adjusting points corresponding to points on a display screen;
calculation means for calculating interpolation convergence adjusting data corresponding to correction points located between at least two adjacent ones of the adjusting points, using convergence data corresponding to the at least two adjacent adjusting points;
conversion means for converting a digital signal output from the calculation means, to an analog signal, thereby obtaining a convergence correction signal;
supply means for supplying the convergence correction signal from the conversion means to a convergence correction coil;
discrimination means for discriminating at least whether an image signal to be displayed on the display screen indicates a point on an odd line or on an even line; and
coefficient supply means for setting, in the calculation means, a coefficient for the odd line or for the even line on the basis of the discrimination result of the discrimination means.
Since the convergence adjusting data which has different values between the odd line and the even line is calculated, a convergence correction signal optimal to each line can be obtained, thereby eliminating image degradation even in the case of a TV signal for non-interlace scanning.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention and, together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a view, showing a first embodiment of the invention;
FIG. 2 is a view, useful in explaining the arrangement of adjusting points employed in the invention;
FIG. 3 is a view, showing a second embodiment of the invention;
FIG. 4 is a view, showing a third embodiment of the invention;
FIG. 5 is a view, showing a fourth embodiment of the invention;
FIG. 6 is a view, showing a fifth embodiment of the invention;
FIG. 7 is a view, showing a sixth embodiment of the invention; and
FIG. 8 is a view, showing a seventh embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiments of the invention will be described with reference to the accompanying drawings.
First, for facilitating the understanding of the invention, an operation thereof assumed when the power supply is turned on, a normal operation, and an operation for convergence adjustment will be described in this order. The normal operation of the invention indicates an operation thereof which is assumed when a convergence correction signal is generated, and by which the invention is characterized.
When the power supply is turned on, the following operation is performed:
When the power supply of the projection type projector, etc. is turned on, a control microcomputer 66 starts to operate, thereby supplying a data transfer control circuit 53 with an instruction to transfer, to a field memory 51, adjusting data for adjusting points stored in a data storage section 67. In response to the instruction, the data transfer control circuit 53 reads the adjusting data from the data storage section 67, and writes the data into that area of the field memory 51 which is indicated by an address selected by a selective circuit 52.
In response to a control signal output from the data transfer control circuit 53, the selective circuit 52 selects one of an address output from the data transfer control circuit 53, and an address output from a field memory address generating circuit 54, and supplies the field memory 51 with the selected address. At the time of data transfer performed when the power supply is turned on, the selective circuit 52 selects the address from the data transfer control circuit 53 in response to an instruction from the circuit 53. The adjusting data from the data transfer control circuit 53 is written into that area of the field memory 51 to which the selected address is assigned.
Thus, the adjusting data for each adjusting point is stored in the field memory 51.
The convergence correction signal generating operation as the normal operation will be described briefly.
After data transfer at the time of turn-on of the power supply is completed, the data transfer control circuit 53 supplies the selective circuit 52 with an instruction to select the output of the field memory address generating circuit 54. The circuit 54 is supplied with a horizontal drive signal of a horizontal scanning cycle and a vertical drive signal of a vertical scanning cycle, and generates a read address based on the drive signals. The read address is supplied to the field memory 51 via the selective circuit 52.
Supposing that interpolation adjusting data is created which corresponds to a line between lines corresponding to adjusting data stored in the field memory 51. In accordance with the read address from the selective circuit 52, adjusting data corresponding to adjusting points of lines between which a target line is situated is read from the field memory 51 and supplied to an interpolation calculating circuit 60.
The interpolation calculating circuit 60 creates interpolation adjusting data by multiplying the adjusting data by a coefficient output from a selective circuit 1. The interpolation adjusting data is converted to an analog signal by means of a D/A converter 62. This analog signal serves as the convergence correction signal. The convergence signal has its high frequency component removed by a low-pass filter (LPF) 63, and then is supplied to a convergence correction coil 64 attached to a neck portion of each projection tube, thereby realizing convergence correction. The convergence correction signal corresponding to a scanning line which corresponds to the adjusting data stored in the field memory 51 is obtained by subjecting the adjusting data read from the memory 51 to D/A conversion.
A convergence adjusting procedure will now be described.
First, the operator (adjuster) supplies, via an input device 65, the control microcomputer 66 with an instruction to start adjusting. The control microcomputer 66 in turn supplies a selective circuit 69 with an instruction to select an adjusting pattern output from an adjusting pattern output circuit 59. As a result, a projection tube 70 projects an image such as a cross-hatching image which can easily be convergence-adjusting.
While observing the image projected on the screen, the operator supplies, via the input device 65, the control microcomputer 66 with an instruction to increase or reduce the amount of adjusting data. Upon receiving the instruction, the control microcomputer 66 updates the adjusting data for the adjusting points stored in the field memory 51 and the data storage section 67, thereby performing convergence adjustment. After the adjustment is finished, the operator supplies, via the input device 65, the control microcomputer 66 with an instruction to finish the adjustment. The control microcomputer 66 in turn supplies the selective circuit 69 with an instruction to select a terminal to which an image signal is input, with the result that a normal image is projected from the projection tube 70.
The apparatus of the invention especially has an odd field coefficient generating ROM 2 and an even field coefficient generating ROM 3. One of the outputs of the odd and even coefficient generating ROMs 2 and 3 is selected by the selective circuit 1 and supplied to the interpolation calculating circuit 60. The selective circuit 1 is controlled by a discrimination signal output from a field discrimination circuit 4 for discriminating the type of a field using the horizontal drive signal and the vertical drive signal. The selective circuit 1 selects a coefficient output from the odd field coefficient generating ROM 2 when the discrimination signal indicates an odd field, and selects a coefficient output from the even field coefficient generating ROM 3 when it indicates an even field. A read address assigned to each data item stored in each of the odd field coefficient generating ROM 2 and the even field coefficient generating ROM 3 is created by a coefficient ROM generating circuit 55 using the horizontal drive signal and the vertical drive signal.
As described above, appropriate interpolation adjusting data is created, regarding whether the type of the field is the odd field or the even field. As a result, an optimal convergence correction signal free from the pairing phenomenon is obtained.
The principle of the convergence correction will be explained in more detail.
If vertical interpolation is performed on the basis of data concerning four adjusting points (i.e. tow upper adjusting points and two lower adjusting points with respect to the line to be interpolated), very accurate interpolation can be realized. In this embodiment, however, interpolation is performed, for easy understanding, on the basis of data concerning only two adjusting points (a single upper point and a single lower point with respect to the to-be-interporated line).
As is shown in FIG. 2, sampling points, called adjusting points, at which adjusting data is sampled, are predetermined on the screen. Thus, convergence correction data z(m(x), n) at an interpolation adjusting point (m(x), n), which is a point on e.g. an x-th line (0≦x<a) from an adjusting point (m, n), is given by
z(m(x), n)=Z(m, n)×k(x)+Z(m+1, n)×k(a-x) (1)
where k(x) represents a weight coefficient which is predetermined, depending upon how much distance x from the adjusting point (m, n), and "a" is member of lines, between the adjusting point (m, n) and (m+1, n).
The position (coordinates) of each scanning line to be convergence-corrected on the basis of the adjusting data will now be explained.
Suppose that the scanning lines included in a first field are an n-th line, an (n+1)th line, an (n+2)th line, . . . . Further, suppose that the scanning lines included in a second field and located between the n-th line and the (n+1)th line of the first field, between the (n+1)th line and the (n+2)th line of the first field, between the (n+2)th line and the (n+3)th line of the first field, . . . are an (n+0.5)th line, an (n+1+0.5)th line, an (n+2+0.5)th line, . . . , respectively.
Where that the vertical coordinates of the n-th line and the (n+1)th line are represented by y(n) and y(n+1), respectively, the vertical coordinate y(n+0.5) of the (n+0.5)th line located therebetween is given by
y(n+0.5)={y(n), y(n+1)}/2 (2)
This is an essential condition for performing interlace scanning.
Further, where that the vertical movement amounts of the n-th line and the (n+1)th line as a result of the convergence correction are represented by Δy(n), Δy(n+1), respectively, and their vertical coordinates after convergence correction by Y(n) and Y(n+1), respectively, the following equations are satisfied:
Y(n)=y(n)+Δy(n) (3)
Y(n+1)=y(n+1)+Δy(n+1) (4)
An explanation will be given of a case where convergence correction is performed using the same interpolation adjusting data in both the first and second fields.
If the same convergence correction amount Δy(n) as that used for the n-th line is used for the (n+0.5)th line located between the n-th line and the (n+1)th line, the vertical coordinate Y(n+0.5) of the (n+0.5) line after the convergence correction is given by ##EQU1##
On the other hand, an ideal vertical coordinate Y(n+0.5) for performing correct interlace scanning at the (n+0.5)th line even after the convergence correction should be given by
Y(n+0.5)={Y(n)+Y(n+1)}/2 (6)
However, if the same correction amount Δy(n) as used at the n-th line is used at each line included in both the first and second fields, the vertical coordinate Y(n+0.5) of the (n+0.5)th line after the convergence correction is given by the equation (5). The difference dY between the values obtained from the equations (5) and (6) is ##EQU2##
As is evident from this, an error will occur between an ideal line position and the actually corrected line position if convergence correction is performed using the same interpolation adjusting data, irrespective of whether the line is included in the first or second field.
To solve the above problem, different coefficients are used in different fields, respectively, to create the interpolation adjusting data.
Specifically, the odd field coefficient generating ROM 2 stores an interpolation coefficient ko {x} (0≦x<a) for the odd field, while the even field coefficient generating ROM 3 stores an interpolation coefficient ke {x} (0≦x<a) for the even field. Thus, the different coefficients are used in the different fields.
The interpolation adjusting data used in each field is obtained as follows, using the equation (1):
In the odd field:
zo(m(x), n)=Z(m, n)×ko(x)+Z(m+1, n)×ko(a-x) (8)
In the even field:
ze(m(x), n)=Z(m, n)×ke(x)+Z(m+1, n)×ke(a-x) (9)
Thus, the interpolation calculating circuit 60 calculates optimal adjusting data for each line on the basis of the correction principle.
As described above, the invention employs the odd field coefficient generating ROM 2 as first interpolation coefficient generating memory means, the even field coefficient generating ROM 3 as second interpolation coefficient generating memory means, and the field discrimination circuit 4 and the selective circuit 1 as means for selecting one of the outputs of the first and second memory means. With this structure, the invention can perform fine correction in both fields and accordingly obtain an optimal convergence signal free from the pairing phenomenon. Moreover, the plural interpolation coefficient generating memory means are dynamically switched from one to the other in different fields, thereby performing vertical interpolation of adjusting data.
Although in the above embodiment, the interpolation coefficient generating memory means are selectively switched from one to the other in units of a field, the switching may be performed in units of a line. Furthermore, interpolation adjusting data may be prepared beforehand and temporarily stored in a calculating circuit.
FIG. 3 shows a second embodiment of the invention.
The second embodiment differs from the first embodiment shown in FIG. 1 in that a coefficient interpolation circuit 5 is used in place with the second interpolation coefficient generating memory means. The coefficient interpolation circuit 5 calculates an average value of two interpolation coefficients successively output from the odd field coefficient generating ROM 2, and supplies the average value to the selective circuit 1.
In this embodiment, considering that there is no great difference between the odd field interpolation coefficient ko(α) and the even field interpolation coefficient ke(α+0.5), the even field interpolation coefficient is obtained using the following approximation:
ke(α+0.5)={ko(α)+ko(α+1)}/2(0≦α<a)(10)
In other words, optimal interpolation free from the pairing phenomenon can be performed by using, as the even field interpolation coefficient, the average value of the two interpolation coefficients successively output from the odd field coefficient generating ROM 2.
Although in the second embodiment, the coefficient interpolation circuit 5 is used in place with the even field coefficient generating ROM 3 of the first embodiment, the same advantage can be obtained if the coefficient interpolation circuit 5 is used in place with the odd field coefficient generating ROM 2.
FIG. 4 shows a third embodiment of the invention.
The third embodiment differs from the first embodiment shown in FIG. 1 in that a coefficient difference generating ROM 7 and an adder 8 are provided in place with the even field coefficient generating ROM 3. The adder 8 adds the output of the odd field coefficient generating ROM 2 to the output of the coefficient difference generating ROM 7, and supplies the addition result to the selective circuit 1. A read address for reading data from the coefficient difference generating ROM 7 is supplied from the coefficient ROM address generating circuit 55.
In the above structure, the difference Δk(α) between the odd field interpolation coefficient ko(α) and the even field interpolation coefficient ke(α+0.5) is stored in the coefficient difference generating ROM 7. Accordingly, an interpolation coefficient for the even field can be obtained by adding the interpolation coefficient ko(α) to the difference Δk(α) by means of the adder 8.
ke(α+0.5)=ko(α)+Δk(α)(0≦α<a)(11)
The thus-obtained output of the adder 8 is supplied as the even field interpolation coefficient to the selective circuit 1. Since there is no great difference between the odd field interpolation coefficient ko(α) and the even field interpolation coefficient ke(α+0.5), the absolute value of the difference Δk is extremely low, which enables the employment of a ROM of a small capacity.
FIG. 5 shows a fourth embodiment of the invention.
As compared with the embodiment of FIG. 1, the fourth embodiment stores both the odd field coefficient and the even field coefficient in a coefficient generating ROM 6. Data obtained by synthesizing the output of the coefficient address generating circuit 55 with the output of the field discrimination circuit 4 is used as the read address. The output of the coefficient generating ROM 6 is supplied to the interpolation calculating circuit 60.
The output of the field discrimination circuit 4 indicates one-bit line data, and the read area of the coefficient generating ROM 6 is changed over in accordance with the contents of the one-bit line data. This embodiment also can perform fine correction and realize optimal convergence correction free from the pairing phenomenon.
FIG. 6 shows a fifth embodiment of the invention.
In the above-described embodiments, explanations have been given, supposing that the NTSC system for performing interlace scanning is employed therein.
However, the broadcast system is not limited to the NTSC system, but also includes the EDTV-2 system for performing non-interlace scanning. In light of this, it is preferable that the convergence apparatus can perform convergence correction in non-interlace scanning, too.
The EDTV-2 system employs 525 scanning lines in units of one field. In light of this, a line discrimination circuit 9 is provided in place of the field discrimination circuit 4. The line discrimination circuit 9 performs line discrimination using the horizontal drive signal and the vertical drive signal, thereby discriminating interlace scanning from non-interlace scanning. Since in the case of the non-interlace scanning, an image is constituted by 525 scanning lines in units one field, the line discrimination circuit 9 controls the selective operation of the selective circuit 1, depending upon whether the present scanning line is odd-numbered or even-numbered. In other words, the selective circuit 1 generates, at each odd line, the output of the odd field coefficient generating ROM 2, and the output of the adder 8 at each even line. On the other hand, in the case of the interlace scanning, the line discrimination circuit 9 controls the selective operation of the selective circuit 1, depending upon whether the present field is odd-numbered or even-numbered. The selective circuit 1 generates, at each odd field, the output of the odd field coefficient generating ROM 2, and the output of the adder 8 at each even field.
In this embodiment, however, in the non-interlace scanning mode, it is necessary to set the vertical line number counting pitch of each of the field memory address generating circuit 54, to 1/2 of the pitch employed in the NTSC system. On the other hand, in the interlace scanning mode, the same mode as in the above-described embodiments is used. Thus, it may be constructed such that the line number discrimination signal from the line discrimination circuit 9 is supplied to the control microcomputer 66, which in turn sets a necessary circuit block operation mode in accordance with the contents of the line discrimination signal.
FIG. 7 shows a sixth embodiment of the invention.
This invention can easily be applied to a digital convergence apparatus for the HDTV system. The HDTV system employs 562.5 scanning lines in units of one field, and performs interlace scanning. Therefore, to perform digital convergence correction, it is necessary to employ four types of interpolation coefficient generating ROMs for even lines and odd lines in the odd field, and odd lines and even lines in the even field, respectively.
In FIG. 7, there are provided four types of interpolation coefficient generating ROMs, each of which is contrived to minimize the required data capacity and the size. The output of the odd field coefficient generating ROM 2 is supplied to an adder 15. The ROM 2 stores coefficients for the odd field of the NTSC system. These coefficients are also used as interpolation coefficients for odd lines in the odd field of the HDTV system.
A coefficient difference generating ROM 11 stores the difference between each interpolation coefficient for odd lines in the odd field of the HDTV system and a corresponding interpolation coefficient for even lines in the odd field of the HDTV system. Accordingly, during scanning the even lines in the odd field of the HDTV system, the output of the coefficient difference generating ROM 11 is selected and supplied to the adder 15. Thus, the adder 15 generates coefficients for the odd line and the even line in the odd field of the HDTV system, respectively. During scanning odd lines in the odd field, the operation of the selective circuit 14 is stopped.
A coefficient difference generating ROM 12 stores the difference between each interpolation coefficient for odd lines in the odd field of the HDTV system and a corresponding interpolation coefficient for odd lines in the even field of the HDTV system. Accordingly, during scanning the odd lines in the even field of the HDTV system, the output of the coefficient difference generating ROM 12 is selected and supplied to the adder 15.
A coefficient difference generating ROM 13 stores the difference between each interpolation coefficient for odd lines in the odd field of the HDTV system and a corresponding interpolation coefficient for even lines in the even field of the HDTV system. Accordingly, during scanning the even lines in the even field of the HDTV system, the output of the coefficient difference generating ROM 13 is selected and supplied to the adder 15.
Thus, the adder 15 generates interpolation coefficients for the odd lines and the even lines included in the even field of the HDTV system.
The selective circuit 14 is supplied with the field discrimination signal from the field discrimination circuit 4 and the line number discrimination signal from the line discrimination circuit 9, and functions as described above on the basis of these two signals.
FIG. 8 shows a seventh embodiment of the invention.
The FIG. 8 embodiment is directed to a digital convergence apparatus applicable to the NTSC interlace scanning, the EDTV-2 non-interlace scanning and all HDTV systems.
In this embodiment, the selective circuit 14 is controlled, in the NTSC interlace scanning, by the field discrimination signal from the field discrimination circuit 4, thereby generating a predetermined one of the outputs of the coefficient generating ROMs 11-13. On the other hand, in the EDTV-2 non-interlace scanning, the selective circuit 14 is controlled by the line number discrimination signal from the line discrimination circuit 9, thereby generating a predetermined one of the outputs of the coefficient generating ROMs 11-13.
The type of a TV signal input to the apparatus is determined on the basis of a selection instruction input to the control microcomputer 66 by the user. Upon receiving the input, the microcomputer 66 performs necessary mode setting.
The microcomputer 66 supplies the selective circuit 14 with an instruction to set a mode adapted to each system. To process a TV signal for the NTSC interlace scanning, the selective circuit 14 responds to a field discrimination signal from the field discrimination circuit 4 and selects, for example, the output of the coefficient difference generating ROM 13 during scanning the even field. On the other hand, to process a TV signal for the non-interlace scanning, the selective circuit 14 selects a selection mode as explained above referring to FIG. 6. In this mode, for example, the output of the coefficient difference generating ROM 11 is selected. Further, when a HDTV signal is processed, the mode is switched to that as explained referring to FIG. 7. The field memory generating circuit 54 and the coefficient ROM address generating circuit 55 are controlled so that necessary addresses can be obtained with pitches appropriate to the employed system. More specifically, when the EDTV-2 non-interlace scanning is performed or a HDTV signal is processed, the circuits 54 and 55 are controlled by the control microcomputer 66 so as to set the counting pitch of the vertical line to 1/2 of that employed at the time of processing the NTSC signal.
As described above, where a TV signal for interlace scanning is processed, the invention can perform optimal convergence in units of one field, which means that the invention is free from degradation of image quality due to the pairing phenomenon. Moreover, the invention can provide a convergence correction signal which is also applicable to the EDTV-2 system and the HDTV system.
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 devices shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | A field memory stores convergence adjusting data which corresponds to a plurality of points on a display screen. An interpolation calculation circuit creates interpolation convergence adjusting data for correction points located between adjacent adjusting points, using a plurality of adjusting data items and interpolation coefficients. The output of the interpolation calculation circuit is subjected to digital/analog conversion and passed through a low-pass filter, thereby forming a convergence correction signal. This correction signal is supplied to each deflection coil. At the time of creating interpolation adjusting data for a point located between adjusting points, an optimal interpolation coefficient is output from a ROM or a ROM, depending upon whether the point is included in the odd or even field. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a sorting device for animals, and in particular to a device wherein livestock are segregated according to weight classifications.
It is a common practice in the livestock industry, especially in the pig or hog raising business to closely watch the weight of various animals and segregate them based upon a predetermined weight which will provide a maximum financial return under prevailing market conditions.
Various conventional devices have been developed for sorting animals in one enclosure into second and third enclosures depending on whether or not respectively the animal has reached a predetermined weight. However, many of the conventional devices are relatively expensive, especially those which work automatically, whereas those which are not expensive are relatively labor intensive and often require several operators.
Therefore, a sorting device is desired which will allow mechanical separation of animals into segregated areas. It is also important to not overly arouse the animals so they will not injure themselves and to minimize dangerous parts common in conventional animal sorters. In addition, it is desirable to have a device which is relatively inexpensive, yet will allow operation thereof by a single operator from a single location and require a minimum number of mechanical operations. It is also desirable to have a device wherein the animal while being weighed cannot easily exit the device in either direction until the weighing process is complete.
SUMMARY OF THE INVENTION
A livestock sorting device is provided which includes a chute suitable for allowing a single animal to ambulate therethrough and weighing means such as a floor scale associated with the chute and providing an indication of the animal's weight to an operator while the animal is within the chute. The chute also includes an entrance, an exit and side animal restraining walls. The sorting device is generally associated with at least three animal segregation areas or holding pens with one pen being located at the entrance to the chute, while the exit of the chute opens into passageways to the second and third pens. The chute entrance has a gate with an associated control mechanism which entrance gate allows an operator to selectively admit a single animal from the first pen to the chute. The chute exit has first and second gates associated therewith. The exit gates selectively prevent egress from the chute by an animal therein or direct an animal egressing from the chute into a desired passageway leading to one of the second and third pens. In this manner an animal is held in the chute until an accurate measurement is made of the animal' s weight after which the exit gates are arranged to allow the animal to pass into either the second or third holding pens wherein the animal is segregated with animals of a certain predetermined similar weight and away from animals having differing weights. In this way those animals which have obtained predetermined market weight can be separated from those animals which have not reached such a weight. The entrance gate and exit gates are preferably manipulated by control mechanisms which allow an operator to remotely change the positions of the various gates and, in particular, to change the gate positions from a centralized location. In this manner a single operator is able to quickly and easily sort a large number of animals with a minimal amount of work being required to close and open the various gates. Also preferably the gates include a securing means or locking mechanism whereby when the gates are placed in a selected position by an operator, an animal cannot easily move the gate and thereby escape from the sorting device before proper weighing or obtain passage into the wrong holding pen. In particular, the exit gates include a slot radially extending from a pivotal end of the gate along the top edge thereof. A horizontally aligned lever arm for each exit gate having a vertically aligned slot follower or pin at a distal end thereof is pivotally mounted on the sorting device a spaced distance from the respective gate such that the pin mates with and slides in the slot. The lever arm is also located with respect to an associated gate such that when the associated gate is in an animal restrictive position the lever arm is generally or preferably slightly over center with respect to a perpendicular line associated with the respective gates; in particular, the lever arm is positioned so as to be slightly on the opposite side of a line perpendicular to an associated gate as the side on which the lever arm normally moves during manipulation of the associated gate to another position. In this manner an animal pushing against the associated gate cannot easily move the latter when the lever arm is perpendicular thereto. In addition when the lever arm is in the over center position, the animal cannot move the associated gate but an insignificant distance. A mechanical advantage means such as a second lever arm is secured to each of the gate operating lever arms such that an operator can easily rotate the gate operating lever arms thereby manipulating the exit gates. The exit gates are also covered with a wire mesh or the like so that an animal to be sorted can see through the sorting device and will therefore be encouraged to enter the device, yet the mesh keeps the animal from fighting or becoming entangled in the gate.
OBJECTS OF THE INVENTION
Therefore the principal objects of the present invention are: to provide a livestock sorter wherein animals may be weighed and segregated according to weight; to provide such a sorter wherein two pivotal gates are arranged whereat the animals egress the sorter to selectively block passage of the animals during weighing and to restrict passage of the animals to one of two holding pens after weighing; to provide such a sorter wherein an entrance of the sorter may also be selectively blocked to prevent animals from entering the sorter or animals already therein from exiting through the entrance; to provide such a sorter wherein one operater may manipulate mechanisms to operate the gates and to block the entrance from a single location; to provide such a sorter wherein the gates are generally secured against movement by an animal when in positions to allow egress or block passage from the sorter; to provide such a sorter which is economical to manufacture, efficient in use, and which is particularly well adapted for the proposed usage thereof.
Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings wherein are set forth by way of illustration and example, certain embodiments of this invention.
The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a livestock sorter, according to the present invention, including a weighing portion with an entrance gate and a pair of exit gates.
FIG. 2 is a front elevational view of the sorter.
FIG. 3 is a side elevational view of the sorter.
FIG. 4 is a rear elevational view of the sorter.
FIG. 5 is a top plan view of the sorter with the exit gates in position to block egress therefrom.
FIG. 6 is an enlarged fragmentary top plan view of the sorter with the exit gates in position to direct egress of an animal into a first holding area.
FIG. 7 is an enlarged fragmentary top plan view of the sorter with the gates in position to direct egress of an animal into a second holding area.
FIG. 8 is an enlarged and partially exploded fragmentary view of a control mechanism for the exit gates.
FIG. 9 is an enlarged and partially exploded fragmentary view of a control mechanism for the entrance gate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As required, detailed embodiments of the present invention are disclosed herein, however, it is to be understood that the disclosed embodiments are merely exemplary of the invention which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
As used herein the terms "front" and "entrance end" mean in the direction of the left hand side of the page with respect to the views seen in FIGS. 3 and 5 and the terms "rear" and "exit end" have the opposite meaning. Other directional terms as used herein have the same meanings as described in the drawings.
The reference numeral 1 generally designates a livestock sorter according to the present invention. As seen in FIG. 1, the sorter 1 is generally positioned such that a first animal holding pen or segregation area 2 is located in adjoining fashion to the entrance end of the sorter 1 and second and third holding pens or segregation areas 3 and 4 are located in adjoining fashion to the exit end of the sorter 1. Passage of animals between the segregation areas 2, 3 and 4 except through the sorter 1 is prevented by fences 5, 6 and 7. Normally animals, such as hogs, to be sorted are held in segregation area 2. Also normally one of the segregation areas 3 or 4 is utilized to hold sorted animals which are ready for market, while the other segregation area is used to hold sorted animals which are not ready for market.
The sorter 1 is comprised of a chute 10 having generally vertical animal restricting side walls 11 and 12 which define an animal enclosing structure having an entrance aperture 13 and an exit aperture 14.
The chute 10 is suitable for allowing a single animal to ambulate thereinto, for holding the animal therein while the animal's weight is determined, and for allowing the animal to ambulate therefrom after the animal's weight is determined. The illustrated chute 10 also includes a housing structure 16 comprising horizontal side slats 17 extending between opposite ends of the chute 10 on either side thereof, spaced top slats 18 also extending between opposite ends of the chute 10, and generally rectangular shaped frames 19 and 20, at opposite ends of the chute 10. The frames 19 and 20 define the entrance and exit apertures 13 and 14 respectively and are fixedly attached to the slats 17 and 18. The front frame 19 comprises vertical side members 24, transverse horizontal top member 25, and transverse horizontal bottom member 26. Mobilization wheels 27 are pivotally attached near the bottom of each of the front frame side members 24. The rear frame 20 comprises vertical side members 30, a pair of closely positioned transverse horizontal top members 31 and 32, and a transverse bottom horizontal member 33.
Associated with the chute 10 are weighing means, such as the illustrated gravity scale 35 or the like. The scale 35 comprises: an animal holding platform 36 to which the side walls 11 and 12 are attached; four platform support wires or lines 37 each positional near and connected to one corner of the platform 36 and extending upwardly therefrom; a pair of horizontal rollers 38 and 39 pivotally attached to the front frame side members 24 and rear frame side members 30 respectively and having the lines 37 wrapped therearound and secured thereto; scale arms 40 and 41 radially extending from the rollers 38 and 39 respectively and being interconnected by link 42 and being connected to a visual weight indicator 43. The weight indicator 43 is hung from a three-sided support frame 47. The frame 47 is attached near the bottom thereof to both top slats 18. When an animal enters the chute 19, it exerts a downward force upon the platform 36 in proportion to the weight thereof. The force is translated to the wires 37 which in turn exert a rotational force on the rollers 38 and 39 which in turn rotate the arms 40 and 41. The arms when rotated downward at the distal ends thereof exert a downward force upon the measurement portion of the weight indicator 43 in proportion to the weight of the animal on the scale 35 which weight is visually shown on the face of the indicator of 43.
An entrance 50 is positioned in the entrance aperture 13 to selectively block access in and out of the chute 10. The entrance gate 50 comprises a pair of spaced bars 51 and a control mechanism 52 for manipulation thereof. The gate bars 51 are best illustrated in FIGS. 1 and 2 and the fragmentary FIG. 9. The bars 51 are attached to horizontal L-shaped members 55 at each end thereof. The bars 51 are slightly arcuate such that when the gate 50 is blocking the entrance aperture 13, that is the gate 50 is closed, then the bars 51 appear vertical from the front, as shown in FIG. 2; whereas when the gate 50 is not blocking the entrance aperture 13, that is the gate 50 is open, then the bars 51 bow or curve outwardly toward the sides of the chute 10 so as to provide a wider opening through which animals may pass. The L-shaped member 55 is pivotally attached near the apex thereof to associated front frame top and bottom members 25 and 26 respectively by pivot bolts 56 and associated fastening hardware 57 or the like (the lower pivot bolts are not shown). A traverse channel shaped member 60 is centered beneath and attached to the front frame top member 25 and extends perpendicularly on opposite sides thereof. The channel member 60 has a longitudinal slot 61 centered transversely in the web 62 thereof with opposite sides of the web 62 being connected near the ends thereof. A slide plate 63 rides on top of the web 62 and has downwardly projecting pivot pin 64 extending through and below the slot 61. A handle 65 extends upwardly from near a front end of the slide plate 63. When positioned to slide on the web 62, the slide plate 63 is prevented from upward movement by a bolt and appropriate fastener 66. A pair of connector links 70 are pivotally mounted at one end thereof to the pivot pin 64 so as to rotate in a horizontal plane and held thereon by a cotter pin 71 or the like. A pivot pin 72 is attached to the opposite end of each connector link 70. The connector link pivot pins 72 are pivotally attached by appropriate hardware 73 to an end of an associated L-shaped member 55 opposite the end to which two bars 51 are attached, such that when the handle 65 is physically manipulated to slide the plate 63 along the web 62, the connector links 70 are moved either from a position wherein they are generally parallel to a position wherein they form angles with one another or vice versa. As the angle increases between the connector links 70, the pivot pins 72 must approach one another which in turn rotates the L-shaped members 55 about the pivot bolts 56 which in turn opens the gate 50. Straightening the connector links 70 relative to each other closes the entrance gate 50. The front frame top member has a slot 75 therein from front to rear and side to side. First and second remote operating arms 76 and 77 which will be discussed in greater detail hereinafter extend through the slot 75. A rivet 78 or the like and one of the bolts 56 is positioned on each side of associated arms 76 and 77 so as to allow free transverse movement of the arms 76 and 77 but to prevent substantial transverse movement thereof with respect to the entrance frame 19.
A first exit gate 80 selectively blocks egress of an animal from the chute 10 when the exit gate 80 is in a closed position. The exit gate 80 also has two open positions which will be discussed below. The first exit gate 80 includes a rectangular frame structure 81 with a wire mesh 82 streched over the frame structure 81 (as used herein, mesh is understood to mean a structural weave having wide enough interstices to allow sufficient light to pass therethrough, such that an animal will be encouraged to enter the chute 10 believing that the exit is open, yet narrow enough interstices to prevent the animal from becoming entangled therein or fighting the gate 80). As is shown in FIG. 1 and FIG. 8, the gate frame structure 81 is attached to a tube 83 on one side thereof. The tube 83 is in turn pivotally attached to one side of the exit aperture 14 by a pivot rod 84 passing through the tube 83, and the top and bottom rear frame members 32 and 33. The pivot rod 84 is secured by cotter pins 85 or the like, such that the gate 80 pivots about a vertical axis at one side of the exit aperture 14. Positioned on top of the frame structure 81 is a riser portion 88 having a generally upwardly opening horizontal slot 89 therein. The slot 89 extends radially outward from the tube 83.
A rectangular gate support frame 90 extends perpendicularly rearward from and is fixedly attached to the exit frame 20 on the opposite side thereof relative to the pivotal attachment of the first exit gate 80 to the exit frame 20. The gate support frame 90 includes a rear side member 91, a top member 92 and a bottom member 93. A cross brace 94 interconnects a rearward end of the gate frame top member 92 with the exit frame top member 32 at the axis of the first gate 80.
A second exit gate 97 is pivotally mounted in the gate support frame 90 near a rearward end thereof so as to have a vertical axis. The gate 97 includes a frame structure 98 having a wire mesh stretched thereover so as to prevent passage of an animal therethrough. A tube 100 is attached to one side of the gate 97. The tube 100 is pivotally attached to the gate support frame top and bottom members 92 and 93 by a pivot rod 101 held in place by cotter pins 102 or the like. A riser portion 103 extends upward from the support frame top member 92 and has an upwardly opening slot 104 extending radially outward from the tube 100 therein. The second exit gate 81 is thus pivotally connected to the chute 10 at a location spaced from the exit aperture 14 and rearwardly of the side of the exit aperture 14 opposite the side thereof to which the first gate 80 is pivotally attached.
Remote manipulation means and securing means are provided for the exit gates 80 and 97; however, since both means are closely related in the present embodiment, they will be discussed contemporaneously.
In particular, a beam 115 extends from approximately midway along the cross brace 94 traversely to approximately midway along the exit frame top member 32 being secured thereat by a suitable fastener 116. A lever arm and mechanical advantage means such as are shown combined in a cross-shaped link member 117 are pivotally attached by a pivot pin 118 at one end thereof to the beam 115 by a suitable receiver thereon and a cotter pin or the like about midway along the beam 115. An opposite end of the link member 117 from the pin 118 has attached thereto another slot follower such as the illustrated pivot pin 119 extending downwardly therefrom and suitable for mating in the slot 89 on the first exit gate 80. The length of the portion 120 of the link member 117 between the two pivot pins 118 and 119 is such that when the pins 118 and 119 are transversely aligned the gate 80 is perpendicular to the exit aperture 14 and when the pins 118 and 119 are traversely aligned the gate 80 is closed. In addition when the pins 118 and 119 are transversly aligned, there is a rearwardly projecting portion 121 of the link member 117 to which the remote operating arm 76 is pivotally attached by bolt 122 or the like at a location spaced from the plane joining the pins 118 and 119. As can be seen in FIG. 6, the slot 89 extends just slightly beyond the location of the pin 119 therein when the gate 80 is perpendicular to the exit aperture 14. The operating arm 76 has a handle 123 which when manually moved rearward by an operator, while the gate 80 is in the position of FIG. 6, places a rearward thrust on the juncture of link member portion 117 and operating arm 76. Since the link member portion 120 is only pivotally attached on one end thereof of the beam 115, a lever arm is produced which is defined by the perpendicular distance between the operating arm 76 and the pin 118, when in the position of FIG. 6. The thrust on this lever arm in turn thrusts the free end of the link member portion 117 with the pin 119 thereon rearward until the pin 119 engages the end of the slot 89. At this point the gate 80 may be canted an insignificant amount with respect to a perpendicular line from the exit aperture 14. This in effect creates an over center locking mechanism for the gate 80. In particular, an animal trying to push the gate 80 counterclockwise, when the pin 119 is touching the outermost end of the slot 89, exerts pressure against the pin 119 and end of the slot 89 but cannot move the gate 80 unless the pin 119 breaks. Likewise, if the animal attempts to push the gate 80 clockwise, the gate 80 will assume the position perpendicular to the exit aperture 14 but will move no further, since that is the maximum extension the length of the link member 117 between the pins 118 and 119 will allow.
In like manner frontwards movement of the operating arm 76, when in the position of FIG. 6, places a frontwards thrust on the interconnection of the operating arm 76 and the link member 117. The link member 117 begins to pivot about the pin 118 which urges the pin 119 along the slot 89, this in turn urges the gate 80 to rotate counterclockwise. As the link member 117 continues to rotate, the lever arm acting to create the rotation continually changes. When the gate 80 has rotated to the position shown in FIG. 5, the gate 80 is closed and the distance along the link member portion 120 between the interconnection thereof with the operating arm 76 and the portion 121 is now effectively acting as the lever arm which will create further movement in the gate 80 if the operating arm 76 is moved. At this point a slight additional functional thrust on the operating arm 76 places the pin 119 again over center and against the end of the slot 89 such that an animal cannot move the gate 80 by pushing thereagainst. Thus the above described mechanism functions both as remote control means and locking or securing means.
For the secondary exit gate 97 the principals of securing and remote control are essentially the same as those discussed above regarding the first exit gate 80. In particular, there is a cross beam 127 secured by suitable fasteners such as bolts 128 to an intermediate location along gate frame top member 92 and cross brace 94 approximately one quarter of the length of each from the axis of the second exit gate 97. A cross shaped link member 130 has a first portion 131 perpendicularly aligned with a second portion 132. The first portion 131 are projecting vertical pins 133 and 134 on opposite sides and ends thereof. The pin 133 pivotally seats in approximately the center of the cross beam 127. The pin 134 mates with the slot 104 in the second exit gate 97. A two part linkage 135 interconnects the link member second portion 132 at a location spaced from the plane of the pins 133 and 134 with the operating arm 77. The linkage 135 comprises a link 140 and a slide member 141. The link 140 has pivotal connectors on opposite sides and ends thereof such as pins 142, for connection to the link member second portion 132. The slide member 141 has, on the end thereof attached to the link 140, a recessed portion 143 suitable for sliding freely along the edge of the gate frame top member 92 and is pivotally attached at the opposite end thereof to the beam 115 and cross brace 94 by bolt 116. Approximately midway therealong the slide member 141 is pivotally attached to the operating arm 77.
For the second exit gate 97, when in the position shown in FIG. 6, a rearward thrust on the operating arm tends to rotate the slide member 141 clockwise which in turn acts through the link 140 and cross-shaped member 130 to rotate the gate 87 counterclockwise into the position shown in FIG. 7. Slight additional thrust on the operating arm 77 will force the pivot pin 134 against the end of the slot 104 furthermost from the axis of the gate 97. Reversal of thrust on either of the operating arms 76 and 77 from that discussed above will reverse the effect stated above.
It is noted that the structure of the illustrated embodiment is such that the exit gates 80 and 97 along with all associated mechanisms and controls can be reversed such that the gates 80 and 97 would be on opposite sides of the chute 10 as compared to the illustrated embodiment.
It is foreseen that other mechanisms of known mechanical advantage could be utilized to replace the operating arms 76 and 77. In particular a system of pulleys and cables or the like may be utilized to rotate the slide member 141 and cross-shaped link member 117.
In use an operator opens the entrance gate 50 by manipulating the slide plate 63 such that the connector links 70 approach being parallel, although in the illustrated embodiment the links 70 do not reach a parallel position, and the entrance gate 50 is open. The operator also manipulates the operating arm 76 to close the first exit gate 80. The operator then urges an animal into the chute 10, closes the entrance gate 50, and determines the weight of the animal by reading the weight indicator 43. A determination is then made as to which segregation pen 3 or 4 the animal should enter based upon the weight. If pen 3 is desired, first the operating arm 77 is pulled frontwardly, thereby positioning the second exit gate 97 generally perpendicular to the exit aperture 14 and the operating arm 76 is pushed rearwardly opening the second exit gate 80, such that the latter is also generally perpendicular to the exit aperture 14. The animal when the gates 80 and 97 are so positioned has an open passageway from the chute 10 into holding pen 3. Should pen 4 be desired, the operating arm is pushed rearwardly until the position shown in FIG. 7 is obtained. The operating arm 76 is then pushed forward until the first exit gate 80 engages the second exit gate 97 such that the gates 80 and 97 are generally aligned. At such a time an animal in the chute 10 is free to egress into holding pen 4. Preferably the operator locks all gates into the secured positions discussed above whenever possible, so that animals cannot force a gate and thereby reach a pen wherein the animal would be of improper weight and also so that the animal cannot leave the chute 10 until weight determination is complete.
It is to be understood that while certain embodiments of the present invention have been described and shown herein, it is not to be limited to specific forms or arrangement of parts herein described and shown. | An animal sorting device is provided wherein the animals are individually weighed in a chute which has an exit opening into two segregation areas. A pair of exit gates and control mechanism therefor allow selective blockage of the exit or alternatively direct egress of an animal from the chute into one of the two areas. The control mechanism for the exit gates allows for remote operation thereof and for securing the exit gates in a desired position such that the animals cannot reposition same. An entrance gate is also provided. The exit gates and entrance gate may be manipulated by a single operator from a single location. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to optical components in silicon oxide and/or other mixed metallic oxides having dimensional precision which has surface roughness tolerance and profilometric accuracy within the specifications described for visible and ultraviolet spectrum ranges.
The above manufactured articles have “final” or “almost final” dimensions as they are obtained by the isotropic dimensional reduction (miniaturization) of amorphous monolithic materials, called aerogels, in turn prepared by means of cold moulding techniques based on sol-gel processes.
The process for the preparation of the above objects involves the accurate geometrical definition of the aerogel by:
the cold filling of a suitable mould with a liquid colloidal dispersion, called sol, formed from specific chemical precursors;
the polycondensation of the sol to obtain the respective gels therefrom (gelation);
the supercritical drying of the gels until aerogels are obtained with dimensions corresponding to the mould used;
the isotropic reduction (miniaturization) of the amorphous monolithic aerogels thus obtained, consisting of silicon oxide alone or in the presence of one or more oxides of elements belonging to groups III to VI of the Periodical Table and exceptionally also other groups.
2. Description of the Background
It is known that optical materials, and in particular transparent optical materials such as silica or molten quartz and optical glass, owing to their hardness and fragility, are difficult to process as the direct hot moulding of these optical components and devices is generally not possible for reasons of product quality.
The traditional method for producing these optical elements is based on the reduction of an adequate preform to the end product by means of slow, precise grinding operations.
Whereas some of these operations, such as reduction with both a flat and spherical surface, can be automized, others, such as aspherical finishing, require complicated manual processes.
This operational difficulty results in a limited process flexibility on an industrial scale and unreasonably high costs to obtain quality products such as optical components and devices based on the above aspherical optical system.
Owing to these technological limitations the optical industry has tried to solve the problem in various ways.
One of these is the moulding at high pressure and temperature of aspherical lenses and other optical components, directly from appropriate preforms of the optical material desired; with this method, which requires extremely sophisticated equipment such as a hot hydrostatic press, high quality products are obtained but also at a high cost and the process consequently necessitates very substantial investments.
One way of reducing the costs is by the use of organic optical materials, in particular plastics.
These materials can be melted and moulded with much more economical processes and can also be very easily processed with machine tools.
Unfortunately the dimensional precision of the optical products obtained generally by melting, is negatively influenced both by the insufficiently controllable shrinking of the material during the cooling operation and by the change of liquid-solid phase which causes a dimensional distorsion and deterioration of the optical quality of the manufactured article.
Also with the use of mechanical processing with machine tools, the optical products obtained from plastic materials do not have an acceptable quality as the material cannot be accurately processes owing to the fact that it is too soft.
In addition, the products which can be obtained with the above plastic materials, by hot moulding or mechanical processing, suffer from limited chemical and dimensional stability and do not reach the durability standards established for inorganic optical materials.
It is also known that optical components with definite dimensions can be obtained by suitably treating a gel deriving from the hydrolysis of a silicon alkoxide.
For example, U.S. Pat. No. 4,680,049 describes a method for the preparation of optical glass based on silicon oxide which involves an initial hydrolysis of a silicon alkoxide, the drying of the above gel and a final thermal syntherization treatment until an optical glass with definite dimensions is obtained.
These “final” optical products however have a very significant deviation with respect to the profile of the aerogel, as is amply illustrated in FIG. 1 .
The two diagrams shown in the above figure represent the configuration of the upper surface of the aerogel (diagram A) and the corresponding surface of the densified product (diagram B) respectively.
In the mould in which the gel is prepared the corresponding surface is rigorously flat: it can be seen how the flat surface of the mould passes to a convex surface in the aerogel to end up as a concave surface in the densified product.
The distorsion of the manufactured article is herein quantified as follows: distorsion from mould to aerogel = 20 μm 3000 μm × 100 = 0.67 % distorsion from aerogel to glass = 40 μm 2000 μm × 100 = 2 %
This process, which herein is simply indicated as “compensated distorsion process”, is severely limited in its industrial applications as there are difficulties in programming specific geometries of the product.
In fact, as there is no biunivocal, continuous correspondence between the geometry of the mould and that of the product, there is also no rational control of the final dimensions of the product itself.
Another attempt at developing the processing technology of optical materials has been made using machine tools with a very high precision numerical control, having a diamond point so as to be also able to process hard materials such as quartz and optical glass and with movement on air bearings to minimize the vibrations of the tool point.
These machines have been successfully developed in the last ten years and reach precision in the profile control of about a tenth of a micrometer and, under favourable conditions, even higher precision in the control of the surface roughness; they are consequently capable of finishing an item with so-called “optical” precision, which means a precision which is suitable for optics limited within the infrared spectrum range.
On the other hand, the above machines are still not adequate for applications in visible and ultraviolet spectrum ranges owing to the more severe specifications of surface roughness and profilometric accuracy required by optical laws within these spectrum ranges.
In addition, this high precision processing, which although economically convenient in special applications such as mirror finishing by laser in copper, aluminium or other materials typically used in infrared, is not generally economical for obtaining transparent optical components based on silica or inorganic glass, for numerous reasons including the hardness and fragility of the materials.
It is known in fact that these machines can be well used in the processing of typical materials for applications in infrared; this is due to their processability characteristics which are much higher than optical glass.
This creates great difficulties in the spectrum ranges, where glass is the prevalent material for which the technology of the single rotating diamond point (S.P.T.D.M.) cannot be used because of its fragility.
As described in Italian patent application MI-92A02038 filed by the Applicant, these high precision machine tools are used on intermediates to obtain perfectly and completely isotropic optical components and devices in “final” or “almost final” dimensions; the above intermediates, as they have the property of isotropically shrinking, are monolithic aerogels ideally amorphous of silica and/or other metallic oxides produced according to the technolgy described in U.S. Pat. No. 5,297,814.
SUMMARY OF THE INVENTION
The Applicant has now found that gels prepared with the technology of U.S. Pat. No. 5,207,814, in suitable moulds, in accordance with what is described in Italian patent application MI92A02038 which can be referred to for any possible point of interest, can be linearly miniaturized into densified products which maintain the proportions of the mould with a precision greater than one part out of 10,000.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B illustrate the configuration of the upper surface of the aerogel, and the corresponding surface of the densified product, respectively, of U.S. Pat. No. 4,680,049.
FIG. 2 illustrates an example of a profilometric determination of the present invention showing that the aspherical profile of the aerogel is comparable to the theonetical profile.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In particular, therefore, the invention relates to the preparation of the above products, according to a process which involves the accurate geometrical definition of the aerogel by:
the cold filling of a suitable mould with a liquid colloidal dispersion, called sol, formed from specific chemical precursors;
the polycondensation of the sol to obtain gels (gelation);
the supercritical drying of the gels until aerogels are obtained with dimensions corresponding to the mould used;
the isotropic reduction (miniaturization) of the amorphous monolithic aerogels thus obtained, consisting of silicon oxide alone or in the presence of one or more oxides of elements belonging to the III° to VI° Group of the Periodical Table and exceptionally also other groups.
These cold moulding techniques are based on the use of special specifically prepared moulds.
These moulds, having much greater dimensions than the manufactured article, have an internal volume which is defined as a “homothetic copy” of the “end”-product itself, which is characterized in terms of profilometric accuracy, surface roughness and scaling ratio with the product itself.
The product thus obtained has “almost final” dimensions i.e. it requires only an optical polishing with the conventional methods or, at the best, it has “final” dimensions i.e. it does not require any conventional optical processing.
The overall result of the present invention is therefore the economical production of optical components and devices made of silica glass or other optical glass using a new cold moulding technique based on specific sol-gel synthesis processes.
The present invention consequently relates to optical articles, components or devices, with “final” or “almost final” dimensions and completely isotropic, consisting of silicon oxide, either alone or in the presence of one or more oxides belonging to groups III to VI of the Periodic Table, and exceptionally also other groups, said optical articles, components or devices having dimensional precision which has tolerance to surface roughness and profilometric accuracy required for the visible and ultraviolet spectrum ranges, characterized in that said tolerance being between ½ and {fraction (1/10)} wave length corresponding to the range 0.350-0.02 micrometers and, preferably, equal to ¼ wave length corresponding on an average, in the visible range, to 0.275 micrometers.
The above and other operating details will be explained in the following illustrative examples which however do not restrict the scope of the present invention.
EXAMPLE 1
Preparation of Preforms of Pure Silica
An example is given of the preparation of silica glass disks, with a diameter of 2.5 cm and height of 1.0 cm, as preforms for optical lenses.
For this purpose, 80 ml of HCl 0.01N are added, under vigorous stirring, to 100 ml (0.44 moles) of tetraethylorthosilicate (TEOS) (molar ratio TEOS:H 2 O:HCl=1:10:1.8×10 −4 ).
After about 60 minutes a limpid solution is obtained and 52.8 g of colloidal silica powder (Aerosil OX50-Degussa) prepared from silicon tetrachloride by oxidation at high temperatures, is added, still under vigorous stirring, to this solution.
The mixture obtained is homogenized using ultrasounds for a duration of about ten minutes and then clarified by centrifugation.
The homogeneous dispersion obtained is poured into cylindrical containers of polyester with a diameter of 5.0 cm and height of 2.0 cm, which are hermetically closed, placed in an oven and maintained at 50° C. for 12 hours.
The gel which is obtained is suitably washed with ethanol and subsequently supercritically dried in an autoclave at a temperature of 300° C. or in any case higher than the critical temperature of the solvent.
An aerogel is obtained which is calcinated at a temperature of 800° C. in an oxidizing atmosphere.
During the heating, the residual organic products coming from the treatment in the autoclave are burnt.
The dimensions of the aerogel obtained are those of the internal volume of the initial cylindrical container.
The disk of silica aerogel, after calcination, is subjected to a stream of helium containing 2% of chlorine, at a temperature of 800° C. and for a duration of 30 minutes to remove the silanolic groups present; the aerogel disk is finally heated in a helium atmosphere to a temperature of 1400° C. for the duration of one hour so that the silica reaches complete densification and consequent miniaturization.
After cooling, the disk reaches the desired final dimensions (diameter 2.5 cm and height 1.0 cm), maintaining a homothetic ratio with the form of the initial aerogel determined by the initial mould.
The densified material has the same physicochemical characteristics as the silica glass obtained by melting (density=2.20; refraction index (at 587.56 nm)=1.4585; Abbe dispersion=67.6).
EXAMPLE 2
Duplication of Optical Surfaces
Moulds are prepared with an internal surface finished with optical specifications (surface roughness less than ⅕ with a wave length corresponding to less than 0.08 micrometers).
The internal volume of the moulds corresponds to a cylinder of 5.0 cm in diameter and 2.0 cm in height.
One of the bases of the cylinder consists of the optical surface to be duplicated.
A colloidal solution prepared by adding to the homogeneous solution, obtained as in example 1, a solution of ammonium hydroxide 0.1N, dropwise under stirring, until a pH of about 4-5 is reached, is poured into the moulds.
The moulds thus filled, are hermetically closed, placed in an oven and maintained at 20° C. for 12 hours.
The production of the gel and subsequent supercritical drying are carried out according to the procedure described in example 1.
The profilometric and surface roughness results, measured on the optical surface of the aerogel, have the same optical quality as the original surface with a roughness of less than 0.1 micrometres, corresponding to ⅕ average wave length of the visible spectrum range.
EXAMPLE 3
Aspherical Lenses
A mould has been designed for providing a preform for a flat/convex lens of which the convex surface corresponds to an aspherical surface defined by the general equation: X = cy 2 1 + 1 - ( K + 1 ) c 2 y 2 + Dy 4 + Ey 6 + Fy 8 + Gy 10
wherein the y axis of the equation corresponds to the optical axis of the lens.
The constants for the densified product, having a diameter of 15 mm±0.05 and height of 6.25 mm±0.10, are the following:
C=0.17364596
K=−1.000000
D=−0.000071
E=0.000022
F=−6.62323E −7
G=7.03174E −9
To obtain the specific dimensions of the densified product, a miniaturization factor was programmed equal to 2, which is equivalent to an internal mould volume with double dimensions with respect to the manufactured article desired.
The transformations for the new constants are:
C′=C/R
K′=K
D′=D/R 3
E′=E/R 5
F′=F/R 7
G′=G/R 8
The appropriate mould was prepared with machine tools having numerical control.
No optical finishing treatment was carried out on the surface of the mould, the objective of the experiment being the average profile of the aspherical lens rather than the optical finishing of the surface.
A silicic sol was prepared with the procedure of example 2.
A series of 3 aerogels was prepared using the above mould according to the procedures described in example 2.
The aerogels were subjected to profilometric analysis as follows: each aerogel was placed in line at the centre of a Mitutoyo series 332 profile projector and compared to the theoretical profile corresponding to the equation of the aspherical profile.
The comparison was carried out by direct placement over the screen.
To increase the sensitivity of the method, each analysis was carried out with photographic aid and subsequent projection on a huge screen providing a sensitivity of up to a ten thousandth of the dimension of the object.
The aerogels were then densified (miniaturized), with the thermal treatment described in example 1 and compared with the respective theoretical profile as in the case of the aerogels.
In both the aerogels and the densified products, the maximum deviation, relating to the respective theoretical profiles is less than 0.002 mm, a value which is considered as the limit of the sensitivity of the method.
An example of profilometric determination is shown in FIG. 2 wherein the aspherical profile of the aerogel is comparable to the theoretical profile generated by the equation (see the dark external line) and the site of the theoretical profile points has been slightly moved towards the outside to facilitate observation of the trend parallel to the surface.
In addition to the profilometric analysis, the dimensional reproducibility was verified, by micrometry, on the main diameters (flat surface) of the densified products.
The results are summarized in Table 1 below:
TABLE 1
SAMPLE
AVERAGE DIAMETER (mm)
STAND. DEVIATION
A 34/44-1
15.3775
0.003
A 34/26
15.3725
0.002
A 34/28
15.3780
0.003 | An optical article, which is a preform for an optical lens, which is isotropic, consisting essentially of silicon oxide or silicon oxide in combination with one or more oxides of elements belonging to Groups III to VI of the Periodic Table,
the article having a dimensional precision which has tolerance to surface roughness and profilometric accuracy required in the spectral interval of 200-800 nm of the electromagnetic spectrum,
the tolerance being between one-half and one-tenth wavelength corresponding to the range of about 0.350-0.02 μm. | 2 |
[0001] The present application is based on Japanese patent application Nos. 2012-163507 and 2013-031811 filed on Jul. 24, 2012 and Feb. 21, 2013, respectively, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a light-emitting device in which a phosphor and a light-emitting element are used and a method of manufacturing the same, and in more particular, to a light-emitting device in which a phosphor and a light-emitting element are used to produce white light and a method of manufacturing the same.
[0004] 2. Related Art
[0005] In so-called COB (Chip-on-Board) modules, plural light-emitting elements such as LED chips are mounted on a general-purpose substrate such as ceramic substrate or metal substrate. In LED lamps, a light-emitting element is mounted on a resin or ceramic package. In light-emitting devices such as COB modules or LED lamps, an LED chip emitting ultraviolet to blue light is used and a phosphor is contained in a sealing portion sealing the LED chip. Phosphor particles are excited by light emitted at the time of driving the light-emitting element and emit a desired wavelength-converted light in blue to red color, and white light is obtained as a mixed light of the light of the light-emitting element and the wavelength-converted light or as a mixed light of the wavelength-converted lights only. As such, in recent years, use of phosphor has become the mainstream when white light is obtained using a light-emitting element.
[0006] The following three typical methods are known as a measure to incorporate phosphor particles into a sealing portion. Here, examples of applying these methods to an LED lamp will be described.
[0007] In the first method, an LED chip 2 is mounted on a package 1 and phosphor particles 3 a are arranged in a sealing portion 3 on a LED chip-mounting side, as shown in FIG. 1A (hereinafter, referred to as a “precipitation arrangement”). The precipitation arrangement has an advantage in that it is possible to convert a wavelength of the phosphor particle 3 a at high efficiency since the phosphor particles 3 a are arranged in the vicinity of the LED chip 2 (see, e.g., JP-A-11-040858, JP-A-2007-227791, JP-A-2009-016779 and JP-A-2012-114416).
[0008] In the second method, the phosphor particles 3 a are arranged so as to be uniformly dispersed in the sealing portion 3 , as shown in FIG. 1B (hereinafter, referred to as a “dispersed arrangement”). This method has an advantage in that it is easy to control color of the light-emitting device (see, e.g., JP-T-2005-524737).
[0009] In the third method, the phosphor particles 3 a are arranged in the sealing portion 3 at a position away from the LED chip 2 which is mounted on the package 1 , as shown in FIG. 1C (hereinafter, referred to as a “separate arrangement”). The separate arrangement has an advantage in that color unevenness due to change in visual angle when viewing the LED lamp from an observer side can be prevented (see, e.g., JP-T-H11-500584).
[0010] When the LED lamp is emitting light, heat is built-up in the LED lamp due to heat generated by driving the LED chip 2 and heat generated by wavelength conversion of the phosphor particles 3 a. This causes problems in that the sealing portion 3 or other components, such as LED chip 2 , constituting the LED lamp deteriorate, resulting in a decrease in brightness and reliability of the LED lamp. Therefore, as a measure against heat generation in the LED lamp, heat is generally dissipated from a mounting surface of the LED lamp through a lead 1 a which is a portion for mounting the LED chip 2 . This method is also used for the COB module in the same manner and heat is generally dissipated from a wiring on a ceramic substrate or a mounting surface of a metal substrate which constitute the LED lamp.
SUMMARY OF THE INVENTION
[0011] Especially in case of the separate arrangement, heat generated by the LED chip 2 is likely to be dissipated through the lead 1 a but heat generated by the phosphor particles 3 a is less likely to be dissipated through the lead 1 a since the lead 1 a is away from the phosphor particles 3 a. Therefore, the separate arrangement has a problem that the heat generated by the phosphor particles 3 a is not sufficiently dissipated and deterioration of the sealing portion 3 is thus likely to occur.
[0012] It is an object of the invention to improve heat dissipation from phosphor particles.
[0013] (1) According to one embodiment of the invention, a light-emitting device comprises:
a base material having a conductor layer on a surface thereof, the conductor layer being configured to be connected to an external power source; a light-emitting element mounted on the base; a phosphor layer arranged above the light-emitting element; and a resin layer contacting both of the phosphor layer and the conductor layer and containing heat-conductive particles dispersed therein,
wherein the heat-conductive particles have a thermal conductivity of not less than 100 W/m·K and an insulator property or a semiconductor property.
[0018] Here, “above the light-emitting element” means contacting with the upper surface of the light-emitting element or being away from the upper surface of the light-emitting element.
[0019] Also, “phosphor layer” means a layer (or matrix) with phosphor particles densely dispersed therein in the form of a layer.
[0020] In the above embodiment (1) of the invention, the following modifications and changes can be made.
[0021] (i) The resin layer comprises the base material.
[0022] (ii) The light-emitting device further comprises a white resin portion between the light-emitting element and the base material.
[0023] (iii) The phosphor layer is in contact with the light-emitting element.
[0024] (iv) The light-emitting device further comprises a sealing portion between the light-emitting element and the white resin portion,
wherein the sealing portion is in contact with and seals the light-emitting element.
[0026] (v) The resin layer comprises a resin sealing portion contacting and sealing the light-emitting element,
wherein an upper portion of the sealing portion away from the light-emitting element has a phosphor particle concentration higher than a lower portion of the sealing portion in contact with the light-emitting element, and wherein the heat-conductive particles are dispersed at least in the lower portion of the sealing portion.
[0029] (vi) The heat-conductive particles comprise at least one of CNT, diamond, c-BN, SiC, BeO and AlN.
[0030] (2) According to another embodiment of the invention, a method of manufacturing the light-emitting device according to the above embodiment (1) comprises:
forming the lower portion of the sealing portion by supplying a first sealing material containing the heat-conductive particles so as to be in contact with the light-emitting element; and forming the upper portion of the sealing portion by supplying a second sealing material containing the phosphor particles on a surface of the first sealing material.
[0033] (3) According to another embodiment of the invention, a method of manufacturing the light-emitting device according to the above embodiment (1) comprises:
supplying a thermosetting sealing material so as to be in contact with the light-emitting element, the thermosetting sealing material containing the heat-conductive particles and the phosphor particles having greater specific gravity than that of the heat-conductive particles; while maintaining the light-emitting device so that gravity acts toward a surface of the thermosetting sealing material, decreasing viscosity of the thermosetting sealing material by heating at a first temperature to precipitate the phosphor particles in the thermosetting sealing material on the surface side; and curing the thermosetting sealing material by heating at a second temperature higher than the first temperature.
Effects of the Invention
[0037] According to one embodiment of the invention, a light-emitting device is constructed such that a phosphor layer is arranged above a light-emitting element, and a resin layer contacts both of a phosphor layer and a conductor layer and contains heat-conductive particles dispersed therein, wherein the heat-conductive particles have a thermal conductivity of not less than 100 W/m·K and an insulator property or a semiconductor property.
[0038] Thus, since the heat-conductive particles are disposed dispersed between the phosphor layer as a heat-generating body and the conductor layer as a heat-dissipating route, the thermal resistance between the phosphor particles and the conductor layer can be reduced so as to enhance the heat dissipation from the phosphor particles. Thereby, it is possible to suppress heat deterioration in members composing the light-emitting device.
[0039] Light-diffusing particles for diffusing light, such as SiO 2 , TiO 2 and Al 2 O 3 are generally contained as a filler in a sealing portion but the thermal conductivities of SiO 2 , TiO 2 and Al 2 O 3 are only about 1.5 W/m·K, 10 W/m·K and 30 W/m·K, respectively, and therefore, an effect of improving a thermal conductivity is insufficient.
[0040] The invention focuses on improvement in thermal conductivity, not on improvement in light-diffusing properties. Therefore, the configuration and effect of the filler are different from the conventional filler contained in a sealing portion. And also, a positional relation between phosphor particles and the filler and an effect resulting therefrom are also different.
[0041] In addition, “a conductor layer connected to an external power source” in the embodiment of the invention includes an external electrical connection lead of the LED lamp and a wiring or metal substrate of the COB module and it is acceptable as long as it is a conductor electrically or thermally connected to the external power source.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Next, the present invention will be explained in more detail in conjunction with appended drawings, wherein:
[0043] FIGS. 1A to 1C are cross sectional views showing conventional light-emitting devices, wherein FIG. 1A is a cross sectional view showing a precipitation arrangement of phosphor particles, FIG. 1B is a cross sectional view showing a dispersed arrangement of phosphor particles and FIG. 1C is a cross sectional view showing a separate arrangement of phosphor particles;
[0044] FIG. 2 is a cross sectional view showing a light-emitting device in a first embodiment of the present invention;
[0045] FIG. 3 is a cross sectional view showing a light-emitting device in a second embodiment of the invention;
[0046] FIG. 4 is a cross sectional view showing a light-emitting device in a modification of the second embodiment of the invention; and
[0047] FIG. 5 is a cross sectional view showing a light-emitting device in a third embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] The first embodiment of the invention will be described below in reference to the appended drawings.
[0049] FIG. 2 is a cross sectional view showing an LED lamp in the first embodiment of the invention.
[0050] The LED lamp in the first embodiment of the invention is composed of a package 1 having a pair of leads 1 a on a bottom surface of a recessed portion, an LED chip 2 which is formed of an inorganic compound semiconductor emitting ultraviolet to blue light and is mounted on one of the pair of leads 1 a , and a sealing portion 3 filling the recessed portion of the package 1 while being in contact with and sealing the LED chip 2 .
[0051] The LED chip 2 is mounted in so-called face-up manner, and positive and negative electrodes thereof (not shown) are respectively electrically connected to the pair of leads 1 a via wires 2 a formed of Au, etc. The pair of leads 1 a protrude outward from side surfaces of the package 1 and the protruding portions thereof function as external connection terminals. The pair of leads 1 a are electrically and thermally connected to the outside via the protruding portions thereof.
[0052] The package 1 is formed of a thermoplastic resin such as polyamide resin or liquid crystal polymer resin, etc., a thermosetting resin such as epoxy resin or silicone resin, etc., or a ceramic such as alumina. When the package 1 is formed of a resin material, white pigment particles of TiO 2 , etc., are contained in the package 1 in order to reflect light and light emitted from the LED chip 2 is reflected and guided toward an opening of the recessed portion of the package 1 .
[0053] The sealing portion 3 is formed of a thermosetting resin epoxy resin or silicone resin, etc., or an inorganic material such as sol-gel glass. The sealing portion 3 contains phosphor particles 3 a with higher concentration in an upper portion than in a lower portion, and heat-conductive particles 3 b are uniformly dispersed in the lower portion.
[0054] Followings are examples of the phosphor particle 3 a used in the first embodiment.
(Blue Phosphor)
BaMgAl 10 O 17 :Eu 2+
(Green to Orange Phosphor)
Y 3 Al 5 O 12 :Ce 3+ (Ba, Sr) 2 SiO 4 :Eu 2+ Ca(Si, Al) 12 (O,N) 16 : Eu 2+ SrSi 2 O 2 N 2 :Eu 2+
(Red Phosphor)
CaAlSiN 3 : Eu 2+ K 2 SiF 6 : Mn 4+
[0065] The heat-conductive particle 3 b used in the embodiments of the invention is a material having such characteristics that thermal conductivity is not less than 100 W/m·K. Followings are examples of the heat-conductive particle 3 b having such characteristics.
CNT (Carbon-Nano-Tube (thermal conductivity: 3000 W/m·K)) Diamond (thermal conductivity: 2100 W/m·K) c-BN (cubic boron nitride (thermal conductivity: 1300 W/m·K)) SiC (silicon carbide (thermal conductivity: 270 W/m·K)) BeO (beryllium oxide (thermal conductivity: 260 W/m·K)) AlN (aluminum nitride (thermal conductivity: 230 W/m·K))
Such materials are insulators or semiconductors arranged in the lower portion of the sealing portion in a dispersed state and thus are less likely to cause short-circuit even if arranged in contact with the LED chip 2 or the wire 2 a.
[0072] In the LED lamp of the first embodiment of the invention having such a configuration, the heat-conductive particles 3 b having thermal conductivity of not less than 100 W/m·K and having insulating properties or semiconducting properties are dispersed in the lower portion of the sealing portion 3 even in the case of the separate arrangement in which the LED chip 2 is sealed with the sealing portion 3 having a higher concentration of the phosphor particles 3 a in the upper portion away from the LED chip 2 than in the lower portion in contact with the LED chip 2 .
[0073] Therefore, the thermal resistance between the phosphor particles 3 a as a heating element and the lead 1 a as a heat dissipation path decreases by dispersing and arranging the heat-conductive particles 3 b between the lead 1 a and the upper portion of the sealing portion 3 having a high concentration of the phosphor particles 3 a, and it is thus possible to enhance dissipation of heat from the phosphor particles 3 a via the lower portion of the sealing portion 3 .
[0074] As a result, it is possible to suppress deterioration of the sealing portion 3 .
[0075] Alternatively, the heat-conductive particles 3 b may be contained in the package 1 . In this case, since heat from the phosphor particles 3 a can be dissipated not only through the lower portion of the sealing portion 3 but also through the package 1 , the thermal resistance in a direction toward the lower portion of the LED lamp further decreases.
[0076] Next, two methods will be described as examples of the method of manufacturing the LED lamp shown in FIG. 2 .
[0077] In the first method, the upper and lower portions of the sealing portion 3 are separately supplied into the recessed portion of the package 1 .
[0078] That is, after supplying a first sealing material containing the heat-conductive particles 3 b so as to be in contact with the LED chip 2 , a second sealing material containing the phosphor particles 3 a is supplied on a surface of the first sealing material. After that, the first and second sealing materials are simultaneously cured by, e.g., heating, thereby obtaining the LED lamp having the sealing portion 3 shown in FIG. 2 .
[0079] In the second method, the upper and lower portions of the sealing portion 3 are simultaneously supplied into the recessed portion of the package 1 .
[0080] That is, a thermosetting sealing material, such as epoxy resin or silicone resin, containing both the heat-conductive particles 3 b having relatively small specific gravity and the phosphor particles 3 a having relatively large specific gravity is supplied so that the thermosetting sealing material is in contact with the LED chip 2 mounted on the bottom surface of the recessed potion of the package 1 and fills the recessed portion of the package 1 . Then, while maintaining the package 1 in a direction (the same direction as a gravity-acting direction) opposite to a direction of supplying a resin (an opposite direction to the gravity-acting direction) so that gravity acts toward a surface of the thermosetting sealing material, the phosphor particles are precipitated in the sealing material on the surface side at a relatively low temperature which decreases viscosity of the thermosetting sealing once.
[0081] At this time, the phosphor particles 3 a are generally precipitated on the surface of the sealing material due to large specific gravity but the heat-conductive particles 3 b are generally hardly precipitated since the specific gravity thereof is small. The thermosetting resin is cured in this state by heating to a curing temperature thereof and it is thereby possible to obtain the LED lamp having the sealing portion 3 shown in FIG. 2 .
[0082] FIG. 3 is a cross sectional view showing an LED lamp in a second embodiment of the invention.
[0083] The second embodiment is different from the first embodiment in that heat-conductive particles 1 b are not contained in the sealing portion 3 unlike the first embodiment but are dispersed and contained in the package 1 and also a white resin portion 4 is formed so as not to overlap with a portion of the sealing portion 3 having a high concentration of the phosphor particles 3 a.
[0084] The white resin portion 4 contains white pigment particles of TiO 2 , etc., and is formed so that a reflectivity with respect to light emitted from the LED chip 2 is higher than the package 1 which contains the heat-conductive particles 1 b.
[0085] For forming the white resin portion 4 in the second embodiment, for example, the package 1 is formed by molding such as injection molding or transfer molding, and then, a thermosetting resin, such as uncured epoxy resin or silicone resin, containing white pigment particles of TiO 2 , etc., is applied by dispensing, etc., along an inner wall of a reflector portion corresponding to the recessed portion of the package 1 and is cured by heating.
[0086] In the LED lamp of the second embodiment of the invention having such a configuration, since the thermal resistance between the phosphor particles 3 a as a heating element and the lead 1 a as a heat dissipation path decreases by dispersing and arranging the heat-conductive particles 1 b in the reflector portion of the package 1 which is in contact with both the lead 1 a and the upper portion of the sealing portion 3 having a high concentration of the phosphor particles 3 a, it is possible to enhance dissipation of heat from the phosphor particles 3 a via the lower portion of the sealing portion 3 .
[0087] As a result, it is possible to suppress deterioration of the sealing portion 3 .
[0088] In addition, since the white resin portion 4 is formed along the inner wall of the reflector portion of the package 1 , the light emitted from the LED chip is reflected by the white resin portion 4 which has a higher reflectivity than the package 1 .
[0089] As a result, it is possible to improve light extraction efficiency of the LED lamp.
[0090] FIG. 4 is a cross sectional view showing an LED lamp in a modification of the second embodiment.
[0091] The present modification is different from the LED lamp shown in FIG. 3 in that the white resin portion 4 reaching to the top surface is formed on the inner wall of the reflector portion of the package 1 and phosphor particles 5 b are dispersed and contained in a plate material 5 which is formed separately from the sealing portion 3 .
[0092] The white resin portion 4 in the present modification can be formed by dispenser coating as described above. And it is also possible to form the white resin portion 4 as follows; for example, the package 1 is formed using a mold corresponding to an outer shape of the package 1 by molding such as injection molding or transfer molding, and then, molding such as injection molding or transfer molding of a resin containing white pigment particles of TiO 2 , etc., e.g., a thermoplastic resin such as uncured polyamide resin or liquid crystal polymer resin, etc., or a thermosetting resin such as epoxy resin or silicone resin, etc., is performed again using a mold corresponding to the shapes of the package 1 and the white resin portion 4 .
[0093] Meanwhile, it is possible to form the plate material 5 containing the phosphor particles 5 b as follows; for example, a thermosetting resin, such as uncured epoxy resin or silicone resin, containing the phosphor particles 5 b is cured so as to have a plate shape and is then attached to the top surfaces of the white resin portion 4 and the sealing portion 3 .
[0094] Alternatively, a thermosetting resin, such as uncured epoxy resin or silicone resin, containing the phosphor particles 5 b is screen-printed on the top surfaces of the white resin portion 4 and the sealing portion 3 and is then cured.
[0095] In the LED lamp of the present modification having such a configuration, in addition to the above-mentioned effects, it is possible to easily provide the phosphor particles 5 b at a high concentration and the manufacturing process is thereby simplified.
[0096] Alternatively, the plate material itself may be a phosphor. In such a case, since the plate material 5 can be formed by sintering a material of the phosphor and then slicing the sintered object without crushing into particles, manufacturing process is further simplified.
[0097] FIG. 5 is a cross sectional view showing an LED lamp in a third embodiment of the invention.
[0098] The third embodiment is different from the first and second embodiments in that so-called flip-chip mounting in which the LED chip 2 is joined to the package at an electrode forming surface and is electrically connected to the lead 1 a via bumps 2 b formed of Au, etc., is employed instead of employing the so-called face-up mounting in which LED chip 2 is joined to the package at a surface opposite to the electrode forming surface and is electrically connected to the lead via the wires, and also in that the sealing portion 3 is not formed.
[0099] In other words, the LED chip 2 is sealed so that the white resin portion 4 and the plate material 5 are in contact with the LED chip 2 .
[0100] For forming the white resin portion 4 in the third embodiment, for example, the package 1 is formed by molding such as injection molding or transfer molding, the LED chip 2 is subsequently flip-chip mounted via the bumps 2 b, and then, a thermosetting resin, such as uncured epoxy resin or silicone resin, containing white pigment particles of TiO 2 , etc., is applied and filled in a space between the LED chip 2 and the package 1 by dispensing, etc.
[0101] It is possible to form by applying the thermosetting resin along the inner wall of the reflector portion corresponding to the recessed portion of the package 1 and then curing with heat.
[0102] Meanwhile, after formation of the white resin portion 4 and subsequent polishing to flatten the top surfaces of the package 1 , the white resin portion 4 and the LED chip 2 , the plate material 5 can be formed by the same method as the modification of the second embodiment. Since the polishing is performed, the bondability between the plate material 5 and the package 1 , the white resin portion 4 and the LED chip 2 is improved by an anchor effect.
[0103] In the LED lamp of the third embodiment having such a configuration, the plate material 5 containing the phosphor particles 5 b is in contact with not only the package 1 containing the heat-conductive particles 1 b but also the LED chip 2 . This enhances heat dissipation to the leads 1 a through both of the package 1 and the LED chip 2 and thus improves heat dissipation properties.
[0104] Although examples of the application of the invention to an LED lamp have been described in the embodiments, the invention is not limited thereto and is applicable to so-called COB modules or any other general light-emitting devices using a phosphor and an LED chip. In addition, although examples of the application of the invention in which an LED chip is used have been described in the embodiments of the invention, it is possible to use other light-emitting elements such as light-emitting thyristor chip or laser diode chip.
[0105] Although the invention has been described with respect to the specific embodiments for complete and clear disclosure, the appended claims are not to be therefore limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art which fairly fall within the basic teaching herein set forth. | A light-emitting device includes a base material having a conductor layer on a surface thereof, the conductor layer being configured to be connected to an external power source, a light-emitting element mounted on the base, a phosphor layer arranged above the light-emitting element, and a resin layer contacting both of the phosphor layer and the conductor layer and containing heat-conductive particles dispersed therein. The heat-conductive particles have a thermal conductivity of not less than 100 W/m·K and an insulator property or a semiconductor property. | 7 |
BACKGROUND
[0001] The invention relates to a jet regulator which can be inserted into the water outlet of a sanitary outlet fitting from the direction of the outlet end side, with it being possible for the jet regulator to be detachably fastened or fixed in the water outlet.
[0002] It is already known for a jet regulator which is to form a homogenous, non-sputtering water jet to be mounted on the water outlet of a sanitary outlet fitting. Such jet regulators are usually inserted into an outlet mouthpiece which can be detachably screwed to the water outlet of the sanitary outlet fitting.
[0003] Since the configuration of the outlet mouthpiece in designing the surface of the sanitary outlet fitting may involve a considerable amount of expenditure, and since the gap remaining between the outlet mouthpiece and the outlet fitting is often perceived as a problem, jet regulators of the type mentioned in the introduction have already been created which can be inserted into the water outlet of a sanitary outlet fitting from the direction of the outlet end side without an additional outlet mouthpiece being necessary for fastening the jet regulator.
[0004] DE-A-31 14 818 has disclosed a jet regulator which can be inserted into the water outlet of a sanitary outlet fitting. To be able to insert the previously disclosed jet regulator into the water outlet of the outlet fitting, a screw head cap which serves as an outlet mouthpiece is provided on the water outlet, which screw head cap can be screwed by means of a peripheral external thread onto an internal thread which is provided on the inner periphery of the adjacent face-end region of the outlet fitting. The jet regulator previously disclosed by DE-A-31 14 818 is provided as an aerated jet regulator which, for the induction of the air which is to be mixed with the water jet, has air admixture openings which are arranged so as to be distributed about the periphery of its jet regulator housing. Here, an encircling annular gap is provided between the jet regulator housing and the adjacent inner wall of the screw head cap which serves as an outlet mouthpiece, via which annular gap the air which is inducted into the water outlet at the end side can enter into the housing interior of the jet regulator via the air admixture openings which are provided in the jet regulator housing. The jet regulator previously disclosed by DE-A-31 14 818 is inserted into the inflow side insertion opening of the outlet mouthpiece which is designed as a screw head cap and which itself can be screwed to the water outlet of the outlet fitting. Here, the jet regulator previously disclosed by DE-A-31 14 818 has an aeration duct which is designed as an annular gap which runs around the jet regulator housing at all sides. Since the jet regulator housing of the previously disclosed jet regulator surrounds an encircling annular gap, the cross section of the emerging water jet is comparatively small in relation to the outer periphery of the water outlet.
[0005] WO-A-98/16695 has already disclosed a jet regulator having a jet diffuser device and a jet regulating device which is connected downstream of said jet diffuser device in the flow direction, with the jet regulating device which is provided in the jet regulator housing of the previously disclosed jet regulator having a plurality of pin-like or annular impact bodies which are spaced apart from one another and which are arranged in the flow path transversely with respect to the flow direction. In all of the exemplary embodiments illustrated in WO-A-98/16695, the jet regulator previously disclosed there has an annular flange which is arranged at the inflow side and which projects beyond the periphery of the jet regulator housing, by means of which annular flange the jet regulator housing can be placed onto the annular shoulder provided at the inner periphery of an outlet mouthpiece. On the jet regulator previously disclosed by WO-A-98/16695 is therefore mounted by means of a conventional outlet mouthpiece on the face-end region, which is provided as a water outlet, of a sanitary outlet fitting. Here, in said previously disclosed jet regulator too, an annular gap is provided between the jet regulator housing and the adjacent inner periphery of the outlet mouthpiece in order that the air for admixture can be inducted into the housing interior of the jet regulator housing via the outlet-side face end of the outlet fitting and the air admixture openings which are distributed about the outer periphery of the jet regulator housing. The jet regulator previously disclosed by WO-A-98/16695 therefore also has the disadvantages already mentioned above with regard to the prior art.
SUMMARY
[0006] With the ever-increasing aesthetic demands on sanitary outlet fittings, the demands made of the jet regulators required also increase. It is therefore the object to create a jet regulator of the type mentioned in the introduction in which the water jet leaving the sanitary outlet fitting geometrically continues the contour of the water outlet or of the outlet water-conducting cross-sectional area of the water outlet and therefore assumes the cross-sectional geometry—perpendicular to the flow direction—of the inner contour of the sanitary outlet fitting, which inner contour differs from the visible outer contour only by the wall thickness of the outlet part.
[0007] This object is achieved according to the invention in the jet regulator of the type mentioned in the introduction in particular in that an aeration duct which is required for aerating the water jet is delimited, at a part of the periphery arranged so as to face away from the visible side of the outlet fitting, between the jet regulator outer periphery and the fitting inner periphery.
[0008] In the jet regulator according to the invention, the aeration duct required for aerating the water jet does not extend—as is conventional—over the entire periphery between the jet regulator periphery and the fitting inner periphery; said aeration duct is in fact delimited at a part of the periphery arranged so as to face away from the visible side of the outlet fitting. Since the air required for generating an aerated jet is inducted not at all sides but rather only at a part of the periphery arranged so as to face away from the visible side of the outlet fitting, the utilization of the available surfaces is increased, which is of particular technical and aesthetic significance in particular in the case of an outlet fitting which is wide but flat in terms of its clear fitting inner periphery.
[0009] To achieve the object stated above, a further, independently patentable proposal provides that the length of at least one dimension of the water jet, perpendicular to the flow direction thereof, at the outlet is equal to the outlet inner dimension minus two times the housing wall thickness of the jet regulator.
[0010] In order that the jet regulator according to the invention can satisfy even high demands and can be advantageously used in a wide variety of outlet fittings, a further independently patentable proposal provides that, to fasten or fix the jet regulator in the water outlet, at least one retaining element is provided which extends through a passage opening provided on the periphery of the fitting housing and which engages, with its end region protruding into the housing interior of the fitting housing, on the jet regulator so as to fix the latter.
[0011] The jet regulator according to the invention may, if required, be inserted into the water outlet of a sanitary outlet fitting from the direction of the outlet end side. To be able to detachably fasten and fix the jet regulator according to the invention there, at least one retaining element is provided which extends through a passage opening provided on the periphery of the fitting housing, with the retaining element engaging, with its end region protruding into the housing interior of the fitting housing, on the jet regulator so as to fix the latter. Since the at least one retaining element may engage on a jet regulator of any desired shape, the jet regulator according to the invention promotes design freedom in the design of new outlet fittings without it being necessary to accept losses in function. Since the jet regulator according to the invention does not require an external thread or a bayonet connection on its housing periphery, it is possible at least in visual terms for practically the entire clear cross section of the outlet fitting, with the exception of the jet regulator housing walls, to serve to conduct water.
[0012] The retaining element may duly also act on the jet regulator so as to fix the latter. However, in order that the comparatively thin-walled jet regulator is not deformed to an excessive extent, it may be advantageous for the retaining element to engage into a fastening opening on the jet regulator.
[0013] The retaining element may be designed as a retaining splint which extends though the passage opening on the fitting housing and through a fastening opening on the jet regulator. One preferred embodiment of the invention, however, provides that the retaining element is designed as a retaining screw which can be screwed into the passage opening and/or the fastening opening.
[0014] It is particularly advantageous if the retaining element has a self-tapping thread and if the retaining element, as it is screwed in, cuts a thread into the fastening opening. It is therefore not necessary for the thread flights in the passage opening on the one hand to be adapted to the thread flights in the fastening opening on the other hand.
[0015] The retaining element no longer has an objectionable appearance at the outer periphery of the fitting housing if the retaining element is designed as a set screw and/or if a tool engagement surface, which is preferably designed as an internal hexagon, is provided on the visible end region of the retaining element.
[0016] It is particularly expedient if the fastening opening has, on its inner periphery, a profile formed from axial projections and depressions. While the retaining element can cut into the axial projections with little force expenditure, the material which is displaced during the thread-cutting process can be pressed into the region of the depressions, where it no longer poses a problem.
[0017] To form a sparkling, soft water jet, it is advantageous if the jet regulator is designed as an aerated jet regulator and if an aeration duct, which is open toward the outlet end side of the water outlet, is provided at least in one partial region between the fitting inner periphery and the jet regulator.
[0018] Here, one preferred embodiment according to the invention provides that at least one fastening opening is arranged on the jet regulator housing in the region of the aeration duct.
[0019] Since no external thread is required on the jet regulator housing for inserting and fixing the jet regulator according to the invention, the jet regulator according to the invention may also have a non-circular and in particular an elongate and/or rectangular outer periphery.
[0020] A further independently patentable proposal according to the invention provides that the jet regulator mentioned in the introduction has a jet regulator housing with a peripheral push-in opening, that at least one push-in guide which is aligned transversely with respect to the jet regulator longitudinal axis is provided in the housing interior of the jet regulator housing, and that at least one preferably jet-forming insert part can be pushed into the at least one push-in guide from the direction of the push-in opening. In the jet regulator according to the invention, the insert parts additionally required for forming the water jet can be pushed into the housing interior of the jet regulator housing from the direction of a peripheral push-in opening. For this purpose, at least one push-in guide which is aligned transversely with respect to the jet regulator longitudinal axis is provided in the housing interior of the jet regulator housing, into which push-in guide at least one preferably jet-forming insert part can be pushed in laterally.
[0021] In order that the clear cross section of the water outlet can be utilized practically completely for forming the water jet, it is advantageous if at least one insert part which is provided in a push-in guide extends substantially over the clear passage cross section of the jet regulator housing.
[0022] One particularly simple and advantageous embodiment according to the invention provides that at least one insert part is of plate-shaped design.
[0023] To perform the function of a jet diffuser, of a homogenizing device and/or of a flow straightener, it may be advantageous if at least one insert part has a preferably jet-forming sieve, grate or mesh structure.
[0024] In order that the different functions can be optimized in the jet regulator according to the invention, it can be advantageous if at least two insert parts can be pushed into the jet regulator housing, which insert parts preferably have different sieve, grate or mesh structures.
[0025] In order to provide the jet regulator housing which has a lateral push-in opening with a sufficient level of stability, it may be advantageous if a jet diffuser device which is preferably designed as a perforated plate is integrally formed in the jet regulator housing.
[0026] To make it possible for the functional units which follow the jet diffuser to be pushed into the jet regulator housing, it is advantageous if the jet diffuser device is formed into the jet regulator housing upstream of the push-in opening at the inflow side.
[0027] To prevent undesired leakage currents between the jet regulator on the one hand and the fitting inner periphery on the other hand, it is expedient if an annular seal, a lip seal or similar encircling seal element is provided between the jet regulator and the fitting inner periphery.
[0028] A seal element of said type can be sealingly inserted in an effective manner between the jet regulator housing on the one hand and the fitting inner periphery on the other hand without it being necessary for the jet regulator housing to be deformed if the jet regulator housing supports, in the region of the jet diffuser device, a seal element which bears sealingly against the fitting periphery.
[0029] To prevent an undesired discharge of water from the push-in opening of the jet regulator housing and to prevent an uncontrolled induction of air through the push-in opening, it is advantageous if a seal is provided between the push-in opening and the fitting inner periphery.
[0030] Here, one embodiment according to the invention which is particularly simple and can be produced with little expenditure provides that the seal is designed, at least in regions, as a sealing lip or similar sealing projection which is integrally formed on the jet regulator housing.
[0031] Since the push-in opening can be sealed off at its inflow-side edge region even by means of the seal element which encircles around the jet regulator housing, it can be sufficient if the sealing lip or similar sealing projection extends linearly over the peripheral edge region, which delimits the push-in opening, of the jet regulator housing at both sides into the region of the seal element.
[0032] One embodiment of the invention provides that a cover is provided to close off the push-in opening and that at least one insert part supports at least one partial region of the cover. When the required insert parts are pushed into the push-in opening, then those partial regions of the cover which are provided on said insert parts finally close off the push-in opening completely.
[0033] To also close off the push-in opening in a satisfactorily sealing manner, it is expedient if at least one pressing projection is integrally formed on the cover or on at least one partial region of the cover, which pressing projection acts on the fitting inner periphery. The pressing projection which bears against the fitting inner periphery and which is pressed radially inward as the jet regulator is pushed into the fitting housing in turn presses the cover or cover partial region sealingly against the jet regulator housing.
[0034] To further promote the simple production of the jet regulator according to the invention, it is advantageous if the at least one pressing projection is integrally formed on the cover or on the partial region of the cover in the region of the insert part.
[0035] To prevent slipping or a release of the insert parts which have been pushed into the jet regulator housing, it may be advantageous if at least one insert part is secured or held in its push-in guide by means of a force-fitting action.
[0036] To prevent an undesired manipulation of the insert parts situated in the housing interior of the jet regulator housing, it may be advantageous if a sieve, grate or mesh structure is integrally formed into the jet regulator housing at the outlet side. The sieve, grate or mesh structure which is integrally formed on the jet regulator housing at the outlet side may not only have a jet-forming action but rather also simultaneously performs the function of a manipulation prevention device.
[0037] In order that it is possible for the jet regulator which has been pushed preferably completely into the fitting housing to be removed again from the fitting housing as required, it is expedient if at least one tool engagement point for a disassembly tool is provided on the jet regulator housing, preferably in the region of the aeration duct.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] Further features of the invention can be gathered from the following description of the Figures in connection with the claims. The invention is described in yet more detail below on the basis of advantageous exemplary embodiments. In the Figures:
[0039] FIG. 1 shows the fitting housing, in a longitudinally cut-away view, of a sanitary outlet fitting which, in the region of its water outlet, has a jet regulator whose outline is elongate and rectangular so as to be matched in terms of shape,
[0040] FIG. 2 shows the fitting housing, having the jet regulator, from FIG. 1 ,
[0041] FIG. 3 shows the jet regulator, inserted into the water outlet of the fitting housing, from FIGS. 1 and 2 in the region of a set screw which fixes the jet regulator,
[0042] FIG. 4 shows the fitting housing of the outlet fitting, illustrated in FIGS. 1 to 3 in an end view of its water outlet,
[0043] FIG. 5 shows the jet regulator from FIGS. 1 to 4 in an exploded perspective illustration,
[0044] FIG. 6 shows the jet regulator from FIGS. 1 to 5 in a longitudinally sectioned perspective illustration,
[0045] FIG. 7 shows a detailed view of the jet regulator illustrated, in a longitudinally sectioned view, in FIG. 6 in the region of the insert parts pushed into the jet regulator housing,
[0046] FIG. 8 shows the jet regulator illustrated in FIGS. 1 to 7 in a cross-sectioned perspective illustration, with a disassembly tool engaging on the jet regulator,
[0047] FIG. 9 shows a cross section of the jet regulator from FIGS. 1 to 8 fixed in the fitting housing,
[0048] FIG. 10 shows a further embodiment of a jet regulator inserted into a fitting housing of a sanitary outlet fitting,
[0049] FIG. 11 shows the jet regulator fixed in the fitting housing from FIG. 10 , with the fitting housing being illustrated in the region of its water outlet which supports the jet regulator,
[0050] FIG. 12 shows the jet regulator, situated in the water outlet of the fitting housing, from FIGS. 10 and 11 in the region of the set screw which fixes the jet regulator,
[0051] FIG. 13 shows the fitting housing of the outlet fitting illustrated in FIGS. 10 to 12 in an end view of its water outlet,
[0052] FIG. 14 shows the jet regulator illustrated in FIGS. 10 to 13 in an exploded perspective illustration,
[0053] FIG. 15 shows the jet regulator from FIGS. 10 to 14 in a longitudinal section,
[0054] FIG. 16 shows a detailed view of the jet regulator illustrated in a longitudinally sectioned view in FIG. 15 ,
[0055] FIG. 17 shows the jet regulator from FIGS. 10 to 16 in a cross-sectioned perspective illustration, with a disassembly tool engaging on the jet regulator outer periphery,
[0056] FIG. 18 shows a cross section of the jet regulator from FIGS. 10 to 17 fixed in the water outlet of the fitting housing,
[0057] FIG. 19 shows the water outlet of a sanitary outlet fitting, wherein the housing of the sanitary outlet fitting is illustrated with hatching and the tube cross-sectional area which is bordered by said sanitary outlet fitting is illustrated without hatching, and
[0058] FIG. 20 shows a jet regulator similar to that in FIGS. 1 to 18 in a plan view of its outflow-side end side, wherein the housing contour of the jet regulator and the flow straightener provided at the outflow side are illustrated with hatching and the water outlet areas bordered by said housing contour and flow straightener are illustrated without hatching.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0059] FIGS. 1 to 9 and 10 to 18 illustrate different embodiments 1 , of a jet regulator which can be inserted into the water outlet 2 of a sanitary outlet fitting 3 from the direction of the outlet end side in order to form a homogenous, sparkling, soft and non-sputtering water jet there. To fasten and fix the jet regulator 1 , 10 , which has a non-circular and in this case elongate rectangular outline, in each case one retaining element 4 is provided which extends through a passage opening 5 provided on the periphery of the fitting housing and which engages, with its end region protruding into the housing interior of the fitting housing, on the jet regulator 1 , 10 so as to fix the latter.
[0060] For this purpose, the retaining element 4 engages into a fastening opening 6 which is provided laterally on the jet regulator housing 7 . The retaining element 4 is designed, in the exemplary embodiments shown in FIGS. 1 to 9 and 10 to 18 , as a retaining screw and in particular as a set screw which can be screwed into the passage opening 5 on the fitting housing and into the fastening opening 6 on the jet regulator housing 7 . In order that the set screw 4 no longer has an objectionable appearance at the outer periphery of the fitting housing, the set screw 4 has, on its visible end region, a tool engagement surface, which is designed as an internal hexagon 8 , for a hexagonal key.
[0061] To facilitate the assembly of the jet regulator in the water outlet of the outlet fitting, the retaining element 4 has a self-tapping thread, by means of which the retaining element 4 , as it is screwed in, cuts a thread into the fastening opening 6 . As is clear from FIGS. 5 and 6 or 14 , the fastening opening 6 has, at its inner periphery, a profile formed from axial projections and depressions, with the retaining element 4 cutting with its self-tapping thread into the projections of the fastening opening 6 , while the material which is thereby displaced can be pressed into the depressions.
[0062] The jet regulators 1 , 10 illustrated in FIGS. 1 to 9 and 10 to 18 are aerated jet regulators in which air is admixed to the water jet. To be able to induct the air required for the air admixture into the housing interior of the jet regulator 1 , 10 , an aeration duct 9 , which is open toward the outlet end side of the water outlet 2 , is provided in one partial region between the fitting inner periphery and the jet regulator 1 , 10 . The aeration duct 9 opens out in the region of aeration openings 11 which are provided in the jet regulator housing 7 and which lead, below a jet diffuser 12 , into the housing interior. Here, the fastening opening 6 is arranged on the jet regulator housing 7 in the region of the aeration duct 9 .
[0063] From a comparison of FIGS. 5 to 7 and 14 to 16 , it is clear that the jet regulators 1 , 10 shown here have a jet regulator housing 7 with a peripheral push-in opening 13 . Here, at least one push-in guide 14 which is aligned transversely with respect to the jet regulator longitudinal axis is provided in the housing interior of the jet regulator housing 7 , such that the insert parts 15 required for forming the water jet can be pushed into the push-in guide or push-in guides 14 from the direction of the push-in opening 13 . To be able to form the water jet over the entire cross section thereof, the plate-shaped insert parts 15 extend substantially over the entire clear passage cross section of the jet regulator housing 7 . It can be seen from FIGS. 5 , 9 and 14 that the insert parts 15 which serve here as a homogenization device have a jet-forming sieve or grate structure.
[0064] A jet diffuser device 12 which is designed as a perforated plate is integrally formed in the jet regulator housing 7 upstream of the push-in opening 13 at the inflow side. To prevent undesired leakage currents between the jet regulator housing 7 on the one hand and the fitting inner periphery on the other hand, an annular seal 16 is provided between the jet regulator 1 , 10 and the fitting inner periphery. The annular seal 16 which is supported by the jet regulator housing 7 in the region of the jet diffuser device 12 can bear sealingly against the fitting housing without the risk of a deformation of the jet regulator housing 7 in said region, since the jet diffuser device 12 serves to stiffen the jet regulator housing 7 and counteracts an undesired deformation.
[0065] It can be seen from FIGS. 1 to 10 that the push-in opening 13 of the jet regulator 1 can be closed off by means of a cover which is formed from a plurality of cover partial regions 17 , 18 which are integrally formed on the insert parts 15 . Pressing projections 19 are integrally formed on said cover partial regions at the outside, which pressing projections 19 act on the fitting inner periphery. As the jet regulator 1 is inserted, said pressing projections 19 are clamped between the fitting inner periphery and the jet regulator housing 7 in such a way that the pressing projections 19 press the cover partial regions 17 , 18 against the peripheral edge region, which delimits the push-in opening 13 , of the jet regulator housing 7 with a sufficient sealing action.
[0066] It can be seen from FIGS. 10 to 18 that the push-in opening 13 of the jet regulator 10 is not assigned any cover. Instead, only a seal 31 is provided here between the push-in opening 13 and the fitting inner periphery, which seal 31 is intended to prevent an undesired discharge of water and an uncontrolled inflow of air. Said seal is also designed here at least in regions as a sealing lip 31 which is integrally formed on the outside of the jet regulator housing 7 . Since the push-in opening 13 is already sealed off at its inflow-side edge region by the annular seal 16 , the sealing lip 31 extends linearly over the peripheral edge region, which delimits the push-in opening 13 of the jet regulator 10 , of the jet regulator housing 7 at both sides into the region of the annular seal 16 .
[0067] It can be seen in FIG. 7 that the insert parts 15 can be pushed with lateral guide rails 21 into the push-in guides 14 which are designed at both sides as guide grooves. Clamping strips 22 project from said guide rails 21 , which clamping strips 22 hold the insert parts 15 in their push-in guide 14 by means of a force-fitting action.
[0068] It is clear from a comparison of FIGS. 8 and 9 that the insert part 15 which is situated directly downstream of the jet diffuser device 12 at the outflow side has at least one centering pin 23 which engages into a centering opening on the jet regulator housing 7 . Correct positioning between the jet diffuser device 12 on the one hand and the functional unit 15 , which follows said jet diffuser device 12 at the outflow side, on the other hand is ensured by means of the centering pin 23 engaging into the centering opening of the jet regulator housing 7 , in such a way that the individual jets formed in the jet diffuser device 12 impinge directly on a crossing node of the sieve or grate structure formed by the outflow-side insert part 15 .
[0069] A sieve or grate structure 24 is integrally formed on the jet regulator housing 7 of the jet regulator 1 , 10 at the outlet side, which sieve or grate structure firstly serves as a flow straightener and secondly also constitutes a manipulation prevention device which is intended to prevent unauthorized manipulation of the insert parts 15 situated in the housing interior of the jet regulator housing 7 .
[0070] It is clear in particular from FIGS. 8 and 17 that a tool engagement point 25 which is designed as a hook-in projection is provided on the jet regulator housing 7 preferably in the region of the aeration duct, for a disassembly tool 26 which is designed here in the manner of a hook. The jet regulator housing 7 which is situated in the water outlet 2 of the sanitary outlet fitting 3 can be removed from the water outlet as required by means of the disassembly tool 26 which engages behind the tool engagement point 25 .
[0071] It is a particular advantage of the jet regulators 1 , 10 illustrated here that their outlet area A 4 which is calculated without the jet regulator housing or the sieve or grate structure and which is bordered and unhatched in FIG. 20 is kept comparatively large in relation to the clear inner cross-sectional area A 3 , which is bordered and unhatched in FIG. 19 , of the water outlet 2 . Calculating the area ratio of the sum A 4 of the individual water outlet areas (illustrated in FIG. 20 ) out of the structure of the jet regulator in relation to the unhatched structural area in the sanitary outlet fitting shown in FIG. 19 yields a water outlet area A 4 of 50% of the available gross area A 3 of the outlet bore at the water outlet 2 of the outlet fitting 3 . Here, it may be advantageous if said water outlet area is greater than/equal to 0.3 and in particular greater than/equal to 0.4 of the gross area, preferably 0.45 and in particular greater than/equal to 0.5 of the gross area of the outlet bore of the fitting outlet. Viewed from the visible side S, the length L 2 of the water jet at the outlet of the jet regulator in comparison to the length L 1 of the clear cross-sectional length of the outlet fitting is >0.8, preferably 0.9.
[0072] From a comparison of FIGS. 1 to 9 on the one hand and FIGS. 10 to 18 on the other hand, it is clear that the jet regulator 1 has, for each of its insert parts 15 , in each case one push-in guide 13 , whereas the jet regulator 10 has only one push-in guide 13 , into which a plurality of insert parts 15 can be pushed. The insert parts 15 of the jet regulator 10 shown in FIGS. 10 to 18 are held with a spacing to one another by means of spacer frames 35 .
[0073] It may be advantageous for the water flow to be subjected to a greater resistance at the side edges of the insert parts 15 . For this purpose, it is possible for a greater number of webs which form the sieve or grate structure to be provided at the side edges of the insert parts 15 , such that only a relatively small water quantity can pass and spraying of the emerging water jet at the jet periphery can be prevented or at least reduced. If, instead, a lower number of webs are provided at the side edges of the insert parts 15 , and if the water jet is thereby subjected to a reduced resistance in the region of the side edges of the insert parts, it is possible to ensure the cylindrical shape of the emerging water jet over a relatively long distance, which is desirable in particular in the case of elongate jet regulators.
[0074] It is particularly advantageous if the sieve or grate structures of the insert parts 15 which are positioned in series with one another to be aligned with the gaps of the adjacent structures. Even if the insert parts 15 are of identical design, this is possible by means of a lateral offset of the sieve or grate structures for example by approximately half of a mesh width. Instead, it is also possible to use asymmetrical sieve or grate structures which can be aligned with the gaps of the adjacent structures by means of a simple rotation of the identically-designed insert parts 15 .
[0075] In each case one ancillary sieve 30 is positioned upstream of the jet regulators 1 , 10 at the inflow side, which ancillary sieve 30 filters out the dirt particles contained in the water. | A jet regulator ( 1 ) which can be installed into the water outlet ( 2 ) of a sanitary outlet fitting ( 3 ), on the front side thereof. The jet regulator ( 1 ) can be arranged in a detachable or fixed manner in the water outlet ( 2 ). The jet regulator includes at least one holding element ( 4 ) for arranging or fixing the jet regulator ( 1 ) in the water outlet ( 2 ), with the holding element being inserted into a passage opening ( 5 ) on the perimeter of the fitting housing and engaging, in a fixed manner, with the end area thereof, the jet regulator ( 1 ), which projects into the interior of the fitting housing. The jet regulator ( 1 ) has a jet regulator housing ( 7 ) with an insertion opening ( 13 ) on the peripheral side, with the housing including in the interior at least one insertion guide ( 14 ) which is oriented across the jet regulator housing longitudinal axis, and at least one, preferably jet-producing, converter piece ( 15 ) can be inserted into the at least one insertion guide ( 14 ) from the insertion opening ( 13 ). | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to methods, apparatus and systems for conveying a tool within a borehole. In several embodiments, for example, the invention relates to methods, apparatus and systems capable of deploying one or more tools within a non-vertical borehole without the necessity of power, or data, lines from the surface.
[0003] 2. Description of Related Art
[0004] The deployment of tools in boreholes is well known. In the petroleum exploration and recovery industries, for example, tools are deployed in subsurface wells for a multitude of purposes, such as to conduct well logging and completion operations. The downhole use of tools in the petroleum exploration and recovery process is generally considered fundamental and essential.
[0005] Various challenges exist in delivering tools into boreholes. For example, the tool may require power from an external source for conducting its desired operations. For another example, it may be necessary to provide instructions to the tool when it is deployed in the borehole.
[0006] Numerous techniques and equipment have been used or proposed for delivering tools into boreholes. Again with reference to the petroleum exploration and recovery industries, for example, tools are often deployed in vertically-oriented wells with the use of a wireline that includes power and data cables extending from the surface. The wireline may also be deployed through coiled tubing or drill pipe to the tool. For another example, tool conveyance devices for propelling the tool along non-vertical or deviated wells have been proposed and used, such as the “tractor” technology disclosed in U.S. Pat. No. 6,179,055 B1, which is incorporated herein by reference.
[0007] In considering existing technology for conveying tools in boreholes, the present invention fulfills a need for methods, apparatus and/or systems having one or more of the following attributes: deploying tools into boreholes without the necessity of power lines extending from the surface; deploying tools into boreholes without the necessity of data transmission lines extending from the surface; deploying tools into boreholes without the necessity of wirelines extending from the surface; using an apparatus that carries one or more tools, the tools being rotatable while deployed in the borehole; allowing tools deployed in a borehole to be rotated, or moved in circular pattern, in the borehole; generating power in the borehole for powering at least one tool without the necessity of power lines from the surface; using fluid to generate power; using drilling mud to generate power; being deployable in a non-vertical borehole; providing cost effective delivery of tools into and within boreholes; providing speedy delivery of tools into and within boreholes; generating minimal friction during the delivery of tools into boreholes; using an easy to control and simple apparatus and technique for moving one or more tools into a borehole; reliable delivery of tools into boreholes; delivering tools in boreholes without the necessity of complex and/or cumbersome mechanical delivery equipment; providing any one or more of the above attributes with the use of existing equipment and technology and/or by retrofitting existing equipment.
BRIEF SUMMARY OF THE INVENTION
[0008] In accordance with the present invention, certain embodiments involve an apparatus useful for conveying a tool into a borehole from the surface without the necessity of power-delivery and communication lines from the surface. The apparatus is in fluid communication with a fluid source, is deployable in the borehole and includes a fluid delivery member and an interface system in fluid communication with the fluid delivery member. The interface system is designed to permit the deployment of standard, unmodified wireline tools and includes power generation and communication systems. A fluid discharge member is in fluid communication with the interface system and engageable with the tool(s). Fluid is provided to the power generation system through the fluid delivery member, utilized by the power generation system to generate power for powering a tool and discharged from the apparatus through the fluid discharge member. The communication system is capable of transmitting data between the surface and a tool without the necessity of data-delivery lines from the surface.
[0009] If desired, the fluid discharge member may be a circulating sub module having a fluid discharge port and being capable of electrically and electronically connecting the power generation system and a tool. The power generation system may include a turbo-alternator capable of generating electricity from the flow of fluid through the power generation system.
[0010] The fluid delivery member may be drill pipe that is controllably movable within the borehole so that the tool is controllably deployable in the borehole, or it may be coiled tubing. If desired, the fluid may be drilling mud and the borehole may be non-vertical or deviated. The fluid delivery member and/or the fluid discharge member may be integral with the power generation system.
[0011] In some embodiments, the power generation system includes a telemetry mud pulser/turbo-alternator module and a data acquisition/memory module. The mud pulser/turbo-alternator module may be capable of deriving power from the flow of fluid within the power generation system and transmitting power and data to the data acquisition/memory module. The mud pulser/turbo-alternator module and the data acquisition/memory module may include fluid flow passageways in fluid communication with one another. The mud pulser/turbo-alternator module may include a modulator and modulator controller, and may transmit data to the surface from the data acquisition/memory module. The data acquisition/memory module may transmit data between the mud pulser/turbo-alternator module and a tool.
[0012] Some embodiments involve a fluid discharge member that includes a discharge port, is connectable between the power generation system and a wireline telemetry sub, and is capable of electrically and electronically connecting the power generation system with a tool.
[0013] Various embodiments involve a tool conveying system useful for carrying a wireline tool and deploying the wireline tool in a non-vertical or deviated borehole from the surface. The tool conveying system includes a downhole power system and a fluid circulation system in fluid communication with one another. The fluid circulation system enables the flow of fluid through the downhole power system. The downhole power system is capable of generating power from the fluid flowing therethrough, providing power to a wireline tool carried by the tool conveying system, and communicating data between a wireline tool and the surface.
[0014] In such embodiments, the downhole power system may, if desired, be capable of generating electricity from the flow of fluid through the downhole power system without the use of power-delivery lines from the surface, and/or communicating data between a wireline tool and the surface without the use of a wireline from the surface. The downhole power system may include a telemetry mud pulser/turbo-alternator module and a data acquisition/memory module.
[0015] In certain embodiments, the present invention involves a method for conveying a tool into a borehole from the surface without the necessity of power-delivery and communication lines from the surface and with the use of a tool conveying apparatus deployable in the borehole. The method includes deploying the tool conveying apparatus in the borehole, transmitting fluid through the tool conveying apparatus, the tool conveying apparatus generating power from the flow of fluid therethrough and providing power to a tool carried thereby, and discharging fluid from the tool conveying apparatus.
[0016] If desired, the tool conveying apparatus may also transmit data between a tool carried thereby and the surface without the necessity of communication lines to the surface. Telemetry/mud pulser technology may be used to transmit data between a tool and the surface. The tool conveying apparatus may be deployable in the borehole by moving a rigid upper member of the apparatus.
[0017] The borehole may be non-vertical or deviated and the fluid may be drilling mud. A turbo-alternator may be included in the tool conveying apparatus that generates unregulated AC power from the fluid flow through the tool conveying apparatus. The tool conveying apparatus may be capable of transforming unregulated AC power to regulated AC and/or DC power. A data acquisition/memory module may be included in the apparatus that receives power and data, stores data and distributes power and data to a wireline tool.
[0018] Accordingly, the present invention includes features and advantages that enable it to advance the technology associated with conveying tools in boreholes. Characteristics and advantages of the present invention described above, as well as additional features and benefits, will be readily apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments and referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] For a detailed description of preferred embodiments of the invention, reference will now be made to the accompanying drawings wherein:
[0020] [0020]FIG. 1 is a schematic view of an embodiment of a tool conveying apparatus in accordance with the present invention, the tool conveying apparatus shown deployed in a borehole;
[0021] [0021]FIG. 2 is a partial cross-sectional view of an example data acquisition/memory module of the tool conveying apparatus shown in FIG. 1;
[0022] [0022]FIG. 3 is a partial cross-sectional view of an example circulating sub/interface module of the tool conveying apparatus shown in FIG. 1; and
[0023] [0023]FIG. 4 is a flow diagram showing an embodiment of a method of operation of conveying a tool in a borehole in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Presently preferred embodiments of the invention are shown in the above-identified figures and described in detail below. In describing the preferred embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
[0025] As used herein and throughout the various portions of this specification, the terms “invention”, “present invention”, and variations thereof are not intended to mean the claimed invention of any particular of the appended claims, or all of the appended claims. These terms are used to merely provide a reference point for subject matter discussed in this specification. The subject or topic of each such reference is thus not necessarily part of, or required by, any particular claim(s) merely because of such reference. Accordingly, the use herein of the terms “invention”, “present invention” and variations thereof is not intended and should not be used to limit the construction or scope of the appended claims.
[0026] Referring initially to FIG. 1, an example tool conveying apparatus 10 in accordance with the present invention is shown. The illustrated tool conveying apparatus 10 is capable of carrying and powering one or more tools 18 and, if desired, communicating data between the tool 18 and the surface (not shown), without the use of a wireline from the surface. Any suitable components and technique may be used in the apparatus 10 to provide such capabilities.
[0027] As used throughout this specification and in the appended claims and abstract, the terms “wireline tool”, “tool”, and variations thereof means one or more device or tool that can be used in a borehole. Some examples of tools which may be used with the present invention, methods of operation thereof, and techniques for communication therewith are described in U.S. Pat. Nos. 4,860,581; 4,936,139; 6,191,588 B1; and 4,937,446, each of which is incorporated herein by reference. However, the present invention is not limited in any way to the particular wireline tools or methods disclosed in the referenced patents, or otherwise by the type or operation of a tool that can be used with the present invention. Also as used throughout this specification and in the appended claims and abstract, the term “surface” and variations thereof means above-ground or thereabouts, or the operator(s) or equipment for operating or controlling the tool conveying apparatus, or another person, entity or equipment, wherever located, that is designated to operate or communicate with the tool conveying apparatus or wireline tool. The present invention is in no way limited by the nature or location of the “surface.”
[0028] The exemplary tool conveying apparatus 10 is shown disposed within a borehole 14 . As used throughout this specification and in the appended claims and abstract, the term “borehole” means any borehole, passageway or area suitable for use with the present invention. While the borehole 14 of FIG. 1 appears vertically-oriented, the present invention is not limited to any particular orientation of the borehole 14 . For example, in a preferred embodiment, the tool conveying apparatus 10 is useful for conveying the tool 18 within a borehole 14 that is non-vertical, such as a “horizontal” or “deviated” well. Unless specifically indicated otherwise, the present invention is in no way limited by the type or orientation of borehole within which it is, or may be, used.
[0029] The tool conveying apparatus 10 of FIG. 1 includes a fluid circulation system 20 and a downhole interface system 30 . The fluid circulation system 20 enables the flow of fluid through the downhole interface system 30 , which utilizes the fluid to generate power, as will be described further below. As used herein, the term “fluid” means drilling mud or any other fluid or fluid/solid mixture suitable for use in accordance with the present invention. In preferred embodiments, the fluid is drilling mud, however, the present invention is not limited by the type of fluid that is, or may be, used.
[0030] The particular fluid circulation system 20 of FIG. 1 includes a fluid delivery member 21 and a fluid discharge member 24 . In the illustrated embodiment, the fluid delivery member 21 is controllably movable, such as from the surface (not shown), to direct or control movement of the tool conveying apparatus 10 and attached tool 18 within the borehole 14 . However, this capability is not required.
[0031] Still referring to the example of FIG. 1, the fluid delivery member 21 may be any suitable component(s) having any desired configuration, shape, and components as is or becomes known, such as drill pipe 22 or coiled tubing. The fluid delivery member 21 may be connectable with the downhole interface system 30 with the use of any suitable mechanical or other connection as is or becomes known. In some embodiments, the fluid delivery member 21 may instead be integral with the downhole interface system 30 .
[0032] The fluid delivery member 21 includes at least one area, or passageway, 26 into which fluid may be provided, such as from the surface, as indicated by flow arrow 28 . At least one such passageway 26 is in fluid communication with the downhole interface system 30 . The fluid delivery member 21 thus allows the flow of, or directs, fluid into the downhole interface system 30 .
[0033] Still referring to FIG. 1, the exemplary fluid discharge member 24 enables ejection of the fluid from the downhole interface system 30 , as indicated by flow arrow 29 , and may be any suitable component(s) as is or become known. One particular embodiment of the fluid discharge member 24 is shown in FIG. 3, in which the fluid discharge member 24 is a circulating sub/interface module 50 connectable between the downhole interface system 30 and a wireline telemetry sub 19 , such as via mechanical connections as is or become known. The illustrated circulating sub/interface module 50 includes at least one fluid passageway, or area, 52 in fluid communication with the downhole interface system 30 , and at least one fluid ejection port 54 to allow the ejection of fluid (via fluid path 58 ) from the tool conveying apparatus 10 into the borehole 14 . If desired, the fluid can be recirculated and reused as is, or becomes, known.
[0034] Still referring to FIG. 3, the illustrated circulating sub/interface module 50 also electrically and electronically connects the downhole interface system 30 and the tool 18 with connections 62 , 68 and power/data wires 64 to allow power and data to be transmitted between the downhole interface system 30 and the tool 18 , as is or becomes known. However, the present invention is not limited to the use of a circulating sub/interface module 50 or any of the details of the exemplary embodiment. For example, if desired, the fluid discharge member 24 may be integral with the downhole interface system 30 . For another example, the fluid discharge member 24 may connect directly to the tool 18 without a telemetry sub 19 .
[0035] Referring back to FIG. 1, the downhole interface system 30 includes a power generation system that generates power from the fluid flowing through passageway 26 , such as for powering the tool 18 , and, if desired, may also include a communication-system to communicate data between the tool 18 and the surface (not shown). In the particular embodiment shown, the downhole interface system 30 includes a telemetry mud pulser/turbo-alternator module 34 and a data acquisition/memory module 40 . The mud pulser/turbo-alternator module 34 is capable of generating electricity from the flow of fluid entering the module 34 from the fluid delivery member 21 , as is or becomes known. Referring to FIG. 2, the power generated in the telemetry mud pulser/turbo-alternator module 34 of this embodiment is transmitted to the data acquisition/memory module 40 via wires 38 and an electrical/data connection 39 .
[0036] Referring again to FIG. 1, the exemplary downhole interface system 30 allows fluid to flow through the mud pulser/turbo-alternator module 34 and data acquisition/memory module 40 . In the example shown in FIG. 2, the modules 34 and 40 include fluid pathways 36 , 42 , respectively, which are in fluid communication with one another. The flow of fluid is illustrated by arrow 48 .
[0037] The exemplary mud pulser/turbo-alternator module 34 is also capable of communicating data to and from the surface (not shown). Referring to FIG. 2, the illustrated module 34 includes one or more mechanical and electronic components 37 capable of effecting communication with the surface. For example, the mechanical and electronic components 37 may include a modulator, modulator controller and/or printed circuit boards capable of “mud pulse” communication with the surface as is or becomes known. In such example, the measurement while drilling, “MWD”, technology of Schlumberger Technology Corporation may be utilized as part of the module 34 to enable two-way telemetry. The illustrated module 34 is also equipped to communicate data with the data acquisition/memory module 40 through the wires 38 and electrical/data connection 39 .
[0038] Still referring to FIG. 2, the exemplary data acquisition/memory module 40 includes electronic components 44 for transmitting and receiving data between the module 34 and the wireline tool 18 , as is or becomes known. The illustrated data acquisition/memory module 40 also stores and processes information. The data acquisition/memory module 40 may be designed, for example, to store some or much of the information received from the tool 18 , reducing the quantity of information that needs to be transmitted to the surface. If desired, for example, only the wireline tool status and basic data need be transmitted to the surface, while other data is stored in the data acquisition/memory module 40 .
[0039] The downhole interface system 30 may include additional components and/or capabilities. For example, tension/compression load cells (not shown) may be included for quick detection of over-compression of the wireline tool 18 . The present invention may also be designed so that such detection can be rapidly communicated to the surface, if desired.
[0040] Further details of the structure and operation of some examples of components that may be used as part of the downhole interface system 30 are described in U.S. Pat. Nos. 5,375,098; 5,249,161; and 5,237,540, each of which is incorporated herein by reference. However, the present invention is not limited to the details above, the use of a telemetry mud pulser/turbo-alternator module 34 or data acquisition/memory module 40 , or the techniques or embodiments disclosed in the referenced patents.
[0041] The above description of exemplary components and the operation thereof is provided for illustrative purposes only and is not limiting upon the present invention. The present invention is thus not limited by the form, components and configuration of the tool conveying apparatus described above. Any components and techniques capable of generating power in the borehole for powering a wireline tool and, if desired, communicating data between the tool and the surface that are or become known may be used.
[0042] [0042]FIG. 4 is a flow diagram illustrating exemplary methods of power and data transmission involving a downhole tool in accordance with the present invention. The right hand side of the flow diagram, the “power” side 80 relates generally to the generation and transmission of power within a tool conveying apparatus of the present invention. The left hand side, the “data” side 84 , relates generally to the receipt, processing, storage, generation and transmission of data (or any combination thereof) in a tool conveying apparatus of the present invention. Path 90 generally represents the transmission of power through the tool conveying apparatus, path 92 generally represents the transmission of data to a wireline tool or tools 18 carried by the tool conveying apparatus, and path 94 generally represents the transmission of data to the surface 100 .
[0043] Referring initially to the power side 80 and power flow path 90 , block 102 represents the supply of fluid through a fluid delivery member (e.g. through a fluid delivery member 21 , FIG. 1) to a power generation system (block 104 ) of a downhole interface system (e.g. 30 , FIG. 1). The power generation system 104 , for example, may include a turbo-alternator capable of generating unregulated AC power from the fluid flow. In some embodiments, the frequency of the AC power generated by the turbo-alternator will depend upon the flow rate of the fluid into the turbo-alternator; e.g. the greater the flow rate, the higher the frequency of the AC power.
[0044] In the exemplary embodiment, the unregulated AC power is conditioned (block 106 ) for use in the tool conveying apparatus 10 and/or wireline tools 18 . For example, one or more electronic circuits may be used to transform the unregulated AC power to regulated AC and/or DC power. In this embodiment, regulated DC power is provided to power a modulator controller (block 120 ) of the telemetry mud pulser/turbo-alternator module 34 , and regulated AC power is provided to the data acquisition/memory module 40 at block 108 .
[0045] Referring to block 108 , the data acquisition/memory module 40 of this embodiment conditions and distributes the power it receives. For example, one or more electrical circuits may be used to provide high level AC power and high level DC power to a wireline telemetry sub 19 (if included), as indicated by arrows 109 , 110 , respectively, and low level DC power (arrow 111 ) may be provided to one or more electronic components 44 in the data acquisition/memory module 40 .
[0046] The wireline telemetry sub 19 , if included, may be equipped to condition power it receives (block 112 ) and/or distribute power to the wireline tool or tools 18 , such as in the form of AC power and DC power (arrows 114 , 115 , respectively). The wireline tool or tools 18 use power received from the wireline telemetry sub 19 to perform their designated tasks, such as to record data from the borehole within which they are deployed.
[0047] Now referring to flow path 92 (the transmission of data to the wireline tool or tools 18 ) beginning at block 104 , data about the fluid flow rate in the power generation device (block 104 ) of the illustrated embodiment is communicated to one or more electronic components 37 , such as printed circuit boards, (block 124 ) of the telemetry mud pulser/turbo alternator module 34 . If included, this capability may have any desired purpose. For example, when mud pulser technology is used, commands or instructions, such as requests for certain types of information to be obtained by the wireline tools, may be transmitted to the tool conveying apparatus from the surface by varying the flow rate of the fluid into the turbo-alternator, as is or becomes known. The power generation device (block 104 ) transmits such information to the electronic component(s) 37 , such as circuitry, which translates, reads or processes the data received (block 124 ).
[0048] One or more electronic components 37 of the telemetry mud pulser/turbo-alternator module 34 of this embodiment transmits data to one or more electronic components 44 (block 126 ) of the data acquisition/memory module 40 . The data transmitted, for example, may include instructions for the wireline tool that are provided via the flow rate information from the power generation device. The electronic component 44 evaluates, sorts, stores or processes the data, or any combination thereof (block 126 ). For example, the component 44 may convert wireline tool instructions received from the electronic component 37 to a digital command.
[0049] The electronic component 44 of the data acquisition/memory module 40 is capable of transmitting data, such as operational instructions, to one or more electronic components of the wireline telemetry sub 19 , or directly to the wireline tool 18 if the sub 19 is not included. When a sub 19 is included, data may be processed therein (block 130 ) and transmitted to the tool 18 , as is or becomes known.
[0050] Reference is now made to the flow path 94 (the transmission of data to the surface), beginning at the wireline tool 18 . In the embodiment shown, information, such as digital data gathered by the wireline tool 18 , is transmitted to one or more electronic components (block 130 ) of the wireline telemetry sub 19 . The wireline telemetry sub 19 may evaluate, sort, store and/or process the data, and/or transmit data to the data acquisition/memory module 40 for formatting (block 136 ) and processing and/or sorting therein (block 126 ). If desired, some data may be stored in memory (block 140 ) therein, and some data may be transmitted to the telemetry mud pulser/turbo-alternator module 34 . In the exemplary module 34 , data received from the module 40 is processed (block 124 ) and transmitted to the surface (block 100 ) via the modulator controller (block 120 ) and modulator (block 122 ), as is or becomes known.
[0051] The present invention does not require each of the techniques or acts described above. Moreover, the present invention is in no way limited to the above methods of power generation, power and data transmission or other operations. Further, neither the methods described above nor any methods that may fall within the scope of any of the appended claims need be performed in any particular order. Yet further, the methods of the present invention do not require use of the particular embodiments shown and described in the present specification, such as, for example, the tool conveying apparatus 10 of FIG. 1, but are equally applicable with any other suitable structure, form and configuration of components.
[0052] Preferred embodiments of the present invention are thus well adapted to carry out one or more of the objects of the invention. The apparatus and methods of the present invention offer advantages over the prior art and additional capabilities, functions, methods, uses and applications that have not been specifically addressed herein but are, or will become, apparent from the description herein, the appended drawings and claims.
[0053] It should be understood that the present invention does not require all of the above features and aspects. Any one or more of the above features or aspects may be employed in any suitable configuration without inclusion of other such features or aspects. Further, while preferred embodiments of this invention have been shown and described, many variations, modifications and/or changes of the apparatus and methods of the present invention, such as in the components, details of construction and operation, arrangement of parts and/or methods of use, are possible, contemplated by the applicant, within the scope of the appended claims, and may be made and used by one of ordinary skill in the art without departing from the spirit or teachings of the invention and scope of the appended claims. All matter herein set forth or shown in the accompanying drawings should thus be interpreted as illustrative and not limiting. Accordingly, the scope of the invention and the appended claims is not limited to the embodiments described and shown herein. | A method for conveying a tool into a borehole with the use of a tool conveying apparatus includes deploying the tool conveying apparatus into the borehole, transmitting fluid through the tool conveying apparatus, the tool conveying apparatus generating power from the flow of fluid therethrough, discharging fluid from the tool conveying apparatus and providing power to at least one tool carried thereby. The tool conveying apparatus also includes a communication system for transmitting data bi-directionally between the tool and the surface. | 4 |
FIELD OF THE INVENTION
This invention is related to the fields of trades and crafts, especially those involved in marking, cutting, and measuring of workpieces. It is particularly concerned with the building trades, especially carpentry, dry wall work, and other construction fields, such as display building.
BACKGROUND OF THE INVENTION
Many measuring, marking, and cutting tasks in the building trades and related fields are characterized by somewhat incompatible goals. The tradesman would like to do his measuring and cutting accurately but he is also concerned with the efficiency of his work including speed, simplicity, and comfort. This is especially true when the tradesman needs to carry out a series of repetitive tasks involving measuring, such as: preparing pickets for a fence, setting up slots for a porch rail, installing studs, and marking and cutting floor and sealing joists and rafters. Such tasks also include marking off sections of plaster board, panel, other wall board, and cardboard, and cutting these materials. Such tasks might also involve marking off metal sections for cutting.
Various complex jigs have been created to mark and cut under such circumstances. Furthermore a number of built-in or retro-fit constructions have been developed for association with tape measuring devices to carry out the simultaneous measuring and marking of a workpiece. These devices are used to make a mark on a workpiece at a given length by attaching the marking device to the case of the tape measure and creating the mark by moving the case back and forth.
There are a number of disadvantages to this later approach. Under some circumstances the friction of the tape measure body or the tape itself on the workpiece causes a jerky movement during the marking which can result in inaccuracies. If the device is being used for cutting soft materials such as plaster board or cardboard, one or more measured marks must be made and then the mark must be extended by the use of a square or the like. Only then can the cut be made. Similarly, if a long mark or cut must be made, then numerous marks must first be made and then joined by the edge of a long straightedge. If a cut must be made, this involves a separate step. In all of the above cases, several tools must be used, or several steps carried out, or both.
These and other difficulties experienced with the prior art have been obviated in a novel and unobvious manner by the present invention. It is therefore a primary object of the present invention to provide for accurate measuring, marking, and cutting of workpieces using a single assembly.
It is another object of the invention to provide a measuring tool adapted to make long marks or cuts parallel to an edge.
A further object of the invention is to provide a measuring tool adapted to mark or cut circles.
It is another object of the invention to provide a measuring tool with which accurate marks and accurate cuts may be made using the same device.
It is a further object of the invention to provide a measuring, marking, and cutting tool which has an aesthetically pleasing visual effect, both as a whole and in each of its main component parts.
It is also an object of this invention to provide a tool as described above which is inexpensive to make and simple to use and which will provide a long useful life with minimum maintenance.
With these and other objects in view, as will be apparent to those skilled in the art, the invention resides in the combination of parts set forth in the specification, illustrated in the drawings, and covered by the claims appended to this specification.
SUMMARY OF THE INVENTION
A measuring tool having a coiled measuring tape is provided, in combination with accurate marking or cutting device in a holder integrally formed on the casing of the measuring tool, the tool further provided with friction reducing means at locations where the tool slides against a workpiece during use. More specifically, friction reducing means are provided on the bottom of the main case of the measuring tool, preferably at both ends. The tape itself has an end clip which is also provided with friction reducing means, preferably in the form of bevels directed away from the tape on the vertical portion of the end clip. In the preferred embodiment, a tape grasping slide handle is provided which is slidable on the tape between the end clip and the main case which is also provided with friction reducing means on the portion normally in contact with the workpiece.
The friction reducing means may also comprise small rollers on the bottom of the case or of the grasping handle, or on the portion of the end clip in contact with the workpiece.
Another aspect of the invention involves the provision of a sharpener attached to the casing of the tool for sharpening the marking or cutting device.
A further aspect of the invention is a novel and unobvious ornamental design for the overall tool, as well as for the main case, for the end clip, and for the grasping handle element.
BRIEF DESCRIPTION OF THE DRAWINGS
The character of the invention, however, may be best understood by reference to one of its structural forms, as illustrated by the accompanying drawings, in which:
FIG. 1 illustrates the use of the invention to make a long mark or cut parallel to the edge of an elongated and extended workpiece,
FIG. 2 is a perspective view of a measuring, marking, and cutting tool according to the present invention,
FIG. 3 is an exploded view of the components of a blade holding assembly to be inserted in place of the marking means,
FIGS. 4 through 10 show the construction and ornamental design of a main case for a measuring device according to the present invention, the views being perspective, front elevation, rear elevation, right side elevation, left side elevation, top plan, and bottom plan, respectively,
FIGS. 11 through 16 show both the structure and ornamental design of the end clip for the tape according to the present invention, the view being perspective, front elevation, rear elevation, top plan, bottom plan, and left and right side elevation views, respectively,
FIGS. 17 through 22 show the construction and ornamental design of a grasp handle slidable on the tape of the present invention, the views being perspective, front elevation, rear elevation, top plan, bottom plan, and left or right side elevation, and
FIGS. 23, 24, and 25 illustrate an alternative friction reducing means on the main case, end clip, and tape grasping slide holder respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, a tradesman as shown using the device of the present invention to mark or cut a long line, parallel to the edge of the workpiece. The tool of the present invention is referred to generally by reference numeral 10. The tradesman is holding, with one hand, the main case 11 on which is integrally formed a cutting or marking device holder 12. With the other hand the tradesman is holding the tape grasping slide holder 14 of the present invention. Although free to move, the slide holder, under normal use, would be located at the extreme left next to the end clip 13.
The friction reducing end clip 13 of the present invention rests along the edge of the workpiece. The tradesman is using the device to make a long mark or cut parallel to this edge.
The details of the present invention are shown more closely in perspective view, FIG. 2. The main case 11 has attached to it a marking and cutting device holder 12. The main case contains and dispenses a conventional measuring tape with a coiled end and a free end and having measuring indicia. The end clip 13 of the present invention is shown with a horizontal attaching portion attached to the tape and a vertical portion extending at right angles to the attaching portion. In this embodiment of the present invention, end clip wings 17 and 18 are provided extending outward from the vertical portion and angled slightly away from the tape. These wings provide for a reduction of the friction along the edge of the workpiece and prevents snagging and facilitates smooth movement of the end of the tape along the edge.
Likewise the main case 11 is provided in this embodiment with friction reducing slide pads 15 and 16. These are preferably provided at each end of the main case, crossing it transversely and having rounded or beveled edges. These slide pads also help to smooth the movement of the device as the marking or cutting is performed. The tape grasping slide handle 14 has a main body 21 which wraps around the tape to form slots such as 24 on each side and to create a friction reducing element such as 22 having rounded edges. Extending upward from the main body 21 of the slide handle is a grip 23 shaped to be held firmly and comfortably by the fingers.
In the preferred embodiment, the marking or cutting device holder 12 is provided with a position indicator 25 integrally formed thereon and adapted to show the exact position of the marking or cutting tool in terms of the measurement on the tape. This indicator is designed to be located an accurately predetermined distance from the far end 27 of the main case of the measuring device. Indicia may be provided to record, on the case, this distance. In this manner, a measurement can be made right up to a wall or other obstruction by adding this predetermined distance to the measurement indicated by the indicator. For example, if the indicator were located exactly 2 inches from the end of the main case, and pointed to 8'3", the distance from end clip to the obstruction would be 8'5". This adds versatility to the tool and is important and valuable for almost all its functions.
The marking device 26, shown in the device holder 12 of FIG. 2, can be replaced by other devices under appropriate circumstances. FIG. 3 shows an assembly for insertion in the device holder for replacing the marking device with a cutting device referred to generally by 30. The assembly includes a blade or scribe holder 31 made of resilient material and having a slot. A collet 32 is provided to press the blade or scribe holder and hold the scribe or blade. A locking nut is provided to assist in holding the assembly tightly in the marking or cutting device holder.
The use and operation of this invention will now be apparent from the above description. To make an ordinary mark for measurement of a distance, the tape end clip is rested against an edge, the tape is extended until the indicator 25 shows the desired distance, and the mark or scribe is made using the marking device 26 by moving the main case 11 on its friction reducing slide pads 15 and 16. The marking tool is of course adjusted in its holders so that its sharpened end rests lightly on the workpiece. If a long cut parallel to an edge is desired, the device is positioned in a similar manner but the tape is grasped at an intermediate point convenient to the user (normally, close to the end clip) by the tape grasping slide handle 14 by pinching it on the grip 23. The tape and the marking or scribing instrument are then moved with a light downward pressure towards the workpiece on both the main case and the tape slide handle and also with a slight bias of the end clip 13 toward the end of the workpiece, taking advantage of the low friction on this specially shaped end clip.
If it is desired to make a cut rather than a mark on the workpiece, the marking device 26 may be removed and the cutting device assembly 30 substituted for it. If a cut is to be made, of course, the blade should be so inserted so that it reaches to the depth of cut desired.
The main case is preferably manufactured in two halves, each half being preferably injection molded, with the marking and cutting device holder integrally molded on one of these halves. It may be preferable to reinforce the connection by means of webs 35 and 36. A tape locking system may also be provided operated by a lock button 40.
By fixing the end clip 13 rotatably about some fixed point, the device may also be used for drawing large circles or cutting such circles and curves. For this purpose a long slot 37 is provided through the end clip for use on a nail head.
Naturally the device holder on the present invention may be fitted with a regular pencil or a mechanical drafting pencil or pen, a felt-tip pen, a scribe or razor-type cutting means, etc., all of which may be either fixed, or retractable and extendable. A sharpening fixture 41 for any of these devices may be attached or integrally formed on the device. Such a fixture for the pencil should preferably produce a short, sharp point for accuracy.
In the preferred embodiment the sharpening fixture is built into the top rear part of the main case 11. The top surface of the top of the sharpening fixture is preferably flush to the top surface of the main case 11.
The device of the present invention should be aesthetically appealing as a whole and in its parts. For this reason the preferred aesthetic and ornamental design of the main case of the present invention, of the end clip of the present invention, and of the tape grasping slide handle of the present invention are fully disclosed in FIGS. 4 through 10, 11 through 16, and 17 through 22, respectively.
If especially smooth and friction-free operation is desired any one of: the main case, the end clip, and the tape grasping slide handle may be provided with small rollers. These can be, for example, ball rollers 37, 38, and 39 as shown in FIGS. 23, 24, and 25, where each element interacts with the workpiece.
Clearly minor changes could be made in the form and construction of this invention without departing from its material spirit. Therefore, it is not desired to confine the invention to the exact form shown herein and described, but it is desired to include all subject matter that properly comes within the scope claimed. | In measuring, cutting, and marking tool incorporating a tape measure having a case with a holder for a marking or cutting device integrally formed thereon. The tool provides reduced friction for marking and cutting tasks involving sliding of the tool. Friction reducing elements are provided on the case, e.g. slide pads or rollers. An end clip on the tape has friction reducing means involving beveled edges, angled wings, or rollers for reduced friction. An intermediary sliding handle between the end of the tape and the case and having reduced friction means and a gripping element is provided. A sharpening device for the marking or cutting tool is integrated in the case. | 6 |
This application is the national phase under 35 U.S.C. §371 of PCT International Application No. PCT/CH98/00480 which has an International filing date of Nov. 11, 1998, which designated the United States of America.
The invention relates to a slit lamp device and a lens supporting unit as an attachment for the device.
BACKGROUND OF THE INVENTION
A slit lamp microscope is known, for example from the company Haag Streit under the name “Original slit lamp 900 BM” and is described with its essential features in DE-A 1 133 911. The known slit lamp device had a viewing unit for stereoscopic examination of the eye and an illumination unit for the eye which is to be examined. The cross section of a illumination spot on or in the eye can be adjusted by a diaphragm which is adjustable in width and height. The illumination unit was located on a vertically running branch of a holding unit. The eye to be examined could be positioned in a roughly horizontally running plane on one side of the holding unit. The viewing unit was located roughly in the plane on the side of the holding unit opposite it. The holding unit had three columns. The illumination optics rested on the two outer columns. On the third middle column which was made as a stub column there was a deflection mirror which guided the beam of the illumination unit to the eye. In the intermediate spaces between one outer column at a time and the stub column the beam paths were guided to the viewing unit.
In U.S. Pat. No. 5,216,456 a three-column slit lamp device is described, the middle column bearing the deflection mirror for illuminating the eye. All three columns are joined via a connecting plate on which then an illumination unit is placed.
In U.S. Pat. No. 4,331,392 the illumination unit is located in the lower part of the slit lamp device and thus necessarily has a construction which is completely different from the invention; in it the illumination unit is located at the top. The arrangement of an illumination unit in the upper part of the slit lamp device compared to the arrangement of U.S. Pat. No. 4,331,392 allows simple replacement of the illumination source. The slit lamp device of U.S. Pat. No. 4,331,392 is foreign to that of the invention and thus not further examined below.
In EP-A 0 091 334 a slit lamp device is described with which the eye could be examined and a laser beam was guided for eye treatment. The slit lamp device of EP-A 0 091 334 was built analogously to that of DE-A 1 133 911, an additional column stub being present for guidance of the laser beam. The analogous structure can be seen especially in FIG. 2 which shows a vertical lengthwise section through the device. FIG. 2 shows cutaway the middle column which bears the deflection mirror. Furthermore, the left side column is shown as seen from the visual field of the patient. The connecting plate for the two side columns on which the illumination unit (here labelled 20 ) sits is shown cutaway.
SUMMARY OF THE INVENTION
The object of the invention is to devise a slit lamp device which allows good patent-physician contact, ensures efficient examination and which can be economically produced in an aesthetically pleasing form with outstanding optical properties.
The invention is characterized by as little material as possible between the observing and examining physician and the patient in order to ensure efficient examination and good patient-physician contact. A structure which avoids material between the physician and patient is achieved by means of a vertically running branch of a holding unit for an illumination unit made as one column with a narrow column cross section. The narrow column area is preferably made at eye height. Efficient examination is furthermore supported by a video recording. The compact configuration achieved likewise enables economical manufacture. The features of the invention also increase the examination efficiency since the viewing, observing or examining individual need no longer turn his gaze from the viewing unit to look for the controls. The most important controls can be operated with only one hand.
If a Greenough microscope is used as an observation unit preferably in conjunction with the slender holding column as a holding unit, a further reduction in the size of the device results. The video viewing arrangement described below with a Greenough microscope can also be used on other slit lamp devices with the corresponding adaptation. Also the size of the device can be reduced; but its mass does not decrease as much as when using the single-column holding unit.
One partial beam which is guided to a recording element of a recording unit is masked out into one of the two beam paths of the Greenough microscope for display and evaluation purposes. If the decoupling of the partial beam as was the case in conventional slit lamp devices, having a different microscope than a Greenough microscope, were to take place, much larger dimensions would result.
The structure described below furthermore easily allows integration of optical filters which enable better observation results.
In one preferred version, a lens supporting unit can simply be slipped on as an accessory. With this accessory part, studies can be done on the vitreous body and on the ocular fundus. These examinations have been done in the past with a so-called “movable Hruby adapter glass”. This means had a rod on which one examination lens was arranged with a capacity to swivel. The rod had a vertically running guide rod which was guided in the direction of the patient in one slot on the slit lamp device. This guide rod led through an attachment plate which was attached to the chin holder for the patient's head. Directly underneath the lens there was a small lever as the handle for moving the lens. The examinations performed with the known “adapter glass” were often not reproducible since when the lever was released generally the lens moved. Photographs for documentation were thus hardly possible.
Embodiments and other advantages of the invention are described below.
BRIEF DESCRIPTION OF DRAWINGS
The following examples of the device and the slit lamp microscope are detailed using the drawings.
FIG. 1 shows a side view of the slit lamp device with assignment to the human eye, here the video recording unit 46 which is shown by way of example in FIG. 6 not being used and therefore the housing opening being closed with a plug 50 b,
FIG. 2 shows a view of the slit lamp device which is shown in FIG. 1, a view turned 90° around a vertical axis, in the direction of viewing II there,
FIG. 3 shows an overhead view proceeding from the patient's eye to a holding unit of the slit lamp device which is shown in FIGS. 1 and 2,
FIG. 4 shows a schematic of known Greenough microscopes,
FIG. 5 shows a cross section through the modified Greenough microscope used in the device from FIGS. 1 and 2 as a viewing unit, here in a single figure two different layers of optical components being shown for one different enlargement each,
FIG. 6 shows a cross section along the section line VI through one beam path of the Greenough microscope shown in FIG. 5 for representation of an arrangement of a video recording unit, to the recording element of which the one partial beam of this beam path is guided,
FIGS. 7 a to 7 f show two embodiments of arrangements of optical components and their distances in the two beam paths of the Greenough microscope which is shown in FIGS. 5 and 6, the reference numbers corresponding to those in the Figures, the numerical data are in millimeters. O′ is the object plane without a protective glass 31 , B is the image plane for visual examination and Bv is the image plane of the video recording element 44 ; FIGS. 7 a , 7 c and 7 e shown the location of optical components for one enlargement and FIGS. 7 b , 7 d and 7 f for the others,
FIG. 8 shows one version of the viewing unit shown in FIG. 5,
FIG. 9 shows a cross section along the section line IX in FIG. 8 for representation of the behavior of the partial beam which is decoupled from one of the observation beams and which is guided onto a video recording element of a video recording unit,
FIG. 10 shows a cross section through the video recording unit which is shown in FIG. 9 as a separate component,
FIG. 11 shows a cross section through an illumination unit of the slit lamp microscope which is shown in FIG. 1,
FIG. 12 shows an overhead view of the illumination unit which is shown in FIG. 11,
FIG. 13 shows a side view of the illumination unit with the viewing direction XIII shown in FIGS. 2 and 12,
FIG. 14 shows an overhead view of a guide lever of the slit lamp device in the viewing direction which is shown in FIG. 1, the cover on the upper part of the guide lever being removed,
FIG. 15 shows the slit lamp device which is shown especially in FIG. 1 with a removable lens supporting unit,
FIG. 16 shows the supporting unit which is shown in
FIG. 15 as a separate accessory part in a larger representation,
FIG. 17 shows the supporting unit which is shown in FIG. 16 in the viewing direction XVII there, and
FIG. 18 shows the supporting unit which is shown in FIG. 17 in the viewing direction XVIII there.
DETAILED DESCRIPTION OF THE INVENTION
The slit lamp device which is shown in FIGS. 1 and 2 as a device for stereoscopic examination of an eye 1 has a viewing unit 3 and an illumination unit 5 . The viewing unit 3 is held with a holding unit 23 and the illumination unit 5 is held with a holding unit 7 . As is detailed below, the illumination unit 5 can be used to produce a light beam 9 as radiation which can be guided via a deflection mirror 10 which is located on the holding unit 7 into or onto the eye 1 . The cross section of the light beam 9 can be adjusted according to the details below, especially as a thin streak of light. The holding unit 7 is located on a foot 11 of the device to be able to swivel via a swivel unit with a vertical swivel axis.
The holding unit 7 is made as a L-shaped component which is located with a swivelling capacity on the foot 11 of the device on the end of a horizontally running leg 13 in a swivel joint 15 which can be swivelled around a vertical axis 14 . The location of the axis 14 is chosen such that it runs past the front of the eye for a human forehead which is placed against a (only suggested in the drawings) forehead band 17 of a head holder (not shown). The other leg 20 of the L-shaped holding part 7 runs vertically and, as stated above, is made as a single column. So that between the viewing unit 3 and the eye 1 of the patient there is only slight optical distortion, a single column is used as shown in FIG. 3 . In the area of the eye height of the patient the horizontal cross section of the holding unit 5 is greatly reduced. There is a deflection mirror 10 on this area 18 which reduces the cross section. The cross section is made as narrow as possible. The reduction of the horizontal cross section is limited by mechanical stability constraints and the width of the deflection mirror 10 which is necessary for illumination beam guidance. Furthermore guidance of the elements described below within the leg 20 which is made hollow inside militates against any reduction in the width of the area 18 .
In its cavity a rod-shaped adjustment mechanism (not shown) runs for adjustment of the slit width in the illumination unit 5 which is located on the top end of the leg ( 20 ). The rod-shaped adjustment mechanism (not shown) acts with a cam which is not shown and which lies within the holding unit 7 in its external area of the union between the two legs 13 and 20 . On each of the two ends of the cam there is a adjustment knob 21 a and 21 b . The surface of each adjustment knob 21 a and 21 b can be easily gripped.
The viewing unit 3 is likewise located on an L-shaped holding unit 23 analogously to the illumination unit 5 . This holding unit 23 also has one horizontally and one vertically running leg 24 and 25 . The end of the horizontal leg 24 is swivel mounted around the vertical axis 14 analogously to the holding unit 7 and with the swivel joint 15 which is elongated downward is swivel-mounted on the foot 11 of the device independently relative to the holding unit 7 . On the outside of the leg 25 a breathing protection shield 27 is interchangeably held. On the top end of the leg 25 the viewing unit 3 is located at a height which makes it possible to look into the eye 1 .
The viewing unit 3 is fundamentally made as a Greenough microscope. The fundamental structure of this stereomicroscope is shown in FIG. 4 as a sample figure from Karl Muetze, “ABC of Optics”, key word “Stereomicroscopy”, 1961, Verlag Werner Dausin, Hanau/Main. According to this reference a Greenough microscope is used for direct three-dimensional viewing. It has two separate microscopes which are tilted by an angle of 14 to 16° against one another, this angle corresponding roughly to the angle of convergence of the human eye axes when viewing an article from the distance of the conventional field of vision of 25 cm. A set of Porro prisms P of the first or second type aligns the image so that it is seen in the same location as the object. This is necessary to obtain an orthoscopic (with correct depth) image.
In a Greenough microscope the objectives are very close to one another, by which according to the statements in the aforementioned citation high apertures are not possible. The device as claimed in the invention is different from a typical Greenough microscope, as is shown by the cross section in FIG. 5 . FIG. 5 shows the two individual microscopes 29 a and 29 b which are separated from one another in a cross section tilted towards one another at an angle of 13°. The beam paths of the individual microscopes 29 a and 29 b are labelled 30 a and 30 b . In the top part of the figure the location of the optical components is shown for one enlargement scale and in the lower half of the figure for another. The enlargement scales are switched with the switch lever 59 which can be seen in FIG. 2 .
At the observation beam inlet into the Greenough microscope 3 there is a single protective glass 31 for the two beam paths 30 a and 30 b in front of the two objectives 33 a for the one enlargement scale and in front of the two objectives 33 b for the other enlargement scale. In the “upper” beam path 30 a a plane-parallel plate 35 for optical matching to the splitter prism 37 which is downstream of the objective 33 a in the “lower” beam path 30 b follows the objective 33 a . The “upper” and the “lower” beam path are the left and right beam path as shown in FIG. 2 . The plane-parallel plate 35 is followed by a Porro prism 36 which is upstream of an eyepiece 39 , especially an interchangeable eyepiece. Both components are shown only in the “lower” beam path.
In the beam path 30 b there is image decoupling for a video recording unit 46 . This is done with a splitter prism 37 which divides the beam path 30 b into one component beam 42 a via the Porro prism 40 to the eyepiece 39 and into another component beam 42 b via a deflection prism 41 and a video objective 43 to a recording element 44 of the video recording unit 46 . The video recording unit 46 consists of a splitter prism 37 , the deflection prism 41 , the video objective 43 and the video recording element 44 . The video recording element 44 is held in a mount 48 a which plugs in an adjustment sleeve 48 b . The mount 48 a is held with a clamp screw 48 c in the adjustment sleeve 48 b . The adjustment sleeve 48 b sits in a housing hole 50 a with the capacity to turn and to be displaced and can be fixed with clamp screws 48 d which fit in a peripheral groove on the outside jacket of the calibration sleeve 48 b . The optical image can be adjusted by moving the mount 48 a and the calibration sleeve 48 b . So that no dirt can penetrate through the housing hole 60 a , this is closed by a removable plug 50 b . The video recording unit 48 can be interchanged as a whole. Likewise the video recording element is interchangeable.
In addition to visual examination, video photographs can thus also be taken for direct observation or for recording (documentation). The arrangement of the recording unit 44 is shown in FIG. 6 .
FIGS. 7 a and 7 f show two optical versions for different enlargement scales. FIGS. 7 a , 7 c and 7 e show a version with one objective 33 a and 33 b each with 1.6× enlargement and in the video beam path with one objective 43 with likewise 1.6× enlargement.
In the other version which is shown in FIGS. 7 b , 7 d and 7 f , the components which are different from those in FIGS. 7 a , 7 c and 7 e are labelled with an apostrophe '. In this version one objective 33 a′ and 33 b′ each with 1:1 imaging and in the video beam path with one objective 43 ′ with the same enlargement are used. Other versions are of course possible.
The illumination unit 5 has two levers 45 a and 45 b which can be swivelled around a horizontal axis and which are arranged on top of one another. With these levers 45 a and 45 b the height and the width of a diaphragm opening can be adjusted. The cross section of this diaphragm opening defines the cross section of the thin streak 9 of light which is to be aimed at the eye 1 . With these two levers, additionally a blue or gray filter can be swivelled into the illumination beam path 9 and out again. The swivelling in and out takes place in the end region of the swivelling process of the pertinent lever 45 a and 45 b.
Likewise a yellow filter 58 can be placed in the beam paths 30 a , 30 a′ , 30 b , and 30 b′ with an adjustment device on the viewing unit 3 . The yellow filter 58 here consists of two partial vapor depositions on the inside of the protective glass 31 . With the adjustment device 47 the protective glass 31 can be turned so that the two partial vapor depositions 58 lie on the one hand in front of the objective 33 a and 33 b (in the beam paths 30 a and 30 b as is suggested in FIGS. 3 and 5) and on the other next to them (not in the beam path 30 a and 30 b ).
If fluorescein is applied to the surface of the eye for example when a contact lens (not shown) is inserted, and is illuminated with blue light (blue filter folded down), yellow fluorescence occurs which can be easily observed with a Greenough microscope 3 when there is a yellow filter in the observation beam path (check of fit of contact lenses).
On the viewing unit 3 there is a switching lever 59 . With this switching lever 59 , depending on the desired enlargement, the objectives 33 a and 33 b and 33 a′ and 33 b′ , as are shown in FIGS. 7 a , 7 c , and 7 c , can be alternately swivelled in the beam paths and then in the other lever position those of FIGS. 7 b , 7 d and 7 f can be swivelled. FIGS. 7 e and 7 f shown the beam behavior in a position swivelled relative to FIGS. 7 a to 7 d by 90°. On the foot 11 of the device there is furthermore a power connection 61 for the light source in the illumination unit 5 and for the recording unit 44 .
To observe the entire visual field, underneath the deflection mirror 10 which is arranged at 45° there is a cold light guide which is not shown. Furthermore a tonometer for measuring the eye pressure can be placed in an adapter 63 on the housing of the Greenough microscope. The brightness of the “slit lamp” in the illumination unit 5 is adjusted by a manual controller 49 which is located on the foot 11 of the device. The electrical cable for brightness control or power supply runs within the hollow holding unit 7 . The positioning of the device horizontally in the X direction and the Y direction is done using a guide lever 51 which is located on the foot 51 of the device, often also called a “joystick”. By lateral deflection 53 the foot 11 of the device can be moved laterally on an axis 52 in the Y direction 54 . Movement in the X-direction 56 is also possible by swivelling 55 of the guide lever 56 forward and backward. The movement in the X-direction takes place via rotary motion of the wheels 57 a and 57 b which are located on either side on the axis 52 and which roll off on rails which are not shown and which are attached to a base which is not shown. On this base there is also a head holder which is not shown and which has a forehead band 17 .
The guide lever 51 can furthermore be turned around its vertical axis. In order to achieve a good turning capacity, the coupling lever 51 is provided in its top jacket area with peripheral ribbing. The turning causes synchronous vertical adjustment of the holding units 7 and 23 and thus a vertical adjustment of the thin streak 9 of light which is to be directed into the eye 1 together with the viewing unit 5 .
Since the leg 20 of the holding unit 7 can be made very slender, for reasons of manufacture the laying the power cable in it can be abandoned. The power supply in this case passes to the power connection 61 , from the latter to the manual controller 49 and from it back again to the power connection 61 and from it then via an external (cable which is not shown) via the (head support which likewise is not shown) into the illumination unit 5 .
Instead of decoupling for the recording unit 44 , as described above, with partially transparent components for example via the splitter prism 37 , only a fraction of the beam cross section can also be decoupled using a decoupling mirror or a decoupling prism, as is shown for example in FIGS. 8 to 10 . FIG. 8 shows one version 65 of the viewing unit 3 (Greenough microscope) which is shown in FIG. 5 . The input objectives 67 a and 67 b of the individual microscopes 69 a and 69 b and their location are made analogously to the objectives 33 and 33 b′ in FIG. 5 . Since decoupling of a component beam 71 a takes place to a video recording element 70 which is made analogously to the video recording element 44 (visible in FIGS. 9 and 10) by decoupling a fraction of the incident beam 73 a (analogously to beam 30 b ), optical compensation by a plane-parallel plate analogous to plate 35 is not necessary. In this way the structure of the viewing unit 65 is greatly simplified compared to the viewing unit 3 .
To decouple a component beam 71 a a prism 75 is used which partially projects into the cross section of the beam 73 a . The decoupled component beam 71 a is deflected one more time with a second prism 76 and is imaged with imaging optics (video objective) 77 on the receiving plane of the video recording element 70 . The video recording unit 79 here consists of a prism 75 which geometrically decouples a component beam, a prism 76 , imaging optics 77 and the video recording element 70 .
The video recording unit 79 (camera) which is shown in FIGS. 9 and 10 can likewise be replaced as a whole, but also only the video recording element 70 alone can be replaced. The prisms 75 and 76 , the imaging optics 77 and the video recording element 70 are located and held in a housing 81 which with optically fitting can be pushed into the housing opening 82 of the viewing unit 65 such that the prism 75 comes to rest correctly in the beam 73 a for decoupling of the component beam 71 a. Also here are there shifting and turning of the video recording element 70 to adjust the image. The housing 81 (FIG. 9) analogously to FIG. 6 likewise has a mount for the video recording element 70 and an adjustment sleeve. Fixing takes place here as well with the clamp screws 83 a and 83 b . By means of the interchangeability of the video recording unit 79 the viewing unit 65 with this video recording unit 79 can be easily refitted among others in terms of salesmanship. Furthermore, after removing the video recording unit 79 the image contrast in both observation beam paths 73 a and 73 b is the same. The viewing unit 65 can be produced more easily and thus also more cost favorably compared to the viewing unit 3 .
The arrangement of a light source 86 which is inserted into the illumination unit 5 is shown in FIG. 11 in an enlarged cross section. As the light source 86 a so-called high temperature quartz lamp can be used which is held interchangeably in a fitted base 87 . The base 87 sits with a clearance fit in a sleeve 89 . The base 87 has contact pins 90 which fit into matching sleeves of a plug piece 91 which can be removed from the base 87 . From the plug piece 91 a cable 93 passes to an electrical connection piece 94 . The base 87 is kept from sliding out with an elastic clip 95 of spring wire which lies in a groove 97 of the base 87 . The clip 95 is wound roughly in a circular cylinder on its one side, with for example five turns here, forming a “tube piece” 99 . The “tube piece” 99 slips onto a pin 100 with a top end which bears a clamp disk (Seeger circlip ring 101 ) which prevents the “tube piece” 99 and thus the clip 95 from sliding out.
The other end of the clip has a pull loop 103 which can be inserted into a peripheral groove 105 in the top of a pin 106 . The clip 95 is elastically pre-bent such that it presses the base 87 into the sleeve 89 and itself presses against the groove 105 . To replace the light source 86 the plug piece 91 must be withdrawn and then the pull loop 103 must be raised only over the upper end of the pin 106 . The light source 86 can now be withdrawn with the base 87 . So that the base 87 can be easily grasped, it projects somewhat over the outer edge of the sleeve 89 .
The advantage of the arrangement for holding the light source is its simple configuration. Furthermore, a tool is not required for changing the light source.
In the top part 109 of the guide lever 51 , as indicated in FIG. 14, there are switching elements 110 b and 110 b for control of the functions of the device or of the functions which control peripheral units which are connected with the viewing device. In the embodiment shown here in the upper part 109 as the switching elements there are two microswitches 110 a and 110 b (toggle switches, . . . ) next to one another as signal-delivering elements. The two microswitches 110 a and 110 b can preferably be operated from the top 111 of the top part 109 preferably with the thumbs. If the device is to be used in a rough environment, the top 111 is covered to be splashproof by an elastic film.
Instead of microswitches, pushbuttons or momentary-contact tumbler switches can also be used. If for example the top part of the switch 110 a which is made as a momentary-contact tumbler switch is pressed, for example via a motor drive which is not shown, the light slit width of the light source can be reduced. If then the lower part of the switch 110 a is pressed, the slit would be enlarged. This function would eliminate manual operation of the adjustment knobs 21 a/b by another hand. Via the switch 110 b brightness could be controlled in a similar manner; this would result in elimination of adjustment via the manual controller 49 . The treating physician can then continually view without having to glance at these adjustment elements. Also here the physician has the hand required previously for adjustment free for treatment manipulations.
With these two switches/momentary-contact tumbler switches 110 a/b other units can be adjusted. Electrical and signal-engineering connection could take place via the terminal 61 or via a separate terminal which is not shown. For example a tonometer could be moved against the surface of the eye.
By actuating the two switches/momentary-contact tumbler switches 110 a/b adjustments can be made using motorized drives. So that at this point the physician knows in which position the pertinent unit or the slit width or the brightness is found, reflecting the data into the beam path of the viewing unit 3 or 65 can be done. The reflection-in would take place now analogously to beam reflection out for the video recording element 44 or 70 . Instead of the video recording element 44 or 70 there would be only one display element with video information which is being reflected in. Then the prism 37 and 75 can be turned 180° relative to the representations in FIGS. 5 and 8 for reflection-in.
If the slit lamp device is also to be used for preferred examination of the vitreous body and the ocular fundus of the patient, the device with a lens supporting unit 203 which can attached and removed again without using tools manually via a coupling 201 is placed with an examination lens 204 in front of the inlet of the observation beam in the viewing unit 3 in the observation beam path, therefore in front of the protective glass 30 . The examination lens 204 is held self-locking with a turning capacity and self-locking in all three-dimensional directions with an adjustment capacity with the lens supporting unit 203 . The lens supporting unit 203 , in contrast to the known Hruby adapter glass which can be used together with a slit lamp, has no mechanical connection to the head holder and chin holder of the patient.
The lens supporting unit 203 has a plate-shaped support part 205 from which a cylindrical stud 207 projects. The cross section of the stud 207 is chosen such that it can be inserted with a clearance fit into an axial hole 209 which is shown in FIG. 1 . The axial hole 209 is formed centrally to the vertical axis of the swivel joint 15 . With the swivel joint 15 the holding part 7 for the illumination unit 5 and the holder 23 for the viewing unit 3 can be swivelled. The pin 207 and the axial hole 209 for a plug coupling 201 . Locking of the lens supporting unit 203 is achieved by the plate edge of the support part 206 being provided with a notch 210 . In the inserted state the projecting part of a sheet strip 211 which is located on the front of the horizontal leg 13 of the holding unit 7 fits into this notch 210 . The support part 205 in an extension upward has a roughly cuboidal base part 213 ; on its horizontal top a first carriage 214 is positioned to be movable in the lengthwise direction of the cuboid (in the installed state in the direction towards the patient's eye 1 and away from it). The carriage 214 is guided on the base part 213 for example in a dovetail guide which can be fixed with a clamp screw 215 which is provided with knurling for better grip. When the clamp screw 215 is loosened, movement by hand is possible. With this guide coarse adjustment of the distance of the lens 204 from the patient's eye 1 can be done. On the first carriage 214 there sits a second carriage 217 which can be moved in the same direction as the first carriage 214 . The movement takes place however via a likewise knurled fine adjustment screw 219 . Horizontally, perpendicularly to the first and the second carriage 214 and 217 there is a third carriage 220 which can be moved likewise via a fine adjustment screw 221 by turning it. With the two fine adjustment screws 219 and 221 fine adjustment of the examination lens 204 in the horizontal plane takes place.
For vertical height adjustment there is a two-part lens post 223 which on its top end bears the examination lens 204 . The lower part 225 sits on the third carriage 220 and tapers prismatically upward. From the top end of the part 225 a blind hole 226 runs centrally into the part 225 in the axis of symmetry. In this blind hole 226 a mandrel 227 sticks which passes into the upper component piece 229 of the lens post 223 . Proceeding from the mandrel projection, the component piece 229 widens prismatically upward. The mandrel 227 can be moved in the blind hole 226 . The vertical height of the examination lens 204 is set manually by this motion. This height adjustment is self-locking based on a frictional force-fit. The self-locking is achieved by a permanent magnet which is captively located in the lower part 225 and which however can move in the direction to the surface of the mandrel 227 . Since the mandrel 227 consists of ferromagnetic material, the permanent magnet in the mandrel 227 which has been inserted into the blind hole 226 is pulled against its surface and thus locks the vertical displacement by self-locking. But locking is only so strong that movement as a result of the inherent weight of the examination lens 204 plus its top component piece 229 is suppressed. But adjustment is possible manually. The location of the permanent magnet is apparent in FIGS. 16 to 18 by a disk-shaped mounting aid 231 .
The examination lens 204 lies in a V-shaped recess 232 on the top end of the component piece 229 on its mount jacket 233 . The examination lens 204 is held with a band-like flexible lens holding element 235 which has a chain-like structure. One end of the element 235 is held with a spring 236 roughly in the center on the end of the lateral lengthwise groove 237 of the component piece 229 . The element 235 as a chain-like structure has nubs 239 which are equally spaced in the lengthwise direction and which are separated by intermediate spaces 240 with a thinner band cross-section. One of these intermediate spaces 240 is hooked between two projections 241 a and 241 b in a lateral lengthwise groove 243 on the side opposite the lateral lengthwise groove 237 . The spring 236 tensions the lens holding element 235 and thus pulls the examination lens 204 into the recess 232 and fixes it. The lens holding element 235 can have a different structure, for example it can be made as a chain, compared to the nubs 239 and the narrow intermediate spaces 240 . When using a chain likewise the two projections 241 a and 241 b could be present; then the chain would be suspended on its outer regions; but also there could be only a single projection into which one chain link at a time is suspended.
As detailed above, the lens supporting unit 203 is locked with the notch 210 and a sheet strip 211 which fits it on the holding unit 7 . But equally well there could be other catch elements such as a pin which is arranged radially to the stud 207 and which fits into a corresponding hole in the holding unit 7 . The locations of the pin and hole can of course be interchanged. Also textured surfaces can be used with structures which fit into one another.
In order to eliminate disruptive reflections in the examination and to deflect the path of the observation beam, the top part 229 of the lens post can be equipped with a tilting means for the examination lens 204 . The tilting means can be a simple swivel axis. But preferably however three swivel joints spaced apart from one another can be used with swivel axes which run parallel to one another, i.e., there is a angle leg with an adjustable apex angle, and the other leg ends can in turn be swivelled with a swivel joint. On the topmost leg end the examination lens 204 is held with a swivelling capacity. With this arrangement tilting of the lens is possible with preservation of the center of the lens at a stipulated point in space.
By using the lens supporting unit 203 the physician can adjust the examination lens 204 optimally to the patient's eye 1 via its precision three-dimensional adjustment. After adjustment he has both hands free for the examination and treatment to be performed. He can also, especially using the video recording unit 46 and 70 , undertake the corresponding documentation. Instead of the video recording unit a camera can also be flanged in order to undertake the corresponding documentation. Since the examination lens remains adjusted in its position by self-locking, at total rest the recording can be done with the choice of the image extract and sharpness adjustments.
Only the embodiment of the invention having the vertically running branch 20 of the holding unit 7 in a single column with the narrow column cross section allows optimum examination of the vitreous body and the ocular fundus using the examination lens 204 which is supported by the lens supporting unit 203 . The lens supporting unit 203 can be used with the initially described, already known slit lamp device which has a three-column holding unit. Also, use together with other slit lamp devices is possible if a corresponding coupling is present. | The present invention relates to a system for the stereoscopic examination of a patient's eye using a slit-lamp microscope ( 3 ), wherein the patient's eye ( 1 ) is illuminated by a light strip of a predetermined cross section which is emitted by a light source ( 5 ). The light source ( 5 ) is arranged on the vertical arm ( 20 ) of a support ( 7 ) and the eye ( 1 ) to be examined is placed in an essentially horizontal plane on one side of said support. The stereo-microscope ( 3 ) is essentially placed on a plane which is located on the side opposite to the first side of the support ( 7 ). The vertical arm ( 20 ) of the support ( 7 ) is made in the shape of a column having a narrow cross section so as to minimize the optical obstruction between the stereo-microscope ( 3 ) and the patient's eye. Using at least one beam ( 30 b ) from the stereo-microscope ( 3 ), a partial ray is stopped down and the image information of said ray is directed to a reception unit ( 44 ) located in said stereo-microscope ( 3 ). | 0 |
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/312,490, filed Mar. 24, 2016, which is herein incorporated by reference in its entirety for all purposes.
FIELD OF THE INVENTION
[0002] The invention relates to power tool safety, and more particularly, to apparatus configured to enhance the safety of a user of power tools and to monitor the user's level of training.
BACKGROUND OF THE INVENTION
[0003] As portable and stationary power tools have become ubiquitous in manufacturing, construction and maintenance, so also have hand injuries that result from the use of power tools. Cut and puncture protective gloves, sleeves and aprons can be very effective against injuries arising from use of hand tools. However, the impact energies and strike rates of power tools are generally too high for personal protective equipment (“PPE”) to be fully effective. Furthermore, in many cases, for example with rotary cutters and similar equipment, wearing of gloves and/or other PPE is not recommended, because some agencies feel that resulting snag and wind-up risks can make injuries more severe if such PPE becomes entangled in the rotary head.
[0004] One approach to reducing power tool injuries is to modify the power tools themselves in ways that reduce their risk. However, some users feel that such modifications can tend to interfere with tool operation. In addition, such safety modifications can be expensive. In particular, it can be prohibitively expensive for a machine shop or factory to replace an existing inventory of existing power tools with new power tools that include active sensors and other safety modifications and devices.
[0005] There is also a lack of standards for such safety devices and modifications, making it extremely unlikely that safety modifications would be consistent across an inventory of power tools purchased from multiple suppliers. As a result, such safety modifications and devices, if implemented on a full inventory of power tools, can impose a significant additional training burden on a machine shop or factory, in that users of the power tools must be trained in the operation of the safety features of each power tool, as well as in use of the tool itself.
[0006] What is needed, therefore, is an apparatus for protecting the hands of a power tool operator without imposing an undue cost and training burden on the owner of the power tool.
SUMMARY OF THE INVENTION
[0007] The present invention is an apparatus for protecting the hands of a power tool operator without imposing an undue cost and training burden on the owner of the power tool. The invention takes advantage of the fact that the key issue in protecting users from power equipment is training. When users are fully trained, they consistently keep their hands out of danger zones when using power tools. Conversely, the risk of injury is always greatest when new operators are being trained.
[0008] Accordingly, the present invention is an apparatus and method that protects the hands of a power tool operator while assisting in the operator's training. Embodiments of the disclosed apparatus can be adapted to existing power tools, further reducing the cost and providing for uniformity of the safety features across a full range of different power tools supplied by different manufacturers.
[0009] Specifically, the disclosed apparatus includes a garment with one or more integrated sensors, at least one target that is attached or attachable to a power tool and is detectable by the sensor, and a controller that monitors proximity of the sensor to the target and initiates a protective response when the sensor proximity is determined to be closer than a specified threshold distance. In various embodiments, the protective response can include one or more of an auditory, visual, and/or tactile alert (such as a vibrating device located near the sensor). In embodiments, the protective response includes cutting power to the power tool.
[0010] In embodiments, the garment further includes sensors that monitor directional and angular positional features of the user's body, accelerating movements of the user's body, and/or vibrations to which the user's body is subjected. Embodiments record and save measurements of position, movement, acceleration, linear and angular position, and vibration for later analysis, evaluation, certification, and training.
[0011] In embodiments, the disclosed garment is a glove that includes a set of sensors distributed over the hand(s) and fingers for measurement of tool proximity, finger and wrist joint angle, and hand and finger movement and acceleration. The disclosed glove system enables measurement of hand and finger proximity to blades and/or other dangerous elements of power tools.
[0012] In various embodiments, the garment is fashioned from a “smart textile,” wherein the sensor or sensors are attached to the fabric or embedded within the fabric, and the interconnections between the sensor or sensors and the controller are provided by conductors that are integral with the fabric.
[0013] Embodiments of the invention enable the predefinition of danger and/or warning zones surrounding dangerous elements of a power tool. In some of these embodiments, the warning and danger zones are delimited by placement of targets at selected locations surrounding the dangerous elements. In various embodiments, a plurality of different types of target are provided, so as to enhance the ability of the sensor(s) to determine positional information relative to the power tool and defined zones. Some embodiments further enable specification of appropriate protective responses depending on the nature of an alert. For example, in embodiments a perceptible warning such as an audible alarm is initiated when a glove sensor enters a defined warning zone, while the power to the tool is cut off if the sensor enters a defined danger zone.
[0014] In some embodiments, the controller is attached to or integral with the glove or other garment. In other embodiments, the controller is a separate unit. Communication between the sensor(s), controller, alert-generating devices, data logging units, and/or the power supply of the power tool can be by any combination of wired and wireless means known in the art, including Bluetooth and USB connections.
[0015] It will be understood by one of skill in the art that while much of the present disclosure is described with reference to a glove, the disclosure applies equally to other parts of a user's body, such as a foot, elbow, or knee, that interact with or otherwise are subject to coming into contact with dangerous aspects of a power tool. In such cases a shoe, elbow pad, knee pad, etc. is substituted in place of the glove described herein.
[0016] A first general aspect of the present invention is an apparatus for enhancing safety of a power equipment user. The apparatus includes a garment, at least one proximity measurement sensor cooperative with the garment, a control system in communication with the proximity measurement sensor, and a responding system cooperative with the control system and configured to provide a protective response when specified conditions are detected by the control system based on measurements made by the at least one proximity measurement sensor.
[0017] In embodiments, the protective response includes a warning signal that is perceptible to the power equipment user.
[0018] In some of these embodiments, the perceptible warning signal includes at least one of a visible warning signal, an audible warning signal, and a vibrational warning signal.
[0019] In any of the above embodiments, the protective response can include terminating delivery of power to the power equipment.
[0020] Any of the above embodiments can further include a logging system configured to log data obtained by the apparatus.
[0021] In any of the above embodiments, the garment can include a piezo thin film laminate sensor and/or a piezo fiber strain sensor.
[0022] In any of the above embodiments, the garment can be a glove, and the at least one proximity measurement sensor can include a sensor that is cooperative with a fingertip of the user. Some of these embodiments include sensors that are cooperative with an index finger of the user, a smallest figure of the user, and a thumb of the user.
[0023] In any of the above embodiments, the at least one proximity measurement sensor can be configured to sense at least one of a magnetic field and an eddy current.
[0024] In any of the above embodiments, the at least one proximity measurement sensor can be at least one of capacitive and inductive.
[0025] In any of the above embodiments, the at least one proximity measurement sensor can be a range finding sensor.
[0026] In any of the above embodiments, the at least one proximity measurement sensor can be configured to measure an electromagnetic spectrum.
[0027] Any of the above embodiments can further include a target that is cooperative with the power equipment and can be sensed by the at least one proximity measurement sensor. Some of these embodiments include a plurality of targets that can be selected so as to define at least one of a warning region and a danger region associated with the power equipment. In any of these embodiments, the target or targets can be configured for retrofit attachment to the power equipment.
[0028] Any of the above embodiments can further include a status sensor that is configured to measure at least one of position, angular joint configuration, acceleration, and vibration.
[0029] And in any of the above embodiments, the control system can be physically cooperative with the garment.
[0030] A second general aspect of the present invention is a garment that includes a sensor and a logging system that is in data communication with the sensor, the sensor and data system being configured to record data pertaining to at least one of proximity of said garment to a designated location, a skin temperature of a user, a finger angle of the user, and a wrist joint angle of the user.
[0031] In any of the above embodiments, the logging system can be configured to execute an algorithm that permits subsequent display of the recorded data. And in some of these embodiments, the algorithm permits subsequent display of the recorded data as a function of time.
[0032] A third general aspect of the present invention is a garment configured for wearing by a user, the garment comprising a sensing system and a responding system, the responding system being configured to provide at least one of an optical signal to the user, a vibrational signal to the user, an acoustic signal to the user, and an electrical signal to the equipment.
[0033] A fourth general aspect of the present invention is a sensing system and a garment controller in communication with an external power equipment control system, said garment controller being configured to deactivate said power equipment according to measurements made by the sensing system.
[0034] In embodiments, the garment controller is in wireless communication with the external control system. In some of these embodiments, the wireless communication is Bluetooth communication.
[0035] In any of the above embodiments, the garment controller can be in wired communication with the external control system.
[0036] And in any of the above embodiments, the garment can be controlled by a control panel that is attached to the garment.
[0037] The features and advantages described herein are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and not to limit the scope of the inventive subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a block diagram illustrating an embodiment of the present invention;
[0039] FIG. 2A illustrates the definition of a hand axis included in a coordinate system that is used to describe embodiments of the present invention;
[0040] FIG. 2B illustrates the definition of a tool axis included in a coordinate system that is used to describe embodiments of the present invention;
[0041] FIG. 2C illustrates the definition of an angle between the hand axis and the tool axis in a coordinate system that is used to describe embodiments of the present invention;
[0042] FIG. 3A illustrates the most likely work-piece hand alignment relative to power equipment of a right hand dominant user;
[0043] FIG. 3B illustrates the least likely work-piece hand alignment relative to power equipment of a right hand dominant user;
[0044] FIG. 3C illustrates the most likely work-piece hand alignment relative to power equipment of a left hand dominant user;
[0045] FIG. 4A is a side view of the most likely work-piece hand position when in an overhand grip on the work-piece;
[0046] FIG. 4B is an end view of the position of FIG. 4A ;
[0047] FIG. 4C is a side view of the second most likely work-piece hand position when in an underhand grip on the work-piece;
[0048] FIG. 4D is an end view of the position of FIG. 4C ;
[0049] FIG. 5A illustrates the most likely work-piece hand alignment to a stationary power tool;
[0050] FIG. 5B illustrates the second most likely work-piece hand alignment to a stationary power tool; and
[0051] FIG. 6 illustrates interaction between sensors in fingertips of a glove and proximity targets located on power equipment.
DETAILED DESCRIPTION
Proximity Sensing Mode
[0052] As noted above, the present invention is an apparatus for protecting the hands (or other body parts) of a power tool operator. Embodiments reduce the cost to a machine shop or other multi-tool facility by taking advantage of the fact that the key issue in protecting users from power equipment is training.
[0000] Accordingly, embodiments of the disclosed apparatus provide features that directly assist with training, evaluating, and certifying new users of power tools, such that extraordinary safety devices and modifications need not be implemented on power tools that are only used by experienced operators.
[0053] Furthermore, embodiments of the present invention can be adapted to existing power tools, further reducing the cost and providing for uniformity of the safety features across a full range of different power tools supplied by different manufacturers. Some of these embodiments require only that passive modifications be applied to existing power tools. Such modifications can be simple for users to make and enable the retrofitting of power tools that have already been purchased. In embodiments, these passive modifications include the mounting by users on the power equipment of magnetic, optical, and/or capacitive targets that can be selected from a set of targets supplied with the disclosed system. The mounting can be adhesive or via any attachment means known in the art.
[0054] With reference to FIG. 1 , in embodiments the disclosed apparatus of the present invention includes a wearable glove 100 or other garment that includes at least one sensor 112 and a controller 114 . In the embodiments of FIG. 1 , the controller 114 is attached to the glove 100 , while in similar embodiments the controller is separate from the garment 100 and in wired or wireless communication therewith.
[0055] In embodiments, the controller 114 includes the following five functional elements:
1) a sensor interface unit 102 ; 2) a value limit comparison unit and data logger 104 ; 3) a user alarm module 106 ; 4) a external communication unit 108 ; and 5) a wireless data link 110 .
[0061] In some embodiments, all of these functional elements are provided by a single microprocessor-based machine controller 114 . In various embodiments, the sensor interface unit 102 is designed to interface with redundant sensors that reduce the potential for a false negative result. In these embodiments, the risk of a false positive is very low, because the only action taken by the system in the case of a false alert is to issue a perceptible warning and/or shut down the power equipment. This is in contrast to some integrated safety systems of the prior art that use a high speed actuator to stop a blade or tool cutter, such that a false safety alert can damage the equipment such that it must be repaired, and a new cutter must be mounted, before the equipment can be used again. Accordingly, because the penalty incurred as a result of a false safety alert is only a small loss in productivity, embodiments of the present invention bias sensor and value limit comparison thresholds to be conservative, thereby limiting risk to the operator.
Work Piece Hand Axis and Tool and Workpiece Axis of Travel
[0062] With reference to FIGS. 2A through 2C , a coordinate system for the description of the axis of a hand 200 and a sensor axis 202 are defined. This reference frame is used herein to describe the geometry of embodiments of glove sensors 112 , including their sensitivity and the corresponding target sensitivity. As shown in FIG. 2C , the angle 204 referred to in the following description is taken from the small finger side of the glove 100 to the tool or work piece axis.
Proximity Sensor Alignment to Tool or Workpiece Travel direction
[0063] As can be seen from FIGS. 3A and 3C , the most likely alignment of hand 100 closest to a work-piece 300 is approximately perpendicular to the direction of travel 302 of the power tool 302 . With reference to FIG. 3B , as the alignment of the work-piece hand 100 goes beyond 90 degrees to the direction of travel 300 , this results in upper arm and shoulder strain for the operator, so this configuration is not very likely. In embodiments, the sensitivity direction of the proximity sensors 112 is aligned approximately 80 degrees from perpendicular to the hand axis 200 . This configuration maximizes the signal in the most likely work-piece hand alignments relative to the direction of tool travel 300 .
Thumb and Small Finger Sensing Configurations
[0064] With reference to FIG. 4A , in many cases when an accident does occur, the most likely affected parts of the hand 100 are the thumb 400 and index finger 402 . Accordingly, in the embodiment of FIG. 4A , sensors 112 are included only in these two locations. With reference to FIG. 4B , the small finger 404 is at risk only in the less likely, underhand work holding position. Accordingly, in the embodiment of FIG. 4B , the sensors 112 are distributed only in the thumb, index, and small finger regions to protection the work-piece hand in the underhand work holding position.
Stationary Power Tool Proximity Configurations
[0065] With reference to FIGS. 5A and 5B , in some embodiments the sensitivity directions of the sensors 112 in the gloves 100 are configured to include 45 degree alignment 204 between the hand axis 200 and the direction of travel 302 .
Proximity Sensors
[0066] With reference to FIG. 6 , in certain embodiments the system of the present invention makes use of magneto-inductive sensors (MIS) 112 and interchangeable, permanent magnet targets 600 . Some of these embodiments provide target magnets 600 that are interchangeable on the power equipment. In embodiments, a magnet set is selected from among a group of magnet sets according to the size and configuration of the power tool, the level of experience of the user, and other factors, wherein each magnet set provides a different combination of magnet strengths. This allows the strengths of the magnetic fields, and hence the sensing distance from the glove sensor 112 to the equipment 600 , to be changed simply by changing to a different set of magnets.
[0067] This approach makes it easy to adjust warning 602 and danger 604 standoff distances simple by exchanging the magnetic targets 600 . Accordingly, in these embodiments there is often no need to adjust the sensing limits in the value limit comparison unit 104 . Instead, the user makes these changes simply by exchanging the magnetic targets 600 .
Safety Control Mode
[0068] For some institutions and companies the desired mode for safety is to require the use of safety gloves 100 during operation of power equipment. To support this operating mode, embodiments of the present invention include lockable plugin bases for all the controlled equipment. The lockable plugin bases are configured such that when they are present, the power to the equipment is not enabled unless the safety gloves 100 are worn. In certain of these embodiments, the proximity sensing is in place and continues to shut off power when the hands are found to be in the danger zone 604 .
Vibration Measurement
[0069] Embodiments of the present invention combine measurement of power tool proximity with sensing of induced vibration in the hands from the power tool. Hand Arm Vibration Syndrome, or “HAVS,” is considered to be an occupational injury, and so it can be desirable to accumulate data that documents the actual vibration exposure and durations experienced by a power tool user. Accordingly, embodiments of the present invention are able to alert the user when preset vibration limits are exceeded.
[0070] Both the warning to the user and the accumulated vibration data can be useful in modifying behavior to help configure the work environment to produce safer, lower vibration impact to the user's hands. The starting point for these limit values is the British HSE values of 2.5 m/sec 2 warning limit and 5 m/sec 2 damage limit. The data logging function in some of these embodiments is also useful in allowing the employer to audit and document the vibration impact from a task. In some embodiments, the measurements made by the system are modeled after
[0000] ANSI 2.70 and ISO53491 2001, which can be found at https://www.aiha.org/LocalSections/html/florida/AIHA%20FL%200509%20rev1C .pdf, incorporated herein by reference for all purposes.
Repetitive Motion and Forces and Impact Measurement
[0071] Embodiments include motion and acceleration sensors that can be used to monitor and warn against injury due to repetitive motions, forces, and impacts. The measured data can be compared with established criteria, such as the US CDC criteria that can be found at
[0000] http://www.cdc.gov/niosh/docs/97141/pdfs/97141e.pdf, which is incorporated herein by reference for all purposes.
Training Mode
[0072] With reference again to FIG. 1 , in embodiments of the present invention, in addition to providing warnings to the user and power interruptions in response to proximity of the sensors to the danger zone 604 of the equipment, the on-garment controller 114 also logs data over a session, and this data is provided to an external display and analysis system such as a smart phone 116 or computer. In various embodiments, the analysis system 116 includes a data base structure 118 that logs user names, start and end times for a session, as well as the type of task, work cell, and or equipment types the user was operating during the data collection session. This data can then be used by employers and/or school personnel to evaluate the level of proficiency of the user. In embodiments, the data includes the number of events where the user's hands were in the warning area 602 , and the number of events when the user's hands were in the danger zone 604 , causing the equipment power to be cut.
[0073] Embodiments include a vibration mode, in which the magnitudes and durations of exposure of the user's hands to vibrations are recorded.
[0074] Various embodiments include a joint angle and impact mode, in which flex events are logged and the number of over-flex events and hyper-flex events are logged.
[0075] Certain embodiments include a productivity mode, in which the flex and vibration patterns are logged, so that by using pattern learning or other forms of pattern recognition the total number of relevant events can be determined. Deviation from the ideal task flex and vibration patterns can be assessed, and data-driven training can be used to help operators improve safety and performance.
[0076] Various embodiments include an analysis function that permits a school or employer to set criteria for maximum numbers and types of incursions into warning zones 602 and danger zones 604 that are allowed for safe qualification of an operator on a task that requires use of a piece of equipment or work cell. In such instances, the operating data provided by embodiments of the present invention can be very useful for schools and/or employers who need evidence that training has been effective.
[0077] The use of the training mode in embodiments integrates very well with behavioral safety programs. For example, when new operators have used the data logging system 118 over enough sessions to demonstrate that they have internalized the safe working positions for their hands, the operator can be qualified on the task. After that, the training mode need only be used again for periodic audits of operator behavior.
[0078] The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. Each and every page of this submission, and all contents thereon, however characterized, identified, or numbered, is considered a substantive part of this application for all purposes, irrespective of form or placement within the application.
[0079] This specification is not intended to be exhaustive. Although the present application is shown in a limited number of forms, the scope of the invention is not limited to just these forms, but is amenable to various changes and modifications without departing from the spirit thereof. One or ordinary skill in the art should appreciate after learning the teachings related to the claimed subject matter contained in the foregoing description that many modifications and variations are possible in light of this disclosure. Accordingly, the claimed subject matter includes any combination of the above-described elements in all possible variations thereof, unless otherwise indicated herein or otherwise clearly contradicted by context. In particular, the limitations presented in dependent claims below can be combined with their corresponding independent claims in any number and in any order without departing from the scope of this disclosure, unless the dependent claims are logically incompatible with each other. | An apparatus for protecting a power tool user includes a glove or other garment having at least one sensor that monitors proximity to the power tool. Glove embodiments can include finger and/or thumb proximity sensors, and/or sensors that detect hand position, finger and/or wrist joint angle, vibration, and/or acceleration. Sensing targets can be retroactively installed on the power tool, and can define warning and/or danger zones. Sensing can be via magnetic, electromagnetic, capacitive, eddy current, and/or range finding means. Sizes of warning and/or target areas can be controlled by selecting targets from a plurality of targets of various detection ranges. Protective responses can vary according to different sensed events, and can include audible, visual, and/or tactile alerts, and/or interruption of power to the tool. Embodiments can record proximity and/or status data during a work session for review, training, and certification purposes. A controller can be physically cooperative with the garment. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to embroidery method and more particularly to a embroidery method.
[0003] 2. Description of Related Art
[0004] Embroidery is the art or handicraft of decorating fabric or other materials with needle and thread or yarn. A characteristic of embroidery is that the basic techniques or stitches of the earliest work such as chain stitch, buttonhole or blanket stitch, running stitch, satin stitch, and cross stitch remain the fundamental techniques of hand embroidery today.
[0005] Contemporary embroidery is stitched with a computerized embroidery machine using patterns “digitized” with embroidery software. In machine embroidery, different types of “fills” add texture and design to the finished work. Machine embroidery is used to add logos and monograms to business shirts or jackets, gifts, and team apparel as well as to decorate household linens, draperies, and decorator fabrics that mimic the elaborate hand embroidery of the past.
[0006] Regarding embroidery software, a number of issues should be noted. The semantics and intent of a supplied custom design may be difficult to detect in an automated fashion. Further, the task of translating an image into stitches of colored threads requires interpretation and artistic judgment during key parts of the process. There are conventional systems that provide a partial solution for automated production of embroidery from a digital image. Typically these systems start with a raster image and perform the steps of translating the raster image into a vector image, applying a stitch pattern and color to each region of the vector image, determining stitching for underlayment using stored data, determining stitch order based on minimizing connecting stitches, and outputting a file containing instructions which embroidery software may edit. However, quality of grayscale images having a resolution about 80 DPI (dot per inch) is poor.
[0007] Thus, it is desirable to provide a novel embroidery method that allows a consumer to provide user content to generate customized embroidery on a product when resolution of a grayscale image (i.e., the custom design) is about 80 DPI.
SUMMARY OF THE INVENTION
[0008] It is therefore one object of the invention to provide an embroidery method comprising the steps of enlarging an image as custom design by a predetermined percentage; converting the enlarged image by running embroidery software to generate a stitch file which is divided into a plurality of regions of shade of gray, each region having a serial number; modifying grayscale of at least one of the regions of shade of gray; determining stitches for underlayment by using the regions of shade of gray; determining a stitch order based on minimizing connecting stitches; and outputting a file containing instructions which embroidery software edits to an embroidery product design tool for designing a product having the custom design for embroidery.
[0009] The above and other objects, features and advantages of the invention will become apparent from the following detailed description taken with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a flow chart illustrating four steps of generating customized embroidery on a product according to a first preferred embodiment of the invention;
[0011] FIG. 2 is a front view of the product (e.g., human head embroidery on a fabric);
[0012] FIG. 3 is a flow chart illustrating three steps of generating customized embroidery on a product according to a second preferred embodiment of the invention; and
[0013] FIG. 4 is a front view of the product (e.g., building embroidery on a fabric).
DETAILED DESCRIPTION OF THE INVENTION
[0014] Referring to FIGS. 1 and 2 , a flow chart of generating customized embroidery on a product according to a first preferred embodiment of embroidery method of the invention is illustrated.
[0015] In step 1 , an image (e.g., the bust of a man as shown in FIG. 2 ) as custom design is enlarged 101-140% including the eyes 2 , the nose 3 , the mouth 4 , the ears 5 and the eyebrows 6 . The image can be selected from an embroidery design library that stores one or more embroidery designs.
[0016] In step 10 , the image is converted by running embroidery software to generate a stitch file. The stitch file is divided into a plurality of regions of shade of gray, each region having a serial number for identification.
[0017] In step 11 , grayscale of each of all regions of shade of gray or grayscale of each of some regions of shade of gray is modified based on artistic judgment and/or designer's experience. Each of the modified regions of shade of gray is stored in a specified file location so that a stitching for underlayment can be determined by using the digitized regions of shade of gray. It is noted that the stitches can be comprised of at least three shades of gray of black and at least three shades of gray of white. Alternatively, the stitches can be comprised of a plurality of shades of gray having a color other than black and white (i.e., stitches of colored threads).
[0018] In step 12 , stitch order based on minimizing connecting stitches is determined, and a file containing instructions which embroidery software may edit is outputted to an embroidery product design tool for designing a product (e.g., fabric) having the design for embroidery.
[0019] It is envisaged by the invention that the stitches can be comprised of at least three shades of gray of black and at least three shades of gray of white because quality of the design for embroidery formed on the product can be very high. Also, this is characteristic of the invention that prior art black and white images cannot achieve. Moreover, color stitching of the invention rendered on the product has many improved characteristics including vividness compared with that rendered by the prior art.
[0020] Preferably, the first preferred embodiment of embroidery method of the invention is applicable to designs of human being, animals, or the like.
[0021] Referring to FIGS. 3 and 4 , a flow chart of generating customized embroidery on a product according to a second preferred embodiment of embroidery method of the invention is illustrated. The characteristics of the second preferred embodiment are substantially the same as that of the first preferred embodiment except that step 1 of the first preferred embodiment of embroidery method is eliminated. Details of the second preferred embodiment of embroidery method of the invention are illustrated below.
[0022] In step 7 , an image 8 (e.g., a building as shown in FIG. 4 ) is converted by running embroidery software to generate a stitch file. The stitch file is divided into a plurality of regions of shade of gray, each region having a serial number for identification.
[0023] In step 70 , grayscale of each of all regions of shade of gray or grayscale of each of some regions of shade of gray is modified based on artistic judgment and/or designer's experience. Each of the modified regions of shade of gray is stored in a specified file location so that a stitching for underlayment can be determined by using the digitized regions of shade of gray. It is noted that the stitches can be comprised of at least three shades of gray of black and at least three shades of gray of white. Alternatively, the stitches can be comprised of a plurality of shades of gray having a color other than black and white (i.e., stitches of colored threads).
[0024] In step 71 , stitch order based on minimizing connecting stitches is determined, and a file containing instructions which embroidery software may edit is outputted to an embroidery product design tool for designing a product (e.g., fabric) having the design for embroidery.
[0025] It is envisaged by the invention that the stitches can be comprised of at least three shades of gray of black and at least three shades of gray of white because quality of the design for embroidery formed on the product can be very high. Also, this is characteristic of the invention that prior art black and white images cannot achieve. Moreover, color stitching of the invention rendered on the product has many improved characteristics including vividness compared with that rendered by the prior art.
[0026] Preferably, the second preferred embodiment of embroidery method of the invention is applicable to designs of buildings, ships, airplanes, automobiles, lotus, etc.
[0027] While the invention has been described in terms of preferred embodiments, those skilled in the art will recognize that the invention can be practiced with modifications within the spirit and scope of the appended claims. | An embroidery method is provided. An individual can provide a design such as images of the parts of a human being. The embroidery method can have it converted into a digitized image and use same to generate customized embroidery that can be placed onto a product such as fabric. The embroidery method can enlarge the design in the first step or not. | 3 |
This application is a continuation-in-part of Ser. No. 07/402,578 filed Sep. 5, 1989, now abandoned.
BACKGROUND OF THE INVENTION
Polyesters utilized in fiber formation are generally produced by a heated reaction of one or more dibasic acids such as terephthalic acid, or the like, with one or more polyhydroxy compounds such as ethylene glycol, propylene glycol, 1,4-cyclohexane dimethanol, or the like, until a product of desired viscosity is obtained. The formed polyesters are characterized in that they contain both terminal hydroxy and carboxy groups. Terminal hydroxy groups are generally more predominant due to the incorporation of an excess of polyol in the reactive mixture.
Polyesters are of great importance in the manufacture of tire cords, and as reinforcement for belts, hoses and many other useful articles. In many of these commercial applications the presence of excessive carboxyl groups in the polymer molecule is detrimental.
Previous attempts at acid group reduction in polyesters have resulted in a loss of average molecular weight in the polyester product due to substantial cleavage in the polyester backbone.
It is an objective of the instant invention to provide improved polyester materials in which the pendant carboxyl groups are either greatly reduced in number or are completely removed.
It is a further object of the invention to endcap free carboxyl groups on polyesters without producing water as a byproduct and while maintaining the molecular weight of the polyesters.
It is a further object of the instant invention to provide polyester materials having reduced sensitivity to water.
SUMMARY OF THE INVENTION
The instant invention relates to melt reaction of a carboxyl group containing polyester with a carboxyl group reactive endcapping agent namely, alkylacetylacetonates; to provide a polyester having a substantially reduced number or no carboxyl groups while maintaining the approximate molecular weight of the carboxyl group containing polyester precursor.
DETAILED DESCRIPTION OF THE INVENTION
In the practice of the present invention the polyester material is first produced in any state-of-the-art commercial manner. A typical process for production of a polyester is the heated reaction of a basic difunctional organic acid with polyol, preferable a diol, optionally together with any other desired components.
Suitable polyesters for treatment in the instant invention are prepared from difunctional organic acids including, but not limited to: terephthalic acid, 1,5-,1,4-, or 2, 6-naphthalic acid, 4,4,'-dicarboxydiphenyl, and the like. Suitable polyols are preferably diols such as, but not limited to, ethylene glycol, propylene glycol, butylene glycol, and the like. The preferred polyesters of the instant invention are homopolyesters such as polyethylene terephthalate, poly-1,4-cyclohexylenedimethylene terephthalate, polyethylene-2, 6-naphthalate, polyester ethers such as polyethylene hydroxybenzoate, poly-p-phenylene bis-hydroxyethoxy-benzoate, poly-p-phenylene bis-hydroxyethoxy-terephthalate; copolyesters or copolyester ethers which comprise mainly ethylene terephthalate units or tetramethylene terephthalate units and other copolymer components such as tetramethylene or ethylene isophthalate, 1,4-cyclohexylenedimethylene terephthalate units, or tetramethylene or ethylene p-hydroxybenzoate units, or the like. The preferred polyester for treatment in the instant invention is polyethylene terephthalate. Polyesters for treatment in the instant invention have an acid value ranging from 40 to 10 equivalents of CO 2 H per 10 6 gm of polyester. Polyesters for treatment in the instant invention should have an average molecular weight ranging from 10,000 to about 60,000.
In the practice of the instant invention a formed polyester is melt reacted with a carboxy reactive group or endcapping agent such as an alkylacetylacetonate in which the alkyl groups are lower alkyl radicals. The use of any of this endcapping agent permits the treated polyesters to retain their approximate molecular weight and viscosity as significant amounts of water which would promote polymer degradation are not generated during endcapping reaction.
The alkylacetylacetonates which are utilized in the instant invention are methyl-, ethyl-, propyl-, butyl-, pentyl- or hexyl acetylacetonate or mixtures thereof, preferably methylacetylacetonate. This capping compound reacts with the polyester carboxyl end group to form a polyester having an ester group and by-products of acetone and carbon dioxide. The alkylacetylacetonates are represented by formula (I) and the endcapping reaction is displayed in reaction (1). ##STR1## wherein R 1 represents a C 1 -C 6 alkyl group.
Since substantial quantities of water are not generated, the capped polymer does not degrade. Thus, the molecular weight and the viscosity of the capped polyester are approximately the same as those of the polyester prior to capping.
In the process of the present invention the melt extrusion reaction of the polyester and the appropriate endcapping agent should occur in a temperature range between 270° C. and 320° C. The endcapping agent feed rate into the melt extruder should range between 1 and 50 millimoles per minute per 100 grams per minute of polyester feed. The reaction residence time of the polyester and the endcapping agent in the melt reaction must be at least 10 seconds to provide for substantial endcapping of the carboxyl groups present on the untreated polyester which is fed into the melt reactor. This residence time allows for endcapping of the acid group thereby effecting acid number reduction of the polyester to an acid number below 10 equivalents of CO 2 H per 10 6 l gm of polyester, preferably below 3 eq. CO 2 H/10 6 gm of polyester.
The polyesters produced in accordance with the instant procedure having less than 10 equivalents of CO 2 H per 10 6 grams of polymer are accorded the status of having substantially all of their carboxyl groups endcapped.
The following examples are presented for the purposes of clarifying the present invention. However, it should be understood that they are not intended to limit the present invention in any way.
The following are specific examples for each of the above groups of the endcapping agents and their use in capping the free carboxyl groups in polyesters. In all of the following examples the treated polyester is polyethylene terephthalate.
In each of the following examples the polyethylene-terephthalate (PET) melt was prepared as follows. Tire cord grade PET was continuously prepared from terephthalic acid and ethylene glycol to give an intrinsic viscosity, [η], of 0.94 dl/gm at 25° C. in 1:1 ratio of phenol:tetrachloroethane. The PET in chip form was dried at 110° C. for at least twelve hours in a rotary dryer under a vacuum of 1.0 mm of Hg. The recovered dry PET polymer was transferred to an Acrison No. 1015Z-C feeder under a nitrogen atmosphere and fed to a Werner-Pfleiider ZSK-30 twin screw compounding extruder which had all zones heated to either 280° C. or 300° C. At a polymer feed rate of 40 gm/min the PET polymer had a melt residence time of 85 or 35 seconds, respectively, in the extruder.
EXAMPLE 1
The compounding extruder zones were heated to 280° C. and the feed rate of the PET polymer was 40 gm/min. During the PET melt residence time of about 35 seconds the last part of zone one of the compounding extruder was continuously injected with .062 cc/min (0.58 millieq/min) of the capping agent methylacetylacetonate using a BIF microfeeder No. 1180-07 piston pump. The extruded polymer was cooled, chopped and analyzed to display an intrinsic viscosity [η]=0.78 dl/gm and 1.1 eq CO 2 H/10 6 gm of PET polymer. The results of this test run and three other runs are displayed in Table 1.
In comparison, a control PET polymer passing through the compounding extruder without the added methylacetylacetonate displayed properties of [η]=0.90 dl/gm and 23.6 eq. CO 2 H/10 6 gm of polymer.
TABLE 1__________________________________________________________________________PET FEED METHYLACETYLACETONATE RECOVERED POLYMERRate CAPPING AGENT FEED [η] CO.sub.2 HSAMPLE gm/mn cc/min millieq/min dl/gm eq/10.sup.6 gm__________________________________________________________________________1 40 0.062 0.58 0.78 1.12 100 0.28 2.6 0.84 6.13 100 0.56 5.2 0.85 2.94 100 0 0 0.84 23.9__________________________________________________________________________ | A method for the melt reaction of polyesters, particularly polyethylene terephthalate, with an alkylacetylacetonate endcapping agent which reacts with terminal carboxyl groups of the polyester to produce polyesters having reduced acidity and PET products produced by the method having reduced acid content. | 8 |
This application claims the benefit of U.S. Provisional Application No. 60/141,054, filed Jun. 24, 1999.
This invention was made with Government support under Contract DE-AC04-94AL85000 awarded by the U.S. Department of Energy. The Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
This invention relates to the field of robotic systems and more particularly to convergent control systems and methods suitable for distributed control of multiple robotic vehicles.
When numerous autonomous robotic vehicles are used in convergent search applications, each vehicle and the distributed control system for each vehicle must be inexpensive in order to be cost effective. Inexpensive on-board sensors can have noisy measurements. Also, the amount of compute power and memory on board each vehicle is likely to be small. This results in the need for robustness to noisy sensor measurements while using a simple controller. Kalman filters can be used to filter noisy sensor data, but Kalman filters can be relatively expensive to implement.
Robotic Vehicle Control Systems
Brook's Subsumption architecture is a widely used approach for control of multiple autonomous vehicles. See Brooks, “A Robust Layered Control System for a Mobile Robot,” IEEE Journal of Robotics and Automation, RA-2, pp. 14-23, March 1986. Brooks teaches a layered control system implemented as an augmented finite state machine. Brooks' architecture is fast and simple to implement, but there is no theory regarding what the control laws should be or when to switch between them. Brook's Subsumption approach provides coordination at a higher level and relies on stable controls at a lower level. Consequently, Brooks provides control without predictable convergence characteristics.
Another category of work involving fuzzy control of robotic vehicles generated fuzzy rules with ad hoc, rather than predictable, convergence characteristics. See Maeda et al., “Behavior-Decision Fuzzy Algorithm for Autonomous Mobile Robots,” Information Sciences, Vol. 71, pp. 145-168,1993; and Marapane et al., “Motion Control of Cooperative Robotic Teams Through Visual Observation and Fuzzy Logic Control,” Proceedings of the 1996 International Conference on Robotics and Automation, pp. 1738-1743,1996. The ad hoc rules of Maeda et al. and Marapane et al. cannot guarantee convergence in finding a target; consequently, they are not suitable where provable convergence is required.
Phase plane analysis and variable structure control techniques have been used for stable control of single and multiple robotic vehicles. Sliding mode control is a subset of variable structure control. See, e.g., Feddema et al., “Explaining Finite State Machine Characteristics using Variable Structure Control,” SPIE Conference on Sensor Fusion and Decentralized Control in Autonomous Robotic Systems, Pittsburg, Oct. 14-17, 1997, hereinafter referred to as Feddema'97; and Feddema et al., “Designing Stable Finite State Machine Behaviors using Phase Plane Analysis and Variable Structure Control,” Proceedings of 1998 IEEE International Conference on Robotics and Automation, Belgium, May 16-21, 1998, hereinafter referred to as Feddema'98. The sliding mode control of Feddema'97 and Feddema'98 are good with robotic vehicles having a lot of on-board compute-power, but are unsuitable for robotic vehicles with limited compute-power and limited memory.
Many ways exist to generate fuzzy rules. See Miyata et al, “Self-Tuning of Fuzzy Reasoning by the Steepest Descent Method and Its Application to a Parallel Parking,” IEICE Trans. Inf. & Syst., Vol. E79-D, No. 5, May 1996, pp. 561-569; Nomura et al, “A Learning Method of Fuzzy Inference Rules by Descent Method,” IEEE International Conference on Fuzzy Systems, March 1992, pp. 203-210; Kim et al, “An Auto-Tuning Fuzzy Rule-Based Visual Servoing Algorithm for a Slave Arm,” IEEE International Symposium on Intelligent Control, August 1995, pp. 177-182; Fukuda and Shimojima, “Fusion of Fuzzy, NN, GA to the Intelligent Robotics,” 1995 IEEE International Conference on Systems, Man, and Cybernetics, Vol. 3, October 1995, pp. 2892-2897. Cho and No developed a provably stable fuzzy controller based upon a linear quadratic regulator theory and Lyapunov stability theory. See Cho and No, “Design of Stability-Guaranteed Fuzzy Logic Controller for Nuclear Steam Generators,” IEEE Transactions on Nuclear Science, Vol. 43, No. 2, April 1996. Cho and No's method can be applied to the control of a single nuclear generator, but Cho and No's method cannot be applied to multiple robotic vehicles.
One example of a need for convergence of robotic vehicles is in military applications where autonomous robotic vehicles are used to locate (converge on) a bomb target. Another example is in chemical applications where autonomous robotic vehicles are used to locate a scent source. In convergent search applications utilizing multiple autonomous robotic vehicles, each vehicle with on-board sensors needs to be inexpensive. An inexpensive system can have a small amount of compute power, a small amount of memory, and noisy on-board sensors. This results in the need for robustness to noisy sensor measurements while using a simple controller. Accordingly, there is an unmet need for a control system suitable for multiple autonomous robotic vehicles that can be used where provable convergence is required.
SUMMARY OF THE INVENTION
This invention provides a distributed control system suitable for controlling one or multiple robotic vehicles to converge to a goal. The present invention controls one or more vehicles without collisions with obstacles, in the presence of noisy measurements and with a small amount of compute-power and memory on board each vehicle. The control system for each vehicle comprises a sensor and a fuzzy controller. The fuzzy controller can comprise a microcontroller, a memory accessible from the microcontroller, and a program stored in the memory that implements fuzzy control rules on the microcontroller. The fuzzy controller can take input from the sensor and can generate a set of vehicle control commands according to fuzzy control rules that result in provable vehicle convergence to a specified goal. The sensor can sense one or more needed inputs or can be a sensor subsystem that senses one or more needed inputs. Control commands can be any set of commands which result in a vehicle converging to a desired goal or scent source.
The present invention provides a new method for distributed robotic vehicle control that can control a single vehicle or multiple vehicles to converge to a goal.
BRIEF DESCRIPTION OF THE FIGURES
The accompanying drawings, which are incorporated into and form part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
FIG. 1 is a schematic of a robotic vehicle controlled by the present invention, showing vehicle reference frame 1 .
FIG. 2 is a schematic illustrating r, φ, and α for a vehicle, the vehicle's goal, and the vehicle's nearest obstacle.
FIG. 3 is a diagram depicting a fuzzy controller according to the control system of the present invention.
FIG. 4 is a flow diagram depicting a robotic vehicle control process according to the present invention with an example of a provably convergent fuzzy control method of controlling the robotic vehicle.
FIG. 5 is a graph depicting membership functions for distance to obstacle.
FIG. 6 is a graph depicting membership functions for direction to goal and direction to obstacle.
FIG. 7 is a graph depicting simulation results for exact controllers.
FIG. 8 is a graph depicting simulation results for fuzzy controllers according to the present invention.
FIG. 9 is a graph depicting a comparative view of the simulation results of FIGS. 7 and 8.
FIG. 10 is a graph depicting exact controller results.
FIG. 11 is a graph depicting Kalman controller results.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a control system for controlling a robotic vehicle to converge to a goal. The present invention provides a distributed control system for controlling multiple vehicles to converge to a goal. The present invention also provides a method for controlling one vehicle to converge to a goal and provides a method for controlling multiple vehicles to converge to a goal.
A robotic vehicle can be responsive to multiple inputs. In a convergence application, a robotic vehicle can have the following noisy measurements available to it: distance to its nearest neighbor vehicle (r, in meters), direction to a goal (for example, a scent source such as a chemical source or unexploded ordnance) in vehicle coordinates (φ, in radians), and direction to its closest neighbor vehicle in vehicle coordinates (α, in radians).
The present invention is suitable for use with nonholonomic vehicles. A nonholonomic vehicle is a vehicle that has fewer degrees of freedom than the space in which it operates. In a nonholonomic robotic vehicle, there can be more than one path generated to reach a specific goal. Nonholonomic vehicles can comprise tracked and wheeled vehicles with the limitation that they cannot instantaneously move in any desired direction but must instead use forward motion and steering to change direction.
Robotic Vehicle Description
An example of a robotic vehicle that can be controlled according to the present invention is given in FIG. 1, which shows a schematic of robotic vehicle 10 and its vehicle reference frame, depicted as frame 1 (whose axes are {overscore (i)} 1 and {overscore (j)} 1 ). To better understand the control process, the following terms can be useful. Point C in FIG. 1 is at the midpoint of two independent driving wheels at points A and B. Point P can be fixed to the vehicle and be offset forward from point C by distance a. Let u 1 and u 2 denote linear velocities of points B and A, respectively (in the {overscore (i)} 1 direction). Also, let R denote one-half the distance between points A and B.
FIG. 2 illustrates the definitions of r, φ, and α for a vehicle with respect to the vehicle's goal and the vehicle's nearest obstacle, for example, the nearest neighbor vehicle. Frame 1 can be fixed to the vehicle, where r is the distance to the nearest neighbor vehicle, shown in frame 2 coordinates; φ is the direction to a goal, denoted by frame 0 ; and α is the direction to the closest neighbor vehicle. Without loss of generality, frame 0 (whose axes are {overscore (i)} 0 and {overscore (j)} 0 ) is a fixed frame whose origin is the goal (for example, a scent source).
As shown in FIG. 2, let θ denote the orientation of the vehicle, denoted as the angle from {overscore (i)} 0 to {overscore (i)} 1 , measured counterclockwise. Let φ be the angle, measured counterclockwise, from {overscore (i)} 1 to the vector that points from the origin of frame 1 to the origin of frame 0 ; that is, φ is the angular direction to the goal in vehicle coordinates. Let α be the angle from {overscore (i)} 1 (of vehicle 1 ) to {overscore (i)} 2 (of vehicle 2 ), and r be the distance between the two vehicles.
Fuzzy Controller
In an example of the present method of controlling robotic vehicles, a non-fuzzy control law can be fuzzified to produce a fuzzy controller according to the present invention. An example non-fuzzy control law, can be a linear quadratic regulator control law. See Driessen et al., “Decentralized Fuzzy Control of Multiple Nonholonomic Vehicles,” Proceedings of the 1998 American Controls Conference, Philadelphia, Jun. 24-26, 1998, incorporated herein by reference. Control laws based on a repulsive force for collision avoidance and an attractive force toward a goal can be used to produce a fuzzy controller according to the present invention.
The simplification of the non-fuzy control law using fuzzy control rules can allow a convergent control system to be implemented on low-cost microcontrollers, for example, an 8-bit microcontroller or other simple and inexpensive microcontrollers, which can be used on multiple robotic vehicles, and even on miniature robotic vehicles (for example, vehicles substantially the size of a paperback book).
FIG. 3 is a diagram depicting fuzzy controller 30 according to the control system of the present invention. Fuzzy controller 30 comprises fuzzifier 32 and defuzzifier 34 , along with fuzzy controller input 31 , fuzzy value 33 , and output vehicle control 35 .
Fuzzy controller input 31 , for example xε 3 , can comprise three inputs: direction to goal, distance to obstacle, and direction to obstacle. Fuzzifier 32 can take controller input 31 and can approximate these exact inputs and output fuzzy value 33 . Fuzzy value 33 can be a discrete controller input along with its associated probability as, for example, those obtained using a fuzzy membership function or other fuzzifier where controller input can be fuzzified and described using a small set of values each with a probability of occurrence and where the probabilities sum to one. FIGS. 5 and 6 are example graphs of fuzzy membership functions. Fuzzy value 33 can be input into defuzzifier 34 . Defuzzifier 34 can take discrete fuzzy value 33 and can output vehicle control command 35 in continuous real values. Vehicle control command 35 can be commanded right and left linear wheel velocities, for example u 1 and u 2 , where uε 2 . Defuzzifier 34 can be a Sugeno Fuzzy Inference System or other defuzzifier known to those skilled in the art.
Control Process
FIG. 4 is a flow diagram depicting a robotic vehicle control process according to the present invention with an example of a provably convergent fuzzy control method of controlling the robotic vehicle.
In setup step 41 of the control process, fuzzy membership functions for direction and distance can be defined. One simulated example control process can use the triangular membership functions shown in FIGS. 5 and 6 for each of the values of three inputs to the controller: distance to obstacle, direction to goal, and direction to obstacle. The fuzzy membership functions can be defined as complementary triangular graphs with vertices at membership probabilities 0 and 1 for specific values of the discrete inputs. For example, in FIG. 5, “small” has a value of 1.5 meters with probability 1 . Other membership functions can also be used.
In an example embodiment, discrete inputs to the controller can be defined to have the following possible values for direction and distance, corresponding to the fuzzy membership functions shown in FIGS. 5 and 6 :
Direction to Goal (φ): Forward 1 , Left, Behind, Right, or Forward 2
Direction to Obstacle (α): Forward 1 , Left, Behind, Right, or Forward 2
Distance to Obstacle (r): Small, Medium, Gone.
Thus, the example embodiment can have 5*5*3=75 possible “fuzzy” discrete input combinations to the controller. The value of “Small” can be chosen to be 1.5 meters, that of “Medium” to be 3 meters, and that of “Gone” to be 10 meters.
In setup step 42 of the process, exact controller outputs can be computed at the discrete input values, defined in step 41 , and stored in a table or database. In the example embodiment, a linear quadratic regulator is implemented as the exact controller.
Steps 43 through 46 are part of a repeatable loop to obtain vehicle-specific inputs, to fuzzify controller inputs, to defuzzify the control to obtain vehicle velocities, and to control a robotic vehicle. The method of the present invention can be applied to multiple robotic vehicles, where the same fuzzy controller can be downloaded onto each vehicle's microcontroller and steps 43 through 46 can be repeated for each vehicle. Coordination between robotic vehicles can be accomplished by each vehicle having awareness of its nearest obstacle, or nearest neighboring vehicle, in order to avoid collisions. The details for steps 43 through 46 are explained below.
In step 43 , the direction φ to a goal and the direction α and distance r to a nearest obstacle can be determined. The directions and distance can be measured by an on-board vehicle sensor or sensor subsystem. Noise on the direction to the obstacle can be taken to be smaller than noise on the direction to the goal since the former can come from communication signals between vehicles, while the latter can be measured with less accurate chemical sensors.
Step 44 is a fuzzify step in which discrete values and probabilities can be determined from fuzzy membership functions. In the example embodiment, each direction and distance value from step 43 can be used with the graphs in FIGS. 5 and 6 and can yield membership probabilities for two discrete values from the membership functions. For example, a given distance can yield “forward1” with probability=0.4 and “left” with probability=0.6.
Step 45 is a defuzzify step in which approximated control values can be obtained by interpolating between the stored exact values of the control, from step 42 . The example fuzzy control embodiment uses a Sugeno Fuzzy Inference System as the defuzzifier. The Sugeno Fuzzy Inference System can be used to interpolate between the exact values of the control as given in Equations 4 and 5, in a following section, at the 75 combinations of discrete data points, defined in step 41 . The resulting fuzzy controller can have the same input-output relationship as the exact controller at these discrete 75 points, but can have different values at any points in between. The Sugeno Fuzzy Inference System is known to those skilled in the art. See Driankov et al., “An Introduction to Fuzzy Control,” Springer-Verlag, New York, 1993, pp. 186-195, for a reference on Sugeno inferencing. Software for Sugeno inferencing also is available; for example, the MATLAB software library has a toolbox which uses this method.
The output of step 45 can be used to control a robotic vehicle, step 46 . The example control embodiment can output u 1 and u 2 , the linear velocities of vehicle wheels at points B and A.
In a more detailed example with multiple robotic vehicles, this example control process can be distributed and applied to each vehicle separately, where the same fuzzy controller can be downloaded onto each vehicle's microcontroller and where steps 43 through 46 can be repeated for each vehicle. Each vehicle's sensor repeatedly can measure new vehicle-specific direction and distance inputs, then controller inputs can be fuzzified and a defuzzifier can be applied to obtain output wheel velocities to control each specific robotic vehicle. The process can continue until each vehicle can achieve convergence on the goal, step 47 .
Non-Fuzzy, Exact Control
A non-fuzzy control law (for example, an exact control law such as a linear quadratic regulator) can be fuzzified to generate a fuzzy control law for implementation according to the description below. The non-fuzzy control solution can have an attractive force component and a repulsive force component.
In order to move a vehicle toward a goal while avoiding collisions with obstacles and other vehicles, the attractive force that pulls the vehicle in the direction φ of the scent source goal can be given by: k ( cos φ sin φ ) , ( 1 )
where the constant k is a scaling coefficient and where the vector in Equation 1 is expressed in vehicle frame 1 coordinates as in FIG. 2 .
Collision avoidance can be obtained by using a 1/r 3 repulsive force exerted along the line from a closest neighbor vehicle to the vehicle under control. The direction of this repulsive force, in frame 1 , can be obtained through measurement of α (angular direction to the closest vehicle, in vehicle coordinates). In particular, this repulsive force, expressed in frame 1 coordinates, can be given by: - kc 2 r 3 ( cos α sin α ) , ( 2 )
where the value of c 2 can be chosen large enough that any pair of vehicles will maintain a safe distance apart to avoid collision. A value of c 2 =10 was used in the example simulations.
The absolute velocity, relative to frame 1 , of a point P on the vehicle under control, 1 {overscore (v)} P , can be specified. Because of a no-slip condition at the two wheels (at points A and B in FIG. 1) in the example, the linear velocity of point C in FIG. 1 cannot be arbitrarily specified. However, motion of point P on the robotic vehicle to be controlled can be specified. An approach can be to let the repulsive and attractive forces determine the velocity of the point P, shown in FIG. 1 . The absolute velocity of point P, expressed in frame 1 coordinates, can be given by: v → P 1 = 1 / 2 [ 1 1 a / R - a / R ] ( u 1 u 2 ) , ( 3 )
where u 1 and u 2 are the linear velocities of vehicle wheels at points B and A.
The determinant of the matrix in Equation 3 is −α/R; therefore, this matrix is nonsingular. So, if absolute velocity 1 {overscore (v)} P is specified, the required inputs u 1 and u 2 the linear velocities of wheels at points B and A that produce the absolute velocity, can be determined.
Combining Equations 1-3, the control can become: ( u 1 u 2 ) = [ 1 R / a 1 - R / a ] v → P 1 ( 4 )
where v → P 1 = k ( cos φ sin φ ) - kc 2 r 3 ( cos α sin α ) . ( 5 )
The direction of motion of point P in Equation 5 can be shown to be the linear quadratic regulator (LQR) solution for a single obstacle, where the LQR cost function J to be minimized (sometimes called a performance index) can be given by: J ≡ 1 2 ( ( x p - x g ) 2 + ( y p - y g ) 2 ) + c 2 1 ( x p - x _ ) 2 + ( y P - y _ ) 2 , ( 6 )
where ({overscore (x)},{overscore (y)}) is the position of the obstacle, (x g ,y g ) is the position of the goal, (x p ,y p ) is the position of the point P on the vehicle, and c 2 is a weighting factor which penalizes the inverse of the distance between the vehicle and the nearest obstacle.
Differentiating Equation 6 with respect to (x p ,y) T , results in: ∇ J = ( x P - x g y P - y g ) - c 2 2 [ ( x P - x _ ) 2 + ( y P - y _ ) 2 ] 2 ( x P - x _ y P - y _ ) . ( 7 )
Note that r = ( x P - x _ ) 2 + ( y P - y _ ) 2 ;
let φ and α be the angular direction from vehicle point P to the goal and the obstacle to point P, respectively, in frame 1 coordinates; and also let s≡{square root over ((x p +L −x g +L ) 2 +L +(y P +L −y g +L ) 2 +L )}. Then Equation 7 can be written as follows: v → P 1 = - ∇ J = s ( cos φ sin φ ) - 2 c 2 r 3 ( cos α sin α ) . ( 8 )
In Equation 8 for this example, the first term is in the same direction as the attractive force in Equation 1 and the second term is in the same direction as the repulsive force in Equation 2.
Convergence with Fuzzy Logic Membership Functions
Fuzzy logic membership functions, with few discrete values, can be used because convergence can be achieved as long as an estimate of the vehicle angle to the goal is within ±90 degrees of the actual angle to the goal. This can be shown by considering a linear perturbation of nonlinear dynamics of the vehicle: ( ( x . = f ( x , u ) ≈ f ( x o , u o ) + ∂ f ∂ x ) x o , u o ( x - x o ) + ∂ f ∂ u ) x o , u o ( u - u o ) , ( 9 )
where xε 3 is the (x,y) position of the point P on the vehicle and orientation θ, uε 2 is the commanded right and left linear wheel velocities, ƒ(x, u) are the first order vehicle dynamics, and x o and u o are linearized operating points. Equation 9 can be rewritten as: ( ( Δ x . = ∂ f ∂ x ) x o , u o Δ x + ∂ f ∂ u ) x o , u o Δ u ( 10 )
where
Δ {dot over (x)} =ƒ( x,u )−ƒ( x o ,u o )
Δ x=x−x o
Δ u=u−u o
The first order model of the skid-driven vehicle {dot over (x)}=ƒ(x,u) is: [ x . P y . P θ . ] = 1 2 [ cos θ - a R sin θ cos θ + a R sin θ sin θ + a R cos θ sin θ - a R cos θ 1 R - 1 R ] [ u r u l ] ( 11 )
or
{dot over (x)}=B ( x ) u,
where R is one-half the wheel base, a is the distance between the vehicle center C and point P, and θ is the orientation of the vehicle with respect to frame 0 .
If u o =0, then ( ∂ f ∂ x ) x o , u o = 0
and Δu=u. Since ( ∂ f ∂ u ) x o , u o = B ( x o ) ,
then
Δ {dot over (x)}=B ( x o )Δ u. (12)
The control can be chosen to be a weighted inverse Jacobian which is a function of the estimated state {circumflex over (x)}. Then,
Δ u=−[WB ( {circumflex over (x)} )] −1 Δp (13)
where W = [ 1 0 0 0 1 0 ] and p = [ x P y P ]
and
Δ p=p−p o
where p o is a linearized operating point. The matrix W can be chosen to drive x p ,y p , to the desired reference position yet leave θ unconstrained.
Considering only the position of the vehicle,
Δ {dot over (p)}=−WB ( x o )[ WB ( {circumflex over (x)} )] −1 Δp (14)
or
[ sI+WB ( x o )[ WB ( {circumflex over (x)} )] −1 ]Δp =0. (15)
For Δp→0, WB(x o )[WB({circumflex over (x)})] −1 must be positive definite. For the skid-driven dynamics in Equation 11, this occurs if and only if −90°<θ o −{circumflex over (θ)}<90°, thus giving convergence. An LQR controller can be designed, as in the example above, using a change of variables that can reduce a control problem from one with three degrees of freedom to a non-singular problem with only two degrees of freedom.
Multi-Vehicle Example
Exact and fuzzy control laws can be applied to a multi-vehicle embodiment of the present invention, where many vehicles can be controlled to reach a goal point or scent source. An obstacle for each vehicle i can be taken to be the vehicle that is nearest to vehicle i. The same control laws can be applied to all vehicles. An additional constraint can be imposed: a maximum wheel velocity (velocity of points A and B in FIG. 1) of v max =0.45 m/s, for a wheeled robotic vehicle, such as a RATLER™, like those developed by Sandia National Laboratories. See Klarer and Purvis, “A Highly Agile Mobility Chassis Design for a Robotic All-Terrain Lunar Exploration Rover,” incorporated herein by reference. The maximum wheel velocity can be associated with a specific robotic vehicle or can be an arbitrary velocity. For the generation of the fuzzy controller data points, the speed-coefficient k (used in Equation 5) can be scaled down to k=0.1136, in order to guarantee that the fuzzy controller cannot generate a wheel velocity greater than the imposed v max . For comparison, the exact controller can also use this value of k and additionally can scale 1 {overscore (v)} P to a small enough value so that neither wheel velocity can exceed v max . The parameter values used in the simulations discussed below are: a=R=0.58 meters, and c 2 =10.
The effect of having a 1-second update rate and noise in φ, r, and α was assessed in an example simulation. FIGS. 7 and 8 are graphs corresponding to simulations with the exact and fuzzy controllers, respectively, in which there was +/−90 degrees of noise (uniform) in the direction-to-goal, +/−9 degrees of noise in the direction-to-obstacle, +/−0.4 meters of noise in the distance to the obstacle (closest vehicle), and a slow 1-second update rate on the inputs to the controller. The controls in this example simulation could be held constant over each such interval. The total integration time for both FIG. 7 and FIG. 8 was 780 seconds. The initial positions of the vehicles for FIGS. 7 and 8 are those path endpoints that are farthest from the goal located at x=0, y=0.
The simulation results for the fuzzy controller shown in FIG. 8 are smoother than the simulation results for the exact LQR controller shown in FIG. 7 . FIG. 9 shows a blown up overlay comparison of one of the simulation paths from FIGS. 7 and 8.
Simulated Comparison of Controllers
Smoothing can be inherent in the fuzzy membership functions and the defuzzification (for example, the Sugeno fuzzy inference system).
On the other hand, a non-fuzzy control law (for example, an exact linear quadratic control law) does not filter out noisy data. A Kalman filter can be used with a linear quadratic regulator (LQR) control law to overcome this deficiency and to filter noisy sensor data for a smoother path. An extended Kalman filter can be implemented to estimate an exact state-transition function, then the estimate can be input to the LQR control to obtain wheel velocity outputs.
FIGS. 10 and 11 show single vehicle simulations with +/−90 degrees of noise on a direction to goal and a 1-second ZOH (zero order hold). In this simulated case, readings are taken at one-second intervals to approximate analog signals with digital and provide a 1-second update rate on the inputs to the controller. FIG. 10 is a graph depicting unfiltered exact controller results. FIG. 11 is a graph depicting filtered Kalman controller results, where a Kalman filter was used with an LQR controller. The Kalman filter is more computationally intensive and can be seen to exhibit more smoothing than the unfiltered exact controller. As seen in FIG. 11, the Kalman filtered controller overshoots the target before circling back to the target; the exact controller does not. The fuzzy controller with LQR set points, as in examples according to the present invention, exhibits more smoothing, like the more expensive and computationally intensive Kalman filter; but the fuzzy controller, like the exact LQR controller, does not overshoot the target.
In the Kalman estimator implementation, measurement of φ, the angular direction to the goal, and u the linear velocities of wheels, are not sufficient to achieve estimation of the full exact input-state x. More measurements, such as the distance to the goal, would be needed to achieve full state estimation. However, the distance to the goal may not be measurable, in scent seeking problems, since the strength of the scent source may be unknown.
The smoothness and performance of the fuzzy controller compared favorably to the controller that used a Kalman estimator, and the fuzzy controller does not require a measurement of the distance to the goal. Decentralized fuzzy control can smoothly control multiple nonholonomic vehicles.
The particular sizes and equipment discussed above are cited merely to illustrate particular embodiments of the invention. It is contemplated that the use of the invention may involve components having different sizes and characteristics. It is intended that the scope of the invention be defined by the claims appended hereto. | A decentralized fuzzy logic control system for one vehicle or for multiple robotic vehicles provides a way to control each vehicle to converge on a goal without collisions between vehicles or collisions with other obstacles, in the presence of noisy input measurements and a limited amount of compute-power and memory on board each robotic vehicle. The fuzzy controller demonstrates improved robustness to noise relative to an exact controller. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of, and claims priority from, commonly-owned, co-pending U.S. patent application Ser. No. 12/535,394, filed on Aug. 4, 2009, which claims priority from U.S. patent application Ser. No. 11/761,234, filed on Jun. 11, 2007, issued as U.S. Pat. No. 7,790,511.
STATEMENT REGARDING FEDERALLY SPONSORED-RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0003] Not Applicable.
FIELD OF THE INVENTION
[0004] The invention disclosed broadly relates to the field of cooling of semiconductor chips, and more particularly relates to attachment of heat sinks to semiconductor chips.
BACKGROUND OF THE INVENTION
[0005] The performance of integrated electronics chips has increased dramatically over recent years. This increased performance has been achieved in part by increasing the chip operating frequency which has resulted in greater chip power (Watts) and chip power density (Watts/cm2). This has increased the need for efficient thermal power management to conduct the heat away from the chip to the ambient surroundings using for example heat sinks, fans, vapor chambers, liquid coolers and other means to cool the chips to maintain an acceptable operating temperature. Today's powerful processors generate so much heat that chips will thermally overheat if the thermal cooling solution is not operational even for a short period of time. A heatsink is a device that is attached to the microprocessor chip to keep it from overheating by providing a thermal conduction path of the heat generated by the chip to the ambient environment by moving air over the heat sink. Basic heat sink structures have a heat spreader which makes thermal contact with the chip via an interface of a thermally conductive adhesive and fins which provide a large surface area to transfer the heat to the ambient air environment. Typically a fan is used to provide an air flow over the fins to optimize the heat transfer from the heat sink to the ambient air.
[0006] Most commercially available computers incorporate a heat sink directly attached to the chip. This combination of the chip and heat sink is often referred to as a “chip package.” The basic design of a chip package is shown in FIG. 1 in which a heatsink 102 is mounted on a chip 120 . The heatsink 102 shown is a conventional passive metal heat sink with fins. The chip 120 makes thermal contact with the heat sink 102 through a thermal interface material 111 . The chip 120 is attached to a chip carrier 122 which has a pin grid array and interfaces to an electrical socket 110 which is mounted onto a printed circuit board 125 . The heat sink 102 is secured to the chip 120 by a frame 112 and mounting screws 116 in order to inhibit horizontal and vertical movement of the heat sink as would occur under external forces, including shock and vibration of the system. FIG. 2 shows the top view of the chip package of FIG. 1 .
[0007] Clearly this design is meant to stabilize and constrain the heatsink 102 and it is effective in doing so. The problem inherent in this design, however, is that the rigid assembly results in deformation of the entire package due to differences in the coefficient of thermal expansion (CTE) between the heatsink 102 and the chip package assembly. The need to constrain the mechanical motion of the heat sink 102 due to external forces (shocks) requires a rigid, non-compliant attachment which unfortunately results in package deformation. Contributing to this problem is the rigidity and non-compliance inherent in heatsinks, which are usually metal structures. Currently produced heatsinks fail to provide for the structural stresses and strains generated during the operation of the electronic device (the chip 120 ). Therefore, there is a need for a solution that overcomes the above shortcomings of the prior art.
SUMMARY OF THE INVENTION
[0008] Briefly, according to an embodiment of the invention, a system and method of attaching a heat sink to an integrated circuit chip includes providing a compliant material for constraining the heat sink mechanical motion while simultaneously allowing for thermal expansion of the heat sink; and providing at least one mechanical limit stop disposed between the heat sink and a frame. Additionally, the invention provides for placing the compliant material between the heat sink and the at least one mechanical limit stop. Further horizontal constraint pads are positioned between the heat sink and the at least one mechanical limit stop. Vertical constraint pads can be positioned between the heat sink and the at least one mechanical limit stop.
[0009] According to another embodiment of the present invention, a structure for attaching a heat sink to an integrated circuit chip includes a set of ball bearings positioned to allow motion of the heat sink in the X and Y directions while constraining motion in the Z direction. The ball bearings are attached using braces with each ball bearing positioned at the corner sidewalls of the heat sink such that force applied to the ball bearing from the heat sink will prevent mechanical movement of the heat sink in a vertical direction.
[0010] According to another embodiment of the present invention, a structure for attaching a heat sink to an integrated circuit chip includes a servo control system. The servo control system includes a voice coil motor to actuate the heat sink. Further, at least one gap sensor creates a position signal between the heat sink and a fixed frame.
[0011] According to another embodiment of the present invention, an attachment structure for attaching a heat sink to an integrated circuit chip includes: a platform for the heat sink; a plurality of horizontal limit stops including compliant material for constraining mechanical motion of the heat sink while allowing for thermal expansion of the heat sink in a chip package, wherein each horizontal limit stop is positioned on the platform such that the compliant material makes contact with the heat sink and the chip; and a plurality of vertical limit stops including compliant material, wherein each vertical limit stop is positioned on the platform such that the compliant material makes contact with a bottom surface of the heat sink and the chip.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] To describe the foregoing and other exemplary purposes, aspects, and advantages of the present invention, we use the following detailed description of exemplary embodiments of the invention with reference to the drawings, in which:
[0013] FIG. 1 is an illustration of a cross-section view of a basic chip package design with a passive heatsink, according to the known art;
[0014] FIG. 2 is an illustration showing the top view of the basic chip package of FIG. 1 , according to the known art;
[0015] FIG. 3 a is a side view of a chip package assembly according to an embodiment of the present invention;
[0016] FIG. 3 b is a top view of the chip package assembly according to an embodiment of the present invention;
[0017] FIG. 3C is a detailed view of the corner of the chip package assembly according to an embodiment of the present invention;
[0018] FIG. 4 is a 3D view of the chip package assembly according to an embodiment of the present invention;
[0019] FIG. 5 a is a side view of an illustration of a chip package assembly with ball bearings, according to an embodiment of the present invention;
[0020] FIG. 5 b is a top view of an illustration of a chip package assembly with ball bearings, according to an embodiment of the present invention;
[0021] FIG. 6 is a close-up cut-away view of one of the ball bearings of FIG. 5 , according to an embodiment of the present invention;
[0022] FIG. 7 is a side view of a chip package assembly using non-contact voice coil motors, according to an embodiment of the present invention;
[0023] FIG. 8 is a top view of the assembly of FIG. 7 , according to an embodiment of the present invention;
[0024] FIG. 9 is an exploded view of a voice coil motor, according to an embodiment of the present invention; and
[0025] FIG. 10 shows a diagram of the servo control system of FIG. 7 , according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0026] We describe an attachment method for a heat sink, according to an embodiment of the present invention. As will be shown, the present embodiment changes the mechanical boundary conditions of the heat sink to allow slowly varying relative motion while still providing mechanical support for shock inputs. This is accomplished by changing the method of heat sink attachment, such that mechanical motion is limited under shock but provides compliance for thermal expansion. As such this will reduce the heat sink/package mechanical interaction due to the mismatch of the coefficients of thermal expansion (CTE) for those materials. A CTE mismatch occurs when the heat sink material experiences thermal expansion at a different rate than that of the frame. This is one of the main causes of package deformation.
[0027] Referring now in specific detail to the drawings, and particularly FIG. 3 a there is shown a side view of a chip package assembly 300 with attached heat sink 302 . According to an embodiment of the present invention, pads 312 and 314 are fabricated from a highly damped elastomeric material such as those commercially available as C-1105 from EAR Specialty Composites. These materials are also viscoelastic in that they exhibit both the properties of a viscous liquid which “flows” at slow deformation speeds and an elastic solid at higher speeds. These materials have a frequency dependent elastic modulus which increases at higher frequencies, thus becoming stiffer if the load changes quickly.
[0028] FIG. 3 b shows a top view of the chip package assembly 300 . The elastomeric material is used in the X and Y pads 314 and 318 at the corner mounts of the heat sink 302 to control motion of the heat sink 302 in the X and Y directions as well as the Z pads 312 at the bottom side of the heat sink 302 corners to control motion in the Z direction.
[0029] As shown in FIG. 3 b the X and Y pads 314 and 318 are disposed at the corner mounts, positioned between the heat sink 302 and the horizontal limit stops 316 . Pads 312 are also positioned between the heat sink 302 and the vertical stops 308 . The viscoelastic material is sufficiently rigid that it limits mechanical motion in the presence of shocks; yet it provides compliance sufficient to handle the thermal expansion mismatch of the heat sink/package 300 . The positioning of the pads will reduce the effects of shock from X, Y, and Z forces exerted on the heat sink 302 . Positioning the pads 314 at the bottom only will limit the effects from a Z force shock only.
[0030] The key advantages of employing the pads 312 , 314 , 318 at the corner mounts and the bottom of the heat sink 302 are: 1) they allow mechanical motion from thermal expansion; and 2) they restrict mechanical motion due to shock. The key aspects of the pads are the viscoelastic properties of the material used and the positioning of the pads with respect to the heat sink 302 .
[0031] FIG. 3 c presents a detailed view of one corner of the chip assembly package 300 of FIGS. 3 a and 3 b . This view shows the corner of the heat sink 302 which is abutted by pads 314 and 318 which may be, for example, attached to the limit stop 316 and the heat sink 302 with an adhesive glue. When a force F 2 is applied to the heat sink 302 , pad 318 is compressed. However, as the elastic modulus of the pad 318 is frequency dependent, the restoring force would depend upon the frequency of the applied force. For slowly varying forces such as would occur with thermal expansion, pad 318 would be soft, but for higher frequency forces the pad 318 would be very stiff. This allows the heat sink 302 to expand due to temperature changes, but provides constraint of the heat sink 302 for high frequency forces. Note that pad 314 experiences a shear force during the applied force F 2 and allows movement of the heat sink 302 both for thermal and high frequency forces.
[0032] For a force F ( 320 ) in the X, Y plane the pad 314 would experience a force F 1 =F cos(θ) and pad 318 would experience a force F 2 =F sin(θ). Each pad would respond as described above.
[0033] As the package may experience a force in any arbitrary direction, the heat sink 302 can experience a force which has components in the X, Y and Z planes. As shown in the three-dimensional (3D) view of FIG. 4 , the pads in the Z direction will compress when a force has a downward Z component. The clamp 304 holds the center of the heat sink 302 in the Z direction and applies a downward bias force on the pads 312 which prevents the heat sink from lifting off the chip 320 when there is an upward Z component. To minimize the deflection of the pad 312 to the bias force a higher modulus elastomer may be deployed or the pad thickness may be reduced. In one example the dimension of the pads may measure 5 mm by 5 mm and have a thickness of 1 mm.
[0034] Another embodiment is shown in FIG. 5 a in which ball bearings 504 allow the heat sink 502 to move in a horizontal direction while limiting motion in the vertical direction. FIG. 5 b illustrates how the horizontal motion is impeded by pads 514 secured to horizontal stops 516 . The pads 514 are viscoelastic as shown in FIG. 4 . The ball bearings 504 are secured by braces 506 attached to the horizontal stops 516 . Note that these bearings 504 are only at the bottom, not the sides.
[0035] FIG. 6 shows a close-up view of one of the ball bearings 504 . The arrows encircling the ball bearing 504 indicate how the ball bearing 504 can rotate, or spin, while remaining in a fixed position. The heat sink 502 is in contact with the top portion of the ball bearing 504 . A slight horizontal motion of the heat sink 502 will produce a swiveling of the ball bearing 504 . The horizontal stops 516 with the pads 514 attached will constrain the heat sink 502 from excessive movement.
[0036] It should be understood that what has been discussed and illustrated serves to provide examples of the possible embodiments within the spirit and scope of the invention; they should not be construed to limit the invention. One with knowledge in the art, after following the discussion and diagrams herein, can employ any viscoelastic material having the same properties as C-1105 bearings from EAR, or flexures properly positioned at the corner mounts as discussed above to provide the advantages of a reduction in package deformation while allowing for limited mechanical motion due to thermal expansion.
[0037] Another approach to limit mechanical motion in the presence of shocks and/or vibrations while allowing for slow thermal expansion is to deploy active servo control of the heat sink. H. Newton, Newton's Telecom Dictionary, 22 nd Edition, Copyright© 2006 Harry Newton, defines a servo as: “Servo: short for servomechanism. Devices which constantly detect a variable, and adjust a mechanism to response to changes.”
[0038] Another embodiment of the present invention is shown in FIG. 7 wherein active servo control is employed to constrain the movement and/or expansion of a heat sink 702 . Voice coil motors are used to actuate the heat sink 702 . FIG. 7 shows one example of a voice coil motor 728 which controls the X motion of one corner of the heat sink 702 . Each voice coil motor includes: a voice coil 726 mounted onto the heat sink 702 and a magnetic circuit consisting of permanently affixed magnets 720 and 722 , with flux return paths and mechanical assembly to hold the magnets in place 724 . The servo method of heat sink constraint differs from the previously described embodiments in that there may be no actual contact made between the heat sink 702 and the board 744 . This is indicated in FIG. 7 by the gaps 799 .
[0039] FIG. 8 shows a top view of the assembly of FIG. 7 with Z direction voice coil motors 710 and 712 . FIG. 8 also shows the voice coils for the X and Y directions, 724 , 726 and 734 and 736 , in opposite corners, which are part of the voice coil motor assembly. For example 726 is the voice coil for voice coil motor 728 as shown in FIG. 7 .
[0040] Gap sensors 735 , 737 , 725 , 727 measure the location of the heat sink 702 edge to a fixed frame in the X and Y directions. Similarly, gap sensors 704 and 706 measure the location of the heat sink 702 to the frame 744 in the Z direction. One example of gap sensors may include proximity sensors using well known capacitance or eddy current measurement methods. The capacitance between two plates is proportional to 1/d, where d is the gap between the plates, thereby the gap can be measured by measuring C and computing 1/C. The voice coil motor and gap sensors are used in a servo loop to control the location of the heat sink 702 relative to the frame 744 .
[0041] As shown in FIG. 8 two vertical axis voice coil motors 710 and 712 are disposed in opposite corners of the top frame 744 to maintain the Z height of the heat sink 702 relative to the frame 744 . For example, a Z position signal Z gap 704 is compared to a Z gap target and the difference between the Z gap target and Z gap 704 will create an error signal as shown in FIG. 10 which is input to the servo controller Gc which produces a signal to control the current to the physical plant Gp which includes Z voice coil motors 710 and heat sink 702 . The current applied to Z voice coil motor 710 will produce a force on the heat sink 702 to actuate it in the +Z or −Z direction until the Z gap value is equal to the target value. Similarly a second servo loop using Z gap 706 would be running in parallel, which for example may have a Z gap target 706 equal to the Z gap 704 target 704 , to maintain the heat sink 702 parallel to the frame 744 .
[0042] To maintain the X and Y position of the heat sink 702 , horizontal axis voice coils 724 , 726 are deployed in one corner of the heat sink 702 and voice coils 734 and 736 are deployed in the opposite corner of the heat sink 702 . These voice coils are part of a voice coil motor assembly, an example of which is shown in FIG. 7 as 728 . A position signal from the difference of Gap X=Xgap 735 −Xgap 725 can be generated by measuring the gap in the X direction using Xgap sensors 735 and 725 and taking the difference between the two signals.
[0043] Similarly, by monitoring the gap in the Y direction using Y gap sensors 737 and 727 a position signal can be generated from the difference of Gap Y=Ygap 737 −Ygap 727 . These signals are input to the servo control system as shown in FIG. 10 . For example, GapX would be compared to a GapX target, which for example may have a value of zero such as would occur when Xgap 735 is equal to X gap 725 and the heat sink 702 is centered with respect to the center of the frame 744 .
[0044] The difference between the GapX and Gap X target will create an error signal as shown in FIG. 10 which is input to the servo controller, Gc, which produces a signal to control the current to Gp, the physical plant, which includes the voice coil motor and heat sink 702 . The current applied to the voice coils 726 , 736 to produces a force on the heat sink 702 to actuate it in the +X or −X direction until the GapX value is equal to the Gap X target value.
[0045] Referring to FIG. 9 there is shown an exploded top view of voice coil motor (VCM) 728 located in the right quadrant of FIG. 8 . This VCM produces a motion of the heat sink 702 in the X direction when a current is applied to the voice coil 726 . The VCM is comprised of permanent magnets 720 and 722 , each of which is made of two magnets with reverse polarity. The magnets 720 and 722 and flux return plates 721 , 723 are held in place by a non-magnetic mechanical fixture 724 . When a current passes through the coil 726 , the coil experiences a force in the +X or −X direction dependent on the direction of the current and transfers that force to the heat sink. Similarly a current passing through voice coil 736 applies a force in the X direction on the opposite corner of the heat sink 702 .
[0046] The coils 726 and 736 are attached to the heat sink 702 and using the servo control system the heat sink 702 will remain centered with respect to the frame 744 in the X direction as previously described while allowing thermal expansion of the heat sink 702 . Similarly, when using the servo control system with voice coils 724 and 734 , the same control of the heat sink 702 in the Y direction can be achieved. In the Z direction, the gap 799 between the heat sink 702 and the frame 744 will be held to a predetermined target value, such that the heat sink 702 remains parallel to the frame 744 .
[0047] Therefore, while there have been described what are presently considered to be the preferred embodiments, it will be understood by those skilled in the art that other modifications can be made within the spirit of the invention. Solutions which combine elements of the described solutions including using mechanical and servo control systems are also possible. | A structure for attaching a heat sink to an integrated circuit chip includes a servo control system and at least one voice coil motor for actuating the heat sink. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to air filter units which are stationary in use, and which include a rotatable mounting to permit the filter cartridge to be rotated under centrifugal force for cleaning without removal.
2. Prior Art
My U.S. Pat. No. 3,998,656 teaches the importance of cleaning cylindrical air filters, and in particular cleaning pleated type paper cartridges and other hollow cylindrical filters by centrifugal force combined with a forced reverse airflow. The device shown therein requires the removal of the air filter cartridge from the filter housing on the vehicle or internal combustion engine with which it is used.
Other devices in the prior art include centrifugal filters which are rotated for filtering action, usually comprising a perforated rotatable drum in a housing to provide air filtering action from the centrifugal force on the rotating unit. This type of filter is not adapted for static operation, and generally does not have as efficient operation as a stationary paper type pleated filter. The centrifugal cleaning action also tends to reduce airflow through the element. Such a device is shown in U.S. Pat. No. 3,857,687 and also in U.S. Pat. No. 3,907,529 for typical showing.
Other air cleaner devices are used which utilize baffles to cause a circumferential flow of air. Patents which illustrate this principle include U.S. Pat. Nos. 3,672,130; 3,740,932; 3,616,618; 3,670,480; and 3,078,650. These devices primarily rely upon the principle of having the air itself rotating or moving annularly so that the entrained particles will be thrown outwardly from the air, while the filter element remains stationary.
U.S. Pat. No. 3,898,066 shows a rotating filter element within a housing that is operated by turbine blades to rotate the filter housing during use from the air that passes through the filter.
An early type air cleaner is shown in U.S. Pat. No. 1,340,058 wherein a plurality of blades rotate during use to attempt to utilize centrifugal force to separate dust from the incoming air in an internal combustion engine.
SUMMARY OF THE INVENTION
The present invention relates to an air filter for intake air of internal combustion engines which utilizes a nonrotating filter cartridge or element during use, but which includes a mounting for the filter element within the air filter housing combined with a power source to permit the rotation of the filter element about a central axis for centrifugal cleaning of the filter element after use.
Efficiency in large internal combustion engines, and in particular, diesel engines operating near maximum horsepower is generally limited by intake air volume. Many engines at the present time operate at a power level wherein insufficient "breathing" or volume of intake air limits the power output, and also reduces the amount of power obtained per pound of fuel. With increasing costs of energy, the inefficiencies in internal combustion engines result in a good bit of unused energy going out the exhaust pipe of the internal combustion engines, and therefore the cost of operation is substantially increased, and usable energy is wasted.
When air filters that have adequate capacity to provide the necessary air supply to the intake of the internal combustion engine are in use, after short periods of operation in dusty conditions the capacity of the filter can be greatly diminished by the collection of particles of dust on the exterior of the filter, particularly in pleated paper type filters which do have high airflow and good filtering characteristics.
As outlined in my previous patent, the need for cleaning exists, but human nature being what it is, any slight additional effort needed for cleaning tends to discourage such cleaning and thus the performance of engines suffers.
In the form of the invention shown herein, small fan blades are mounted to rotate with the filter cartridge or element when it is being cleaned to create a small flow of air that tends to urge the dust particles being thrown outwardly toward a provided dust outlet opening. The device thus forms a readily usable unit that is mounted integrally with the vehicle on which the internal combustion engine is used, or can be mounted closely adjacent to the internal combustion engine as a unit. After a period of use, the filter element can be cleaned immediately to increase the likelihood of desirable cleaning to maintain the efficiency of the filter and thereby conserve fuel through more efficient operation of internal combustion engines.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary side view of a typical tractor showing an internal combustion engine utilizing a filter assembly made according to the present invention installed on the tractor;
FIG. 2 is a sectional view taken as on line 2--2 in FIG. 1;
FIG. 3 is a sectional view taken as on line 3--3 in FIG. 1;
FIG. 4 is a longitudinal sectional view of the filter assembly taken as on line 4--4 in FIG. 3; and
FIG. 5 is a fragmentary enlarged sectional view of an air seal between the facing rotating surfaces at one end of the filter housing.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A typical air filter utilizing a cleaning system made according to the present invention is illustrated at 10, and as shown includes an outer housing 11 which has a mounting frame 12 held in position with suitable attaching members 13. The mounting frame 12 in turn is attached to a support pedestal 14 that is attached to the frame 15 of a tractor in the form shown. The tractor has an internal combustion engine 16, of usual design, and of course the internal combustion engine may be a diesel engine, or a gasoline engine. Tractors operate in extremely dusty conditions, and it is important to keep the flow of intake air to the engine at a high rate to provide adequate "breathing" for the engine to permit it to efficiently utilize fuel. As shown, a normal outlet connection tube 17 of the filter assembly is connected through a hose 18 to the air intake of the internal combustion engine 16.
The bracket or mounting pedestal 14 mounts the housing 11 and the internal filter element closely adjacent the internal combustion engine 16 with which it is used.
The internal construction of the filter assembly 10 is shown in detail in FIGS. 2 through 5. As shown, the outer housing 11 has an air intake port 21 connected to a stack 22 that has the usual weather cap 23 with a screen 24 in the cap intake.
The outer housing 11 is a cylindrical drum housing, and has a first end plate or cap 25 attached to the housing with suitable connector bolts 26. The end cap 25 in turn supports the outlet tube 17 which in the form shown is cylindrical. A filter assembly 27 is mounted in the interior of the housing. The opposite end of the housing 11 from cap 25 is closed with a second removable end cap 30 that is held in place with fastening studs 31 including wing nuts 31A that permit the end plate 30 to be removed with relative ease.
The filter assembly 27 includes a filter element or cartridge 32 that is of usual pleated paper design and has an inner perforated shell 33, and an outer perforated shell 34, which is concentric with and spaced outwardly from the inner shell 33. A pleated paper filter element indicated generally at 35 is mounted between the inner and outer shells 33 and 34. The inner and outer shells 33 and 34 are held together by end caps 36, which are annular bands that extend around and hold the shells in assembled condition. These end caps 36 have small flanges 36A overlapping the inner and outer shells to hold the assembly together. This type of a filter element is a standard element that is available commercially, and normally is used with conventional type air filters or air cleaners. The elements are generally mounted nonrotationally in position inside of an interior housing.
The mounting for filter assembly 27 in the present invention includes a main filter support or mounting member 40, which has a generally radially extending flange 41 and a center internal tubular hub 42. The hub 42 is mounted in suitable bearings 43 within the outlet tube 17. It should be noted that outlet tube 17 is attached to the end plate 25 securely, and forms a bearing cage usable for supporting the hub 42. The interior passageway 44 of the hub 42 is the normal air outlet for filtered air as will be explained.
The flange 41, on its interior facing surface, is turned down to form a support shoulder indicated at 45 on which the inner flange 36A of one end plate 36 of the filter element or cartridge is piloted. The shoulder 45 forms an annular shoulder surface for supporting the cartridge 32 and centering it relative to the axis of rotation of the hub 42. The flange portion 41 that extends radially out from shoulder 45 forms a backing for support and sealing of the filter element.
As shown, suitable seal members 46 can be used annularly around the outer edge of the flange 41 to seat adjacent end cap 36 to prevent air leakage along this face toward outlet 44. Additionally, on the outer surface of the shoulder 45 suitable mounting and sealing means can be provided as shown at 47, to insure a tight air seal around this interior end of the filter cartridge or element 32.
In order to provide an adequate air seal for the rotating hub 42 relative to the outer housing 17 and bearings 43, a seal assembly indicated generally at 50 (see FIGS. 4 and 5) is provided between the inner surface of the end plate 25 and the facing surface of the filter element support or mounting member 40. This seal assembly 50 includes a first annular disc 51 of suitable low friction seal material such as tetraflouroethylene (Teflon), positioned between a pair of fiber or other suitable material discs 52, one on the interior of the housing and the other mounted on the support 40.
These facing seals 51 and 52 will ride in contact with each other and will provide an air seal under static (nonrotating) conditions, which is when the air seal is important because that is when filtered air is provided out the passageway 44. The passage of unfiltered air through this junction into the outlet tubes 17 and 18 is to be avoided.
The filter element 32 is supported at its opposite end with an internal pilot plug 53 which fits within the interior opening of the inner shell 33. This interior opening is illustrated generally at 54. The pilot plug 53 supports a disc 55 that is attached to the plug and extends radially outwardly along the end cap 36 at this end of the cartridge and beyond the outer surface of the outer shell 34. The disc 54 has a plurality of radially extending blades 56 formed thereon which are formed so that the plane of the blade extends in direction of the axis of rotation of the hub 42, and extends outwardly from the outer shell 34. Disc 55 prevents the plug 53 from being pulled axially into the interior opening or chamber 54 of the cartridge 32 more than a desired amount.
The filter element support 40 supports a strap bracket 57 that is attached with suitable cap screws 58 to support 40, and which bracket has a central opening that receives a mounting stud 60. The stud 60 is held in place with lock nuts 61, as shown, and extends substantially along the central axis of the filter element interior chamber 54, and thus along the central axis of the shells 33 and 34 toward the end plate 30 of the housing. The stud 60 passes through an opening in the plug 53, and has a threaded end portion 62 that extends outwardly beyond this plug. It should be noted that the disc 55 has a central opening indicated at 55A and the plug 53 has a recess 53A formed in it. A suitable elastomeric donut seal 63 is provided over the stud 60, and the seal abuts against the outer surface of the plug 53. A hand nut 64 is threaded over the threaded portion 62 to push the plug 53 axially toward the support 57 and toward consequently the support 40. The seal or donut 63 provides an air seal around the stud 60, and the plug 53 pilots the end of the filter element remote from the shoulder 45 and tends to center it. Tightening the nut 64 also forces the filter element 32 against the seal 46, and holds it so that its central axis is substantially along the central axis of the rotating hub 42. The disc 55 seals the end of the chamber 54 and seats the filter element on shoulder 45, against the seals 46 and 47. The plug 53 provides a pilot for centering purposes.
The end plate 30 of the housing as shown has a shoulder that pilots it into place with respect to the housing 11 so that plate 30 is also centered on the housing 11, and the outer surface of the end plate 30 is used for mounting a drive motor 65 of usual design that can be 12 volt, 24 volt, or even can be a 110 volt AC motor. The motor 65 has an output shaft that drives a hub 66 that forms a coupling for receiving the end portion of the stud 60. The end of the stud 60 has a slot 67 to receive a driving tang 68 mounted in the hub 66. The hub 66 thus centers the stud 60 with respect to the hub and by properly mounting the motor 65 so that the center of the hub 66 is in the center of the plate 30, the stud 60 can be very closely aligned with the axis of rotation of the hub 42 at the opposite end of the housing. The motor 65 is controlled through a suitable switch 70 operating from a power source 71 which can be the batteries of the tractor 15, or can be a remote 110 volt source.
In normal operation when the internal combustion engine 16 is running, the air intake tube 18 will be carrying intake air to the internal combustion engine and the airflow will be through the screen 24, stack 22 and into the interior chamber of the housing 11. The air then will pass through the perforated apertures of the outer shell 34, through the paper filter element 35, and into the interior chamber 54. The support 57, is only a strap-like support so that the passageway 44 is substantially completely open to the interior chamber 54 of the filter element. Air will then flow out through the interior passageway 44 to the internal combustion engine, after being filtered. The seals 46, 47, 51, 52 and 63 insure that the air going through the passageway 44 is filtered air. Seals on plate 55 to close chamber 54 may be provided.
The motor 65 remains unenergized during normal use of the filter, and this permits the air to flow easily through the paper element, with the shells 33 and 34 stationary or nonrotating. It should be noted that in many elements using centrifugal force, the air itself is affected by the centrifugal force and tends not to flow through the filter elements so that the capacity of the filter is reduced by centrifugal action. No such problem exists with the present device because the filter element itself is stationary, and the air will flow through the paper filter as desired.
After the engine 16 has been run and used and in particular in dusty conditions, and cleaning of the filter is desired, the switch 70 will be closed, and the motor 65 will rotate the complete filter assembly 27 including the fan blades 56, at a desired direction and at a desired speed. For example, speeds of 1250 to 2,000 rpm have been found to be suitable and tend to throw the dirt vigorously outward from the outer surfaces of the paper filter element 35 into the chamber indicated at 11A that is formed between the outer shell 34 and the inner surface of the housing 11. The fan blades 56 will create a flow of air that will tend to cause a reverse flow through the passageway 44 and outward toward the outside of the filter element. This will also tend to dislodge dirt, although the airflow is relatively small. The dirt of course will be thrown outwardly toward the outer wall of the housing and will tend to slide down to the bottom of housing 11. This dirt will be forced out through a discharge opening 73 formed adjacent one side of the housing, as perhaps best seen in FIGS. 2 and 3. The discharge opening 73 is open to a small rectilinear shaped conduit 74, that discharges downwardly. A lever operated valve 75 that normally is closed is provided in the conduit, and except during cleaning, the airflow tending to come in through the sleeve or tube 74 will be stopped by the valve 75 in closed position.
The dislodged dirt will be forced out by the flow of the air formed by the fan blades 56 and thus the dirt that is collected on the outside of the filter will be discharged out of the housing, and will not again be picked up.
The time of cleaning can be very short, so the actual time of rotation of the filter element is not a significant factor. There is no need for extremely precise bearings that are sometimes necessary for filters that rotate continuously in use.
Thus, the benefits of rotational, centrifugal cleaning are available as well as the benefits of instantaneous cleaning when ever desired. The entire cleaning device is incorporated in with the housing assembly used with the internal combustion engine. By short bursts of cleaning, the efficiency of the paper filter can be maintained at a high level, particularly under extremely dusty conditions. Further, the disadvantages of having air that is being filtered subjected to centrifugal forces is not present with the present device because the filter remains stationary during use.
The filter is rotated at a speed sufficient to cause substantial centrifugal force on the dust particles to tend to throw the dirt off the filter element or cartridge. | An air filter for use on internal combustion engines which operate primarily in heavy dust conditions, and which includes a mounting member as part of the air filter housing that permits the spinning of the air filter cartridge for centrifugal cleaning in place on the internal combustion engine, without removal of the filter cartridge from the air filter housing. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2001-082594, filed Mar. 22, 2001, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to an optical scanner driving apparatus and an optical scanner driving method of driving an optical scanner which scans a light from a light source one-dimensionally or two-dimensionally.
[0004] 2. Description of the Related Art
[0005] There are generally known optical scanners that are prepared based on semiconductor manufacturing technologies for scanning a light from a light source one-dimensionally or two-dimensionally (see U.S. Pat. No. 5,606,447). These scanners are characterized by compactness and low profile.
[0006] [0006]FIG. 1 illustrates a principle of an optical scanner. Referring to FIG. 1, a moving plate 1 having a side to be used as a mirror has a thin rectangularly parallelepipedic profile. A pair of spring sections (elastic members) 2 made of metal or a semiconductor material are arranged respectively at middle positions of the longitudinal edges thereof. A coil pattern (to be referred to as a “driving coil” hereinafter) 3 is arranged on the back side of the moving plate 1 . A pair of permanent magnets 4 is arranged opposing to the respective lateral edges of the moving plate 1 . The permanent magnets 4 generate a magnetic field having a component running in a direction (B) perpendicular to the wiring section 3 a of the driving coil 3 that is parallel with the lateral edges of the moving plate 1 .
[0007] As an AC current having a driving frequency f flows through the driving coil 3 of an optical scanner having the configuration as described above, a magnetic field of the permanent magnets 4 generates a force according to the Fleming's left hand rule in a direction perpendicular to the major surfaces of the moving plate 1 . The magnetic field of the permanent magnets 4 is generated perpendicular to the direction of the electric current flowing in the wiring section 3 a. Then, the moving plate 1 vibrates around the spring sections 2 operating as rotary axis with a frequency of f due to the generated force and the resilient force of the spring sections 2 . If the AC current I is expressed by I=I 0 sin(2πft), the intensity of the magnetic field is H (magnetic flux density B), the number of turns of the driving coil 3 is N, the area of the driving coil 3 is S and the magnetic permeability in vacuum is μ 0 , the scan angle θ and the generated torque F are defined by the equation (1) below:
F=μ 0 NHSI 0 sin(2πft)·cos θ (1)
[0008] In the equation (1), the scan angle θ can be determined by solving the equation of motion (2) below:
J{umlaut over (θ)}=−kθ−C{dot over (θ)}+F (2)
[0009] where k is the spring constant of the spring sections 2 , C is the attenuation coefficient and J is the moment of inertia of the optical scanner. If the mechanical resonance frequency of the optical scanner is fc, k is expressed by equation k=J·(2π·fc) 2 .
[0010] Meanwhile, if the scan angle θ is small and cos θ≈1 can be assumed, the relationship between the scan angle θ and the driving frequency f of the AC current I is expressed by equation (3) below by using the above equations (1) and (2):
θ ( f ) = μ 0 NHSI 0 J 1 { k - ( 2 π f ) 2 } 2 + B 2 · ( 2 π f ) 2 ( 3 )
[0011] [0011]FIG. 2A shows the frequency response characteristics relative to the scan angle θ determined by the above equation (3). FIG. 2B shows the frequency response characteristics relative to a phase difference between the scan angle θ and the driving signal. In FIG. 2A, the vertical axis indicates the scan angle θ and the horizontal axis indicates the driving frequency f. In FIG. 2B, on the other hand, the vertical axis indicates the phase difference θ and the horizontal axis indicates the driving frequency f. From FIG. 2A, it can be seen that a large scan angle θ (resonance amplitude) can be obtained by making the driving frequency f correspond to the mechanical resonance frequency fc. Therefore, it is a common practice to make the driving frequency f of the AC current I and the mechanical resonance frequency fc correspond to each other when driving the moving plate 1 . Note that, as shown in FIG. 3B, the phase of the scan angle θ (equivalent to the vibration of the moving plate 1 ) of the moving plate 1 delays by 90° relative to that of the driving signal (or the AC current I) shown in FIG. 3A.
[0012] The state of vibration of the moving plate 1 needs to be monitored constantly in order to stably drive the optical scanner. Therefore, the moving plate 1 is provided with a sensor for detecting the state of vibration of the scanner. Such a sensor is disclosed, for example, in U.S. Pat. No. 6,188,504. The sensor disclosed in this patent document has a configuration as shown in FIG. 4. On the surface of the moving plate 11 ′, a coil pattern (to be referred to as a “sensing coil” hereinafter) 5 that differs from the driving coil 3 is arranged. An electromotive force is generated by linking the magnetic field of the permanent magnets 4 with the sensing coil 5 when the moving plate 11 ′vibrates. The electromotive force Vr generated in the sensing coil 5 is defined by the equation (4) below:
Vr=N S BS S ·dθ/dt· cos θ (4),
[0013] where N S is the number of turns of the sensing coil 5 , B is the magnetic flux density and S S is the area of the sensing coil 5 .
[0014] If the driving signal (i.e., the AC current I) applied to the optical scanner is I=I 0 sin(2πf C ·t) in the above arrangement, a phase of the vibration of the optical scanner delays by 90° for the driving signal. Therefore, the above equation can be replaced by θ=−θ 0 cos(2πf C ·t). Then, if the scan angle θ (θ 0 ) is small, the electromotive force expressed by the equation (4) can be approximated by the equation (5) below.
Vr=N s BS s θ 0 2 πf c sin(2 πf c t )cos{−θ 0 cos(2 πf c t )}≈ N s BS s θ 0 2 πf c sin(2 πf c t ) (5)
[0015] Therefore, as shown in FIG. 3C, the phase of the electromotive force (or the sensing signal) generated in the sensing coil 5 advances by 90° with reference to that of the vibration of the moving plate 11 ′ shown in FIG. 3B. Note that the sign of the electromotive force is inverted and the phase of the electromotive force delays by 90° when the connections of the opposite ends of the sensing coil 5 are switched. In this specification, however, it is assumed that the phase of the electromotive force advances by 90°. The phase difference is always 90° regardless of the driving frequency. Thus, driving the optical scanner based on the resonance frequency provides phase relationships as illustrated in FIGS. 3A through 3C among the driving signal, the vibration of the moving plate 11 ′, and the electromotive force (sensing signal) of the sensing coil. The phase of the driving signal corresponds to that of the sensing signal.
[0016] [0016]FIG. 5 shows an example of the driving apparatus as described above. A moving plate 11 has a driving coil 11 a and a sensing coil 11 b. When an operation controller such as a personal computer (not shown) supplies a control circuit 12 with a control signal indicating specification values for the vibration amplitude (scan angle) and the vibration frequency of the moving plate 11 , the control circuit 12 outputs a driving reference signal to the driving circuit 13 according to the control signal. The driving circuit 13 outputs a driving signal to the driving coil 11 a according to the driving reference signal. As a result, the moving plate 11 vibrates with a predetermined scan angle and a predetermined vibration frequency. At this time, an electromotive force (sensing signal) is generated at both ends of the sensing coil 11 b by the electromagnetic induction caused by the linkage between the sensing coil 11 b and the magnetic field. From the equation (5), it is possible to assume that the sensing signal has an amplitude proportional to the vibration frequency and the scan angle of the moving plate 11 and forms a sinusoidal wave having the same frequency as the vibration frequency. The sensing signal is transmitted to the control circuit 12 by way of a detection circuit 14 . The control circuit 12 monitors the sensing signal and corrects the driving reference signal output to the driving circuit 13 when the vibration amplitude (scan angle) and the vibration frequency of the moving plate 11 deviate from respective predetermined values. In this way, the moving plate 11 is controlled based on the sensing signal.
[0017] The above-mentioned optical scanner driving apparatus requires the sensing coil 11 b to be arranged along with the driving coil 11 a on the same surface of the moving plate 11 . Then, the area and the number of turns of the driving coil 11 a are limited, reducing the drive efficiency of the optical scanner. While this problem may be avoided by using the large moving plate 11 , the large moving plate 11 reduces the resonance frequency. Then, the scope of application of such an optical scanner will become limited. Further, the manufacturing process will become complicated, reducing the reliability and increasing the manufacturing cost. A sensor other than the sensing coil may be introduced. However, such a sensor may be costly and necessitate a cumbersome operation of regulating the alignment with the optical scanner.
[0018] To solve the above identified problem, for example, there is disclosed a driving circuit to detect an angular velocity zero moment of the vibration mirror and start an oscillation pulse (Japanese Patent Application KOKAI Publication No. 10-207973). However, this method cannot continuously control the vibration amplitude and the vibration frequency. The high-precision control is unavailable.
BRIEF SUMMARY OF THE INVENTION
[0019] The object of the present invention is to provide an optical scanner driving apparatus and an optical scanner driving method that can accurately control the vibration amplitude and the vibration frequency of the moving plate without requiring the use of a specifically designed sensor.
[0020] An optical scanner driving apparatus according to a first aspect of the present invention, is characterized by comprising: a moving plate having a reflection plane and comprising a driving coil integrally formed therewith; a magnetic field generating section arranged in a vicinity of the moving plate; a driving circuit configured to supply a driving signal to the driving coil, the moving plate performing a torsional vibration by the driving signal; first output acquiring means for acquiring an output containing an electromotive force generated in the driving coil by an electromagnetic induction on the basis of the magnetic field generated by the magnetic field generating section and the torsional vibration of the driving coil; second output acquiring means comprising an impedance element having a corresponding impedance to an impedance of the driving coil, for acquiring an output generated by the impedance element by supplying the driving signal to the impedance element; and a control section configured to control a state of the torsional vibration of the moving plate according to the electromotive force generated in the driving coil on the basis of the output acquired by the first output acquiring means and the output acquired by the second output acquiring means.
[0021] In the optical scanner driving apparatus according to the first aspect of the present invention, preferred manners are as follows. Any of the following manners may be used independently or in combination with the others.
[0022] (1) A support member which supports the moving plate; and an elastic member which connects the moving plate with the support are further provided.
[0023] (2) A differential amplifier configured to receive an output of the first output acquiring means and an output of the second output acquiring means, obtain a difference therebetween and output a difference to the control circuit is further provided.
[0024] (3) The control section controls the vibration amplitude of the moving plate according to the difference between an externally given amplitude reference value and an amplitude of the electromotive force.
[0025] (4) The control section includes a PI circuit configured to amplify a difference between an amplitude reference value and an amplitude of the electromotive force, and a gain control circuit configured to control a vibration amplitude of the moving plate according to an amplified difference output from the PI circuit.
[0026] (5) The control section includes a phase shift circuit configured to coincide a phase of the driving signal supplied to the driving coil with a phase of the electromotive force.
[0027] An optical scanner driving method of driving a optical scanner comprising a driving coil and a moving plate supported with free vibration according to a second aspect of the present invention, is characterized by comprising: supplying a driving signal to the driving coil; acquiring a first output containing an electromotive force generated in the driving coil by an electromagnetic induction caused by a drive of the driving coil; supplying the driving signal to an impedance element corresponding to the driving coil; acquiring a second output generated in the impedance element; detecting the electromotive force generated in the driving coil on the basis of the first output and the second output; and controlling the driving signal supplied to the driving coil according to a detected electromotive force.
[0028] An optical scanner driving apparatus according to a third aspect of the present invention, is characterized by comprising: an optical scanner comprising a moving plate having a reflection plane and comprising a driving coil integrally formed therewith, a support member configured to support the moving plate, an elastic member configured to connect the moving plate and the support member, and a magnetic field generating section arranged in a vicinity of the moving plate; a driving circuit configured to supply a driving signal to the driving coil, the moving plate performing a torsional vibration according to the driving signal; first output acquiring means for acquiring an output containing an electromotive force generated in the driving coil by an electromagnetic induction on the basis of the magnetic field generated by the magnetic field generating section and the torsional vibration of the driving coil; second output acquiring means comprising an impedance element having a corresponding impedance to an impedance of the driving coil, for acquiring an output generated by the impedance element by supplying the driving signal to the impedance element; and control means for controlling a state of the torsional vibration of the moving plate according to the electromotive force generated in the driving coil on the basis of the output acquired by the first output acquiring means and the output acquired by the second output acquiring means.
[0029] In the optical scanner driving apparatus according to the third aspect of the present invention, preferred manners are as follows. Any of the following manners may be used independently or in combination with the others.
[0030] (1) The control means controls the vibration amplitude of the moving plate according to the difference between an externally given amplitude reference value and an amplitude of the electromotive force.
[0031] (2) The control means controls a vibration frequency of the moving plate by a phase shift control which coincides a phase of the driving signal supplied to the driving coil with a phase of the electromotive force.
[0032] An optical scanner driving method of driving an optical scanner comprising a moving plate on which a driving coil is formed, a support member and an elastic member according to a fourth aspect of the present invention, is characterized by comprising: supplying a driving signal to the driving coil; acquiring a first output containing an electromotive force generated in the driving coil by an electromagnetic induction caused by a drive of the driving coil; supplying the driving signal to an impedance element corresponding to the driving coil; acquiring a second output generated in the impedance element; detecting the electromotive force generated in the driving coil on the basis of the first output and the second output; and controlling the driving signal supplied to the driving coil according to a detected electromotive force.
[0033] A driving and sensing circuit applied to an electromagnetic driving optical scanner comprising a support member, a moving plate on which a driving coil is formed, an elastic member connecting the support member and the moving plate, and a magnetic field generating section arranged in opposite to the moving plate, according to a fifth aspect of the present invention, is characterized by comprising: a first acquiring circuit configured to acquire a voltage difference between both ends of the driving coil; an impedance element which corresponds to the driving coil; a second acquiring circuit configured to acquire a voltage difference between both ends of the impedance element; and a difference detection circuit configured to obtain a difference between an output from the first acquiring circuit and the second acquiring circuit. With this configuration, it is preferable that a control circuit configured to feedback an output from the difference detection circuit to a driving circuit for the driving coil is further provided.
[0034] A detection method applied to an electromagnetic driving optical scanner comprising a support member, a moving plate on which a driving coil is formed, an elastic member connecting the support member and the moving plate, and a magnetic field generating section arranged in opposite to the moving plate, according to a sixth aspect of the present invention, is characterized by comprising: acquiring a first voltage difference between both ends of the driving coil; acquiring a second voltage difference between both ends of the impedance element which corresponds to a resistance of the driving coil; and obtaining a difference between the first voltage difference and the second voltage difference.
[0035] Each aspect of the present invention makes it possible to extract the electromotive force generated by the electromagnetic induction of the driving coil of the moving plate and control the driving signal supplied to the driving coil according to the extracted force. Therefore, no external sensor is needed for accurately controlling the vibration amplitude and the vibration frequency of the moving plate.
[0036] Additional objects and advantages of the present invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the present invention. The objects and advantages of the present invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0037] The accompanying drawings, which are incorporated in and constitutes a part of the specification, illustrates presently preferred embodiments of the present invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the present invention.
[0038] [0038]FIG. 1 is a schematic perspective view illustrating a configuration of an optical scanner;
[0039] [0039]FIGS. 2A and 2B are graphs illustrating the relationships between an amplitude and phase of the scan angle and the driving frequency of an optical scanner;
[0040] [0040]FIGS. 3A to 3 C are graphs illustrating the relationships among the driving signal, the scan angle and the sensing signal of an optical scanner at resonance;
[0041] [0041]FIG. 4 is a schematic perspective view of a known optical scanner;
[0042] [0042]FIG. 5 is a schematic block diagram illustrating a configuration example of a known optical scanner driving apparatus;
[0043] [0043]FIG. 6 is a schematic block diagram of an optical scanner driving apparatus according to a first embodiment of the present invention;
[0044] [0044]FIG. 7 is a schematic circuit diagram of a driving and sensing circuit used for the first embodiment;
[0045] [0045]FIG. 8 is a schematic circuit diagram of a control circuit used for the first embodiment; and
[0046] [0046]FIG. 9 is a schematic circuit diagram of a control circuit used for a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0047] Hereinafter, the present invention will be described referring to the accompanying drawings.
[0048] (First Embodiment)
[0049] [0049]FIG. 6 schematically shows a configuration of an optical scanner driving apparatus according to the present invention. Referring to FIG. 6, a moving plate of an optical scanner has substantially the same configuration as the moving plate 1 shown in FIG. 1 and hence will not be illustrated nor described any further.
[0050] The first embodiment of optical scanner driving circuit according to the present invention comprises a control circuit 23 and a driving and sensing circuit 22 . As shown in FIG. 6, a driving coil 21 a is connected to the driving and sensing circuit 22 . The control circuit 23 is connected to the driving and sensing circuit 22 .
[0051] The operation of optical scanner driving circuit will be described referring to FIGS. 6 through 8.
[0052] An operation controller such as a personal computer (not shown) supplies the control circuit 23 with a control signal showing reference values of the vibration amplitude (scan angle) and the vibration frequency of the moving plate 21 . The control circuit 23 outputs a driving reference signal to the driving and sensing circuit 22 according to the control signal. The driving and sensing circuit 22 by turn outputs a driving signal to the driving coil 21 a according to the driving reference signal from the control circuit 23 . As a result, the moving plate 21 vibrates with a predetermined scan angle and a predetermined vibration frequency.
[0053] When the moving plate 21 vibrates, the driving coil 21 a, at its both ends, links with the magnetic field of the permanent magnets (or electromagnets, although not shown). As a result, the electromagnetic induction generates an electromotive force (sensing signal). The generated sensing signal is then transmitted to the control circuit 23 via the driving and sensing circuit 22 . The control circuit 23 monitors the sensing signal. Whenever the vibration amplitude (scan angle) and the vibration frequency of the moving plate 21 deviate from the predetermined respective values, the control circuit 23 corrects the driving reference signal to be output to the driving and sensing circuit 22 . As a result, it is possible to control the scan angle and the vibration frequency of the moving plate 21 according to the sensing signal from the driving coil 21 a.
[0054] [0054]FIG. 7 is a schematic circuit diagram of the driving and sensing circuit 22 of the optical scanner driving circuit according to the first embodiment.
[0055] Basically, the driving and sensing circuit 22 comprises a first amplifier 31 , a second amplifier 32 and a resistance element 36 .
[0056] Referring to FIG. 7, the driving signal (alternative voltage) V d of the control circuit 23 is applied to a positive input terminal of the first amplifier 31 and that of the second amplifier 32 .
[0057] The first amplifier 31 operates as a first output acquiring means. A negative input terminal of the first amplifier 31 connects with a resistance element 33 whose resistance is R 0 . The driving coil 21 a (an equivalent circuit 21 a of the driving coil in FIG. 7) of the moving plate 21 is connected between an output terminal of the first amplifier 31 and a connection point between the negative input terminal and the resistance element 33 . In FIG. 7, the driving coil 21 a is represented by an equivalent circuit, i.e., a series circuit comprising a coil having inductance L coil and a resistance element having resistance of R coil . Assume that the inductance L coil is negligible relative to the resistance R coil . The output terminal of the first amplifier 31 is connected to one of the input terminals (positive input terminal in FIG. 7) of a differential amplifier 34 .
[0058] The second amplifier 32 operates as a second output acquiring means. A resistance element 35 with resistance R 1 is connected to the negative input terminal of the second amplifier 32 . A resistance element 36 with resistance R 2 is connected as an impedance element between the output terminal of the second amplifier 32 and the connection point between the negative input terminal of the second amplifier 32 and the resistance element 35 . The resistance element 36 has a resistance equivalent to the resistance R coil of the driving coil 21 a. The output terminal of the second amplifier 32 is connected to the other input terminal of the differential amplifier 34 .
[0059] The differential amplifier 34 operates as electromotive force detection means. The differential amplifier 34 outputs a detection signal V s , i.e., a difference output V 0 −V 1 between the output V 0 of the first amplifier 31 and the output V 1 of the second amplifier 32 .
[0060] With the above described arrangement, the control circuit 23 supplies the first amplifier 31 with the driving signal V d . In response to the driving signal V d , the first amplifier 31 supplies an electric current having a current value of V d /R 0 to the driving coil 21 a of the moving plate 21 . Then, a potential difference is generated at both ends of the driving coil 21 a. The potential difference is equal to the sum of (R coil /R 0 ) V d and the electromotive force (sensing signal) V r generated when the driving coil 21 a links with the magnetic field. Therefore, the output V 0 of the first amplifier 31 is expressed by the equation (6) below.
V 0 =V d +R coil /R 0 V d +V r (6)
[0061] On the other hand, when the driving signal V d receives the second amplifier 32 , it supplies an electric current having a current value of V d /R 1 to the resistance element 36 . Then, a voltage of (R 2 /R 1 ) V d is generated at both ends of the resistance element 36 . Therefore, the output V 1 of the first amplifier 31 is expressed by the following equation (7).
V 1 =V d +R 2 /R 1 V d (7)
[0062] The output V 0 of the first amplifier 31 and the output V 1 of the second amplifier 32 are then output to the differential amplifier 34 . The differential amplifier 34 outputs a difference of the outputs, or V 0 −V 1 , as a detection signal V S . From the above equations (6) and (7), the detection signal V S is expressed by the following equation (8).
[0063] [0063] V s = V 0 - V 1 = ( R coil R 0 - R 2 R 1 ) V d + V r ( 8 )
[0064] The first term of the right side of the equation (8) can be cancelled if resistances R 1 and R 2 of the resistance elements 35 and 36 are so selected as to make (R coil /R 0 )=(R 2 /R 1 ). Then, the differential amplifier 34 can detect the electromotive force (sensing signal) V r of the driving coil 21 a. Only with the exception of the different detection sensitivity, the electromotive force (sensing signal) V r detected by the driving and sensing circuit 22 shown in FIG. 7 can be handled almost the same as the electromotive force of the sensing coil in FIG. 5.
[0065] The above description assumes the inductance L coil of the driving coil 21 a to be negligible. If it is not negligible, its influence can be cancelled by connecting an extra coil having the same inductance to the resistance element 36 in series. In this case, however, the resistance of the extra coil is added to the resistance of the resistance element 36 . Therefore, when an extra coil is connected to the resistance element 36 in series, the circuit needs to be so configured as to eliminate the influence of the resistance of the extra coil.
[0066] If the temperature coefficients of the resistors differ from each other, it is expected that an error is generated when the temperature changes. However, assuming that the temperature coefficients of the driving coil 21 a and the resistance elements 33 , 35 and 36 are α coil , α 0 , α 1 and α 2 respectively, the influence of a temperature change can be cancelled by selecting the resistance elements so as to satisfy the equation (9) for them.
R coil ( 1 + α coil ) R 0 ( 1 + α 0 ) = R 2 ( 1 + α 2 ) R 1 ( 1 + α 1 ) ( 9 )
[0067] [0067]FIG. 8 shows a configuration example of the control circuit 23 according to the first embodiment. Referring to FIG. 8, an operation controller such as a personal computer (not shown) supplies the oscillation circuit 41 with a frequency reference value as a control signal. Then, the oscillation circuit 41 generates a sinusoidal wave signal having a predetermined amplitude according to the frequency specified in the frequency reference value. The oscillation circuit 41 is connected to a gain control circuit 42 . The gain control circuit 42 controls (regulates) the amplitude of the sinusoidal wave signal output from the oscillation circuit 41 according to the output of a PI circuit 47 , which will be described in more detail hereinafter. Then, the gain control circuit 42 outputs the sinusoidal signal with the controlled (regulated) amplitude as a driving reference signal to the driving and sensing circuit 22 .
[0068] The driving and sensing circuit 22 connects with an amplifier circuit 43 . The driving and sensing circuit 22 supplies a sensing signal to the amplifier circuit 43 . The amplifier circuit 43 amplifies the amplitude of the input sensing signal by a predetermined factor.
[0069] The amplifier circuit 43 is connected to a filter circuit 44 . The filter circuit 44 comprises a band pass filter for extracting only a vibration frequency component (the frequency component specified in the frequency reference value). The filter circuit 44 eliminates a noise component in the output supplied from the amplifier circuit 43 . While it is most desirable that the filter circuit 44 comprises a band pass filter, there may be provided a low pass filter and a band-pass filter depending on noise situations. According to cases, filter circuits may be omitted. It may be also preferable to invert the connecting relation between the amplifier circuit 43 and the filter circuit 44 .
[0070] The filter circuit 44 is connected to an amplitude detection circuit 45 . The amplitude detection circuit 45 detects an amplitude value (or an RMS value) of the sensing signal whose noise component has been eliminated by the filter circuit 44 . The amplitude detection circuit 45 then outputs the detected value to a subtraction circuit 46 . The subtraction circuit 46 determines a deviation of the sensing signal amplitude from the amplitude reference value supplied as a control signal from the operation controller (not shown).
[0071] The subtraction circuit 46 is connected to the PI circuit 47 . The PI circuit comprises an I circuit (integration circuit) and a P circuit (proportional circuit). The PI circuit 47 amplifies a difference signal from the subtraction circuit 46 according to the frequency component by a predetermined gain. Then, the PI circuit 47 supplies the amplified difference signal (to be referred to as a “control signal” hereinafter) to the gain control circuit 42 . The gain control circuit 42 controls the amplitude of the driving signal by means of the control signal from the PI circuit 47 . Consequently, a combination of the gain control circuit 42 and the PI circuit 47 may be referred to as an “amplitude control section” hereinafter.
[0072] Now, the operation of the above arrangement will be described below.
[0073] While the moving plate 21 is in a non-vibrating state (to be referred to as an “initial state” hereinafter), the operation controller such as a personal computer (not shown) may supply the oscillation circuit 41 with a frequency reference value (to be assumed as a “resonance frequency” here) as a control signal. In this case, the oscillation circuit 41 generates a driving signal. The driving signal is fed to the driving coil 21 a of the moving plate 21 via the gain control circuit 42 and the driving and sensing circuit 22 .
[0074] In the initial state, the driving and sensing circuit 22 outputs a zero sensing signal to the amplifier circuit 43 . When the operation controller such as a personal computer (not shown) supplies the subtraction circuit 46 with an amplitude reference value as a control signal in the initial state, the deviation obtained by the subtraction circuit 46 becomes a maximum value. As a result, a large control signal is output from the PI circuit 47 . Then, the gain control circuit 42 controls the driving signal so as to increase the amplitude of the driving signal.
[0075] As a result, the moving plate 21 starts vibrating with the resonance frequency.
[0076] Thereafter, the amplitude control section controls the driving signal so as to increase the driving signal amplitude until the deviation produced by the subtraction circuit 46 becomes zero relative to the amplitude reference value. As the vibration amplitude of the moving plate 21 becomes sufficiently large, the sensing signal from the driving and sensing circuit 22 increases. When the output (difference signal) of the subtraction circuit 46 becomes zero, the amplitude control section controls the driving signal so as to maintain the driving signal amplitude. If the deviation produced by the subtraction circuit 46 becomes negative relative to the amplitude reference value, the amplitude control section controls the driving signal so as to reduce the amplitude of the driving signal.
[0077] In this way, the amplitude control section controls so as to always keep the vibration amplitude of the moving plate 21 at a value that corresponds to the amplitude reference value.
[0078] According to the above described first embodiment, the driving coil 21 a of the moving plate 21 links with the magnetic field of the magnets to induce the electromotive force. The induced electromotive force is extracted as a sensing signal. The extracted sensing signal is monitored by the control circuit 23 . When the vibration amplitude of the moving plate 21 deviates from the vibration reference value, the driving signal output to the driving and sensing circuit 22 is corrected. As a result, the moving plate 21 can be controlled so that the vibration amplitude thereof is kept at a predetermined value. Therefore, the vibration amplitude of the moving plate 21 can be controlled highly accurately without providing the optical scanner with a sensing coil or an additional sensing circuit as conventionally practiced.
[0079] (Second Embodiment)
[0080] [0080]FIG. 9 outlines a configuration of the control circuit 23 that can be used for the second embodiment of the present invention. The mutually corresponding parts in FIGS. 9 and 8 are designated by the same reference numerals and a detailed description will be omitted for simplicity. Since the moving plate of the second embodiment is identical with that of the first embodiment, it will not be illustrated nor described here.
[0081] Referring to FIG. 9, the control circuit 23 comprises a phase shift circuit 48 instead of the oscillation circuit 41 . The phase shift circuit 48 is connected between the output terminal of the filter circuit 44 and the input terminal of the gain control circuit 42 . The phase shift circuit 48 regulates phases so that the phase of the driving signal output from the gain control circuit 42 agrees with that of the sensing signal supplied to the amplifier circuit 43 (oscillation based on the resonance frequency provides a match between the phases of the driving signal and the sensing signal). In other words, the phase shift circuit 48 regulates the phase of the output signal from the filter circuit 44 and supplies a result to the gain control circuit 42 . The extent of phase regulation by the phase shift circuit 48 depends on a phase displacement that is produced as signals pass through the amplifier circuit 43 , the filter circuit 44 and the gain control circuit 42 .
[0082] The control circuit 23 according to the second embodiment is always provided with positive feedback. More specifically, in the initial state, a loop gain becomes greater than or equal to 1 and the oscillation starts by the amplitude control section. The moving plate 21 vibrates with the resonance frequency. Like the first embodiment, the amplitude control section also controls the vibration amplitude. Namely, the amplitude control section controls the vibration frequency of the moving plate 21 so as to follow the mechanical resonance frequency. Additionally, the amplitude control section controls the vibration amplitude of the moving plate 21 so as to maintain a predetermined value.
[0083] As described above, like the first embodiment, the second embodiment can also highly accurately control frequencies of the moving plate without the need for any external sensor.
[0084] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the present invention in its broader aspects is not limited to the specific details and representative devices, and illustrated examples shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | An optical scanner driving apparatus comprises a moving plate having a reflection plane and a driving coil, a magnetic field generating section arranged in a vicinity of the moving plate, a driving circuit to supply a driving signal to the driving coil, a first output acquiring section to acquire an output containing an electromotive force generated in the driving coil by an electromagnetic induction, a second output acquiring section comprising an impedance element having a corresponding impedance to an impedance of the driving coil, to acquire an output generated by the impedance element by supplying the driving signal to the impedance element, and a control circuit to control a state of the torsional vibration of the moving plate according to the electromotive force generated in the driving coil on the basis of the outputs acquired by the first output acquiring section and the second output acquiring section. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a novel process for producing methyl methacrylate from acetone and methyl formate, or from acetone, methanol and carbon monoxide as starting materials.
A large amount of methyl methacrylate is used as a starting material for production of various polymers and the methyl methacrylate is a greatly important intermediate in industrial use.
2. Description of Related Arts
For production of methyl methacrylate on a commercial scale, an acetone cyanhydrin method in which prussic acid and acetone are used as starting materials, and methyl methacrylate is produced through acetone cyanhydrin (hereinafter referred to as "ACH") formed from the starting materials, and a C 4 oxidation method in which isobutylene or tert-butanol is used as a starting material have been put into practical use.
In addition, it has been proposed that methyl methacrylate can be produced by an oxidation-dehydrogenation of isobutyric acid, or a condensation-dehydration of propionic acid or propion aldehyde and formaldehyde. But, these methods have not been put into practice.
In accordance with the ACH method, ACH is synthesized from prussic acid and acetone, and then the resulting ACH is reacted with methanol in the presence of an excess amount of concentrated sulfuric acid to produce methyl methacrylate. This ACH method is widely carried out now, because the reaction proceeds easily with high yields. The ACH method, however, has disadvantages in that large amounts of waste sulfuric acid and ammonium sulfate are by-produced and the treatment thereof increases production costs of methyl methacrylate.
Also the C 4 method has disadvantages in that a number of side reactions are caused, the yield of methyl methacrylate is low, purification costs are high, the operations are complicated, and an expensive reactor is required. In addition, isobutylene and tert-butanol to be used as starting materials are not easily available.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a novel process for production of methyl methacrylate from starting materials easily available and in stable supply.
Another object of the present invention is to provide a process for production of methyl methacrylate with simple operations at low cost.
Still another object of the present invention is to provide a process for production of methyl methacrylate in which starting materials can circulate by regeneration during reactions.
The present invention relates to a process for producing methyl methacrylate which comprises:
(I) a step of reacting prussic acid and acetone to form acetone cyanhydrin (ACH);
(II) a step of hydrating ACH obtained in the above step (I) to form α-hydroxyisobutyric acid amide;
(III) a step of dehydrating α-hydroxyisobutyric acid amide obtained in the above step (II) to form methacrylic acid amide;
(IV) a step of reacting methacrylic acid amide obtained in the above step (III) with methyl formate or with methanol and carbon monoxide to form methyl methacrylate and formamide; and
(V) a step of dehydrating formamide separated from the product obtained in the above step (IV) to form prussic acid and recycling the prussic acid as a regenerated starting material in the step (I).
DESCRIPTION OF PREFERRED EMBODIMENTS
The process of the present invention eventually employs acetone and methyl formate, or acetone, methanol and carbon monoxid as starting materials. Although the process of the present invention produces the objective methyl methacrylate through ACH, it is not accompanied by by-production of ammonium sulfate at all unlike the conventional ACH method.
Acetone is formed as a by-product in large amounts and at low cost in production of phenol by a cumene method. If necessary, it can easily be produced from propylene.
Methyl formate can easily be produced through carbonylation or dehydrogenation of methanol which is commercially available in large amounts and at low cost.
In the process of the present invention, ACH is produced by reacting prussic acid and acetone by the conventional methods. More specifically, ACH can be produced in a high yield by reacting prussic acid and acetone at a temperature as low as about 10° C. in the presence of a basic catalyst such as alkalis or amines.
α-Hydroxyisobutyric acid amide is produced by reacting ACH and water in the presence of a catalyst. As such catalysts, those effective for the hydration reaction of nitriles can be used. Although strong acids such as sulfuric acid can be used, metal or metal oxide catalysts are desirable from an economical standpoint including post-treatment. More specifically, manganese, copper, nickel and their oxides are effective, with manganese oxide being particularly preferred.
The weight ratio of ACH to water is suitable to be in a range of 10:90 to 90:10. In the reaction system, a solvent such as acetone or methanol can be also present. When manganese oxide is used as a catalyst, the reaction temperature is preferably 20° to 150° C. and more preferably 40° to 100° C. The reaction time is preferably 0.3 to 6 hours and more preferably 0.5 to 3 hours. The reaction can be carried out batchwise or continuously.
Although production of methacrylic acid amide by a dehydration reaction of α-hydroxyisobutyric acid amide can be carried out by a liquid phase reaction using, for example, sulfuric acid or phosphoric acid, it can be carried out more effectively by a gas phase reaction using a solid catalyst.
In connection with catalysts for the gas phase catalytic reaction, Japanese Patent Application Laid-Open No. 183654/1983 discloses a process in which a solid acid catalyst such as solid phosphate is used. This process, however, has a disadvantage in that a large amount of methacrylic acid is by-produced. In the process of the present invention, normally the nitrogen atoms are recycled between amide and nitrile in the reaction system, but undesirable by-production of methacrylic acid leads to taking nitrogen atoms out of the reaction cycle whereby it becomes difficult to make the process advantageous from an economical standpoint.
According to the present invention, use of an amide compound as a diluent in the dehydration reaction prevents methacrylic acid as a by-product from forming and permits production of the objective product with high selectivity at a high conversion of the starting materials.
Amide compounds which can be used include dimethyl formamide, dimethylacetamide, and N-methylpyrrolidone. Of these compounds, N-methylpyrrolidone is particularly preferred.
In the process of the present invention, the reaction of methacrylic acid amide and methyl formate, or the reaction of methacrylic acid amide, methanol and carbon monoxide for production of methyl methacrylate can be effectively carried out in the presence of a solvent and a catalyst, although it proceeds only by heating a mixture of methacrylic acid amide and methyl formate in the absence of a catalyst.
Since the above reaction is an equilibrium reaction, the yield of methyl methacrylate varies with the molar ratio of methacrylic acid amide to methyl formate, or to methanol and carbon monoxide. The molar ratio of methacrylic acid amide to methyl formate, or to methanol and carbon moxide is preferably 1:1 to 10:1 and more preferably 2:1 to 5:1.
Addition of a solvent is effective in increasing the solubility of solid methacrylic acid amide, and the selectivity of the reaction. As the solvent to be used, methanol is most preferable, and the molar ratio of methanol to methacrylic acid amide is preferably 2:1 to 10:1.
Known catalysts to be used in the above reaction include inorganic acids, organic acids, alkalis, and their salts as described in Japanese Patent Application Laid-Open Nos. 55444/1983 and 78937/1985. However, when these known catalysts are used, both the rate of reaction and selectivity are insufficiently low.
Alkali metal alcolate and alakaline earth metal oxide are excellent as catalysts for use in the above reaction.
Representative examples of the alkali metal alcolate to be used as a catalyst in the process of the present invention are methylate, ethylate and butyrate of sodium and potassium. They can be prepared from metallic lithium, sodium or potassium and lower alcohol.
The alkaline earth metal oxide to be used as a catalyst in the process of the present invention includes magnesium oxide, calcium oxide, and barium oxide.
In connection with reaction conditions, when the alkali metal alcolate or alkaline earth metal oxide is used as a catalyst in the process of the present invention, the suitable amount of the catalyst used is 0.001 to 0.30 per mol of methacrylic acid amide under conditions that the reaction temperature is 20° to 100° C. and the reaction time is 0.5 to 6 hours.
Japanese Patent Application Laid-Open No. 3015/1977 discloses that an alkali metal alcolate catalyst is used in production of carboxylic acid ester from carboxylic acid amide and alcohol.
This alcoholysis, however, has a disadvantage in that the yield of carboxylic acid ester is low, as well as operational disadvantages in that the reaction temperature must be as high as 200° C., high pressure is needed and the intermittent release of the pressure in the reaction system is required since ammonia is generated during the reaction.
On the contrary, in the process of the present invention, when an esterification reaction by using methyl formate is carried out, the aforementioned disadvantages can be all dissolved.
In the process of the present invention, the reaction product is separated and recovered by an operation such as distillation, and unreacted materials can be used again as starting materials.
Formamide by-produced along with the objective methyl methacrylate is subjected to a dehydration reaction to produce prussic acid. This prussic acid is separated and recovered, and then reintroduced to the reactor for production of ACH.
In the process of the present invention, the reaction proceeds with high selectivity at each step, and thus methyl methacrylate can be produced with high selectivity from acetone and methyl formate, or from acetone, methanol and carbon monoxide. Moreover, undesirable by-products, such as ammonium sulfate produced in the conventional methods, are not formed at all, and thus the process of the present invention is of high industrial value.
The present invention is described in greater detail with reference to the following examples, although it is not limited thereto.
EXAMPLE 1
Step (I)
Synthesis of ACH from prussic acid and acetone
116 g of acetone and 1 ml of a lN aqueous sodium hydroxide solution were placed in a 500-milliliter flask equipped with a stirrer, a thermometer, and a dropping funnel for prussic acid, and 59.4 g of prussic acid was dropped thereto while maintaining the temperature in the flask at 20° C. After dropping of prussic acid was completed, the reaction was completed by maintaining the mixture at 20° C. for 2 hours. Then 50% sulfuric acid was added thereto to adjust the reaction solution to pH 3.
The flask was connected to a vacuum system, and unreacted prussic acid was distilled away to obtain 171 g of ACH.
The purity of ACH was 98.4%, and the yield of ACH based on acetone was 99%.
Step (II)
Synthesis of α-hydroxyisobutyric acid amide by hydration of ACH
63.2 g of potassium permanganate and 500 g of water were placed in a 1-liter flask equipped with a stirrer, a reflux cooler and a thermometer, and stirred while heating at 70° C. Then, 240 g of an aqueous solution containing 96.2 g of manganese sulfate and 40 g of 15% sulfuric acid were added thereto, and reacted at 70° C. for 3 hours.
The contents in the flask were cooled, and then a resulting precipitate was suction filtered and washed with 2.4 L (L=liter) of water. The precipitated cake was dried at 60° C. overnight to obtain 74 g of active manganese dioxide, which was used as a catalyst in the subsequent step.
150 g of ACH obtained in the step (I), 350 g of water, 100 g of acetone, and 60 g of manganese dioxide were placed in a 1-liter flask equipped with a stirrer, a reflux cooler and a thermometer, and reacted by heating at 60° C. for 5 hours while stirring.
The reaction solution was cooled with ice, and then the catalyst was removed by suction filtration. A gas chromatographic analysis of the filtrate showed that the conversion of ACH was 99.5%, the yield of α-hydroxyisobutyric acid amide was 95%, and small amounts of acetone and formamide were contained.
The above filtrate was distilled under reduced pressure to obtain 155 g of α-hydroxyisobutyric acid amide with a purity of not less than 99.5% as a main component.
Step (III)
Synthesis of methacrylic acid amide by dehydration of α-hydroxyisobutyric acid amide
20.3 g of sodium hydroxide was dissolved in 100 ml of water, and 10.1 g of magnesium oxide was suspended therein. To this suspension, 116.4 g of 85% phosphoric acid was gradually poured and mixed. Then, the resulting mixture was heated while stirring to evaporate water, thereby making it paste-like, and this paste was calcined at 700° C. for 12 hours. This calcined material was ground to 10-16 mesh, and a 20 ml portion thereof was packed in a tubular reactor made of Pyrex glass with an inner diameter of 18 mm. On the calcained material as packed above, 10 ml of a porcelain Raschig ring with a diameter of 3 mm was placed to form an evaporation zone. While maintaining the reactor at 320° C. and flowing nitrogen gas from the top of the reactor at a rate of 10 ml/min, a 30 wt% N-methylpyrrolidone solution of α-hydroxyisobutyric acid amide obtained in the step (II) was supplied at a rate of 10.5 g/hr.
Reaction gas was collected by cooling with ice and analyzed by a gas chromatography.
The conversion of the α-hydroxyisobutyric acid amide as starting material was 95.8%, and the yield of methacrylic acid amide based on the converted starting material was 81.6 mol %. In addition, 10% of acetone and 4% of acetonitrile were formed, and no methacrylic acid was detected.
600 g of the reaction solution was distilled under reduced pressure to obtain 113 g of methacrylamide with a purity of not less than 98% as a main component.
Step (IV)
Synthesis of methyl methacrylate and formamide from methacrylic acid amide and methyl formate
85.6 g of methacrylic acid amide obtained in the step (III), 180 g of methyl formate, 96 g of methanol, and 1.1 g of sodium methylate were placed in a 1-liter stainless steel autoclave equipped with a stirrer, and reacted by heating at 60° C. for 2 hours while stirring.
The reaction product was cooled, and analyzed by gas chromatography. This analysis showed that the conversion of methacrylic acid amide was 94%, the selectivity of methyl methacrylate based on methacrylic acid amide was 91%, and the selectivity of formamide was 98%. In addition, 8% of methyl α-methoxyisobutyrate was obtained in a yield of 8%.
After neutralization of sodium methylate in the reaction solution with hydrochloric acid, distillation was conducted by the usual method to recover methyl formate, methanol and methacrylic acid amide, and at the same time, 79 g of methyl methacrylate with a purity of 99% and 40 g of formamide with a purity of 99% were obtained.
Step (V)
Production of prussic acid by dehydration of formamide
30 ml of a spherical α-alumina catalyst (calcined at 1,500° C. for 2 hours) with a diameter of 2 mm was packed in a SUS 316 reactor with an inner diameter of 18 mm, and a small amount of dilution nitrogen gas and formamide obtained in the step (IV) were continuously supplied under conditions that the pressure was 80 Torr, the temperature was 450° to 500° C, and the contact time was 0.1 second. The reaction was continued for 10 hours. Non-condensed gas was introduced into a gas washing container containing water to make prussic acid accompanied absorbed therein.
The condensed solution and the absorbing solution were analyzed. This analysis showed that the conversion of formamide was 98%, and the yield of prussic acid based on formamide was 92%.
Upon distillation of the product, high purity prussic acid was obtained. This prussic acid was recycled as a starting material for production of ACH.
COMPARATIVE EXAMPLE 1
At the step (III) of Example 1, the reaction was carried out in the same manner as in Example 1 except that an aqueous solution was used in place of the N-methylpyrrolidone solution. As a result, the conversion of the α-hydroxyisobutyric acid amide as starting material was 98.6%, and the yield of methacrylic acid amide based on the converted starting material was 41.8 ol %. In addition, 32% of methacrylic acid, 10% of acetone, and 8% of methacrylonitrile were formed.
EXAMPLE 2
At the step (IV) of Example 1, 200 g of methanol was supplied in place of 180 g of methyl formate and 96 g of methanol, and carbon monoxide was introduced under a pressure of 40 atm. The reaction was carried out by heating while stirring.
When the temperature in the autoclave reached 60° C., carbon monoxide was introduced so as to maintain the reaction pressure at 40 atm, and the reaction was further continued for 3 hours.
Then, the temperature in the autoclave was lowered to 10° C. by cooling, and the pressure was gradually decreased to atmospheric pressure. Thereafter the reaction product was taken out and analyzed by gas chromatography. This analysis showed that the conversion of methacrylic acid amide was 87%.
The selectivity of methyl methacrylate, and the selectivity of formamide both based on methacrylic acid amide were 95% and 94%, respectively. | Disclosed is a process for producing methyl methacrylate which comprises:
(I) a step of reacting prussic acid and acetone to form acetonecyanhydrin;
(II) a step of hydrating the acetonecyanhydrin obtained in the step (I) to form α-hydroxyisobutyric acid amide;
(III) a step of dehydrating the α-hydroxyisobutyric acid amide obtained in the step (II) to form methacrylic acid amide;
(IV) a step of reacting the methacrylic acid amide obtained in the step (III) and methyl formate to form methyl methacrylate and formamide; and
(V) a step of dehydrating formamide separated from the product obtained in the step (IV) to form prussic acid and recycling said prussic acid as a starting material in the step (I).
The process produces methyl methacrylate with high selectivity without undesirable by-product such as ammonium sulfate. | 8 |
BACKGROUND OF THE INVENTION
The human cardiovascular system is composed of the heart and blood vessels through which blood moves nutrients to cells, tissues and organs, and carries metabolic products away for use or disposal. Since the capillaries are porous, there is a continual exchange of nutritive and waste materials between the blood stream and the body tissues. There is also a continual net flow of plasma fluid out through the capillary walls, adding to the tissue fluid. The blood vessels in the microcirculation region can reabsorb some of the lost fluid, but excess fluid and some plasma protein is returned to the venous circulation path via an elaborate system of collecting vessels, called the lymphatic system. Proper functioning of the lymphatic and muscle pump systems ensures that excessive lymph will not accumulate in the lower extremities. This is important since accumulation of lymph leads to edema with side effects of pain, fibrotic tissue changes, dermal ulceration, infection and, possibly, loss of limb. When trauma or paralysis prevents a patient from exercising the legs, the natural pumping action of the calf muscles is lost, and the result can be lymphedema and tissue fibrosis. Thus, people who are most likely to have lymphedema are sedentary adults such as those recovering from surgeries and those with spinal cord injuries. Lymphedema can also lead to more serious effects such as venous stasis with secondary deep venous thrombosis (DVT). In turn, DVT may lead to life threatening pulmonary embolism. Since DVT has the greatest possibility of occurring in a patient within 90 days of a spinal cord injury, it is advantageous for treatment of edema begin during this period. Generally, it is highly advantageous to treat edema as it is occurring or as soon as possible thereafter.
Where the treatment for edema is not commenced upon occurrence, treatment to reduce the swelling can be lengthy and uncomfortable for patients.
All prior art compression devices known to the inventors operate pneumatically, are bulky, are not portable, and are not responsive to edema levels. That is, none of the devices function to monitor the edema or sense the occurrence of edema for initiating the compression.
SUMMARY OF THE INVENTION
A portable, hydraulic extremity pump apparatus for treatment of edema is disclosed. The apparatus consists of a flexible compression unit configured to wrap around an individual's extremity. The compression unit has a plurality of annular compartments. Each compartment contains a prefill bladder and a compression bladder which are connected to a hydraulic pump for pressurizing the bladders. Prefill control valves are inserted between the pump and each prefill bladder and similarly compression control valves are inserted between the hydraulic pump and each compression bladder. Pressure sensors are connected to prefill bladders. The control valves and pressure sensors are connected to a programmable control processor to operate the valving and monitor the bladder pressures. The prefill bladders are pressurized by way of operating the hydraulic pump and opening the prefill valves until an appropriate pressurization is achieved. The prefill valves are then closed and the pump shut down with the compression unit molded around the extremity. The occurrence of edema is then detected by the monitoring of the pressure in the prefill bladders by way of the pressure sensors and control processor. Upon detecting an increase in pressure, the control processor activates the pump and opens the compression control valves in a sequential manner beginning with the control valve connected to the most distal bladder with respect to the extremity. This causes a sequential pressurization and creates a wave of compression moving proximally on the extremity. After each sequence the compression control valves are opened and the compression control valves are depressurized. The pressure sensors and control processor continue to monitor the pressures after each wave of compression to detect any reduction in the edema to determine whether to continue additional sequential pressurizations. The characteristics of the pumping action and the edema detection are controllable and programmable by way of the control processor for meeting individual patient needs.
A principal feature and advantage of the invention is that the compression of the extremity is provided by hydraulic means as opposed to pneumatic means providing easier maintenance, quieter operation and facilitating the portable nature of the apparatus. Leaks are readily detectable and easily repaired.
An additional feature and advantage of the invention is that the invention continually monitors the edema and controls the operation of the device based on the existence of edema.
A feature of the invention is that the pumping parameters are sequencing are easily programmable into the apparatus and readily changeable.
A principal feature and advantage of the invention is that the invention provides sequential pumping action to create a wave of compression moving proximally on the extremity.
An additional advantage and feature of the device is that it is programmable to provide a gradient of pressure in the different bladders, with the more distal bladders having the higher pressures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective of the extremity compression apparatus in position on an individual's leg.
FIG. 2 shows a diagrammatic view of the apparatus including a cross-sectional view of the compression unit showing the prefill bladders and compression bladders.
FIG. 3 shows an elevational view of the compression unit in an expanded view revealing the inside face that contacts the individual's extremity.
FIG. 4 shows an elevational view of the outside of the compression unit exposing valves and tubing.
FIG. 5 shows a cross-sectional of the compression unit take at line 5--5 of FIG. 4.
FIG. 6 shows a cross-sectional view of the compression unit taken at line 6--6 of FIG. 4.
FIGS. 7A, 7B, and 7C shows a schematic diagram of the control processor unit.
FIG. 7D shows a schematic of the pressure sensor circuitry.
FIG. 8 shows a flow chart diagram of a suitable program for the microcontroller.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a perspective view of the portable, hydraulic extremity pump apparatus is shown, designated by the numeral 20, and is shown as it is intended to be placed on an individual's extremity. The apparatus is comprised principally of a compression unit 24, a control processor unit 26, a pump unit 28, a fluid reservoir 30, and a battery 32 to provide power to the control processor unit 26 and pump unit 28. Also shown is tubing 34 connecting the reservoir 30 with the pump unit 28 and the compression unit 24. Similarly, cables 36 connect the compression unit 24 to the control processor unit 26.
FIG. 2 shows a block diagrammatic view of the apparatus 20 including a sectional diagram of the compression unit 24. The compression unit 24 is depicted in the hollow, substantially cylindrical or frustoconical shape designed to suit the individual extremity as it would appear in place on an individual's extremity. The compression unit 24 is shown to have six compartments 42, 44, 46, 48, 50, 52 including a most distal compartment 52 and a most proximal compartment 42. Each compartment contains a dual bladder 55 comprising an outer prefill bladder 56 and an inner compression bladder 58. The prefill bladders 56 and the compression bladder 58 are connected to the hydraulic pump 28 by way of connecting line 62, manifold 64, prefill flow line 66, and compression flow lines 68. Compression control valves 70 are inserted in the compression flow lines 68 to control the pressurization of the compression bladders 58. Similarly, prefill control valves 72 are inserted in the prefill flow lines 66 providing for control of the pressurization of the prefill bladders 56. The compression control valves 70 and the prefill control valves 72 are electrically connected to and controlled by the control processor unit 26 by way of electrical cables 74. Also connected to the prefill bladders are pressure sensors 76 which are connected by way of flow lines or tubes 78. The pressure sensors also are electrically connected to the control processor unit by way of electric cables 80. Three-way valves 81, 82 connect to the inlet 83 and outlet 84 of the pump unit 28 to alternately allow either filling or draining of the bladders and reservoir 30.
Referring to FIG. 3, the compression unit 24 that wraps around the individual's extremity is shown in an unwrapped position. The compression unit is depicted showing its inside face 85 which comes into contact with the extremity. The compression unit includes a securing flap 86 with a zipper 88 attached to the end and a cover flap 90 which is attached on the side opposite the inside face 85. The flow line 62 and the connecting cables 74, 80 are shown extending upwardly from the side opposite the inner surface 84. Also depicted in FIG. 3 is the configuration of the compartments in the compression unit 24 which in cross section are roughly parallelogram or trapezoidal in shape. Notably each compartment and bladder slightly overlap the adjacent compartment and bladder.
Referring to FIG. 4, the outside surface 92 of the compression unit 24 is shown. Positioned on the outside surface 92 of the compression unit 24 is the manifold 64, the prefill control valves 72, the compression control valves 70, and the pressure sensors 76. The valves, sensors, and manifold may be mounted on the outside surface 92 by any convenient method such as straps or hook and loop material. The cover 90, shown in an open position, folds over to cover the valve sensors, tubing and wiring. The cover may be fastened by any convenient means such as hook and loop material 94 attached to the flap with cooperating hook and loop material 94 on the outside surface 92. Also mounted on the outside surface of the compression unit 24 are zipper strips 98 allowing for adjustability in the wrapping of the compression unit around the extremity. Hook and loop material may be substituted for the zipper straps.
Continuing to refer to FIG. 4, the tubes extending from the pressure sensors 76 attach into the prefill bladder connecting point 100 by way of flow lines 78. The prefill control valves 72 connect into the prefill bladder at connecting points 102 by way of flow lines 68. The compression control valves 70 are connected into the compression bladders 58 at connecting points 104 by way of the flow lines 66. The pressure sensors 76 are shown mounted on a circuit board 106. The compression unit may be comprised of a fabric such as fine nylon or similar materials for fabrication of the compartments 42, 44, 46, 48, 50, 52 flap 86 and cover 90.
Referring to FIGS. 5 and 6, cross-sectional views are shown of the compression unit 24 taken at lines 5--5 and 6--6 respectively. These views further detail the configuration of the compartments, the prefill bladders 56 and the compression bladders 58. The bladders are generally annular in shape when wrapped around the extremity and may be fabricated out of flexible sheet material such as a 12 gage frosty clear, 2-S hand polyvinyl-chloride. In the preferred embodiment the bladder material is substantially inelastic. When hydraulically pressurized the bladder expands primarily by filling the bladder and maximizing its volume. Elastic expansion of the bladder material is considered to be minimal. The overlap of each bladder with the adjacent bladder functions to smooth out the compression wave created by the sequential pressurizations of the compression bladders.
FIG. 5 shows the pressure sensors 76 mounted on the circuit board 106 hydraulically connected to the prefill bladders 56 by way of the tubes 78 and connecting points 108, and nipples 110 which extend into the interior 111 of the prefill bladders 56. The compartments 42, 44 are sized for the prefill bladders 56 and allow an overlap of adjacent prefill bladders. The circuit board 106 on which the pressure sensors 76 are mounted may be attached to the outside surface 92 of the compression unit 24 by any suitable means such as straps or hook and loop material.
FIG. 6 shows two of the prefill control valves 72 and two of the compression control valves 70 connected in the flow lines 66 to control the communication between the bladders and the manifold 64. Flow lines 66 connect to the nipples 110 at the connecting points 102. The flow lines may be fabricated from plastic tubing such as the TYGON® brand manufactured by Norton Performance Plastics Corporation, P.O. Box 3660, Akron, Ohio 44309-3660.
FIGS. 7A, 7B, 7C and 7D comprise a schematic diagram of the control processor unit. The heart of the circuitry is a 68HC11E2FN microcontroller manufactured by Motorola and designated by the numeral 116. The control processor unit 26 monitors signals from the pressure sensors 76 and generates control signals in accordance with the provided programming to the microcontroller 116 for operating the pump unit 28B, the compression control valves 70, the prefill control valves 72, and the three-way valves 81, 82. The pressure sensors 76 connect to connector CON1 118 to provide the input for the microcontroller 116. An appropriate pressure sensor is a Model 1210B-002G-3L sensor manufactured by ICSensors located at 1701 McCarthy Blvd., Milpitas, Calif. 95035-7416. Each pressure sensor has a connected instrumentation amplifier manufactured by Linear Technology, Model LT1101CS shown in FIG. 7D set at a gain of 100 to provide amplified pressure signals to the analog digital inputs to the microcontroller via signal lines 124 as shown on FIG. 7A. Regulated 5 volt DC power for the pressure sensors 76 and the instrumentation amplifier is provided by a conventional 78L05 regulator chip also shown in FIG. 7D.
An 8 MHz crystal oscillator 128 sets the clocking speed for the microcontroller 116. The microcontroller 116 controls the prefill control valves 72 by way of signal lines 132 which go to metal-oxide-semiconductor-field-effect-transistor (MOSFET), switches 136 which switch on the light emitting diodes (LED's) for providing indicator lights. The signal lines 132 also connect to high-power MOSFETS 138 such as an IRF510 available from Motorola or other conventional sources. The high-power MOSFETS 138 connect to connector 142 on the schematics. The connector 142 mates with a cooperating connector, not shown, and connects to the cable 62 which goes to the prefill control valves 72 on the compressor unit 24. An appropriate valve for the prefill control valves would be an ASCO Model AL4112 available through Angar Scientific Company Inc., 52 Horse Hill Road, Cedar Knolls, N.J. 07927-2098.
Continuing to refer to FIGS. 7A, 7B and 7C, output from the microcontroller 116 controls the three-way valves 81, 82 by way of signal lines 144 going to the MOSFET 146 to operate the LED's 147 as an indicator light and additionally to the high-power MOSFET 150 which then goes to the connector 142. The connector 142 mates with a cooperating connector, not shown, that connects to cabling which goes to the 3-way valves. The suitable three-way valves, Model No. D311 manufactured by SIRAI Elettromeccanica, located at Strada Per Cernusco, 19-20060 Bussero-Milano, Italy.
Additionally, the pump unit 28 which is comprised of a hydraulic motor, not specifically shown, which is operated by the microcontroller 116 by way of a signal line 148 which controls the high-power switching MOSFET 150 with an output connected to connector 142. Said signal line 148 also goes to a switching MOSFET 152 connected to a light-emitting diode 154 to provide an indicator signal as to when the pump is operating. A suitable hydraulic motor is a TUFFY™ Jr. Series 1000 pump available from Smart Products, Inc. 2365 Paragon Drive, Unit H, San Jose, Calif. 95151.
The circuitry for the compression control valves 70 is similar to that for the prefill control valves 72. Signal lines 156 control the MOSFETS 158 which operate the LED's which provide an indicator signal as to which control valves are operating. The compression control valve signal line 156 also connects to the high-power MOSFETS 162 which then output to the connector 163 on the schematic. The MOSFETS that control the light emitting diodes may be a Si995504 manufactured by Siliconix Incorporated.
Push button switches 164, 166, 168 shown on FIG. 7A control the operation of the extremity pump apparatus 20 by way of activating the microcontroller. The power to the apparatus may be provided by a 12 volt battery source offering portability or other suitable conventional 12 volt power supply.
FIG. 7B also shows an audio beeper switched by a MOSFET connected to an output of the microcontroller 116. The microcontroller can be programmed to provide an audio signal upon the occurrence of any particular sensing parameters, such as an increase in pressure due to edema, or to signal a specific function of the apparatus, such as the pump unit start up.
The 68HC11E2FN microcontroller 116 is conventionally programmed as desired to perform the various functions. Technical specification and programming instruction are available in the technical data book for the 68HC11EFN available from Motorola Literature Distribution, P.O. Box 20912, Phoenix, Ariz. 85036. One suitable program would follow the flow diagram of FIG. 8.
The flow diagram is generally self-explanatory. Necessary inputs would be the pressure parameters P2, P3, and P4. P2 refers to the prefill bladder pressure which molds the compressor unit 24 to the extremity. P3 refers to the pressure level which is specified to indicate an occurrence of edema. P4 is the compression pressure, that is, the pressure level in the prefill bladder when the extremity is compressed. SX and S1, S2, S3, S4, S5, S6 refer to the pressure level measurements from the pressure sensors 76. Note that sequential operation of the compression bladders 58 commencing with the most distal bladder and proceeding to the most proximal bladder occurs in box 180 under "sequence."
The extremity pump apparatus 20 operates as follows: Referring to FIGS. 4 and 1, the compression unit 24 is wrapped around and secured to an individual's extremity. The zipper strip 88 is engaged with the appropriate cooperating zipper strip 98 to facilitate a snug fit around the extremity. Flap 90 closes to cover the valves, tubing, and sensors on the compression unit. With power applied to the unit, the unit is activated. Controlled by the microcontroller 116, the hydraulic motor is turned on, prefill control valves 72 open and the three-way valves 81, 82 are set to a fill position or mode to direct the hydraulic fluid to the bladders from the pump unit 28. The prefill bladders 56 are filled and thereby pressurized to a specified pressure as measured by the pressure sensors 76 at which point the prefill control valves 72 are then closed sustaining the pressure in the prefill bladders 56. In that the compression unit 24 and bladders encompass the extremity, the compressive pressure applied to the extremity is substantially the pressure in the adjacent prefill bladder. The extremity pump apparatus 20 is then ready to detect the existence of any increase in pressure indicating the existence of edema. An edema causes an increase in diameter of the extremity thus compressing outward the surrounding bladder causing an increase in the pressure levels in the bladders.
Upon sensing of a specified increase in pressure the pressurization sequence is commenced. The microcontroller operates to sequentially open the compression control valves 70 beginning with the control valve 70 attached to the most distal compression bladder. Each compression control valve 70 remains open until a specified compressive pressure is obtained in the respective prefill bladder as measured by the pressure sensors 76 and monitored by the control processor unit 26. The compression control valves are sequentially opened preceding up to the compression control valve positioned most proximally to create a compressive wave that moves proximally. After a specified delay the compression control valves 70 are then opened, the 3-way valves are switched to a drain position or mode to relieve the pressure from the compression bladders by way of pumping the fluid into the reservoir 30. After a specified delay the sequence is repeated.
Note that the pressure sensors 76 are utilized to both control the level of pressurization of the bladders and to detect any edema in the extremity. Each prefill bladder thus constitutes an edema sensing bladder.
The pressure sensors 76 monitor the edema intermediate each compression sequence. When the readings of the pressure sensors 76 are reduced to substantially the original or other specified pressure level indicating that the edema has been reduced, the compression sequences cease until further edema is sensed.
The pressure sensors in combination with the control processor unit thus constitutes an edema sensing or monitoring means.
The apparatus 20 may be programmed to provide a pressure gradient on the extremity where each prefill bladder has a pressure slightly higher than the adjacent more proximal prefill bladder. Correspondingly, the more distal veins and lymphatics are pressurized to a higher level than the more proximal veins and lymphatics. This gradient can be provided during the compression sequence and/or during the period the compression sequence is not occurring.
Notably the programmability of the device offers extreme flexibility in detection of desired pressure increases for detecting edema and in pressurizing the bladders to desired specified pressures. Additionally, extreme flexibility is provided in the timing of the compression sequences. The compression unit may be configured to extend beyond the calf area of the individual's leg, down to completely cover the lower extremity from any specified point. Similarly, the compression device may be configured and similarly utilized for the upper extremities.
For example, the invention may be practiced without the prefill bladders, utilizing only compression bladders with an initial pressurization to mold the compression unit around the extremity and then a second pressurization sequentially to each compression bladder to provide the compression wave, the pressure sensors would be connected to the compression bladders in such a configuration.
Significantly, the control unit constitutes a signal means whereby any number of different signals may be generated when an edema is detected. For example, the signal may activate the compression sequence, or may activate an alarm or the beeper as shown in FIG. 7A.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention. | A portable, hydraulic extremity pump apparatus for treatment of edema is disclosed. The apparatus consists of a flexible compression unit that wraps around an individual's extremity. The compression unity has a plurality of prefill bladders each containing a separate compression bladder. The bladders are connected to a hydraulic pump through valves. Pressure sensors are connected to prefill bladders. The valves, the pump and the pressure sensors are all connected to a programmable control processor to operate the valves and pump and to monitor the bladder pressures. The valves to the prefill bladders are closed at an appropriate pressurization and the pump is shut down to mold the compression unit around the extremity. The occurrence of edema may then be detected by the monitoring of the pressure in the prefill bladders. Upon detecting an increase in pressure, indicating edema, the control processor activates the pump and opens the valves connected to the compression bladders in a sequential manner to create a sequential pressurization and a wave of compression moving proximally on the extremity. The pressure sensors and control processor continue to monitor the pressures after each wave of compression. | 8 |
FIELD OF THE INVENTION
The present invention relates to a sintered body of a carbonitride alloy with titanium as a main component which has improved properties particularly when used as cutting tool material in cutting operations requiring high toughness. More particularly, the present invention relates to a carbonitride based hard phase of specific chemical composition with an extremely solution-hardened Co-based binder phase. Said binder phase has properties similar to the binder phase of WC—Co based materials except, that it has been possible to increase the solution hardening beyond the point where eta-phase normally would appear.
BACKGROUND OF THE INVENTION
Titanium-based carbonitride alloys, so called cements, are produced by powder metallurgical methods and comprise carbonitride hard constituents embedded in a metallic binder phase. The hard constituent grains generally have a complex structure with a core surrounded by a rim of a different composition. In addition to titanium, group VIa elements, normally both molybdenum and tungsten, are added to facilitate wetting between binder and hard constituents and to strengthen the binder by means of solution hardening. Group IVa and/or Va elements, e.g. Zr, Hf, V, Nb, and Ta, are also added in all commercial alloys available today. The carbonitride forming elements are usually added as carbides, nitrides and/or carbonitrides. Historically, the binder phase in cermets has been nickel, most likely because Ti has a high solubility in Ni to facilitate sufficient wetting to obtain a low porosity level. During the 1970s a solid solution binder of cobalt and nickel was introduced. This was probably made possible by improved raw material quality, in particular, a lower impurity level of oxygen. Today all commercial alloys contain 3-25 wt % of a solid solution binder with relative proportions Co/(Co+Ni) in the range 50-75 at %.
Cermets are today well established as insert material in the metal cutting industry. Compared to WC—Co based materials, cermets have excellent chemical stability when in contact with hot steel, even if the cermet is uncoated, but have substantially lower strength. This makes them most suited for finishing operations, which generally are characterized by limited mechanical loads on the cutting edge and a high surface finish requirement on the finished component. Unfortunately, cermets suffer from unpredictable wear behavior. In a worst case, complete tool failure is caused by bulk fracture which may lead to severe damage of the work piece as well as tool holder and machine. More often, tool failure is caused by small edge line fractures, which abruptly change the surface finish or dimensions obtained. Common for both types of damages is that they are stochastic or sudden in nature and occur without previous warning. For these reasons cermets have a relatively low market share especially in modern, highly automated production which relies on a high degree of predictability to avoid costly production stops.
One way to improve predictability would be to increase the toughness of the material and work with a larger safety margin. However, so far this has not been possible without simultaneously reducing the wear and deformation resistance of the material to a degree, which substantially lowers productivity.
SUMMARY OF THE INVENTION
It is an object of the present invention to solve the problems described above and others. It is indeed possible to design and produce a material with substantially improved toughness while maintaining deformation and wear resistance on the same level as conventional cermets. This has been achieved by working with the alloy system Ti—Ta—W—C—N—Co. Within this system, a set of constraints has been found rendering optimum properties for the intended application area.
In one aspect of the invention provides a titanium based carbonitride alloy containing Ti, Ta, W, C, N and Co, particularly useful for toughness demanding finishing operations characterized in that the binder is formed of 12-16 at % Co with only impurity levels of Ni and Fe.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In preferred aspects of the present invention, conventional Ni containing binder phase of a cermet alloy is replaced with a Co-based binder as in WC—Co alloys, i.e, the chemically stable hard phase of cermets is combined with the tough binder phase of cemented carbides. Co and Ni behave substantially differently during deformation and dissolve substantially different amounts of the individual carbonitride formers. For these reasons Co and Ni are not interchangeable as has previously commonly been believed. For, applications such as semi finish turning of steel, including interrupted cuts and profiling, or finish milling, the amount of Co required is 12-16 at %, preferably 12-14.5 at %.
The binder must be sufficiently solution hardened. This is accomplished by designing the hard phase in such a way that substantial amounts of predominantly W atoms are dissolved in the Co. It is well known that Ti, Ta, C and N all have low or very low solubility in Co, while W has high solubility. Thus, within this alloy system the binder will be essentially a Co—W solid solution as is the case for WC—Co alloys. Solution hardening is usually measured indirectly as relative magnetic saturation, i.e. the ratio of the magnetic saturation of the binder phase in the alloy compared to the magnetic saturation of an equal amount of pure cobalt. For WC—Co alloys close to the graphite limit, a relative magnetic saturation of “one” is obtained. By decreasing the carbon content of the alloy solution hardening is increased and reaches a maximum at a relative magnetic saturation of about 0.75. Below this value, eta-phase is formed and solution hardening can no longer be increased. For the alloys in the present invention it has been found that solution hardening can be driven substantially further compared to WC—Co alloys by a combination of relatively high N content, high Ta content and low interstitial balance. The exact reason for this is unknown, but leads to improved properties probably since thermal expansion of the cermet hard phase is larger than for WC and thus higher solution hardening is required to avoid fatigue by plastic deformation of the binder phase during thermo-mechanical cycling. The relative magnetic saturation should be kept below 0.75, preferably below 0.65 and most preferably below 0.55.
To combine high toughness and deformation resistance with good edge line quality a material with a high binder phase content combined with a small hard phase grain size is generally required. The conventional way to decrease the grain size in cermets has been to decrease the raw material grain size and increase the N content to prevent grain growth. However, for the alloys of the present invention a high N content alone has not proved sufficient to obtain the desired properties. The solution has instead turned out to be a combination of a relatively high N content (N/(C+N) in the range 25-50 at % (at %=atomic %), preferably 30-45 at %, and most preferably 35-40 at %) and a Ta content of at least 2 at %, preferably in the range 4-7 at % and most preferably 4-5 at %. For alloys with Co-based binder, the grain size is best determined by measuring the coercive force, Hc. For the alloys of the present invention the coercive force should be above 11 kA/m, preferably above 13 kA/m and most preferably 14-16 kA/m.
Within reasonable limits, the amount of W added to the material does not directly influence the properties. However, the W content should be above 2 at %, preferably in the range 3-8 at % to avoid an unacceptably high porosity level.
The material described above is extremely reactive during sintering. Uncontrolled sintering parameters, e.g. conventional vacuum sintering, may lead to several undesirable effect. Examples of such effects are large compositional gradients towards the surface due to interaction with the sintering atmosphere and high porosity due to gas formation within the alloy after pore closure. Thus, sintering of the material described above is preferably carried out under controlled conditions, such as those described in U.S. patent application Ser. No. 09/563,347 filed concurrently herewith, the disclosure of which is incorporated herein by reference in its entirety. Using such a process a material is obtained which, within reasonable measurement limits and statistical fluctuations, has the same chemical composition from the center to the surface as well as all evenly distributed porosity of A06 or less, preferably A04 or less.
For cutting operations requiring high wear resistance it is advantageous to coat the body of the present invention with a thin wear resistant coating using PVD, CVD or a similar technique. It should be noted that the composition of the body is such that any of the coatings and coating techniques used today for WC—Co based materials or cermets may be directly applied. Of course the choice of coating will also influence the deformation resistance and toughness of the material.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a scanning electron microscopy image of the microstructure obtained for the inserts produced according to the invention.
EXAMPLE 1
Powders of Ti (C, N), WC, TaC and Co were mixed to obtain the proportions (at %) 35.9 Ti, 3.6 W, 4.2 Ta, 12.4 Co and a N/(C+N) ratio of 38 at %. The powder was wet milled, spray dried and pressed into TNMG160408-pf inserts.
Inserts in the same style were produced from another powder, which is a well established grade within its application area.
This grade (P 15) was used as a reference and has the following composition (atom %): 34.2 Ti, 4.1 W, 2.5 Ta, 2.0 Mo, 0.8 Nb, 8.2 Co, 4.2 Ni arid a N/(C+N) ratio of 37 at %.
Inserts from the reference powder were sintered using a standard process while the inserts according to the invention were sintered according to the sintering process disclosed in Serial No. 09/563,347.
Measurements of physical properties are shown in the table below:
rel.
porosity
Hc (kA/m)
magn. sat.
density (g/cm 3 )
(ISO-4505)
Reference
n.a.
n.a.
7.26
A02 (A08 center)
Invention
14.9
0.56
7.25
A02-A04
Note that coercive force and relative magnetic saturation are not relevant measurement techniques for Ni-containing alloys since coercive force does not have a clear relationship to grain size, and relative magnetic saturation is predominantly a measurement of all the other elements dissolved in the binder apart from tungsten. Inserts from both powders were coated with a standard Ti (C, N)-PVD layer.
EXAMPLE 2
Cutting tests in a work piece requiring a cutting tool with high toughness were done with following cutting data:
Work piece material: SCR420H
V=200 m/min; f=0.2 mm/r; d.o.c=0.5 mm; coolant
Result: (No. of passes before breakage, average of 4 edges)
Reference: 46
Invention: 97
EXAMPLE 3
Wear resistance tests of the same materials were done with following cutting data.
Work piece material: Ovako 825B
V=250 m/min; f=0.15 mm/r; d.o.c=1 mm
The table below shows the Vb-value (as mm) as a function of time, tool life criteria was Vb≧0.25 mm (average of two edges)
Minutes
4
8
12
16
20
24
28
32
36
Reference
0.04
0.07
0.09
0.10
0.14
0.17
0.25
—
—
1/100 mm
Invention
0.04
0.05
0.07
0.07
0.09
0.15
0.19
0.23
0.25
From the examples above it is clear that compared to a prior art material, inserts produced according to the invention have substantially improved toughness while maintaining comparable wear resistance. While the invention has been described by reference to the elements Ti, Ta, W, C, N and Co, it is obvious that these may to some extent be replaced by small amounts of alternative elements without violating the principles of the invention. In particular, Ta may partly be replaced by Nb and W may partly be replaced by Mo.
The principles, preferred embodiments and mode of operation of the present invention have been described in the foregoing specification. The invention which is intended to be protected herein, however, is not to be construed as limited to the particular forms disclosed, since these are to be regarded as illustrative rather than restrictive. Variations and changes may be made by those skilled in the art without departing from the spirit of the invention. | The present invention relates to a sintered body of a carbonitride alloy with titanium as main component which has improved properties particularly when used as cutting tool material in cutting operations requiring high toughness. This has been achieved by combining a carbonitride based hard phase of specific chemical composition with an extremely solution hardened Co-based binder phase. | 2 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to document stacking, and especially to envelope stacking in a mail sorting machine.
There are existing mail handling machines which are utilized for processing letter mail from the U.S. Post Office as it is received from the public. The letter mail received from the public is infinitely variable in respect to size and weight. For this reason alone, it becomes increasingly difficult to handle the letter mail, as it is generally placed into a stack for feeding from or subsequently being directed to an area where stacking of the letter mail takes place.
Typically, mixed letter mail is fed through a mail sorting machine which separates each mail piece so that there is a vertically oriented stream of mail progressing along a conveyor towards an optical code reading device which reads the address. Immediately thereafter, each mail piece is imprinted with a bar code representing the address zip code commensurate with a determined verification of the address zip code as checked by a cooperating computer which is connected to the mail sorter.
The OCR mail sorter processes letter mail at 128 inches per second. There are OCR mail sorters having as many as 60 sorting bins and as few as 12. Typically, each bin holds up to 425 average sized envelopes.
There is a need to have a substantial stacking capacity in each sorting bin since the sorter production rate is high, and since many of the machines in the field have the larger number of bins, it becomes necessary to be concerned about keeping the bins unloaded without down time when the machine is running.
It is particularly desirable to have great reliability in handling the envelopes as they are conveyed, approach, and are pushed into the stacking bins, against the supporting abutment member located on the stacking support of the stacker bin. If there are jams in this area of the machine, there is a great potential for damaging the envelopes, in addition to causing machine down time. Unfortunately, the present designs for envelope stackers have not provided the reliability required to address the jam problem, and in addition the design of the stackers remain complicated without eliminating the jam problems. For example, in one envelope stacking apparatus, an envelope abutment member rests upon a conveyor belt which is horizontally disposed beneath the upstanding envelopes. When the envelopes develop a pushing force at the input gate of the stacker, they push a sensing lever pivotally mounted at the input gate. Often, the sensing device causes the envelopes to travel or become skewed in a vertical plane with respect to the conveyor path, thereby causing a jam. A switch is then actuated which in turn energizes a motor connected to the conveyor belt to move the envelope abutment member a distance commensurate with the distance moved by the sensing lever and so forth. The problem with this system lies in the response time since there is a rapid accumulation of envelopes during the cycle time described, which leaves a potential for a jam by not allowing envelopes to move from the input gate during the time interval when the abutment member is stationary and then caused to move.
Another device applied to the envelope stacking apparatus to provide a uniform force to the envelope abutment member is a sash weight and pulley system. The sash weight is operatively connected to a cable which is supported on guide pulleys. When the envelopes enter the stacking bin, an accumulation of them provides a pushing force which subsequently pushes back the envelope abutment member. There is also some form of mechanical pushing device such as a brush at the input gate which keeps the envelopes moving towards the envelope abutment member. The problem with this system is that it is bulky, and particularly cumbersome and there is a potential that the cable will break, thereby permitting the envelope abutment member to slam and be damaged against its stop. This situation then presents a further potential for losing the use of the machine.
Therefore, it is intended that the present invention eliminate the foregoing mentioned problems with increased reliability, better response, versatility, and application of a uniform resisting force to the envelope stack to eliminate jams at the input side of the envelope stacker.
SUMMARY OF THE INVENTION
The problems defined above, are solved by the present invention wherein an envelope stacking machine has a conveyor for feeding envelopes along a path of travel leading to envelope stacking bins. Each envelope stacking bin has an elongate envelope stacking support for receiving the envelopes. The envelopes are pushed into the stacking bin against a uniform resistive force provided by a force converting device connected to an envelope abutment member.
More broadly, within an envelope stacking machine there is a conveyor for feeding substantially vertically oriented envelopes in succession along a predetermined path of travel. There is an elongate envelope stacking support disposed adjacent to the conveyor with its longitudinal axis positioned substantially perpendicular to the path of travel of the envelopes. A transfer device intercepts the envelopes moving along the path of travel and redirects them for movement along the elongate envelope stacking support. The envelopes are pushed by the successively fed envelopes against an envelope abutment member which moves along a parallel path with respect to the longitudinal axis of the elongate envelope stacking support as the envelopes accumulate. There is a resilient member interposed between the elongate envelope stacking support and the envelope abutment member for normally urging the envelope abutment member towards the transfer device. A force converting device is interconnected between the resilient member and the movable envelope abutment member for maintaining a uniform resisting force on the envelope abutment member in opposition to the pushing force exerted by the incoming envelopes. There is a resilient member interposed between the stacking support and the movable abutment member for normally urging the abutment member toward the transfer device, thereby maintaining a resisting force on the abutment member in opposition to the pushing force imposed thereon by the envelopes. A force converting device interconnected between the resilient member and the movable abutment member prevents the resisting force from increasing as the resilient member expands in response to movement of the abutment member away from the transfer device. Therefore, the abutment member exerts a uniform or gradually decreasing degree of resistance, during movement of the abutment member away from the transfer device to the transfer of envelopes from the conveyor apparatus to the stacking support to prevent envelopes from jamming at the transfer device.
The force converting device includes a first flexible member connected to a free end of the resilient member, and a second flexible member connected to the abutment device. And, a rotary displacement device interconnecting the flexible member to move a variable distance for a given amount of angular displacement of the rotary displacement device in response to movement of the second flexible member over a predetermined distance during the angular displacement of the rotary displacement device.
With the foregoing in mind, it is a primary object of the present invention to provide an envelope stacking apparatus having substantial reliability through reduction of potential jams at the input gate of the stacking bin.
It is another object of the present invention to provide an envelope stacking apparatus which has an envelope abutment member having a constant force acting upon accumulating envelopes in the envelope stacking bin in response to incrementally added envelopes at the input gate.
DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a plan view of a portion of an envelope stacking machine having a conveyor for feeding vertically oriented envelopes in succession towards one of a number of envelope stacking bins.
FIG. 2 represents a partial isometric view taken from FIG. 1 along the lines of movement of the envelope towards a stacking bin to illustrate instrumentalities within the stacking bin.
FIG. 3 illustrates a partial isometric view taken from FIG. 1, as viewed from the front side of the envelope stacking machine to show details of the force converting apparatus, of the present invention.
FIG. 4 is a top view of the force converting apparatus, as taken from FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 there is shown a portion of an envelope stacking machine 10, having a number of envelope stacking bins. There is an envelope stacking bin 14, which is representative of a number of similar stacking bins in the letter mail sorting equipment utilized in a U.S. Post Office. In fact, the envelope stacking machine 10 is basically representative of the Pitney Bowes Inc. OCT Bar Code mail sorter, currently in use in U.S. Post Offices all over the United States. The present invention is directed towards that machine, or similar machines as an improvement to handling letter mail beyond present capability and reliability of the Pitney Bowes Inc. Bar Code mail sorter.
Referring once again to FIG. 1, there is a conveyor path 18 for envelopes proceeding from an input station (not shown). The envelopes are oriented substantially vertically as they are transported along the conveyor path 18, and as they approach a gating area 22 which leads to a transfer device 24 for imparting a nudging action to the envelopes directed to the particular envelope stacking bin that the envelopes are being directed to.
The envelopes are stream fed, through the previously mentioned conveyor path 18, to the transfer device 24, from where they proceed to an elongate envelope stacking support 34 within which the instrumentalities of the present invention are operatively connected.
The elongate envelope stacking support 34 is arranged to receive a stream of envelopes such as an envelope 38 shown in FIG. 2. There is a supportive structure (not shown) beneath the elongate envelope stacking support 34 such that the entire envelope stacking machine 10 is appropriately capable of handling the envelopes on a generally horizontal plane 42 which is generally set to a convenient height for the operator. The horizontal plane 42 will be understood to be provided by appropriately arranged horizontal members which the envelopes bottom edges guide and rest upon during conveyance. In other words, a surface 40 of the elongate envelope stacking support 34 is within the horizontal plane 42 and substantially perpendicular to the conveyor path 18, in order to support the envelopes since the envelopes, such as the envelope 38, are oriented in a substantially vertical position while being conveyed through the conveyor path 18.
Now, referring to FIG. 2 where details of the stacker bin 14 are shown, there is an elongate shaft 46 supported at both ends (unshown) fixed structure connected to the envelope stacking machine 10. The elongate shaft 46 has a reciprocable bearing member 48 to which there is an envelope abutment member 50 appropriately attached. The abutment member 50 as such, has a plastic foot 44 attached to the member 50 to rest upon the surface 40 during sliding, reciprocable motion.
The envelope abutment member 50 moves in a parallel direction, indicated by an arrow 52 which direction is substantially along the lines of the longitudinal plane of the elongate envelope stacking support 34. Within FIG. 2, there is shown a stack of vertically standing envelopes 54 which is typical of the intent of the envelope stacking machine 10.
The envelopes fed through the conveyor path 18 are individually pushed onto the elongate envelope stacking support 34, and the process whereby the envelope abutment member 50 resists with a uniform or gradually decreasing input force directed against the transfer device 24 will now be explained. It is intended that any given envelope, such as the envelope 38 be deflected from the conveyor path 18, at such predetermined time that a gate 56 is operatively moved to deflect an envelope to the appropriate envelope stacker bin. It is seen in FIG. 2 that the envelope 38 has been deflected, from the conveyor path 18, and is traveling along a deflected path 58 towards the transfer device 24, and the stacker bin 14.
The transfer device 24 consists of a roller spindle 60 which is operatively driven by appropriate connecting timing belts (not shown) beneath the envelope stacking support 34. The other belts and conveying devices illustrated in the accompanying drawings are also operatively connected to appropriate motors, and reduction instrumentalities which are not shown in the drawings, but understood by those skilled in the art to provide the requirements of conveying letter envelopes at the rate of 128 inches per second.
In the present invention, there is a flexible finger assembly 62 mounted for rotation with the roller spindle 60.
The flexible finger assembly 62 constitutes the principle pushing element of the transfer device 24, which forces the individual envelopes into the stacking bin 14.
It will be seen in FIG. 2 that the envelope abutment member 50 is approximately one half of the distance across a span 64 which represents an opening for a capacity of 425 average sized envelopes at such time as the abutment member 50 reaches a maximum capacity position 68. The envelope abutment member 50 normally starts its path of travel through the span 64 at a position 66, where the initial envelopes immediately engage a face plate 70 of the envelope abutment member 50. The unstacked envelopes continue to be fed along the conveyor path 18, and be diverted to the alternate individual appropriate envelope stacking bins according to predetermined zip code designations. While diverted envelopes continue to flow into the elongate stacking support 34, the envelope abutment member 50 continues to provide a uniform resisting force against the nudging force of the transfer device 24 as represented by a force vector in the form of a dotted line and arrow 72 (FIG. 3). The uniform resisting force remains exactly at 1.5 pounds, for the present application, but will be applied in a different force level according to the particular job being done in other applications where, for example, substantially heavier envelopes are processed. At this time it will be mentioned that there is an alternate embodiment of the degree of application of the force to the envelope abutment member 50, as the member 50 is normally pushed away from the transfer device 24. The alternate application of force is gradually uniformly decreasing, instead of uniform. It will be readily understood that it is entirely possible to choose and adjust the particular force desired in other similar envelope sorting applications, and as mentioned, the first applied force being presently described is considered uniform.
The application of the uniform resisting force to the envelope abutment member 50 will be readily understood from the description of the force converting system to now be explained.
Beneath the elongate stacking support 34, there is a force converting apparatus 74 which is appropriately mounted for operation in response to incremental movement of the envelope abutment member 50 caused by individual envelopes such as the envelope 38 shown in FIG. 2 as they are pushed into the envelope stacking bin 14 by the transfer device 24.
Referring to FIG. 3, there is shown an isometric view of the principle instrumentalities of the force converting apparatus 74. It will be understood that the upper portions of the envelope stacking machine 10 have been removed including the elongate envelope stacking support 34 to provide the details illustrated in FIGS. 3 and 4, and furthermore that the force converting apparatus 74 is illustrated in an angular orientation that the envelope stacking machine 10 operator sees while standing in front of the machine, as opposed to the FIGS. 1 and 2 where the views are taken obliquely from the opposite side.
An opposite side 76 of the envelope abutment member 50 is facing the operator as represented in FIG. 3, and the envelope abutment member 50 is shown in the maximum capacity position 68 representative of a fully loaded stacker. The maximum capacity position 68 furthermore provides a clear view of portions of the force converting apparatus 74, which would be otherwise somewhat obstructed from view when the envelope abutment member 50 is in its starting position adjacent to the transfer device 24 and the roller spindle 60.
There is a rotary displacement device 80 mounted for rotation about an appropriate stud 78 which is suitably fastened to the underside of the elongate envelope stacking support 34. The rotary displacement device 80 is formed of a first pulley 82, which has a portion of its circumference having a varying radius 84 while a second pulley 86 has a large diameter with a uniform radius 88.
There is a resilient member 90 mounted for lineal expansion and contraction in a parallel direction 92 with respect to the elongate shaft 46 so that an end 94 is attached to a bracket assembly 96, having an adjustment member 100 for adjustment of the resilient member 90 when necessary. The resilient member 90 is preferably a wound tension spring, having ends formed from the coils. The end 94 is connected to a hole 101 in the adjustment member 100 and an appropriate screw 104 is threaded into the member 100 as such to accomplish the adjustment as required.
On a free end 106 of the resilient member 90, there is suitably attached a first flexible member 108 which spans from the free end 106 to a horizontally mounted, rotatable pulley 110. The rotatable pulley 110 is conveniently mounted under the elongate envelope stacking support 34. The first flexible member 108 is a suitable non-stretching form of cable which will easily bend when turned about a groove in a relatively small flanged pulley.
Reaching from the rotatable pulley 110 to the rotary displacement device 80, the first flexible member 108 is suspended upon the first pulley 82 having the varying radius 84. The first flexible member 108 is conveniently secured to the first pulley 82, and similarly the second flexible member 112 is secured to the second pulley 86. Given an angular displacement of the rotary displacement device 80 caused by a stream of envelopes being pushed into the stacker 14, the second flexible member 112 moves a predetermined distance, which is represented by a lineal distance 114 (FIG. 3), alongside of the envelope abutment member 50. And, since the second flexible member 112 is suspended in a groove 118 within the second pulley 86 having the uniform radius 88, it will cause a clockwise angular rotation 200 of the second pulley 86 and a corresponding angular rotation of the attached first pulley 82 as the second flexible member 112 unwinds from the second pulley 86. As the first flexible member 108 is wound on the first pulley 82, it stretches the tension spring 90 and thereby produces an increasing tension in the first flexible member 108. Since it is evident to those skilled in the art that the tension in the second flexible member 112 will be the tension in the first flexible member 108 multiplied by the varying radius 84 and divided by the constant radius 88, the varying radius 84 must decrease in length as the pulleys rotate and stretch the spring 90, if the tension in the second flexible member 112 is to be maintained constant with the movement of the abutment 50. Therefore the varying radius 86 decreases in an inverse proportion to the spring constant of spring 90. It is mentioned once again, that the system being described herein is intended to produce a uniform input force to the envelope abutment member 50, and as such, the description of the force converting apparatus 74 accomplish the required uniform force through the described geometry of the first pulley 82. It will therefore be recognized that various shapes and profiles to the varying radius 84 of the first pulley 82 will produce the alternate embodiment previously described where a uniformly decreasing input force is applied to the envelope abutment member 50.
Accordingly, the second flexible member 112 is spanned along a path leading to an appropriately mounted, grooved pulleys 116 and 117 which are used to change direction of the second flexible member 112 to a path substantially parallel to movement of the envelope abutment member 50, to which the member 112 as such is suitably attached.
It will be recognized that the span 64 (FIG. 2) which the envelope abutment member 50 moves through when receiving the stream of envelopes is a substantial distance in comparison to the deflection of the resilient member 90. And, the resilient member 90 is typical in respect to a wound coil spring which as the ability to produce a maximum force coincident with a maximum deflection, and a minimum force coincident with a minimum deflection beyond the free state. The degree of variation thereby given by the wound string would ordinarily produce a variation of force resulting in a gradually increasing degree of force upon the envelope abutment member 50 in the present case but for the force converting apparatus 82.
The desired result of the application of the force converting apparatus 82 is given at the envelope abutment member 50 where a uniform resisting force is maintained over the span 64 of movement caused by the stream of envelopes entering the envelope stacker bin 14, and being nudged towards the envelope abutment member 50. As the envelopes are pushed towards the envelope abutment member 50, by the transfer device 24, a reciprocal uniform resisting force is maintained through application of the previously described force converting apparatus 74.
Since there is no extended response time for the envelope abutment member 50 to move in accordance with envelopes being added to the envelope stacker bin 14, there is no potential for jams at the gating area 22 or the transfer device 24. Since the mass of the force converting apparatus 74 can be made less than a corresponding sash weight it will be recognized that the energy stored in the spring 90 will only be about sixty percent of that stored in a sash weight raised to a corresponding height position with respect to the movement of the abutment 50. Therefore the likelihood of breaking the second flexible member 112 is greatly reduced if not eliminated as compared to the sash weighted abutment described earlier.
Having described an embodiment of the present invention for an envelope stacking machine, it is pointed out that various modifications may be made to the parts described within the foregoing specification and drawings which will serve the same purpose outlined and captured by the accompanying following claims. | An envelope stacking machine has a conveyor for feeding envelopes in a substantially vertical orientation along a predetermined path of travel. There is an elongate envelope stacking support for receiving envelopes directed to the support from a transfer device which pushes the envelopes against an envelope abutment member having a force converting apparatus attached thereto for maintaining a substantially uniform resisting force against the incoming stream of envelopes. The force converting apparatus contains resilient and flexible devices which operate in conjunction with a rotary displacement device to achieve the substantially uniform resisting force. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a roof ventilation element with a vent cap to be located in the ridge, slope, or arris region of a roof and which has at least one elastically flexible sealing member which adjoins the vent cap on its edge area.
2. Description of Related Art
Use of foam sealing members in ventilation elements of the type under consideration is known. The disadvantage is that, for various spacing differences and/or sharp-edged transitions, due to its structure, the foam is not able to achieve sufficient tightness, for example, against blowing snow and driving rain. Furthermore, it is disadvantageous that the foam is not resistant to aging, and therefore, embrittles and crumbles over time, so that serviceability is not ensured. Furthermore, foam requires strong compression which makes placement difficult and often leads to unsatisfactory working and sealing results. Finally, accessible areas are exposed to bird damage.
Use of a brush strip as the sealing member for ventilation elements is furthermore known, the brush strip having a host of elastic brush filaments located in a packing which is flow-tight, at least for the most part. The disadvantage is that the fine filaments can, therefore, bend at the individual filament tips, for example, when they come into contact with barriers such as rough spots, edges, etc., endangering tightness. Finally, in critical areas, for example, in corner areas, it is not ensured that the brush filaments extend into these areas. Furthermore, the brush filaments tend to line up or when greatly heated to rise and when cooled no longer return to their initial position, by which blowing snow and driving rain can penetrate into the areas exposed in this way, especially with wind pressure. Still Further, there is the danger that ambient effects and strong incident solar radiation (UV radiation) embrittle and break the very fine brush filaments; this in turn greatly reduces tightness. Another disadvantage is that, with strong wind pressure, the brush filaments are spread apart in the shape of a wedge, and thus, large entry openings for blowing snow and driving rain are formed. It also happens that the fine brush filaments stick together due to ambient effects and clog up like rake teeth, creating open spaces through which blowing snow and driving rain can penetrate. In addition, the loose brush filaments lose their most important property, that is, elasticity, by which tightness is greatly reduced.
SUMMARY OF THE INVENTION
In view of the foregoing, a primary object of the invention is to provide a ventilation element of the initially mentioned type in which an optimum seal is ensured and which adapts uniformly and homogeneously to any roofing material.
This object is achieve by a ventilation element according to the present invention in which the sealing member is made as a hollow body with a preferably pear-shaped cross section, which is closed in its areas which are closest to and farthest from the edge area of the vent cap. Because the sealing member is made as an elastically deformable body, it is able to adapt to any roofing material, for example, a tile-shaped roofing material, corrugated roofing material or roofing material with some other profile. The sealing member made according to the invention can be placed very easily both in depressions and also on elevations of the roofing material. This largely prevents the entry of blowing snow and driving rain.
In the ventilation element according to the invention, the hollow body of which the sealing member is comprised is formed, preferably, by a wrapped or folded flat base material. Two sides of the flat base material are placed on top of one another, yielding a hollow body which, as already stated, has a, preferably, somewhat pear-shaped cross section. By wrapping or folding the flat base material into the hollow body which forms the sealing member, the properties of the flat base material, especially elasticity, are more advantageously used, specifically by the hollow body formed in this way having high adaptability, ensuring uniform sealing between the vent cap and the roofing material.
For ventilation elements of the type under consideration, it applies that, fundamentally, venting takes place via the air passage openings in the vent cap; these air passage openings can have any cross section, especially a round or oval cross section. The sealing member which acts between the vent cap and roofing material has essentially two functions. On the one hand, the sealing member, as already stated, is designed to prevent the entry of blowing snow and driving rain. On the other hand, the sealing member also is designed to prevent air which can adversely affect the ventilation function of the ventilation element overall, therefore, mainly the ventilation function of the vent cap, from entering underneath the vent cap into the interior.
With consideration of what has been stated above on the basic function of the ventilation elements according to the invention, the hollow body can have slits, notches, undercuts, or recesses which lead mainly to an increase in the elasticity of the sealing member. These notches, undercuts or recesses, surprisingly, do not have an adverse effect on the above described basic function of the ventilation elements. Rather, these slits, notches, undercuts or recesses can even provide an advantage in terms of ventilation engineering above and beyond the function of increasing the elasticity of the sealing member. Surprisingly, it has been found that the design of the sealing member according to the invention leads to different flow resistances. While the flow resistance from the outside to the inside, as required, is relatively great, the flow resistance from inside to outside is much less. Consequently unwanted penetration of air from the outside to the inside is prevented, but air is enabled to flow from the inside to the outside via the sealing member.
If, in the ventilation element according to the invention, the hollow body has slits, they run preferably transversely to the length of the sealing member, especially at an angle of less than 90°. In particular, the slits can run at an angle to the lengthwise direction of the sealing member such that, in the area adjacent to the edge area of the vent cap, the strip-shaped parts which are formed by the slits overlap or cross, in part or in whole.
The ventilation element according to the invention can be formed of a vent cap and one or more separate sealing members, and therefore, can be made in several pieces. Then, it is recommended that the sealing member be provided with a connecting strip in its area adjacent to the edge area of the vent cap. In this version, the sealing member can be inserted with a connecting strip into a groove provided in the edge area of the vent cap.
One especially advantageous embodiment of the ventilation element according to the invention is has the vent cap and the sealing member or the vent cap and the sealing members made of a one-piece construction. This has advantages for both production and installation.
Finally, an embodiment of the ventilation element according to the invention that is especially advantageous has the ventilation element made as a flexible sealing strip which, in particular, can be wound onto or off of a roll. This embodiment makes it possible to first wind the ventilation element or ventilation strip which is produced in relatively long lengths so that space-saving storage or space-saving transport is possible. On site, specifically on the roof to be equipped with such a ventilation element, the ventilation element or sealing strip is simply rolled out over the ridge lath, positioned and attached. The time and cost required for mounting of the ventilation element made in this way is, consequently, extremely low.
The subject matter of the invention is not only the above described ventilation element, but also a process for producing such a ventilation element. This process is comprises extrusion of the vent cap and the flat base material for the sealing member, after which the flat base material for the sealing member is joined on one side to the vent cap in its edge area and then, finally, the flat base material for the sealing member is folded to form a hollow body and its free side in the edge area of the vent cap is joined to the vent cap or to the base material in the area of this flat base material for the sealing member which adjoins the edge area of the vent cap.
If the ventilation element to be produced is one in which the vent cap and the sealing member or the vent cap and the sealing members are made in one piece, the above described process can be accomplished such that the vent cap and the base material for the sealing member are extruded in one piece.
The joining of the base material for the sealing member to the vent cap which is necessary in the above described process for producing a ventilation element according to the invention can be done in various ways. In particular, it is recommended that welding or cementing be used.
These and further objects, features and advantages of the present invention will become apparent from the following description when taken in connection with the accompanying drawings which, for purposes of illustration only, show several embodiments in accordance with the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross section through the ridge area of a roof of a building having a first embodiment of a ventilation element according to the invention;
FIG. 2 shows a representation corresponding to FIG. 1, but with a second embodiment of a ventilation element according to the invention;
FIG. 3 shows a perspective view of the ridge area of FIG. 1;
FIGS. 4(a) & (b) show, respectively, a side view and a plan view of the ventilation element according to the invention for use in the FIG. 1 embodiment;
FIGS. 5(a) & (b) are views corresponding to FIGS. 4(a) & (b) showing another embodiment of the ventilation element according to the invention;
FIGS. 6(a) & (b) show, respectively, a side view and a plan view of a spacer of the invention, and FIG. 6(c) is an enlarged view of detail A in FIG. 6(b);
FIGS. 7(a), (b) & (c) show, respectively, a side view, a plan view and a perspective view of another embodiment of the sealing member of a ventilation element according to the invention;
FIG. 8 shows a perspective view of a preferred embodiment of a ventilation element according to the invention;
FIGS. 9(a), (b) & (c) show, respectively, a plan view, a modified plan view and a perspective view of another embodiment of the sealing member of a ventilation element according to the invention;
FIGS. 10(a) & (b) show, respectively, a side view and a plan view of another embodiment of the sealing member of a ventilation element according to the embodiments of FIGS. 7 and 9;
FIGS. 11(a) & (b) show, respectively, a side view and a plan view of another embodiment of the ventilation element according to the invention which is similar to that shown in FIGS. 4 and 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows ventilation element 1 which can be used in the ridge, slope, or arris region of a roof. Ventilation element 1 has a strip-shaped vent cap 3 with a first edge area 4, a middle area 5, a second edge area 6 and sealing members 7 joined to the edge areas 4, 6. A lath holder 11, which has a U-shaped profile 13 into which ridge lath 15 is inserted, is attached to counterlaths 9. Furthermore, a lathwork, of which only the laths 17 are shown, is attached to counterlaths 9. Tiles 19 are hung on the laths 17.
Vent cap 3 rests with its middle area 5 on the ridge lath 15 and is held on the ridge lath 15 by spacers 21 which are shown in FIG. 6 and which are spaced apart along the length of the vent cap 3. Each spacer 21 is attached to the ridge lath 15 by means of its attachment area 23 using nail-like pins 25. Ridge clamps which are used to fix ridge files 31 are attached to ridge lath 15 using screws 27. The ridge files 31 are borne by bearing edges 22 of spacers 21. Spacers 21 shape vent cap 3 by edges 24, i.e., vent cap 3 is pressed down by spacers 21, by which it is reversibly or elastically deformed.
Sealing members 7 are attached to both edge areas 4, 6 of the vent cap 3. This can be done, for example, by means of a clip connection, adhesive bond, or screw connection. Alternatively, a one-piece implementation is also conceivable. "One-piece" means that ventilation element 1 is formed from a single piece of material. Sealing members 7 are used to close the irregularly sized gaps between the top 20 of tiles 19 and the bottom 32 of ridge tiles 31 such that, on the one hand, air circulation in the ridge area is possible and that, on the other hand, penetration of blowing snow and driving rain is prevented.
According to the invention, each sealing member 7 is made as a hollow body 10 which is closed in the area of its free end (i.e., the end which is away from the edge areas 4, 6 of the vent cap 3 and in its area which is adjacent to the edge areas 4, 6 of the vent cap 3. This means that the hollow body 10 extends from the area of the sealing member 7 which adjoins edge areas 4, 6 of the vent cap 3 as far as its end remote from edge areas 4, 6 of the vent cap 3.
For the essence of the invention, however, it is not necessary for the hollow body 10 to extend on both sides as far as has already been explained. It is possible that the hollow body 10 does not begin immediately where sealing member 7 adjoins edge areas 4, 6 of the vent cap 3. It is also possible for hollow body 10 to end inward the free end of the sealing member 7.
Sealing members 7 are shown folded and have slits 41 which cannot be seen in FIG. 1, but are shown in FIGS. 3-5, 7 and 9. The slits 41 are spaced apart and extend transversely to the longitudinal extension of the sealing element 7. The slits 41 are made in sealing member 7 such that the ends 42 and 42' of slits 41 are at a distance from the area in which the two edges of the base material of sealing member 7 lie on top of one another in the folded-together state. The base material for sealing member 7 is folded over after slits 41 are made and the folded-over portions are held together in the aforementioned manner at connection area 43. Slits 41 are made in the ventilation element 1 by a punching or cutting process while element 1 is in its original, flat form before the folding process. If, in this machining process, material is removed at the separation point, undercuts are made. In the case of slits, no material is removed.
How sealing member 7 works will now be explained with reference to the arrows in FIG. 1 which represent the air circulation paths. The air flow 35 travels in the roof superstructure from the eaves to the ridge where it is divided into two air flows 37 and 36. Air flow 37 passes through air passage openings 8 of strip-shaped vent cap 3 and reaches an intermediate space 47 which is formed between the ventilation element 1 and the ridge tile 31. From there, air flow 37 passes to the outside through a gap which is formed between the bottom 32 of ridge tile 31 and the top 49 of the sealing element 7. Air flow 36 passes through slits 41 of hollow body 10, i.e., the air flows through slits 41 into hollow body 10 and from there through slits 41 to the outside. It is also possible, under special weather conditions, for the air flow 35 to escape exclusively as flow 37 via the air passage openings 8 and the gap between the bottom of ridge tile 31 and the top of sealing member 7. The air passage openings 8 through which venting takes place can have any cross-sectional shape, especially a round or oval cross section as shown in FIGS. 4(b) and 5(b).
It is also not required for the flow 36 through the seal element 7 to be possible. Thus, instead of slits 41, the hollow body can have corresponding notches, undercuts, or recesses which served to increase the elasticity of the sealing members 7 without creating an air flow path through them.
FIG. 3 shows a perspective representation of the ridge area of the roof according to FIG. 1. In this embodiment tiles 19 have a corrugated surface on which the sealing member 7 lies, such that sealing of the ridge area against blowing snow and driving rain is ensured. The parts of sealing member 7 produced by the slits lie tightly against one another in the depression between the two corrugations of tile 19 and against the surface of tile 19, while they are spaced apart on the corrugations of tile 17, i.e., the intermediate space between two parts of sealing member 7 is enlarged so that air flow 36 explained in FIG. 1 can flow through hollow body 10 without greater resistance.
In another embodiment, tiles 19 can have a different surface shape against which hollow body 10 rests in a suitable manner. Regardless of the embodiment of tiles 19, the desired seal against blowing snow and driving rain, and the air circulation in the ridge area of the roof, are ensured by ventilation element 1 according to the invention.
FIG. 2, likewise, shows a cross section of the roof in the ridge area. Another embodiment of ventilation element 1 is shown. The same parts have the same reference numbers so that reference can be made to the description of FIG. 1 for a description of such parts. However, in this case, vent cap 3' is made of a stiff material so that it also assumes the function of the spacers 21 in the FIG. 1 embodiment, and thus replaces them. Sealing member 7 is attached to edge areas 4, 6 of vent cap 3' in the aforementioned manner.
FIG. 4(a) shows a side view and 4(b) a plan view of ventilation element 1. Ventilation element 1 has three parts, specifically vent cap 3' and two sealing members 7. In middle area 5 of vent cap 3' there are air passage openings 8 in the form of longitudinal holes. The three parts are made of a flat material, i.e., a mat-like material. For this reason, it is very easily possible to make slits 41 and air passage openings 8.
FIGS. 5(a) & (b) show an embodiment of ventilation element 1 which is made in one piece, i.e., vent cap 3 and sealing members 7 are produced from the same piece of flat material. Such a one-piece ventilation element 1 is preferably produced by extrusion. FIGS. 7(a)-(c) show a sealing member 7 in which the joined ends 42 and 42' are clipped together in strip form, e.g., by the provision of a projecting bead 44 on end 42 which engages in a mating recess 45 on the end 42' to form a connecting strip 50. A separate clamp bar can also be used for joining ends 42 and 42' together into a connecting strip 50 as in FIG. 9(C). To mount sealing member 7, its connecting strip 50 is pushed into a receiver of vent cap 3; see, FIG. 2.
FIG. 8 shows ventilation element 1 according to FIG. 1 in a rolled-up state. The compact form of ventilation element 1 makes it possible to transport it without special cost. Thus, transporting of the ventilation element 1 is greatly simplified.
The sealing element 7 of a one-piece vent cap 3 can have a lower material thickness than vent cap 3. In this way, vent cap 3 is reinforced in an area in which the nail-like pins of spacer 21 penetrate it, yet sealing member 7 maintains its elasticity.
Another embodiment of the ventilation element according to the invention is characterized in that ventilation element 1 is made of different materials. Thus, for example, vent cap 3 can be made of metal and sealing element 7 of plastic.
FIG. 9(A) shows a sealing member 7 in which a plurality of circular openings A or oval openings B replace the slits 41, while FIG. 9(B) shows the use of a plurality of elongated rectangular openings C or square openings D are used. FIG. 10 shows a sealing member 7 in which slits 41 have a zig-zag shape.
Finally, FIG. 11 shows an embodiment of a ventilation element 1 according to the invention which has been extruded, such that the hollow body 10 is already present after extrusion, and therefore, wrapping or folding of the flat base material is not necessary. Openings 8 and slits 41, would, on the other hand, be provided subsequently in a separate machining operation.
In conclusion, it is pointed out that the ventilation element 1 according to the invention has the major advantage that the sealing members 7 need not be cemented to the roofing material. As a result, ventilation element 1 can be easily placed or replaced in any weather.
While various embodiments in accordance with the present invention have been shown and described, it is understood that the invention is not limited thereto, and is susceptible to numerous changes and modifications as known to those skilled in the art. Therefore, this invention is not limited to the details shown and described herein, and includes all such changes and modifications as are encompassed by the scope of the appended claims. | A ventilation element (1) for roofs having a vent cap (3) to be located in the ridge, slope, or arris region of the roof and having at least one elastically flexible sealing member (7) which adjoins the edge area (4, 6) of the vent cap (3). According to the invention, an optimum seal between the vent cap (3) and the roofing material is ensured by the fact that the sealing element (7) is made as a hollow body (10) with a preferably roughly pear-shaped cross section, which is closed in a free edge area and in its area which is adjacent to the edge areas (4, 6) of the vent cap (3). Slits (41) can be provided in the hollow body to allow the egress of air from the roof, in part, through the hollow body without adversely affecting its sealing function. | 4 |
RELATED APPLICATION
This application is a 371 of PCT/U594/03523, filed Mar. 30, 1994, which is a continuation-in-part of U.S. application Ser. No. 08/039,868, filed Mar. 30, 1993 (now abandoned).
FIELD OF THE INVENTION
The invention relates to agricultural, e.g. pesticide, spray mixtures. More particularly, this invention relates to a methods for preparing agricultural spray mixtures characterized by superspreading with low foaming, and for spraying them. Spray mixtures are treated with trisiloxane silicone surfactants which impart superspreading and yet exhibit low foaming, a combination of properties not previously available.
Agricultural spray mixtures can be in the form of solutions, emulsions, suspensions and dispersions, and are used in agriculture for applying agricultural chemicals which can be formed into one of the noted types of mixtures for application to plants, soil and insects. Among the typical agricultural chemicals are pesticides such as herbicides, insecticides, fungicides, growth regulators, and nutrients and micronutrients to plants and insects. They typically contain surfactants to enhance spreading when applied. When prepared with conventional surfactants, foaming often impedes mixing and creates problems even before the mixture is completely formed. Once formed, agricultural spray mixtures can foam and overflow containment vessels when transported, pumped, or subjected to motion such as vibration. Such spillage can result in loss of the agricultural spray mixture and in the contamination of surfaces by potentially toxic substances as well as losses of time and money.
Conventional trisiloxane surfactants have the ability to impart the property of superspreading to agricultural spray mixtures. By "superspreading" is meant the ability of a drop of the mixture to spread to a diameter at least 9 times as great as a doubly-distilled drop of water on a hydrophobic surface such as the leaf of a plant. However, the conventional use of trisiloxane surfactants for superspreading typically increases mixture foaming relative to the mixture in the absence of the trisiloxane surfactant.
There is a need to prevent a superspreading agricultural spray mixture from foaming or overflowing its containment vessel while not adversely affecting the mixture's spreading capability.
Silicone antifoams typically have such low surface tension values that adding such a defoamer as a separate composition to reduce surface tension doesn't work. Thus, there is a need for a new superspreading spray additive which does not create the foam problem in the first place. Likewise, there is a need for methods for preparing and utilizing a low-foam additive which still has superspread. By the term "low-foaming", it is meant that a silicone exhibits foaming of less than 50 millimeters (mm) initially and less than 15 mm after 5 minutes, using the Ross-Miles technique (ASTM method D 1173-53). Using this technique, 200 milliliters (ml) of a solution to be evaluated for foaming is allowed to fall from a height of 90 centimeters (cm). The maximum initial foam height and the foam height after 5 minutes are recorded.
The methods and compositions of the invention are based on the use of superspreading, but low-foam additives with unique molecular structures for this purpose which permit use alone or with known defoamers. It is an advantage that the low-foam, superspread-promoting additives can be used without conventional defoamers or with decreased amounts of them.
SUMMARY OF THE INVENTION
The invention provides methods for preparing and applying superspreading agricultural spray mixtures with low foaming, but without adversely affecting spreading of the mixtures when sprayed. The methods comprise adding to an agricultural spray mixture a superspreading, low-foaming surfactant comprising a trisiloxane of the following formula, hereinafter designated Formula I: ##STR1## wherein n has a value from about 2 to 4; y has a value of 3 to 10; z has a value from about 0 to 5; Q is selected from the group consisting of hydrogen and alkyl having 1 to 4 carbon atoms, with the provisos that
when z is 0, and:
when Q is hydrogen, y is 4 to 6;
when Q is methyl, y is 5 to 7;
when Q is ethyl, y is 6 to 8;
when Q is propyl, y is 7 to 9;
when Q is butyl, y is 8 to 10; and
when z is >0, and y+z are ≦15, and y/z =1.2 to 1.8, and:
when Q is hydrogen, y is 3 to 5, and z is 1 to 4;
when Q is methyl, y is 4 to 7, and z is 2 to 4;
when Q is ethyl, y is 5 to 8, and z is 3 to 5;
when Q is propyl, y is 4 to 9, and z is 4 to 6; and
when Q is butyl, y is 5 to 10, and z is 5 to 7.
DETAILED DESCRIPTION OF THE INVENTION
In the methods of the invention, an agricultural spray mixture is treated with the superspread-promoting, low-foaming trisiloxane surfactant set forth in Formula I (above). The superspread-promoting, low-foaming trisiloxane surfactant of Formula I can be added to a agricultural spray mixture along with the individual components during its formulation. It has been found that the order of addition of the trisiloxane surfactant to the agricultural spray mixture or its combination with the individual components of the agricultural spray mixture is not critical. It is understood that the trisiloxane surfactant can be added to a agricultural spray mixture immediately prior to spraying on plants or insects as well as its being included in the formulation of an agricultural spray mixture for spraying at a later time. By utilizing low-foaming surfactants meeting the standard described in Example 2, the final spray mixture tends to have low foaming potential relative to mixtures containing conventional organosilicone surfactants.
Superspreading, Low-foaming trisiloxane surfactants
The superspreading, low-foaming trisiloxane surfactants described by Formula I above can be prepared using procedures well known to those skilled in the art. In general, the superspreading, low-foaming trisiloxane surfactant is obtained by hydrosilylation of an alkenyl ether (e.g., vinyl, allyl, or methallyl) onto a 1,1,1,3,5,5,5-hepta-methyltrisiloxane in accordance with procedures described by W. Noll in The Chemistry and Technology of Silicones, Academic Press (New York: 1968). The superspreading, low-foaming trisiloxane of Formula I in which Q is hydrogen is formed by reacting an uncapped alkenyl polyether with a 1,1,1,3,5,5,5-heptamethyl-trisiloxane in the presence of chloroplatinic acid at temperatures ranging from about 80° C. to 100° C. The trisiloxane of Formula I in which CI is an alkyl group having 1 to 3 carbon atoms is prepared by the reaction of an uncapped alkenyl polyether and sodium methoxide in the presence of a solvent such as toluene with heating to form the sodium salt of an allyl polyether. The salt of the allyl polyether is reacted with a 1-alkyl (C 1 to C 3 ) halide to form a capped alkenyl polyether which is hydrosilated with hydrotrisiloxane as set forth above.
Agricultural Spray Mixture
In general, an agricultural spray mixture contains water and an active agricultural chemical ingredient, such as a pesticide (including herbicide, insecticide, fungicide and growth regulator). Typically, at least 50 percent of the agricultural spray mixture is composed of water. Optionally, the agricultural spray mixture can contain at least one component selected from the group consisting of organic surfactant, an antifoam agent and an organic solvent. Agricultural spray mixtures are commercially available as ready-to-use products or can be prepared in a containment vessel from an agricultural chemical concentrate, water, and optionally one or more surfactants and/or antifoaming agents. It is to be understood that the low-foaming trisiloxanes employed in the present invention can be used in place of a conventional foaming trisiloxane surfactant found in any agricultural spray mixture. Conventional foaming trisiloxane surfactants as are disclosed, for example, in U.S. Pat. Nos. 3,299,112 and 4,933,002 and are available, for examples, as Silwet L-77® (OSi Specialties Inc., Danbury, Conn.) and Sylgard® 309 (Dow Corning), respectively.
The amount of the active ingredient (i.e., agricultural chemical) will be any amount effective for the intended purpose, but typically ranges from about 0.001 to about 5 percent by weight based upon the total weight of the agricultural spray mixture, e.g., from about 0.03 percent to about 0.5 percent, preferably from about 0.07 percent to about 0.25 percent based upon the total weight of the agricultural spray mixture. When the agricultural spray mixture contains an organic surfactant, the amount of the organic surfactant ranges from about 0.1 to about 5 percent by weight based upon the total weight of the agricultural spray mixture. When an antifoam agent is employed in the agricultural spray mixture it is present in an amount ranging from about 0.001 to about 0.2 percent based upon the total weight of the agricultural spray mixture. When present, the amount of the organic solvent ranges from about 0.1 to 10 percent by weight based upon the total weight of the pesticide spray mixture. The bulk or remainder of the agricultural spray mixture is comprised of water.
Illustrative pesticides which can be employed as the active ingredient in the agricultural spray mixture of the present invention include those from the groups consisting of growth regulators, photosynthesis inhibitors, mitotic disruptors, lipid biosynthesis inhibitors, cell wall inhibitors, and cell membrane disruptors.
Growth regulators:
Phenoxy Acetic Acids, such as 2-4-D (2,4-Dichlorophenoxy)acetic acid!
Phenoxy Propionic Acids, such as Dichlorprop (RS)-2-(2,4-dichlorophenoxy)propionic acid! Mecoprop (RS)-2-(4-chloro-o-tolyloxy)propionic acid!
Phenoxy Butyric Acids, such as 2,4-DB 4-(2,4-Dichlorophenoxy)butyric acid!
Benzoic Acids, such as Dicamba 3.6-dichloro-o-anisic acid!
Other growth regulators, such as Fluoroxypyr 4-amino-3,5-dichloro-6-fluoro-2-pyridloxyacetic acid! Picloram 4-amino-2,3,5-trichloro-2-carboxylic acid! Triclopyr 3,6-dichloropyridine-2-carboxylic acid! Copyralid 3,6-dichloropyridine-2-carboxylic acid! Gibberellic acid (3S, 3aR, 4S, 4aS, 7S, 9aR, 9bR, 12S) -dihydroxy-3-methyl-6-methylene-2-oxoperhydro-4a, 7-methano-9b,3-propenoazuleno 1,2-b!furan-4-carboxylic acid
Photosynthesis inhibitors:
Traizines and s-Triazines such as Hexazinone 3-cyclohexyl-6-dimethylamino-1-methyl-1,3,5-triazine-2,4(1H,3H)-dione! Metribuzin 4-amino-6-tert-butyl-3-methylthio-1,2-3-triazine-5(4H )-one ! Atrazine 6-chloro-N 2 -ethyl-N 4 -isopropy!1-1,3,5-triazine-2,4-diamine! Simazine 6-chloro-N 2 ,N 4 -diethyl-1,3,5-triazine-2,4-diamine! Cyasnazine 2- 4-chloro-6-(ethylamino)-1,3,5-triazin-2-yl!-amino!-2-methylpropanenitrile Prometon N 2 , N 2 4-di-isopropyl-6-methoxy-1,3,5-triazine-2,4-diamine! Ametryn N 2 -ethyl-N 2 -isopropyl-6-methylthio-1,3,5 triazine-2,4-diamine!
Substituted ureas, such as Diuron 3-(3,4-dichlorophenyl)-1,1-dimethylurea(I)! Fluometuron 1,1-dimethyl-3-(a,a,a,-trifluoro-m-tolyl)urea(I)! Linuron 3-(3,4-dichlerophenyl)-1-methoxy-1-methylurea(I)! Tebuthiuron 1-(5-tert-butyl, 1,3,4-thiadiazol-1-yl)-1,3-dimethylurea(I)!
Uracils, such as Bromacil 5-bromo-3-sec-butyl-6-methylureacil(I)! Terbacil 3-tert-butyl-5-chloro-6-methyluracil(I)!
Other photsynthesis inhibitors, such as Bentazon 3-isopropyl-1H-2,1,3-benzothiadazin-4(3H)-one 2,2-dioxide(I)! Desmedipham ethyl 3'-phenylcarbamoyloxycarbanilate; ethyl 3-phenylcarbamoyloxypenylcarbamate; 3-ethoxycarbonylaminophenyl phenylcarbamate.! Methazole 2-(3,4-dichlorophenyl)-4-methyl-1,2,4- oxadiazolidine-3,5-dione(I)! Phenmedipham methyl 3-(3methylcarbaniloyloxy) carbanilate; 3'-methoxycarbonylaminophenyl 3'-methylcarbanilate.! Propanil 3',4'-dichloropropionanilide(I)! Pyridate 6-chloro-3-phenylpyridazine-4-yl S-octyl thiocarbonate!
Pigment Inhibitors: such as
Amitrole, 1H-1,2,4-triazol-3-ylamine; 3-amino-1H-1,2,4-triazole! Clomazone 2-(2-chlorobenzyl)-4,4-dimethyl-1,2-oxazolidin-3-one; 2-(2-chlorobenzyl)-4,4-dimethylisoxzazolidin-3-one! Fluridone 1-methyl-3-phenyl-5-(a,a,a-trifluoro-m-tolyl)-4-pyridone! Norflurazone 4-chloro-5-methylamino-2-(a,a,a-trifluoro-m-tolyl)pyridazine-3(2H-one!
Mitotic disruptors:
Dinitroanilines, such as Isopropalin 4-isopropyl-2,6-dinitro-N, N-dipropylaniline! Oryzalin 3,5-dinitro-N,N-dipropylsulfanilamine(I)! Pendimethalin N-(1-ethylpropyl)-2,6-dinitro-3,4-xylidine! Prodiamine 5-dipropylamino-1,a,a-trifluoro-4-6-dintro-o-toluidine; 2,6-dinitro-N 1 ,N 1 -dipropyl-4-trifluormethyl-m-phenylenediamine! Trifluralin a,a,a-trifluoro-2,6-dinitro-N,N-dipropyl-p-toluidine(I)!
Inhibitors of amino acid synthesis, such as Glyphosate N-(phosphonomethyl)glycine(I)!
Sulfonylureas, such as Bensulfuron a-(4,6-dimethoxypyrimidin-2-ylcarbamolysulfamoyl)-o-toluic acid! Chlorimuron 2-(4-chloro-6-methoxypyrimidin-2-ylcarbamoylsulfamoyl)benzoic acid! Chlorsulfuron 1-(2-chlorophylsulfonyl)-3-(4-methoxy-6-methyl-1,3,5-triazin-2-yl)urea! Metsulfuron 2-(4-methoxy-5-methyl-1,3,5-triazin-2-ylcarbamoylsulfamoyl)benzoic acid! Nicosulfuron 2-(4,6-dimethoxypyrimidin-2-ylcarbamoylsulfamoyl)-N,N-dimethyl-nicotinamide; 1-(4,6-dimethoxy-pyrimidin-yl)-3-(3-dimethylcarbamoyl-2-pyridylsulfonyl)urea! Primisulfuron 2- 4-6-bis-(difluoromethoxy)pyrimidin-2-ylcarbamoylsulfamoyl!benzoic acid! Sulfometuron 2,(4,6-dimethylpyrimidin-2-ylcarbamoylsulfamoyl)benzoic acid; 2- 3-(4,6-dimethylpyrimidin-2yl)-ureidosulfonyl!benzoic acid! Thifensulfuron 3-(4-methoxy-5-methyl-1,3,5-triazine-2-ylcarbamoylsulfamoyl)thiophen-2-carboxylic acid! Trisulfuron 1- 2-(2-chloroethoxy)phenylsulfonyl!-3(4-methoxy-6-methyl-1,3,5-triazin-2yl)urea! Tribenuron 2- 4-methoxy-6-methyl-1,3,5-triazin-2-yl(methyl)carbamoylsulfamoyl!benzoic acid!
Imidazolines, such as Imazamethabenz a reaction product comprising (+)-6-(4-isopropyl-4-methyl-5-oxo-2-imadazoli n-2-yl)-m-toluic acid (i) and (+)-2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-p-toluic acid (ii)! Imazapyr 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)nicotinic acid! Imazaquin (RS)-2-(4-isopropyl-4-methyl-5-oxo-2-imadazolin-2-yl)quinoline-3-carboxylic acid! Imazethapyr (RS)-5-ethyl-2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)nicotinic acid!
Inhibitors of lipid biosynthesis, such as Clethodim (+)-2- (E)-3-chloroallyloxyimino!propyl!5 2-(ethylthio)propyl!-3-hydroxycyclohex-3-enone! Diclofop-methyl (RS)-2- 4-2,4-dichlorophenoxy)phenoxy!propionic acid! Fenoxaprop-ethyl +-2- 4-(6-chloro-1,3-benzoxazol-2-yloxy)phenoxy!propionic acid; (+)-2- 4-(5-chlorobenzoxazol-2-yloxy)phenoxy!propionic acid! Fluazifop-P-butyl (R)-2- 4-(5-trifiuromethyl-2-pyridlyoxy)phenoxy!propionic acid! Haloxyfop-methyl (RS)-2- 4-(3-chloro-5-trifluoromethyl-2-pyridyloxy)phenoxy!propionic acid! Quizalofop (RS)-2 4-(6-chloroquinoxalin-2-yloxy)phenoxy!propionic acid! Sethoxydim (+)-(EZ)-2-(1-ethoxyiminobutyl)-5- 2-(ethylthio)propyl!-3-hydroxycyclohex-2-enone!
Cell wall inhibitors, such as Dichlobenil 2,6-dichlorobenzonitrile(I)! Isoxaben N- 3-(1-ethyl-1-methylpropyl)-1,2-oxazol-5-yl!-2,6-dimethoxybenzamide; N- 3-(1-ethyl-1-methylpropyl)isoxazol-5-yl!-2,6-dimeth-oxybenzamide!
Cell membrane disruptors:
Bipyridylium compounds such as Diquat 9,10-dihydro-8a-diazoniaphenanthrene; 6-7-dihydrodipyridol 1,2-a:2',1'-c!pyrazine-5,8-di-ium; 1,1'-ethylene-2,2'-bipyridyldiylium! Paraquat 1,1'-dimethyl-4,4'bipyridinium(I)!
Diphenylethers, such as Acifluorfen 5-(2-chloro-a,a,a-trifluro-p-tolyoxy)-2-nitrobenzoic acid!
Preferred pesticides include, for example, glyphosate available as Roundup® from Monsanto; gibberellic acid available as Pro-Gibb® from Abbott Laboratories; and triclopyr available as Garlon® from Dow Elanco.
Organic surfactants that can be employed in the invention are defined as surfactants which have a hydrocarbon based group as the hydrophobic moiety (i.e., he water insoluble component of the surfactant such as, for example an alkyl group having 7 to 12 carbon atoms). Organic surfactants contained in an agricultural spray mixture are readily commercially available. For example, they can be obtained from McCutcheon's, Emulsifiers & Detergents, North American Edition (MC Publishing Co., Glen Rock, N.J., 1992). Illustrative organic surfactants can include, for example, carboxylic acid salts such as Dresinate® TX, Hercules Inc. (Wilmington, Del.); linear alkyl benzenesulfonates such as BioSoft® LAS-405, Stepan Co. (Northfield, Ill.); ligninsulfonates such as Lignosite® 231, Georgia Pacific Corp. (Atlanta, Ga.); a-olefin sulfonates such as Calsofi® AOS-40, Pilot Chemicals Co. (Santa Fe Springs, Calif.); sulfosuccinate esters such as Aerosol® OT, American Cyanamid (Wayne, N.J.); sulfates of linear primary alcohols such as Polystep® B-3, Stepan Co. (Northfield, Ill.); sulfated polyoxyethylenated straight-chain alcohols such as Neodol® 25-3A, Shell Chemical Co. (Houston, Tex.); quaternary ammonium salts such as Emcol® CC-9, Witco Corp. (New York, N.Y.); amine oxides such as Admox® 1214, Ethyl Corp. (Baton Rouge, La.); polyoxyethylenated alkylphenols such as DeSonic® N, DeSoto Inc. (Fort Worth, Tex.); polyoxyethylenated straight-chain alcohols such as Brij® 30, ICI Americas, Inc. (Wilmington, Del.); polyoxyethylenated polyoxypropylene glycols such as Pluronic® L63, BASF Corp. (Parsippany, N.J.); N-alkylpyrrolidones such as Surfadone® LP-100, GAF Chemicas Corp. (Wayne, N.J.); N-alkylbetaines such as Mirataine® BB, Miranol Inc. (Dayton, N.J.). Preferably the organic surfactant is selected from the group consisting of sulfated polyoxyethylenated straight chain alcohol, polyoxyethylenated straight chain alcohol, and a sulfate of a linear primary alcohol. The preferred organic surfactants preferably have 7 to 12 carbon atoms in the hydrophobic moiety of the organic surfactant.
Antifoam agents which can be used in an agricultural spray mixture are also readily commercially available. Typically, these antifoam agents are silica-filled silicone emulsions. Illustrative antifoam agents can include, for example, SAG® MARK X and SAG® 10, available from Union Carbide Chemicals and Plastics Company Inc. (Danbury, Conn.); GE AF-9020®, available from General Electric Co. (Waterford, N.Y.); FOAM BUSTER® (Helena Chemical Company; Memphis, Tenn.); and FIGHTER F®, available from Loveland Industries, Inc. (Loveland, Colo.).
Optionally, an organic solvent can be employed in the agricultural spray mixture. When employed, the solvent can include a lower molecular weight alcohol having 1 to 5 carbon atoms such as, for example, methanol, ethanol, n-propanol, isopropanol, n-butanol, t-butanol, and n-amyl alcohol. Ketones having 1 to 6 carbon atoms such as, for example, acetone and methyl-butyl ketone can also be used as a solvent.
The following specific examples are presented to further illustrate and explain certain aspects of the present invention. However, the examples are set forth for illustration only, and are not to be construed as limiting on the present invention. In the following examples, all percentages and parts are by weight unless otherwise specified.
EXAMPLE 1
The trisiloxane surfactants employed in the Examples are set forth below in Table 1.
TABLE 1______________________________________Trisiloxane Surfactants ##STR2##TRISILOXANE y z Q______________________________________SILICONE 1 8 0 CH.sub.2 CH.sub.2 CH.sub.3SILICONE 2 6 0 CH.sub.3SILICONE A 8 0 CH.sub.3SILICONE B 8 0 CH.sub.2 (CH.sub.2).sub.3 CS.sub.3SILICONE C 3.5 0 H______________________________________
In each structure above, the amount of (C 2 H 4 O) represents an average. Silicone A is sold under the trademark SILWET L-77® by OSi Specialties Inc.
Spreading Test
Superspreading of trisiloxane surfactants makes them of use for agricultural applications. A low-foaming surfactant should possess the ability to superspread. Substrates on which spreading was evaluated were Parafilm M (paraffin wax film) and polyster film (IR 1174 from 3M).
Spreading tests on Parafilm M were performed as follows. A 10-microliter drop of the mixture was placed, using an automatic micropipetter, on a piece of Parafilm M stretched across the mouth of a jar on a level table top. At the point of maximum spreading, or after 5 minutes, the largest and smallest diametric dimensions of the spread drop were measured. Each material was tested at least twice and the measurements were averaged.
Spreading tests on polyester film (IR 1174) were performed as follows. A 10-microliter drop of the mixture was placed, using an automatic micropipetter, on a piece of polyester film. At the point of maximum spreading, or after 5 minutes, the largest and smallest diametric dimensions of the spread drop were measured. Each material was tested at least twice and the measurements were averaged.
The spreading factor on each surface was calculated as the ratio of the average diameter of a drop of the surfactant solution to that of a doubly distilled water drop. For purposes of this calculation the doubly distilled water drop was designated as having a value of 1. Superspreading was present when a spreading factor was greater than 9 on each surface. Results of the spreading tests are shown in Table 2.
TABLE 2______________________________________Spreading Factors for 0.1% Trisiloxane Surfactant MixturesRun Trisiloxane On Parafilm On Polyester Film______________________________________1 SILICONE 1 11.9 12.62 SILICONE 2 9.7 13.0A SILICONE A 9.4 11.0B SILICONE B 2.3 6.0C SILICONE C 4.0 3.7______________________________________
It can be seen that Silicones 1 and 2, in accordance with the present invention, superspread. In addition, Silicone A also superspreads. Silicones B and C did not superspread, and, hence were not evaluated further for foaming.
EXAMPLE 2
Surfactant Foaming Requirements
Silicones 1,2 and A which superspread in Example 1 were tested for foaming. Foaming tests were performed using the Ross-Miles technique (ASTM method D 1173-53). Using this technique, 200 milliliters (ml) of a solution to be evaluated for foaming is allowed to fall from a height or 90 centimeters (cm). The maximum initial foam height and the foam height after 5 minutes were recorded. For this evaluation, a silicone should exhibit foaming of less than 50 millimeters (mm) initially and less than 15 mm after 5 minutes. Results are shown in Table 3, to be considered low foaming.
TABLE 3______________________________________Ross-Miles Foaming Using 0.1% Surfactant Mixtures Initial 5 minuteRun Trisiloxane Foam Height (mm) Foam Height (mm)______________________________________3 SILICONE 1 18 94 SILICONE 2 39 9D SILICONE A 90 85______________________________________
From Table 3 it is seen that SILICONE 1 and SILICONE 2 have foam heights less than 50 mm initially and less than 15 mm after 5 minutes. In contrast, the comparative Silicone A showed foaming greater than 50 mm initially and greater than 15 mm after 5 minutes.
EXAMPLE 3
Use of Low-foaming Siloxane in an Agricultural Spray Mixture
SILICONE 1 and SILICONE A were each separately blended into a conventional pesticide spray solution (RoundupRun® Ready-To-Use from Monsanto Co., St. Louis, Mo.). SILICONE A is a conventional trisiloxane surfactant such as those taught in U.S. Pat. No. 3,299,112 and commercially available as Silwet L-77®. To 20 milliliters of an agricultural spray mixture, containing 0.20 milliliters of the pesticide glyphosate, was added 0.04 grams to make a 0.2% trisiloxane surfactant in the agricultural spray solution in a 100-ml graduated cylinder which was then stoppered. The stoppered cylinder was shaken vigorously by hand 30 times. All the experiments were performed by the same operator. The foam volume was recorded as a function of time and these results are set forth in Table 4.
TABLE 4______________________________________Foaming Properties of Agricultural Spray Mixture/Trisiloxane SurfactantRun Trisiloxane Time (Min.) Foam Volume______________________________________5 SILICONE 1 0 60 5 42 10 17E SILICONE A 0 65 5 50 10 48______________________________________
From Table 4, it can be seen that Agricultural Spray Mixture/Silicone 1 (Run 5) produced less foam than Agricultural Spray Mixture/Silicone A (Run E).
EXAMPLE 4
Effect of Antifoam in an Agricultural Spray Mixture
A commercially available, conventional antifoam (SAG® MARK X from Union Carbide Chemicals and Plastics Company Inc., Danbury, Conn.) 0.002 grams, to make 0.01% of antifoam in the agricultural spray mixture was employed and evaluated with both Silicone 1 and Silicone A, as done in Example 3. Results are shown in Table 5.
TABLE 5______________________________________Foaming Properties of Agricultural SprayMixture/Antifoam/Trisiloxane SurfactantRun Trisiloxane Time (Min.) Foam Volume (ml)______________________________________6 SILICONE 1 0 32 1 5 5 2 10 2F SILICONE A 0 63 1 48 5 40 10 23______________________________________
From Table 5, it can be seen that the agricultural spray mixture containing the superspread-promoting, low-foaming trisiloxane surfactant (Silicone 1) is more easily defoamed than the mixture incorporating Silicone A whose chemical structure is different from that of the low-foaming trisiloxane surfactant of the present invention.
EXAMPLE 5
Use of Superspreading, Low-foaming Trisiloxane with Other Agricultural Chemicals
This Example demonstrated that the low-foaming trisiloxane can be employed with agricultural chemicals other than that contained in the pesticide Roundup® (i.e., glyphosate). Gibberellic acid (as Pro-Gibb® from Abbott Laboratories, Chicago, Ill.) and triclopyr (from a 44.4% active concentrate of Garlon® 3A from Dow-Elanco, Indianapolis, Ind.), were employed. The amount of agricultural chemical in each solution was typical of use levels in the field. The same experimental technique employed in Example 3 was used. Results are shown in Tables 6 and 7.
TABLE 6______________________________________Foaming Properties of Spray Mixtures Containing40 ppm of Gibberellic Acid and 0.2% of a Trisiloxane SurfactantRun Surfactant Time (Min.) Foam Volume (ml)______________________________________6 SILICONE 1 0 33 1 9 5 6 10 6G SILICONE A 0 40 1 20 5 16 10 13______________________________________
TABLE 7______________________________________Foaming Properties of Spray Mixtures Containing1.6% Triclopyr and 0.2% of a Trisiloxane SurfactantRun Surfactant Time (Min.) Foam Volume (ml)______________________________________8 SILICONE 1 0 7 1 7 5 6 10 6H SILICONE A 0 50 1 40 5 30 10 27______________________________________
From the results, it can be seen that the Agricultural Spray Mixtures/Silicone 1 (Runs 7 and 8) produced less foam than Agricultural Spray Mixtures/Silicone A (Runs G and H).
The above description is for the purpose of teaching the person of ordinary skill in the art how to practice the present invention, and it is not intended to detail all of those obvious modifications and variations of it which will become apparent to the skilled worker upon reading the description. It is intended, however, that all such obvious modifications and variations be included within the scope of the present invention which is defined by the following claims.
For conciseness, several conventions have been employed with regard to listings of chemicals and ranges. The listings of chemical entities throughout this description are meant to be representative and are not intended to exclude equivalent materials, precursors or active species. Also, each of the ranges is intended to include, specifically, each integer, in the case of numerical ranges, and each species, in the case of chemical formulae, which is encompassed within the range. The claims are meant to cover the claimed components and steps in any sequence which is effective to meet the objectives there intended, unless the context specifically indicates the contrary. | Methods for preparing and applying agricultural sprays without undue foaming of the spray mixture employ a superspread-promoting, low foaming trisiloxane surfactant. Agricultural spray mixtures with super-spread properties, but limited foaming, comprise (A) a superspreading, low foaming trisiloxane surfactant and (B) an agricultural chemical spray mixture comprising water, an agricultural chemical (e.g., a pesticide), and optionally an organic surfactant, antifoam agent, and an organic solvent. | 0 |
FIELD OF THE INVENTION
The present invention relates to an enzyme sensor used for measurement of several components in a solution. More particularly, the present invention relates to "Enzyme sensor, which comprises both an enzyme-modified electrode and a counter electrode, said enzyme-modified electrode comprising, as electrode components, an enzyme and/or an enzyme-containing substance and a mediator."
According to the present invention, an object component can be measured easily and rapidly. Hence, the present invention is not only useful as a measurement sensor in the areas of fermentation industry and chemical industry, but is also useful as a measurement sensor of several biological components in a sample from the living body, in the area of clinical tests, and can be used widely for diagnosis and examinations of several diseases, too.
BACKGROUND OF THE INVENTION
Enzyme sensor, in which the high specificity of an enzyme toward its substrate is used, is found to be useful for measurement of several compounds, and the enzyme sensor has already been practiced in quantitative analyses of glucose, etc. The enzyme sensor now practiced, in which an enzyme possessing high specificity toward a substance to be measured is immobilized, is used for determination of an object substance in a sample, by electrochemically detecting an amount of hydrogen peroxide formed, or of oxygen consumed when an enzyme acts on an object substance in a sample. Accordingly, enzymes to be employed in enzyme sensors of this type are restricted to oxidation enzymes, so-called "oxidases," which form hydrogen peroxide.
Usually, oxidases, which selectively oxidize substances to be measured, are separated from microorganisms selected through screening and are purified for use. However, a microorganism which produces an object enzyme is not always found through the screening process, and even if it is found, there are many cases where the microorganism cannot be employed owing to enzymatic properties, such as substrate specificity, the K m value, and stability. In addition, because of low productivity by microorganisms or difficult separation and purification, there are many cases where enzyme sensors do not come into practical use, and an enzyme sensor serving for practical use is only a glucose sensor under the present situation.
Concerning oxidase, an enzyme sensor is developed for measurement of ethanol by use of an alcohol oxidase originated in yeast, and its practical use is examined in the system of using a hydrogen peroxide electrode or an oxygen electrode, but actually, it does not bring about a commercial success. This is because substrate specificity of the enzyme is low and a life-time of the enzyme is considerably short.
On the other hand, as enzyme other than the oxidases above described, there are dehydrogenases which donate electrons occurring in the oxidation process to prosthetic groups, such as PQQ, FAD, NAD, and NADP, being not always accompanied by oxygen consumption nor hydrogen peroxide generation. In this type of enzymes, there are greater number of types than are oxidases. Of the dehydrogenases, the presence of enzymes suitable for sensor is also known.
Accordingly, the present inventors developed a new enzyme sensor with a substrate specificity higher than, and with a stability superior to, the sensor by means of enzyme originated in yeast in the preceding publication (Japanese Patent Application No. 253,850/87). The enzyme used in the sensor was an alcohol dehydrogenase having PQQ (pyrroloquinoline quinone) as a prosthetic group originated in acetic acid bacteria. By this invention, a sensor superior to the sensor by means of an enzyme originated in yeast was developed, resulting in one success.
However, dehydrogenases other than alcohol dehydrogenases have hardly been employed yet as a source of enzymes for the sensor. This is because the coenzymes, i.e. PQQ, FAD, NAD, and NADP, are of high prices, which leads to high analysis costs. In order to solve the problem, it was attempted, for example, to immobilize NAD and to regenerate for use, which does not come into practical use yet, though. On the other hand, a method employing an artificial electron acceptor as a mediator (an electron transport intermediate) is developed, thereby preparing an enzyme sensor for a high specificity toward glucose, etc., as well as toward ethanol, and its practical use is examined. However, it is evident that the cost is high even if an artificial mediator is employed, and mediators usually employed are usually coloring substances, so that the waste fluids are colored, to cause a problem of waste water treatments if discarded as it is. In addition, a high-priced mediator is wasted every measurement, thereby resulting in a further higher cost, so that the improvement has been desired.
It is proposed that an artificial mediator in the form of a thin film is applied to the surface of an electrode, which is then coated with an enzyme, followed by being further covered with a semipermeable membrane (EP 78636B1). In other methods, it was proposed that a mediator hardly soluble in water is incorporated into a electrode material (Agric. Biol. Chem., 52, 1557, (1988), and that in the case of a highly water-soluble mediator, first the mediator is added to an electrode, then a thin film is made of a mixture comprising an ionic high molecular compound and an enzyme, so as not to elute the mediator into an electrolyte (Agric, Biol. Chem., 52, 3187 (1988)). However, in both of the cases, it is troublesome to prepare the electrodes, and the enzyme is employed so as to form a thin film, after the incorporation of mediator. In the latter case, there is no examination of employment of dehydrogenase.
As earlier described, conventional enzyme-modified electrodes have several problems; the preparation is troublesome; very difficult operations are required for mass-production of quality-controlled product; in addition, their life-time for repeating use is short; and enzymes that can be utilized are limited. Accordingly, instead of the conventional troublesome process of successive covering of the thin membrane layer of a mediator, the thin membrane layer of enzyme, and the layer of a semipermeable membrane with the surface of an electrode, the present inventors made an electrode material with a homogeneous composition from electron carriers, such as graphite carbon pastes, which are usually employed as an electrode material, an enzyme, and a mediator, by the addition of suitable vehicles like liquid paraffin, by mixing them to a homogeneous composition thereby the surface of an electrode substrate (e.g. carbon electrode) being covered with the electrode material (referred to as an enzyme-modified electrode material), and by this considerably easy method, the present inventors established a process of the preparation of an enzyme-modified electrode for respective enzymes, to complete the present invention after several researches for the purpose of providing the enzyme-modified electrode-incorporated sensor excellent in properties.
SUMMARY OF THE INVENTION
The present invention provides an enzyme sensor which comprises an enzyme-modified electrode and a counter electrode, wherein the enzyme-modified electrode comprises, an enzyme and/or an enzyme-containing substance and a mediator. The enzyme-modified electrode is a further aspect of the invention.
The enzyme-containing substance may, for example, be selected from the group consisting of cells, a cultured medium and disrupted cells of a microorganism producing said enzyme, and fractionation components, cellular extracts, cell membrane fraction and a crude enzyme from said disrupted microorganism cells. The enzyme is suitably a dehydrogenase, for example, alcohol dehydrogenase, aldehyde dehydrogenase, glucose dehydrogenase, fructose dehydrogenase, sorbitol dehydrogenase, or glycerol dehydrogenase.
The term mediator, as used herein, refers to a substance which can mediate in the transfer of electrons, such as a redox compound and/or a coenzyme. Suitable examples include p-benzoquinose, ferrocene, dimethylferrocene, potassium ferricyanide, phenazine methosulphate, 2,6-dichlorophenol indophenol, PQQ, FAD, NAD, and NADP. Particularly suitable combinations of enzyme and mediator include the following pairs: aldehyde dehydrogenase and p-benzoquinone; fructose dehydrogenase and dimethylferrocene; sorbitol dehydrogenase and dimethylferrocene; and glycerol dehydrogenase and potassium ferricyanide.
The electrode components contain carbon or graphite.
The present invention further provide a method for preparing an enzyme-modified electrode which comprises preparing, an enzyme-modified electrode material by dissolving a water-insoluble mediator in an organic solvent, adding liquid paraffin thereto, followed by removing the solvent and mixing the resultant mixture with graphite powder and an enzyme and/or an enzyme-containing substance, and applying the resulting material to the surface of a carbon electrode.
The enzyme-modified electrode may also be prepared by mixing reversed micells, into which a water-soluble mediator is incorporated, with graphite powder and an enzyme and/or an enzyme-containing substance, to yield an enzyme-modified electrode material which is then applied to the surface of a carbon electrode.
The enzyme-modified electrode material which can be used for the preparation of the enzyme-modified electrode of the invention may also be prepared by mixing a water-insoluble complex of a ferricyanide compound and a cationic surface active agent with liquid paraffin and then with graphite powder and an enzyme and/or enzyme-containing substance.
The invention further provides measuring equipment, which comprises a reaction chamber, a constant voltage power supply part, a current voltage converting part, and an amplifier part, said reaction chamber being equipped with a sample injection port, an electrolyte inlet, a waste liquid outlet, a stirring device, a counter electrode, and an enzyme-modified electrode of the invention.
The present invention has provided a novel enzyme-modified electrode prepared by an extremely easy method, and a novel enzyme sensor which comprises combining said enzyme-modified electrode and a counter electrode, wherein the enzyme-modified electrode is formed in the state of an enzyme and a mediator being uniformly mixed together with other electrode components, and the enzyme sensor shows a little change in electrode components caused by elution of the mediator, etc., as well as shows stable property, in repeating uses. The enzyme sensor according to the present invention is excellent in responsibility and reproductibility of measured values, and since the present invention can employ a wide variety of enzymes, selection of an enzyme according to its substrate specificity for use makes various component measurements possible. In particular, there is a great advantage in the employment of dehydrogenases which have hardly been employed as a sensor enzyme.
According to the present invention, a mediator, together with enzyme, is firmly immobilized to an electrode, so that a mediator or enzyme of high price is not eluted, and the mediator can be used for long time for repeating uses and thus a great economical effect can be achieved. In addition, since colored mediators employed in many cases are not eluted, so that colorination of waste liquids is prevented, resulting in a significant effect, i.e., elimination of the problem for waste liquid treatment.
Therefore, by use of the present invention, a very small amount of a compound in foods or a component in the living body can be measured rapidly and correctly, and it can also be used in diagnosis of diseases, control of fermentation process, and control of a reaction process.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 the structure of an enzyme-modified electrode.
FIG. 2A shows the structure of reaction chamber and FIG. 2B shows a measuring apparatus.
FIG. 3A, 3B, 3C, and 3D show the response curve to a 10% ethanol solution in the case where four kinds of mediator were used.
FIG. 4, FIG. 5, FIG. 6, FIG. 7, FIG. 8, FIG. 9, and FIG. 10 show one example of a calibration curve for measurement of ethanol, glucose, aldehydes, fructose, sorbitol, glycerol, or sucrose, respectively, using the enzyme sensors according to the present invention.
In FIGS. 1, 2A and 2B, the numerals indicate as follows:
1 . . . enzyme-modified electrode
2 . . . graphite electrode
3 . . . conductive adhesive
4 . . . copper screw
5 . . . nut (double)
6 . . . Ag/AgCl 2 electrode
7 . . . sample injection port
8 . . . magnetic stirrer
9 . . . stirrer
10 . . . reaction chamber
11 . . . pump
12 . . . electrolyte
13 . . . waste liquid
PS . . . constant-voltage power source
CV-A . . . current-voltage conversion and amplifier
A/D . . . A/D conversion
RE . . . recorder
CP . . . computer
DETAILED DESCRIPTION OF THE INVENTION
Enzymes employed in the present invention may be any of ones if they can catalyze a oxidation-redox reaction of substances to be measured and can transfer electrons originated in the reaction. For example, dehydrogenases having coenzymes, such as PQQ, FAD, NAD, and NADP, are preferably used.
More particularly, the following dehydrogenases are preferably used; for ethanol measurement, alcohol dehydrogenases originated in Acetobacter aceti IFO 3284, Gluconobacter suboxydans IFO 12528, Acetobacter altoacetigenes FERM BP-491; for measurement, of acetaldehyde, aldehyde dehydrogenases originated in the three bacteria above described; for glucose measurement, glucose dehydrogenases originated in Gluconobacter suboxydans IFO 12528 and Gluconobacter suboxydans IFO 3254; for fructose measurement, fructose dehydrogenase originated in Gluconobacter industrius IFO 3260; for sorbitol measurement, sorbitol dehydrogenase originated in Gluconobacter suboxydans IFO 3254; for glycerol measurement, glycerol dehydrogenase originated in Gluconobacter industrius IFO 3260.
In addition, sucrose can be measured with an enzyme sensor having an electrode comprising, as its components, an enzyme which degrades sucrose to produce glucose or fructose, such as invertase originated in baker's yeast or Candida utilis, together with glucose dehydrogenase or fructose dehydrogenase.
Among enzymes utilized in the present invention, particularly preferable enzymes can include ones which are accumulated in the state of being bound to the cell membranes of microorganisms when cultured (referred to as a membrane-bound enzyme, hereinafter). The membrane-bound enzymes are superior in stability when mixed as an electrode component, the enzyme is hardly eluted when the electrode is used, good reproducible measured values are given, and there is also an advantage in that they are available with low prices as an enzyme source.
In the present invention, enzyme-containing substances as well as enzymes above described can widely be used. The enzyme-containing substance is suitably selected from the group consisting of fractionation components, extracts, cell-membrane fractions, membrane-bound enzymes, and crude enzymes from said enzyme-producing microorganisms, said enzyme-producing microorganisms culture said disrupted microorganisms. If purified enzyme is desired, microorganism is disrupted by a common method, such as sonication or French pressure, followed by ammonium sulfate fractionation or fractionation by means of several types of chromatography, to separate and purify an object enzyme. In the case of employment of a membrane-bound enzyme, as shown above, good results can be given even if the disrupted microorganism is employed without the enzyme being highly purified.
The mediators used in the present invention are not particularly restricted, if they can transfer electrons occurring in the enzyme reaction, but mediators used are preferred to be selected so as to proceed in transferring the electrons smoothly. In addition, it is also possible to employ two or more mediators simultaneously. Specifically, artificial mediators, such as p-benzoquinone, ferrocene, dimethylferrocene, potassium ferricyanide, 2,6-dichlorophenol indophenol, can preferably be employed singly or in combination, but original enzyme's prosthetic groups, such as PQQ, FAD, NAD, and NADP can also be employed.
The electrode components utilized in the present invention comprises an enzyme and a mediator as essential components. However, any one other than these components can be employed, if it is an electron carrier capable of constituting the electrode. As such an electron carrier, usually carbon or graphite is preferably employed.
The preparation of an enzyme-modified electrode comprising both an enzyme and a mediator as electrode components can be carried out, e.g., according to the following method.
For employment of a water-insoluble mediator, such as p-benzoquinone, ferrocene, and dimethylferrocene, first the mediator is dissolved in a solvent like ether, etc. and the solution is added to a suitable amount of liquid paraffin and mixed well. After removing the solvent by a common method, such as by use of reduced pressure, the remaining product is mixed with an enzyme and graphite powder.
The adopted ratio of liquid paraffin to graphite powder to enzyme is generally (1-3):(0.5-1.5):1, and a minimum enzyme activity is 0.5 to 1 unit of alcohol dehydrogenase activity per 1 mg of protein.
In place of liquid paraffin, a hydrophobic or water-insoluble substance which is liquid at room temperature, such as hydrocarbons having 10 or more carbon atoms can be used.
For employment of a water-soluble mediator, such as potassium ferricyanide, phenazine methosulphate, and 2,6-dichlorophenol indophenol, a mediator-containing reversed micells are formed with a surface active agent, in order for the mediator to be incorporated into an electrode material, and mixed with an enzyme and graphite powder, to prepare an enzyme-modified electrode material containing mediator.
Also, in the case of potassium ferricyanide, a water-insoluble complex can be prepared by mixing a cationic surface-active agent therewith. The resultant complex was added to liquid paraffin in a suitable ratio, well mixed, and then mixed with an enzyme and graphite powder, so that an enzyme-modified electrode comprising a mediator can be prepared. The cationic surface-active agent which may be preferably used in the step includes dimethyl di-n-octadecyl ammonium bromide, trioctyl methyl ammonium chloride, cetyl pyridinium chloride, dodecyl pyridinium chloride, tetradecyl dimethylbenzyl ammonium chloride, etc.
The mixing ratio of a mediator-containing liquid paraffin or potassium ferricyanide--a cationic surface-active agent to graphite powder to enzyme is preferably employed in the range of (1-3):(0.5-1.5):1.
Any other than graphite powder, liquid paraffin, or a surface active agent can also be employed if it is an electrode material capable of being mixed with the enzyme.
As described above, various types of compounds, such as prosthetic groups, redox compounds (e.g., quinone, methylene blue, etc.) and the like can suitably be employed as mediators.
FIG. 1 shows the illustrated example of an enzyme-modified carbon electrode relating to the present invention. In the example, the mixture, in which graphite powder and a mediator are mixed well in an appropriate proportion, is uniformly mixed with an enzyme, and the resulting mixture is applied to the surface of an electrode, to prepare the enzyme-modified carbon electrode.
The amount of an enzyme electrode material to be applied is not particularly restricted if the electrode can respond to a substance to be measured. However, from a viewpoint of workability, a response speed, and an economical factor, it is preferably applied in the range of 0.3 to 2 mg per 1 mm 2 of the electrode surface or 50 to 500 μm in thickness.
The electrode thus prepared is attached to an apparatus shown in FIG. 2, and an object substance in a sample solution is measured. That is, first, a reaction chamber is set up as shown in FIG. 2A. In the middle of the reaction chamber, a sample chamber or an electrolytic cell is made, and a stirring equipment like magnetic stirrer, etc. is provided therewith. The sample chamber is equipped with an enzyme-modified electrode (FIG. 1) and a counter electrode (e.g., Ag/AgCl 2 electrode), together with a sample inlet, an electrolyte inlet, and a waste fluid drain, and thus the assembly of the reaction chamber is finished.
Using the reaction chamber thus set up, measurements are carried out with an apparatus illustrated in FIG. 2B.
That is, an enzyme-modified carbon electrode illustrated in FIG. 1 is attached to the sample chamber (electrolytic cell), and the sample chamber is filled with electrolyte by use of a pump, to which a voltage is applied while a suitable counter electrode being used. Then, a sample containing a measured substances is injected in an appropriate amount through a sample injection port. The current value of oxidation current occurring by the reaction of a measured substance included in a sample with the enzyme in the enzyme-modified carbon electrode is recorded with a recorder after being converted to a voltage value with a current-voltage converting circuit, or is measured with a computer by sending the current to the computer after the A/D conversion. By comparing an observed oxidation current of a sample with those of standard solutions of predetermined concentrations, a substance to be measured which the sample contains can be determined. In this case, the surface area, in contact with a liquid to be measured, of the enzyme-modified electrode according to the present invention may generally be as small as about 3 mm 2 . The measurements can be carried out at temperatures of 10° to 40° C. and in the range of pH 4 to 8.
The present apparatus can be used as a flow-injection type apparatus by continuous feeding of an electrolyte during measurement. By using an apparatus of the flow-injection type, it is possible to extend the range of concentrations to be measured.
The present invention is explained more detail, referring to the examples below.
It is only shown in the examples below that precipitates obtained by ultracentrifugation of the disrupted cells of dehydrogenase-producing bacteria are used as enzyme. However, the present invention is not restricted to the examples described below, and suitably purified enzyme can be employed, or enzyme can be selected for use, according to the type of a substance to be measured.
EXAMPLE 1
Preparation of a Cell Membrane-Bound Alcohol Dehydrogenase and a Cell Membrane-Bound Aldehyde Dehydrogenase
A cultivated both of Acetobacter altoacetigenes FERM BP-491 was centrifuged and collected, and the obtained bacterial cells were disrupted with a French pressure. After the disrupted cells were subjected to ultra centrifugation (100,000 g, 60 min. 4° C.), precipitates were employed as a cell membrane-bound alcohol dehydrogenase and as a cell membrane-bound aldehyde dehydrogenase.
EXAMPLE 2
Preparation of a Cell Membrane-Bound Glucose Dehydrogenase and a Cell Membrane-Bound Sorbitol Dehydrogenase
A cultivated broth of Gluconobacter IFO 3254 was treated in the same manner as in Example 1 above described, and the obtained precipitates were employed as a membrane-bound glucose dehydrogenase and a membrane-bound sorbitol dehydrogenase.
EXAMPLE 3
Preparation of a Membrane-Bound Alcohol Dehydrogenase-Modified Carbon Electrode Comprising a Water-Insoluble Mediator
1 g of dimethylferrocene was dissolved in 1 ml of ether, 1 ml of liquid paraffin was added and mixed well, and the ether was removed by evaporation under reduced pressure. With the mixture were mixed graphite powder of not greater than 250 mesh size and the enzyme prepared in Example 1 above described in the ratio of 3:3:1 (ratio by weight) and the mixture was subjected to dehydration treatment for 3 hrs. under reduced pressure, to prepare an enzyme-modified electrode material.
The electrode material prepared was applied to the surface of a carbon electrode part contacting liquid as shown in FIG. 1 in a small amount, to prepare a membrane-bound alcohol dehydrogenase-modified carbon electrode comprising dimethylferrocene.
A membrane-bound alcohol dehydrogenase-modified carbon electrode comprising p-benzoquinone was prepared in the same manner as the above-described method except that p-benzoquinone is employed.
EXAMPLE 4
Preparation of a Membrane-Bound Alcohol Dehydrogenase-Modified Carbon Electrode Comprising a Water-Soluble Mediator
To 1 ml of α-bromonapthalene was added 0.025 g of Aerosol OT, and the mixture was dispersed well. Aqueous solution of 0.1 ml of 1 M potassium ferricyanide was added to the resultant dispersion and was then subjected to sonication for 20 min, while sometimes being shaken. The water remaining in the upper part was absorbed into a filter paper for removement. In this manner, α-bromonaphthalene containing reversed micells into which potassium ferricyanide was incorporated was prepared. Separately, α-bromonaphthalene, graphite powder of not greater than 250 mesh size, and the enzyme prepared in Example 1 described above were mixed in the ratio of 3:3:1, respectively, and the mixture was treated for dehydration under reduced pressure.
To the resultant mixture was added the above α-bromonaphthalene containing the reversed micells in the ratio of 1:2 and mixed well, to prepare an enzyme-modified electrode material.
Using the electrode material thus prepared, a membrane-bound alcohol dehydrogenase-modified carbon electrode comprising potassium ferricyanide was prepared in the same manner as in Example 3 described above.
A membrane-bound alcohol dehydrogenase-modified carbon electrode comprising phenazine methosulphate was prepared in the same manner as in the above-described method except that the mediator is phenazine methosulphate in place of potassium ferricyanide.
EXAMPLE 5
Preparation of a Membrane Bound-Glucose Dehydrogenase-Modified Carbon Electrode Comprising a Water-Soluble Mediator
Using the enzyme prepared in Example 2 described above, a membrane-bound glucose dehydrogenase-modified carbon electrode comprising potassium ferricyanide was prepared in the same manner as in Example 4 described above.
EXAMPLE 6
Measurement of Ethanol Concentration
The enzyme-modified carbon electrode comprising the mediator prepared in Example 3 or 4 previously described was attached to the apparatus shown in FIG. 2, and the reaction chamber was filled with an electrolyte which was prepared by degassing 0.1 M phosphate buffer containing 0.1 M KCl (pH 6.0) under reduced pressure by use of a pump, and a magnet in the reaction chamber was stirred with a stirrer. A constant voltage of +0.6 V was applied to a silver/silver chloride electrode as another electrode in the reaction chamber, and the current value was recorded with a recorder. The reaction chamber was kept at 20° C.
5 μl of the sample containing 10% (W/V) ethanol was injected from a sample injection port by use of a microsyringe, and the current value obtained under the above-described reaction conditions was measured, to obtained the response curve as shown in FIG. 3.
Even if any of the mediator was employed, by injection of a ethanol-containing sample, the oxidation current was increased and finally turned constant. In a sample not containing ethanol, no oxidation current increase was observed.
When the respective mediators were employed, the oxidation currents, converted into their voltage values are as follows: 14 mV in case dimethyl ferrocene was employed, 5 mV in case p-benzoquinone was employed, 44 mV in case potassium ferricyanide was employed, 8 mV in case phenazine methosulphate was employed. Using the enzyme electrode comprising potassium ferricyanide by which the highest current value could be obtained, the effect of ethanol concentration was examined. As a result, data as shown in FIG. 4 were obtained where the current measured values increased in response to the ethanol concentration. In addition, in order to investigate the electrode stability, the standard deviation of the current values obtained were 1.9% in the case where the same sample (ethanol concentration; 10%) was examined successively 13 times, which showed the reproductibility to be considerably high.
EXAMPLE 7
Measurement of Glucose Concentration
The enzyme-modified carbon electrode comprising the mediator prepared in Example 5 above described was attached to an apparatus shown in FIG. 2, and under the same conditions as in Example 6 as above described, each 5 μl of a sample containing glucose of various concentrations was injected through the sample injection port by use of a microsyringe, and current values obtained were recorded with a recorder. By plotting the relationship between the current values and the glucose concentrations, the result shown in FIG. 5 was obtained, and the measured values increased in response to the glucose concentrations in the samples were obtained.
EXAMPLE 8
Preparation of a Membrane-Bound Fructose Dehydrogenase and a Membrane-Bound Glycerol Dehydrogenase
A cultured broth of Gluconobacter industrius IFO 3260 was treated in the same manner as in Example 1 above described. The resultant precipitates were employed as a membrane-bound fructose dehydrogenase and as a membrane-bound glycerol dehydrogenase.
EXAMPLE 9
Preparation of a Membrane-Bound Aldehyde Dehydrogenase-Modified Carbon Electrode Comprising a Water-Insoluble Mediator
1 g of p-benzoquinone was dissolved in 1 ml of ether, and 1 ml of liquid paraffin was added thereto, followed by being mixed well, and the solvent was removed by evaporation under reduced pressure. To this mixture were mixed graphite powder not larger than 250 mesh size and the enzyme standard prepared in Example 1 above described were mixed in the ratio of 1:1:1 (ratio by weight). The mixture was then subjected to a dehydration under reduced pressure for 1 hr., to prepare an enzyme-modified electrode material. Using the enzyme-modified electrode material prepared, a membrane-bound aldehyde dehydrogenase-modified carbon electrode comprising p-benzoquinone was prepared in the same manner as in Example 3 above described.
EXAMPLE 10
Preparation of a Membrane-Bound Fructose Dehydrogenase Modified Carbon Electrode Comprising a Water-Insoluble Mediator
Using the enzyme prepared in Example 8 above described, a membrane-bound fructose dehydrogenase-modified carbon electrode comprising dimethyl ferrocene was prepared in the same manner as in Example 3 above described.
EXAMPLE 11
Preparation of a Membrane-Bound Sorbitol Dehydrogenase-Modified Carbon Electrode Comprising a Water-Insoluble Mediator
Using the enzyme prepared in Example 2 above described, a membrane-bound sorbitol dehydrogenase-modified carbon electrode comprising dimethyl ferrocene was prepared in the same manner as in Example 3 above described.
EXAMPLE 12
Preparation of a Membrane-Bound Glycerol Dehydrogenase-Modified Carbon Electrode Comprising a Water-Soluble Mediator
Using the enzyme prepared in Example 8 above described, a membrane-bound glycerol dehydrogenase-modified carbon electrode comprising potassium ferricyanide was prepared in the same manner as in Example 4 above described.
EXAMPLE 13
Measurement of Acetaldehyde and N-Hexaldehyde Concentrations
The enzyme modified-carbon electrode comprising the mediator prepared in Example 9 above described was fixed in an apparatus shown in FIG. 2, and under the same measuring conditions as in Example 6 above described, each 10 μl of samples containing acetaldehyde or n-hexaldehyde of various concentrations was injected from a sample injection port by means of a microsyringe. After sample injection, current value change for 2 min. was recorded with a recorder. By plotting the relationship between the current values being constant after 2 min. and the concentrations of acetaldehyde or n-hexaldehyde in samples, the result shown in FIG. 6 was obtained, so that the measured values increased in response to the aldehyde concentrations in samples could be obtained.
EXAMPLE 14
Measurement of Fructose Concentration
The enzyme-modified carbon electrode comprising the mediator prepared in 10 above described was attached to an apparatus shown in FIG. 2, and under the same measuring conditions as in Example 6 above described, each 10 μl of a sample containing fructose of various concentrations was injected from the sample injection port by use of a microsyringe. Following sample injection, current values after 2 min. were recorded with a recorder. By plotting the relationship between the current values and the fructose concentrations, the current values corresponding to the fructose concentrations in samples were measured, as shown in FIG. 7.
EXAMPLE 15
Measurement of Sorbitol Concentration
The enzyme-modified carbon electrode comprising the mediator prepared in Example 11 above described was attached to an apparatus shown in FIG. 2, and measurements were carried out under the same measuring conditions as in Example 6 above described. 10 μl of a sample containing sorbitol of various concentrations was injected from the sample injection port by use of a microsyringe. The change of current values was recorded with a recorder. By plotting values based on the current change for 2 min. after the injection and the sorbitol concentrations in samples, the measured values, as shown in FIG. 8, were correlated with the sorbitol concentrations.
EXAMPLE 16
Measurement of Glycerol Concentration
Using the enzyme-modified carbon electrode comprising the mediator prepared in Example 12 above described, the relationship between the glycerol concentrations and the measured current values was determined in the same manner as in Example 15 above described. Results show, as shown in FIG. 9, that the glycerol concentrations and the measured current values were correlated.
EXAMPLE 17
Preparation of a Membrane-Bound Glucose Dehydrogenase--Invertase-Modified Carbon Electrode Comprising a Water-Insoluble Mediator
The enzyme prepared in Example 2 above described was mixed with invertase (from Sigma, Ltd., baker's yeast origin, 400 units/mg) in the ratio of 2:1. Using the resultant enzyme mixture containing membrane-bound glucose dehydrogenase and invertase, a membrane-bound glucose dehydrogenase--invertase modified-carbon electrode comprising p-benzoquinone was prepared in the same manner as in Example 9 above described.
EXAMPLE 18
Measuring of Sucrose Concentration
Using the enzyme-modified carbon electrode comprising the mediator prepared in Example 17 as above described, the relationship between the sucrose concentrations and the measured current values was determined in the same manner as in Example 15 above described except that an injection sample amount is 5 μl. Results showed, as shown in FIG. 10, that the sucrose concentrations and the measured current values were correlated.
EXAMPLE 19
Preparation of a Complex of Potassium Ferricyanide and a Cationic Surface-Active Agent
100 ml of 10 mM aqueous solution of dimethyl di-n-octadecyl ammonium bromide and 10 ml of 30 mM aqueous solution of potassium ferricyanide were prepared. The both solutions were combined, and mixed well by stirring for 30 min. The formed solids were separated by centrifugation (6,000×g, 10 min.) and obtained as precipitates. The precipitates were well washed twice with water. The obtained precipitates were allowed to stand one whole day at room temperature and dried enough, to obtain a complex of water-insoluble potassium ferricyanide--dimethyl di-n-octadecyl ammonium bromide (500 mg).
EXAMPLE 20
Preparation of a Cell Membrane-Bound Alcohol Dehydrogenase-Modified Carbon Electrode Comprising the Complex of Potassium Ferricyanide--Dimethyl Di-N-Octadecyl Ammonium Bromide
80 mg of the complex of potassium ferricyanide--dimethyl di-n-octadecyl ammonium bromide prepared in Example 19 above described was mixed well with 1 g of liquid paraffin. To 25 mg of the mixture were added 10 mg of the enzyme standard prepared in 1 above described and 10 mg of graphite powder not larger than 250 mesh size, and homogeneously mixed, to prepare an enzyme-modified electrode material. A small amount of the electrode material prepared was applied to a part of the surface of the electrode shown in FIG. 1, said part of the surface being to come into contact with a liquid. Thus, a cell membrane-bound alcohol dehydrogenase-modified carbon electrode comprising the complex of potassium ferricyanide--dimethyl di-n-octadecyl ammonium bromide was prepared.
EXAMPLE 21
Measurement of Ethanol Concentration
Using the enzyme-modified carbon electrode comprising the mediator prepared in 20 above described, the relationship of the ethanol concentrations in a sample and the measured values of current was determined in the same manner as in Example 6 above described. As shown in FIG. 11, the ethanol concentrations and the measured values of current were correlated.
EXAMPLE 22
Preparation of a Cell Membrane-Bound Alcohol Dehydrogenase-Modified Carbon Electrode Comprising a Complex of Potassium Ferricyanide--Cetyl Pyridinium Chloride and Measurement of Ethanol Concentration
Cetyl pyridinium chloride was used in place of dimethyl di-n-octadecyl ammonium bromide in Example 19 above described, and a complex of potassium ferricyanide--cetyl pyridinium chloride was obtained according to the same method as in Example 19 above described. Using the resultant complex, an enzyme-modified electrode material was prepared in the same manner as in 20 above described. A small amount of the electrode material prepared was applied to a part of the surface of the electrode shown in FIG. 1, said part of the surface being to come into contact with a liquid, whereby a cell-bound alcohol dehydrogenase-modified carbon electrode comprising the complex of potassium ferricyanide--cetyl pyridinium chloride was prepared. Using the prepared enzyme-modified carbon electrode comprising the mediator, the relationship between the ethanol concentrations and the measured values of current was determined in the same manner as in Example 6 above described. As shown in FIG. 12, the ethanol concentrations and the measured values of current were correlated. | An enzyme sensor, which comprises an enzyme-modified electrode and a counter electrode, wherein the enzyme-modified electrode comprises, as electrode components, an enzyme and/or an enzyme-containing substance and mediator. The enzyme sensor is useful in analysis, such as the analysis of compounds in foods or components in the living body, the diagnosis of diseases and the control of reaction processes. The preparation of the enzyme-modified electrode is also described. | 8 |
STATEMENT OF GOVERNMENT INTEREST
[0001] An award from the Health Resources and Services Administration of the US Department of Health and Human Services was used in the development of this invention. Accordingly, the invention described herein may be manufactured and used by and for the Government of the United States of America for Governmental purposes without the payment of any royalties thereon or thereto.
FIELD OF THE INVENTION
[0002] The present invention relates generally to information management systems and, more particularly, to a network-based distributed health information exchange system and method for disjointed health and human service providers in a regionally defined area.
BACKGROUND OF THE INVENTION
[0003] For over thirty years there has been a clear understanding that health care in this country would be vastly improved if health care providers had real time access to the comprehensive set of health related information available for each patient. Web based technologies that allow for secure transmissions of protected health information are widely recognized as critical to both quality improvement and cost reductions in the health care industry. However, currently, most health related information for an individual patient is resident, on average, in at least seven different locations within one community. For example, a primary care provider has one set of data, multiple medical specialists have additional sets of data, various laboratories, outpatient procedure and urgent care facilities have additional sets of data, pharmacies, emergency departments, and inpatient facilities have additional sets of data. Although much of the data is duplicative, each provider also has data unique to the record resident in her office.
[0004] Within the health care industry, the estimated 8% of provider/organizations investing in health information technology are focused primarily on inpatient services, and importing legacy data. Most commonly adopted health information technology (HIT) services are practice management systems that maintain electronic appointment books, insurance inquiries, and billing information for a particular provider organization. Larger provider systems have been outsourcing review of laboratory results using electronic health information technology, and implementing enterprise systems that electronically integrate multiple services and documentation within the hospital.
[0005] For the most part, the early adoption of HIT has been in the private sector and has focused on improved quality of care and reduced administrative cost and burden for individual provider systems. There are a plethora of proprietary products being developed or customized by vendors for provider organizations with little to no attention focused on interoperability across products to facilitate the exchange of information from one provider system to another. Additionally, vended systems are typically written on platforms that require purchase of less accessible software and have had multiple layered functionalities requiring extensive programming for interface between systems or previous versions of the same system. Little attention to date has been focused on outpatient services, and even less attention has been focused on health care services provided in the public sector to those patients without health insurance.
[0006] The remaining 92% of the health care industry is still watching and waiting—primarily because there remain very few national standards for products and processes development in the industry, and because of the prohibitive cost involved in the migration from paper to electronic records. Additionally, most potential users are reluctant to purchase proprietary systems developed by vendors and customized for each individual provider or provider network, because there is not yet a strong market incentive for these systems to be able work together, that is, they are not routinely interoperable.
[0007] Health and human services organizations, which provide outpatient services for those lacking health insurance, are required to comply with federal privacy and security regulations under the Health Information Portability and Accountability Act (HIPAA). Currently, there is no standards-based health information technology that is readily adaptable to existing non-compliant systems. In addition, public health and emergency preparedness organizations need to quickly access and map information from health information records related to outbreaks of infectious diseases, or the impact of biohazards as documented through client/patient encounters at multiple public sector facilities.
SUMMARY OF THE INVENTION
[0008] It is against the above background that the present invention provides an electronic health information exchange system for disjointed health and human service providers in a regionally defined area, such as a state or county to improve access to healthcare and care management for those individuals and their related household members typically lacking health insurance. The system is implemented over a public network, such as the Internet, through a virtual private network and provides a secure private web site. Via the private web site, the system provides web pages to view and input information in health information records maintained in a relational database. The system permits authorized users to record demographic information at the individual and household levels, as well as services utilization data of the individual and related household members in the health information records. With such records, the system facilitates more efficient and effective enrollment of people into available health and human services in the region, and to help ensure that the participating individuals and their related household members are receiving the necessary care from the variety of disjointed health and human services.
[0009] The above noted and additional advantages and features of the present invention will be apparent from the following description and the appended claims when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic diagram of an illustrative system with a plurality of components in accordance with an embodiment of the present invention;
[0011] FIG. 2 is a schematic diagram of a representative hardware environment in accordance with an embodiment of the present invention; and
[0012] FIGS. 3-35 are various screen images of a user interface embodiment for accessing, composing and reviewing live health information records.
DESCRIPTION OF THE INVENTION
[0013] The following description of the embodiments of the invention directed to a network-based distributed information management system, method, and article of manufacture for managing a health and human services regional network is merely exemplary in nature, and is in no way intended to limit the invention or its applications or uses.
[0014] FIG. 1 illustrates an exemplary distributed regional health information exchange system 100 with a plurality of components 102 in accordance with an embodiment of the present invention. As shown, such components 102 include a public network 104 which take any form including, but not limited to a local area network, a wide area network such as the Internet, etc. Coupled to the public network 104 is a plurality of computers, which may take the form of desktop computers 106 , laptop computers 108 , hand-held computers 110 , or any other type of computing hardware/software. Various computers in the system 100 are connected to the public network 104 by way of a server 112 , which is equipped with a firewall for security purposes. A representative hardware environment associated with the various components 102 of FIG. 1 is depicted in FIG. 2 .
[0015] FIG. 2 illustrates a representative workstation 200 by which embodiments of the present invention may be carried out. In the present description, the various sub-components of each of the components 102 may also be considered components of the system 100 . For example, particular software modules executed on any component 102 of the system 100 may also be considered components of the system 100 . The hardware configuration of the workstation 200 illustrated in FIG. 2 includes a central processing unit 210 , such as a microprocessor, and a number of other units interconnected via a system bus 212 .
[0016] The workstation 200 further includes a Random Access Memory (RAM) 214 , Read Only Memory (ROM) 216 , and an I/O adapter 218 for connecting peripheral devices such as disk storage units 220 to the bus 212 . The workstation 200 further includes a user interface adapter 222 for connecting a keyboard 224 , a mouse 226 , a speaker 228 , a microphone 230 , a video camera 232 , and/or other user interface devices such as a touch screen (not shown) to the bus 212 . The workstation 200 further includes a communication adapter 234 for connecting the workstation 200 to the public network 104 ( FIG. 1 ) and a display adapter 236 for connecting the bus 212 to a display device 238 . The workstation 200 typically has resident thereon an operating system such as, from Microsoft, IBM, MAC, UNIX, or LINUX. Those skilled in the art will appreciate that the present invention may also be implemented on platforms and operating systems other than those mentioned. For example, the workstation 200 could alternatively be a graphical terminal connected to a mainframe, mini-, or super-computer.
[0017] In general, enrolled referring health and human service provider personnel have secure access to the regional health information exchange system 100 according to the present invention via a public key encryption system using Virtual Private Network (VPN) software or hardware or SSL-class security. In one embodiment, the system 100 is implemented and communicates over the network 104 utilizing TCP/IP and IPX protocols, with data transport across the network 104 carried out via Virtual Private Network encryption, or encryption via wavelet compression or other comparable technique. Password access and public key encryption, preferably in accordance with the Health Information Portability and Accountability Act (HIPAA) is used throughout the system 100 .
[0018] As shown by FIG. 1 , the health information exchange system 100 further provides an internal network or core domain 111 which is protected from the public network 104 by a series of firewalls, namely, a perimeter firewall 113 a, and a core firewall 113 b. The perimeter firewall 113 a protects a perimeter application server 115 by determining what inbound traffic from the network 104 is valid and thus can be passed to the perimeter application server 115 and what is invalid and thus blocked. The perimeter application server 115 acts as the VPN host, public web site server, and email server and is connected to the core firewall 113 b which protects an internal network or core domain 111 from unauthorized user access. In the core domain 111 , a core server 114 provides further VPN authentication, and acts as the Primary Domain Controller, providing Active Directory services, Internet Information Services, and hosting a .Net framework to authorized users gaining access through the perimeter and core firewalls 113 a and 113 b via user and password authentication as explained hereafter in later sections. In addition, the core domain 111 has a database server 116 connected to a relational database 118 which stores all the content of the system 100 , such as health information records 120 . One function of the data server 118 is to use the data in the health information records 120 to automatically fill out a Medicaid application. In addition, all data tables in each of the health information records 120 of the database 118 have been designed to support source and time stamps, as well as associated log tables to audit changes and access operations. This is achieved through a combination of database functions, triggers, and stored procedures which since being conventional, no further discussion thereon is provided. It is to be appreciated that the system 100 has been designed to conform to a scalable multi-tier application architecture built to begin operations with the minimum hardware configuration inside design parameters.
Authorization
[0019] To gain access to the internal network or core domain 111 over the system 100 , a user organization must execute a data sharing and business associate agreement with a service provider of the core domain 111 which defines the terms under which authorization to use the system 100 and core domain 111 is granted to both organizations and individuals within organizations. After this organization level agreement is established, the individual user goes to the public website provided by the perimeter server 115 of the system 100 to apply for a password and complete the required information. This information is then transmitted to the system administrator who authorizes access to the core domain 111 . When approved, the user then receives an e-mail provided from the perimeter server 115 that will include the user name, password, and instructions on how to install the VPN client software on the user's computer.
VPN Connection
[0020] The VPN client software is required for connection to the core domain 111 of the system 100 . In one embodiment, there is an installed capacity of 1500 concurrent user VPN connections in the system 100 to the core domain 111 . In one embodiment, there is a special one-time use password to download the VPN Client software provided in the email. In one embodiment, the VPN client software is downloaded from the network 104 via a link provided in the email to the VPN software vendor's server or the perimeter server 115 . Instructions on how to install and use the software to access the core domain 111 is also sent to the user via the e-mail authorizing access to the core domain 111 .
[0021] FIGS. 3-35 are screen images of software utilized by the system 100 and of various web pages provided by a private web site embodiment hosted by the core server 114 according to the present invention that authorized users use to compose and review live health information records 120 on a workstation 200 in the system 100 such as described in FIG. 2 . The screen images are a non-limiting series of screen shots, which demonstrate some of the fundamental methodology underlying the system 100 and the health information records 120 .
[0022] FIGS. 3-5 are screen images showing how a user accesses the core domain 111 of the system 100 using a VPN client program 300 . Go to the Start menu on the user computer, click on Programs. In the program list, look for the VPN client program 300 , which in the illustrated embodiment is Cisco Systems' VPN Client software. On the extended menu, the user clicks on the VPN Client program icon 310 as shown by FIG. 3 . Next, as shown by FIG. 4 , the user Click on a “Connect” icon 400 in the VPN program 300 . The user will be prompted in a user authentication dialog box 500 provided by the VPN program 300 for the user name and password, such as shown by FIG. 5 . The user name and password is provided in the e-mail that was sent to the user when the user was authorized to access the core domain 111 .
Basic Rules of the System
[0023] In FIG. 6 , after the user is authenticated by the perimeter server 115 , the user will then get a VPN Client Banner dialog box 600 . After reading the banner information, the user clicks on a “Continue” button 610 . The user's display screen will then go back to whatever the user was working on before the user connected to a private web site 1010 ( FIG. 10 ) hosted by the core domain server 114 using the VPN program 300 .
[0024] The VPN connection must be maintained during the user session with the core domain 111 in order to allow the transmission of information between any one of the user computer 106 , 108 , 110 and the core server 114 . The core server 114 will disconnect if the user connection is idle for 30 minutes. The core server 114 only knows the user is interacting with it when the user makes an action like a submission or a search. If the user is entering data into a form, the core server 114 does not know the user is active until the user sends the data. Therefore, it will not hurt to submit frequently because the core server 114 will update the health information record 120 with each submission. For example, the user may put in a child's name in a demographic form and submit, but then realize that the user spelled the name incorrectly. The user can then go back to the form, select the field where the error occurred, correct the spelling, and submit the form again to the core server 114 .
[0025] If for some reason the user's connectivity to the network 104 is terminated before the user log out of the VPN client program 300 , the core server 114 will retain the user connection for about 20 minutes. If the core server 114 is unaware of the network interruption and the user tries to log in again, the user may not be able to get back in until the user original connection reaches its time out limit. The core server 114 remembers everything the user did. The core server 114 is configured so that health information records 120 are never deleted or erased or written over; any changes the user submits are written as a new line of data. The core server 114 is designed to address HIPAA audit trail compliance, which means that the old information can be retrieved, and most importantly, the core server 114 tracks what user has read a record, what user has changed a record, and what the changes were made to a record.
[0026] After establishing the VPN connection using the VPN client program 300 through the firewall 113 a to the perimeter server 115 , the user now opens a web browser 700 , which in the illustrated embodiment of FIG. 7 , is Microsoft's Internet Explorer. In the address bar 710 of the web browser 700 , the user types or selects from a favorites list the domain name address 720 of the core domain 111 of the system 100 and presses “Enter.” If the core domain 111 is up and running with no problems, a start html page 800 will be displayed to the user and, if necessary, provide a system status message 810 as illustrated by FIG. 8 . To access the core domain 111 , the user then clicks on the HealthLink Information Exchange™ (the system) link 820 , which opens a Network Password dialog box 900 as illustrated by FIG. 9 . In the Network Password dialog box 900 , the user types the same user name and password the user received with the user authorization email from the perimeter server 115 .
General Features of the Core Domain
[0027] A home page 1000 of the private web site 1010 in the core domain 111 is then presented to the user by the core server 114 , which is illustrated by FIG. 10 . To navigate around the private web site 1010 to the home page 1000 and to other pages or forms in the private web site 1010 , for example, a tab navigation bar 1015 supporting tab browsing is provided across the top of the page. In the illustrated embodiment, the tab navigation bar 1015 provides a HOME tab 1020 , a SUPPORT tab 1030 , a USER INFO tab 1040 , a MY TASKS tab 1050 and a REPORTS tab 1060 are available to persons authorized as client/patient contact professionals. It is to be appreciated, depending on the access level provided to the authorized user various tabs may be hidden or inaccessible to the user in the tab navigation bar 1015 . In addition, the tab navigation bar 1015 dynamically changes to present additional pages that may be tabbed too and viewed from the page in the private web site 1010 that the user is currently viewing.
[0028] If the user wishes to learn or provide information about the system 100 , the user clicks on the SUPPORT tab 1030 to view a SUPPORT page 1100 . On the SUPPORT page 1100 , users will find user and administrator posting area sections as illustrated by FIG. 11 . A TIPS AND TRICKS posting area section 1110 is provided to give administrators and supervisors a place to post information about developing practices and changes in methods of using the system. An ERROR EVENTS posting area section 1120 is also provided on the SUPPORT page 1100 where health advocates and other authorized users who encounter problems can post error events as illustrated by FIG. 12 . The noted error events in the ERROR EVENTS posting area section 1120 allow administrators to track problems in both the private web site and database applications. Events are removed once they have been addressed. Errors in the health information records 120 may be recorded also in the ERROR EVENTS posting area section 1120 . Selecting the USER INFO tab 1040 will display the USER INFO page 1300 which lists contacts 1310 and documents 1320 posted to the private web site 1010 for user use and reference as illustrated by FIG. 13 . The next two tabs—MY TASKS tab 1050 and REPORTS tab 1060 —permit access to client information and data reports.
Searching for Individuals and Households in the System
[0029] Selecting the MY TASKS tab 1050 will present a My Tasks page 1400 having a search box 1410 which permits the user to see if there is a health information record 120 on a person having a health care encounter with a health and human service provider in the system 100 . In the search box 1410 the user inputs what is known of the person in a number of various search term fields as illustrated by FIG. 14 . Such search term fields in one embodiment include: first name field 1412 , middle name field 1414 , last name field 1416 , date of birth (DOB) field 1418 , phone number field 1420 , social security number (SSN) field 1422 , and head of household identification number (HHsID) field 1424 . In the illustrated embodiment, a search result tab section 1426 indicates that no health information records 120 in the database 118 matched the search terms entered by the user in the search box 1410 . At this point, the user two options are to start a new record by selecting a new household record link 1428 provided on the My Tasks page 1400 or to modify the terms search used in the search box 1410 . Starting a new household record is covered in a later section; in the following section, additional search options permitted by the private web site 1010 are discussed.
[0030] If the user is unsure of the spelling of this person's name, the user can give the search less specific data to produce a larger number of results, for instance. Instead of using the full last name, the user might just include the part of the name that the user is sure about, such as Test, and perhaps just the first initial of the first name. In addition, the private web site 1010 permits advance searching using a variety of filters under a filters section 1430 and options under an options section 1431 which are expanded and shown by FIG. 15 .
[0031] In the filters section 1430 of the search box 1410 searches can be performed by filtering for a registry agency filter 1500 , a registry sources filter 1510 , a registry statuses filter 1520 , an all records filter 1530 , an assignable advocate filter 1540 , a referral source filter 1550 , and/or a service requested filter 1555 . By default, “all” is selected for each filter to provide the most inclusive search. Selecting the registry agency filter 1500 permits the user to search and view only those health information records 120 that have been “started” or registered by a particular agency of the system 100 . It is to be appreciated that all registry agencies participating in the system 100 will be shown by a drop down box (not shown) for selection. For example, selecting the referral source filter 1550 allows the user to search and track all or a particular source of each patient referral. The available sources which can be selected individually are provided in a drop down box list (not shown) when the referral source filter 1550 is selected. In many cases, individuals come to a community health center (CHC) from one of the hospital emergency departments, and these individuals are subsequently assisted with Medicaid applications. With this data the user can tell which people came from more than one hospital or agency. Accordingly, the system 100 provides a way in which the user may track the service utilization patterns of individuals and their family members that are associated together under a particular household identification number.
[0032] The service requested filter 1555 searches for all or a particular requested service, such as for example, a dental service. The available services which can be selected are provided in a drop down box (not shown) when the service requested filter 1555 is selected. For example, it may be useful when a new resource or agency becomes available in the system 100 to see all health information records 120 intended for that particular service, and to mark the health information records 120 with an indication or message that prompts another health or human service provider who may be seeing the individual to provide such information to the individual and to schedule such an appoint with the new resource or agency. With some of the services for which the users refer an individual it may be also important to know the status of workflow items, which may indicate where there may be potential problems, as in the case where court dockets slow a pro se application process for child custody, or in the case of Medicaid, how many are in a pending status past 90 days. The registry status filter 1520 when selected provides a drop down box (not shown) of such workflow status items, such that a search result of the health information records 120 for such workflow items can be provided to the user to track such problems. The assignable advocate filter 1540 permits the user to search records assigned to a particular advocate, or with an all selection, which provides a filter to delineate all clients assigned to an advocate from those individuals whom have not been assigned to an advocate. The all records filter 1530 w will result in a search of all health information records 120 in the database 118 for individuals on whom demographic data is available and excludes individuals having a “Later” status in their health information record 120 with only contact information. However, in the options section 1431 , the user may select a My cases only option 1560 which will result in a search of only those individuals assigned to the user if a designated advocate, an uninsured only option 1570 , which will result in a search of only the records of those individual identified as uninsured, and head of household only option 1580 , which will result in a search of only those records identified as a head of household. Time periods can also be entered by the user for a registry date range 1585 , a referral date range 1590 , and a follow up date range 1595 .
[0033] In one illustrated example, a search for a first name “Test” in the search box 1410 resulted in 6 health information records 120 being listed on the search page 1400 in a search result main grid 1600 . As shown in the illustrated embodiment of FIG. 16 , the main grid 1600 lists in tabular format the following information from the queried and returned health information records 120 : action icon(s) 1610 , a first name 1630 , a middle name 1635 , a last name 1640 , a social security number 1640 , a phone number 1650 , a follow-up 1660 , a last update date 1670 , an updated by indicator 1675 , and a contact 1680 . For convenience of the user, by default, the search results in the main grid 1600 are sorted first by the entered sort term, in this case first name 1630 , and then by head of household. Other sorting of the search result however may be selected by the user double clicking on one of the column headings of the main grid 1600 .
[0034] As shown by FIG. 16 , Developer Test is the designated head of household since listed first and also having a full array of action icons 1610 , and Clinic Test is an individual in the same household as Developer Test. To differentiate who is a head of household and who is an individual, the simplest way to tell is that heads of household have a full array of icons in the search result main grid 1600 . As shown by FIG. 16A , a close up section view of the main grid 1600 , the following action icons are provided to the user: a Household Express action icon 1690 takes the user to a Household Express summary page ( FIG. 17 ); a Household Members action icon 1691 takes the user to a Household Members section of the Registry page ( FIG. 18 ); a Referrals action icon 1692 takes the user to a Household Referrals page ( FIG. 25 ); a Medicaid action icon 1694 opens an electronic document (e.g., .pdf) providing a Healthy Start/Healthy Families application (not shown) that new individuals filled out during the intake interview, wherein it is to be appreciated that other government program applications may also be provided; a PRC action icon 1695 takes the user to another electronic document (e.g., .pdf) (not shown) also used during the intake summary for the county in charge of the regional health and human services in the health information exchange system 100 , and a Person health action icon 1696 takes the user to an Individual Immunization page ( FIG. 27 ) of the individual's health information record 120 .
[0035] Returning back to FIG. 16 , if the user wants to know if there is anyone else in a household, such as for example, with January or Sonny, the user may click the Household Express action icon 1690 , the Household Bikers action icon 1691 , or right clicks on the mouse 226 ( FIG. 2 ) in any cell of the main grid 1600 in a row for the individual and select either a household express hover tab 1682 or a registry hover tab 1684 . FIG. 17 shows a household express summary page 1700 returned after selecting either household express action icon 1690 or the household express hover tab 1682 . A household express tab 1710 may also be provided which the user may select to view the household summary 1700 . FIG. 18 shows a household registry page 1800 returned after selecting either household registry action icon 1692 or the registry hover tab 1684 , which provides the user with the complete health information records 120 for a particular HHsID 1620 . A registry tab 1810 may also be provided which the user may select to the household registry page 1800 . In addition, each section in the registry view can conveniently be expanded or collapsed via a display/hid selection 1820 at the bottom of each section.
Entering Client Data
[0036] To enter client data into a health information record 120 of the system 100 , the user should first search to see if the individual is already in the database 118 . For example, as shown by FIG. 14 , a search for “Kinship Test” resulted in no record being found in the database 118 . Accordingly, the user will need to add the individual as a new health information record 120 . To start a new household, the user clicks on the New Household link 1420 , which then presents to the user a new household entry form 1900 for populating the new health information record 120 as shown by FIG. 19 . The user then enters the available data into the data entry fields provided on the new household entry form 1900 , such as for example, name, address, phone number, number of household members, registry source, period record is valid, follow-up date, and remarks. Then the user chooses among an Express entry link 1910 , a Registry entry link 1920 , a Later entry link 1930 , or Cancel entry link 1940 , which is self explanatory.
[0037] The Express entry link 1910 is selected as a quick way to get basic information of each individual of a household entered into a health information record via an Express entry form 2000 , which is illustrated by FIG. 20 . It is to be appreciated that the database server 116 will automatically assign a unique HHsID 1620 to the new health information record 120 and to all health information records 120 listed as being a member under the individual designated as “Self(Head)” in a Relation box 2010 provided on the Express entry form 2000 . Using the Express entry form 2000 , the user may also entry into the health information record 120 : a date of birth (DOB) 2020 ; a social security number (SSN) 2030 ; gender 2040 ; self-reported health issues 2050 , such as asthma, hypertension, diabetes, epilepsy, cancer, and stroke; special groups 2060 , such as pregnant, veteran, disable, senior, and non-US citizen; insurance information 2070 ; and income information 2080 . The user may also enter such data for each additional member of the household, such as for example, “Kinkid Test” the spouse and head of household of Kinship Test as shown in the illustrated embodiment. Additional members can be added under the HHsID 1620 via the Add member link 2090 .
[0038] The Registry entry link 1920 ( FIG. 19 ) is selected to enter detailed information known about each individual of a household entered into the health information record 120 via a Registry entry form 2100 , which the various sections thereof are illustrated by FIGS. 21 , 22 , and 23 . With reference first to FIG. 21 , a Household summary section 2110 is provided at the top of the Registry entry form 2100 which displays the data entered from the Household entry form 1900 . Below the Household summary section 2110 is a Household members section 2120 . It is to be appreciated that the Household members section 2120 provides data entry fields in addition to those provided on the Express entry from 2000 , such as for example, expanded demographics 2130 permitting entry into the health information record 120 data on race, ethnicity, education, marital status, and occupation. In addition, the Household member section 2120 provides income and insurance boxes 2140 and 2150 , respectively, which allow the user to add more than one source of insurance or income and the amounts for each. The Household members section 2120 also provides a member remarks area 2160 which permits the user to view information about the health information record 120 , such as when last updated and by whom.
[0039] Additional sections of the Registry entry form 2100 include a Household addresses section 2200 and a Household contacts section 2210 as illustrated by FIG. 22 . Each of the sections 2120 , 2200 , 2210 on the registry entry form 2100 can be expanded to show details, including household ID summary and details for each individual, details for addresses and contacts, by using their respective sections Display/Hide selections 2220 , 2230 , 2240 , or for all sections, a Display/Hide all selection 2250 provided at the bottom of the Registry entry form 2100 . In the illustrated embodiment of FIG. 22 , the Household members section 2120 along with the household summary section 2110 , and the Household Contact section 2210 are hidden, with details regarding the Household Addresses section 2200 being expanded, which are self explanatory, and thus no further details are provided. In the illustrated embodiment of FIG. 23 , the Household members section 2120 along with the household summary section 2110 , and the Household Addresses section 2200 are hidden, with details regarding the Household Contact section 2210 being expanded, which are self explanatory and thus no further details are provided.
[0040] The “Later” entry link 1930 ( FIG. 19 ) is used when there is not enough time to complete the information collection with the individual at an initial interview or even at a later health encounter with any one of the providers of the system 100 . If selected, the health information record 120 is then later viewable by selecting a Contact Later tab 2400 as shown by FIG. 24 . On the record display in the Contact Later tab 2400 , the user can record the history of the contacts in a history box 2410 . Typically, this is only completed when the user do not succeed in contacting the individual after the initial intake interview.
Demographics Definitions
[0041] With reference again to FIG. 20 , the check boxes provided under the Health Issues category 2050 are used to delineate those health issues that are eligible for disease management programs or special services. These health issues in one embodiment as shown include Asthma 2051 , Hypertension 2052 (high blood pressure), Diabetes 2053 , Seizure disorder 2054 , Stroke 2055 , and Cancer 2056 . The check boxes under the Special category 2060 relate to the Medicaid application for a state. Selecting pregnant 2061 makes the individual automatically eligible for Medicaid and medical documentation must be provided, which is automatically filled out from the health information record 120 by the data server 118 . Checking veterans 2062 , Disabled 2063 , and Senior Citizens (aged 65+) 2064 will flag the health information record for review for any special service that may be provide to such individuals. Checking Non US citizens 2065 will flag the health information record 120 as not being eligible for Medicaid.
[0042] The insurance box 2140 allows users to indicate more than one source of insurance and the monthly amount it costs. Selectable categories under the Insurance box 2140 include in one embodiment NONE (no health insurance), CareSource (Medicaid Managed care program), Medicaid (for low income and disabled), Medicare (for seniors), Military (CHAMPUS), Anthem (private plan usually through employers), United Health Care (private plan usually through employers), and Other.
[0043] Referring again to FIG. 21 , the income box 2150 allows users to indicate more than one source and amount of income per person. Definitions for each category are: NONE (no income), Wages (indicate total per month), SS Disability (social security disability), SS Retirement (social security retirement), SS Other (other Social Security programs such as those for disabled children, deceased parents, etc.), SSI (Supplemental Security Income for the disabled), and Child Support. It is to be noted that the payment of child support is indicated by placing the minus sign in front of the amount paid, so for example −25 would indicate a $25 per month payment. In addition, due to variations in parentage among household members, the amount of child support received is included as income for the child for whom it is paid. Non-custodial parents can be recorded under household contacts, see below. Other information includes state specific programs, such as for example, in one embodiment, TANF Temporary Assistance for Needy families is a program of the Ohio, Department of Job and Family Services, Workers Compensation, OWF Child Subsidy, Kinship Subsidy, and other such programs. All amounts are considered monthly and are inputted as whole dollars.
[0044] Head of household is defined as the person who is filing the Medicaid application, if applicable, or the person to whom the Advocate is speaking. For each individual in the household, information collected includes gender and relation to the head of household. Please note that it is acceptable to be speaking to the wife of a male-headed household. She will appear on the top line of the Demographics Summary, but under Relation to head of Household, she would be identified as “Spouse.” For example, as illustrated by FIG. 21 , the individual “Kinship Test” is marked as the “Main contact” in a main contact box 2162 to indicate that she is the individual who gave the latest information. The husband's information “Kinkid Test” appears on the second line. As Kinkid Test is the head of the household; therefore, “Self (head)” is selected in a “Relation to head of household” box 2164 for him in the health information record 120 . The selectable choices from the Relation to head of household box 2164 in one embodiment include: Self (head), spouse, aunt/uncle, child, cousin, foster child, friend, grandchild, grandparent, nephew/niece, parent, sibling, significant other, stepchild and other.
[0045] Race is not a required item and choices are configurable. Current options are based on individual state Medicaid application requirements and the selectable choices from a race drop down box 2166 include in one embodiment American Indian/Alaskan, Asian, Black/African American, Native Hawaiian, White, Other, and Missing/Refused. Ethnicity is not a required item and the selectable choices from an ethnicity drop down box 2168 include in one embodiment Hispanic or Not Hispanic. Gender in a gender drop down box 2170 is not required and is based on self-report. Education is sometimes a problem as there is often a difference between those who complete 12 years of high school AND those who got a diploma or a GED. Accordingly, the selectable choices from an education drop down box 2172 include in one embodiment 1-8 years, 9-12 years, HS diploma, GED, Some college, Associate degree, Bachelor's, Masters, PhD, and other. The selectable choices from a Marital Status box 2174 include in one embodiment Single, Married, Separated Divorced Widowed, and Other. The selectable choices from an Occupation drop down box 2176 in one embodiment is broken down into typical department of commerce categories, and in other embodiment include: professional, technical, scientist, computer programmer, manager/admin, store manager, program administrator, sales, sales clerk, counter help, insurance sales, clerical, administrative support staff, file clerks, typists, crafts, carpenter, plumber electrician, potter, operatives, tool and die makers, machine operators, transportation, cab drivers, bus drivers, service, hotel staff, waitresses, waiters, laborers, day labor, ditch digger, highway worker, farm owner/manager, farm laborer/foreman, unclassifiable, active military, and special categories (not dept of commerce), disabled, retired, and student.
[0046] Referring again to FIG. 22 , on the registry page 2100 , the user can also change or edit the information provided in the Household Address section 2200 and the Household Contacts section 2210 . The Household Address section 2200 shows an address 2202 for the household. In addition to the standard information on the household address 2202 , the user can indicate dates which this address has been valid, permitting a housing history for those who need it. To do this the user enters a date into “Since” and “Through” fields 2204 and 2206 , respectively. If the user knows that a family is moving, the user uses the Through field 2206 on the old address and the Since field 2204 on the new address. Additionally the user can add directions in a directions posting area 2207 , remarks in a remarks posting area 2208 , and with an address type drop down box 2209 indicate the type of address. In one embodiment, valid types of addresses include: Home, Shelter, Home (owned), Homeless, Home (renter), Jail, Work, Mailing, Relative, Other, and Friend.
[0047] Referring again to FIG. 23 , in the Household Contacts section 2210 the user can record personal and professional contacts 2212 for the household. The user can also indicate dates which each contact has been valid, permitting a reference history for those who need it. To do this the user enters a date into “Since” and “Through” fields 2214 and 2216 , respectively. Additionally the user can add information from the contact in a contact comments posting area 2217 , remarks about the contact in a contact remarks posting area 2218 , and with a contact type drop down box 2219 indicate the type of contact. In one embodiment, valid types of contacts include: for personal contacts, Guardian, Non-custodial parent, Biological Father, Biological Mother, Relative, and Friend; for Health contacts, Emergency, Guarantor, Primary Care Physician, Clinic home, Hospital, and Pharmacy; for professional contacts, Caseworker, Social Worker, Case Manager, Probation Officer, Payee, and Employer.
Referrals
[0048] Referring now to FIG. 25 , in order to track needs of clients and where they are sent (referred) for services, the user uses a Referral page 2500 . The Referrals page 2500 may be viewed by the user by either selecting the House Referrals action icon 1692 ( FIG. 16A ) from the action icon section 1610 of main grid 1600 on search result page 1400 ( FIG. 16 ) or selecting a Household Referrals tab 2510 when provided in the tab navigation bar 1015 . Referrals 2515 listed in a Referrals section 2520 are tracked by the HHsID 1620 and are used to track the process and progress toward completion of all referrals for the household. From the Referral page 2500 , the user may update an existing referral shown in the Referral section 2520 by clicking on a listed referral 2515 which populates the existing information in the referral details section 2530 for editing or may add a new referral to the referrals section 2520 by selecting the Insert New Referral selection 2535 .
[0049] For example, to add a new referral, the user begins by recording a date requested in a Date requested field 2540 . In one embodiment, clicking on the Date requested field allow the user to use a calendar pop up to select date. Next, the user can list in a Source field 2542 the source (agency) of the referral. The source filed lists in a drop down box all participating members in the system 100 . For example, if a first agency asks the client to contact a second agency to initiate a Medicaid application, them the source is the first agency, or if Juvenile Court asks the client to contact an individual to take care of a child custody issue, then the source is Juvenile Court. Recording the source of the referral permits the user to track beyond the first contact service utilization patterns of the household.
[0050] Next, the user selects the type of service requested from a Service drop down box 2544 . In one embodiment, the selectable choices include: Child Custody, Childcare, Clothing, Dental, Education, Emergency Shelter, Employment, Financial, Food, Furniture, Housing, Income Programs, Legal, Medicaid, Medical, Mental Health, Optical, Other, PRC Application, Prenatal/Maternity, Prescriptions, Transportation, and WIC. For each of the services types, there is a customized list of resources provided in a Resources drop down box 2546 to which the user may select, and which will change by location, specialty, etc.
[0051] As mentioned above in a previous section, the system 100 permits the user to track the progress and process that each referral 2515 takes in order to document problems that may be systemic. The current status of the workflow and outcome for each referral 2515 is shown in Workflow and Outcome cells 2550 and 2552 , respectively, listed in the Referral section 2520 . The user may update the status of the workflow of each referral 2515 using a Workflow History section 2554 which provides a Workflow Status indicator drop down box 2556 , a Workflow Date box 2558 , a Workflow Time spent box 2560 , and a Workflow Remarks box 2562 for recording such information. In addition, the user may update the status of the outcome of each referral 2515 using an Outcome history section 2564 which provides also an Outcome Status indicator drop down box 2566 , an Outcome Date box 2568 , an Outcome Time spent box 2570 , and an Outcome Remarks box 2572 for recording such information. It is to be appreciated that the outcome history of a household tracks what has happened to the referral in the system 100 and the associated dates permit the user to compare this against standards for performance. For example, it is a problem when a Medicaid application is pending more than 90 days. The system can provide reports on pending status over time because these items show the entire history of both workflow and outcome as shown.
[0052] The user may setup a follow up with either clients or other agencies using a Follow up date field 2574 (calendar pop up), and provide a reason in a Follow up reason drop down box 2576 . In one embodiment the reasons provide by the Follow up reason drop down box 2576 includes: Client follow up (suggesting calling the client to check on status); Eligibility check (with either client or agency); Final Attempt (need to make a last attempt to contact the client); Letter needed (final attempt made, letter letting client know status); Other; Outcome Information (checking on what the outcome was. e.g. did the client follow up); Recertification date (to remind the client it is time to apply again so there is no lapse in coverage); and Verifications (calling to inform that more substantiation of their economic or other conditions are required). If the user checks a Set reminder box 2578 , a message will appear on the users My Tasks page 1050 on the date entered in the Follow up date field 2574 . Additional fields include a Validate from field 2580 and Expires on field 2582 to input a time period for the referral 2515 , and a Remarks area 2584 for an other information regarding the referral.
Scanned Documents
[0053] Referring to FIG. 26 , a Household Document page 2600 is shown which lists in a document summary section 2610 any documents that have been scanned into the health information record 120 identified by the HHsID 1620 . The Household Document page 2600 is viewed by the users selecting the House Documents action icon 1693 ( FIG. 16A ) from the action icon section 1610 of main grid 1600 on search result page 1400 ( FIG. 16 ) or selecting a Household Document tab 2620 when provided in the tab navigation bar 1015 .
[0054] Document details are viewable by selecting on any of the listed documents in the document summary section 2610 which populates the fields provided in a Document Details section 2630 . The user clicking on a Add new document selection 2640 will clear the fields provided in the Document Detail section 2630 if populated such that the information regarding the new document can be entered. As the fields shown in the Document Details section 2630 are either self explanatory or function in the same manner as other similar fields in other Details sections of the private web site 1010 , for brevity, no further details regarding are provided.
[0055] It is to be appreciated that additional pages are included in the private web site 1010 , such as for example, an Individual Immunization page 2700 ( FIG. 27 ), an Individual Problems page 2800 ( FIG. 28 ), an Individual Medication summary page 2900 ( FIG. 29 ), an Individual Medication details page 3000 ( FIG. 30 ), an Individuals Procedure page 3100 ( FIG. 31 ), an Individual Note page 3200 ( FIG. 32 ) providing individual notes, as well as an Individual Documents page 3300 ( FIG. 33 ) providing scanned document concerning the individual, an Individual Contacts page 3400 ( FIG. 34 ) providing addition contacts of the individual, and an Individual Referrals page 3500 ( FIG. 35 ) providing the referrals of the individual. As the Individual Documents page 3300 , the Individual Contacts page 3400 , and the Individual Referrals page 3500 provide the same information and detail section functions as the Household Document page 2600 ( FIG. 26 ), the Household Contacts page 2400 ( FIG. 24 ), and the Household Referrals page 2500 ( FIG. 25 ), respectively, except pertaining to the individual and not the household, for brevity, no further discussion on these pages 3300 , 3400 , and 3500 is provided.
[0056] Referring to FIG. 27 , data such as shot, medication, and prescription for each household member is recorded via the Individual Immunization page 2700 . As mentioned previously above, the Individual Immunization page 2700 is viewed by the user by selecting the Person health action icon 1696 ( FIG. 16A ) from the action icon section 1610 of main grid 1600 on search result page 1400 ( FIG. 16 ) or selecting a Individual Immunization tab 2720 when provided in the tab navigation bar 1015 . An alert section 2720 is provided on the page 2700 to bring to the user's attention any special alerts 2722 , allergies 2724 , and medications 2726 of the individual, each with a date and description. Clicking on any of the listed description in the alert section 2720 with bring up the details of the alert, allergies, or medication on an alert page (not shown), which is also accessible view a Alerts tab 2730 when provided in the navigation tab bar 1015 .
[0057] An Individual Immunization summary section 2740 lists the immunizations of the individual and provides tabulated information such as for example, vaccine group, status, status data, expire on date, last dose date, next dose date, administer by, update date and updated by information. As with the other pages of the private web site 1010 , clicking on cell in the summary section 2740 will populate the fields provided in an Immunization Detail section 2750 . As the fields shown in the Immunization Detail section 2750 are either self explanatory or function in the same manner as other similar fields in other Details sections of the private web site 1010 , for brevity, no further details regarding are provided.
[0058] Referring to FIG. 28 , an Individual Problems page 2800 is shown which, as with the Individual Immunization page 2700 , shows the alert section 2720 . The Individual Problems page 2800 is accessible by the user from an Problems tab 2810 when provided in the navigation tab bar 1015 and also lists in a Individual Problems summary section 2820 the problems of the individual. Problem details are viewable by selecting on any of the listed problems in the Individual Problems summary section 2820 which populates the fields provided in a Problem Details section 2830 . As the fields shown in the Problem Details section 2830 are either self explanatory or function in the same manner as other similar fields in other Details sections of the private web site 1010 , for brevity, no further details regarding are provided.
[0059] Referring to FIG. 29 , an Individual Medication page 2900 is shown which, as with the Individual Immunization page 2700 , shows the alert section 2720 . The Individual Medications page 2900 is accessible by the user from an Individual Medication tab 2910 when provided in the navigation tab bar 1015 and also lists in an Individual Medications summary section 2920 the medications of the individual. Query box 2930 and query result section 2940 are provided which provides the user a RX dictionary and an auto insert function 2950 which populates a medication description, medical direction, and compliance information in a detail section for adding a new medication. It is to be appreciated that the RX dictionary is supported by the Unified Medical Language System from the National Library of Medicine and is based on the standards described in the Continuity of care Record from ASTM. Specifically, in one embodiment, drugs are keyed to RXNORM, and problems and procedures are keyed to SNOMED CT. For example, if a user types in “zym” a list like ZYMAR, ZYMINE, ZYMINE-HC, ZYMINE-D, with a list of generic names associated is provided. Dosage data is captured, as well as who filled the prescription, who administered the medication, and a patient report to track actual usage. As shown by FIG. 30 , medication details are viewable by selecting on any of the listed medications in the Individual Medications summary section 2920 which populates the fields provided in a Medication Details section 2960 . As the fields shown in the Medication Details section 2960 are either self explanatory or function in the same manner as other similar fields in other Details sections of the private web site 1010 , for brevity, no further details regarding are provided.
[0060] Referring to FIG. 31 , an Individual Procedures page 3100 is shown which, as with the Individual Immunization page 2700 , shows the alert section 2720 . The Individual Procedures page 3100 is accessible by the user from a Procedures tab 3110 when provided in the navigation tab bar 1015 and also lists in a Individual Procedures summary section 3120 the procedures for the individual. Procedure details are viewable by selecting on any of the listed procedures in the Individual Procedures summary section 3120 which populates the fields provided in a Procedure Details section 3130 . As the fields shown in the Procedure Details section 3130 are either self explanatory or function in the same manner as other similar fields in other Details sections of the private web site 1010 , for brevity, no further details regarding are provided.
[0061] Referring to FIG. 32 , an Individual Notes page 3200 is shown which is accessible by the user from a Notes tab 3210 when provided in the navigation tab bar 1015 and also lists in a Individual Notes summary section 3220 notes on the individual. Note details are viewable by selecting on any of the listed notes in the Individual Notes summary section 3220 which populates the fields provided in a Note Details section 3230 . As the fields shown in the Note Details section 3230 are either self explanatory or function in the same manner as other similar fields in other Details sections of the private web site 1010 , for brevity, no further details regarding are provided.
[0062] Referring now generally to the implementation of the above-described embodiments, many alternative approaches can be employed to achieve these embodiments. For example, selection devices for manipulating the cursor and other screen images or HTML objects can include a mouse, trackball, touch screen, light pointer, or optical or ultrasonic three-dimensional pointing system. Further types of input devices might include voice recognition, which includes voice dictation software. It is further to be appreciated that other pages, such as the alert page, vitals page, HIPPA page, admin page, medical equipment page, dental page, appointments page, results page, are not described herein but also form part of the invention, and as some aspects may be conventional are not described for brevity of the description.
[0063] In one embodiment, the system architecture is based on the Microsoft Systems Architecture. The application also uses the ASP.NET Portal Application software. An embodiment of the present invention may be written using JAVA, C, and the C++ language and utilize object oriented programming methodology (OOP), such as encapsulation, inheritance, polymorphism, composition-relationship, and application frameworks. The benefits of OOP can be summarized, as follows. Objects and their corresponding classes break down complex programming problems into many smaller, simpler problems. Encapsulation enforces data abstraction through the organization of data into small, independent objects that can communicate with each other. Encapsulation protects the data in an object from accidental damage, but allows other objects to interact with that data by calling the object's member functions and structures.
[0064] Subclassing and inheritance make it possible to extend and modify objects through deriving new kinds of objects from the standard classes available in the system. Thus, new capabilities are created without having to start from scratch. Polymorphism and multiple inheritances make it possible for different programmers to mix and match characteristics of many different classes and create specialized objects that can still work with related objects in predictable ways. Class hierarchies and containment hierarchies provide a flexible mechanism for modeling real-world objects and the relationships among them.
[0065] Application frameworks free application programmers from the chores involved in displaying menus, windows, dialog boxes, and other standard user interface elements for personal computers. An event loop monitors the mouse, keyboard, and other sources of external events and calls the appropriate parts of the programmer's code according to actions that the user performs. The programmer no longer determines the order in which events occur. Instead, a program is divided into separate pieces that are called at unpredictable times and in an unpredictable order. By relinquishing control in this way to users, the developer creates a program that is much easier to use.
[0066] Application frameworks reduce the total amount of code that a programmer has to write from scratch. However, because the framework is really a generic application that displays windows, supports copy and paste, and so on, the programmer can also relinquish control to a greater degree than event loop programs permit. The framework code takes care of almost all event handling and flow of control, and the programmer's code is called only when the framework needs it (e.g., to create or manipulate a proprietary data structure).
[0067] A programmer writing a framework program not only relinquishes control to the user (as is also true for event loop programs), but also relinquishes the detailed flow of control within the program to the framework. This approach allows the creation of more complex systems that work together in interesting ways, as opposed to isolated programs, having custom code, being created repeatedly for similar problems.
[0068] Thus, as is explained above, a framework basically is a collection of cooperating classes that make up a reusable design solution for a given problem domain. It typically includes objects that provide default behavior (e.g., for menus and windows), and programmers use it by inheriting some of that default behavior and overriding other behavior so that the framework calls application code at the appropriate times.
[0069] There are three main differences between frameworks and class libraries. Class libraries are essentially collections of behaviors that the user can call when the user want those individual behaviors in the user program. A framework, on the other hand, provides not only behavior but also the protocol or set of rules that govern the ways in which behaviors can be combined, including rules for what a programmer is supposed to provide versus what the framework provides. With a class library, the code the programmer instantiates objects and calls their member functions. It's possible to instantiate and call objects in the same way with a framework (i.e., to treat the framework as a class library), but to take full advantage of a framework's reusable design, a programmer typically writes code that overrides and is called by the framework. The framework manages the flow of control among its objects. Writing a program involves dividing responsibilities among the various pieces of software that are called by the framework rather than specifying how the different pieces should work together. With class libraries, programmers reuse only implementations, whereas with frameworks, they reuse design. A framework embodies the way a family of related programs or pieces of software work. It represents a generic design solution that can be adapted to a variety of specific problems in a given domain. For example, a single framework can embody the way a user interface works, even though two different user interfaces created with the same framework might solve quite different interface problems. Thus, through the development of frameworks for solutions to various problems and programming tasks, significant reductions in the design and development effort for software can be achieved.
[0070] A virtual private network (VPN) is a private data network that makes use of the public telecommunication infrastructure, maintaining privacy using a tunneling protocol and security procedures. A virtual private network can be contrasted with a system of owned or leased lines that can only be used by one company. The idea of the VPN is to give the company the same capabilities at much lower cost by using the shared public infrastructure rather than a private one. Phone companies have provided secure shared resources for voice messages. A virtual private network makes it possible to have the same secure sharing of public resources for data. Companies today are looking at using a private virtual network for both extranet and wide-area intranet.
[0071] Using a virtual private network involves encrypting data before sending it through the public network and decrypting it at the receiving end. An additional level of security involves encrypting not only the data but also the originating and receiving network addresses. Microsoft, 3Com, and several other companies have developed the Point-to-Point Tunneling Protocol (PPTP) and Microsoft has extended Windows NT to support it. VPN software is typically installed as part of a company's firewall server.
[0072] Transmission Control Protocol/Internet Protocol (TCP/IP) is the basic communication language or protocol of the Internet. It can also be used as a communications protocol in a private network (either an intranet or an extranet). When the user is set up with direct access to the Internet, the user computer is provided with a copy of the TCP/IP program just as every other computer that the user may send messages to or get information from also has a copy of TCP/IP.
[0073] TCP/IP is a two-layer program. The higher layer, Transmission Control Protocol, manages the assembling of a message or file into smaller packets that are transmitted over the Internet and received by a TCP layer that reassembles the packets into the original message. The lower layer, Internet Protocol, handles the address part of each packet so that it gets to the right destination. Each gateway computer on the network checks this address to see where to forward the message. Even though some packets from the same message are routed differently than others, they will be reassembled at the destination.
[0074] TCP/IP uses the client server model of communication in which a computer user (a client) requests and is provided a service (such as sending a Web page) by another computer (a server) in the network. TCP/IP communication is primarily point-to-point, meaning each communication is from one point (or host computer) in the network to another point or host computer. TCP/IP and the higher-level applications that use it are collectively said to be “stateless” because each client request is considered a new request unrelated to any previous one (unlike ordinary phone conversations that require a dedicated connection for the call duration). Being stateless frees network paths so that everyone can use them continuously. Note that the TCP layer itself is not stateless as far as any one message is concerned. Its connection remains in place until all packets in a message have been received.
[0075] Many Internet users are familiar with the even higher layer application protocols that use TCP/IP to get to the Internet. These include the World Wide Web's Hypertext Transfer Protocol (HTTP), the File Transfer Protocol (FTP), Telnet (Telnet) which lets the user logon to remote computers, and the Simple Mail Transfer Protocol (SMTP). These and other protocols are often packaged together with TCP/IP as a “suite.”
[0076] Personal computer users usually get to the Internet through the Serial Line Internet Protocol (SLIP) or the Point-to-Point Protocol (PPP). These protocols encapsulate the IP packets so that they can be sent over a dial-up phone connection to an access provider's modem.
[0077] Protocols related to TCP/IP include the User Datagram Protocol (UDP), which is used instead of TCP for special purposes. Other protocols are used by network host computers for exchanging router information. These include the Internet Control Message Protocol (ICMP), the Interior Gateway Protocol (IGP), the Exterior Gateway Protocol (EGP), and the Border Gateway Protocol (BGP).
[0078] Internetwork Packet Exchange (IPX) is a networking protocol from Novell that interconnects networks that use Novell's NetWare clients and servers. IPX is a datagram or packet protocol. IPX works at the network layer of communication protocols and is connectionless (that is, it doesn't require that a connection be maintained during an exchange of packets as, for example, a regular voice phone call does). Packet acknowledgment is managed by another Novell protocol, the Sequenced Packet Exchange. Other related Novell NetWare protocols are: the Routing Information Protocol (RIP), the Service Advertising Protocol (SAP), and the NetWare Link Services Protocol (NLSP).
[0079] Hypertext Markup Language (HTML) is the set of markup symbols or codes inserted in a file intended for display on a World Wide Web browser page. The markup tells the Web browser how to display a Web page's words and images for the user. Each individual markup code is referred to as an element (but many people also refer to it as a tag). Some elements come in pairs that indicate when some display effect is to begin and when it is to end.
[0080] HTML is a formal Recommendation by the World Wide Web Consortium (W3C) and is generally adhered to by the major browsers, Microsoft's Internet Explorer and Netscape's Navigator, which also provide some additional non-standard codes. The current version of HTML is HTML 4.0. However, both Internet Explorer and Netscape implement some features differently and provide non-standard extensions. Web developers using the more advanced features of HTML 4 may have to design pages for both browsers and send out the appropriate version to a user. Significant features in HTML 4 are sometimes described in general as dynamic HTML. HTML 5 is an extensible form of HTML called Extensible Hypertext Markup Language (XHTML).
[0081] Extensible Markup Language (XML) is a flexible way to create common information formats and share both the format and the data on the World Wide Web, intranets, and elsewhere. For example, computer makers might agree on a standard or common way to describe the information about a computer product (processor speed, memory size, and so forth) and then describe the product information format with XML. Such a standard way of describing data would enable a user to send an intelligent agent (a program) to each computer maker's Web site, gather data, and then make a valid comparison. XML can be used by any individual or group of individuals or companies that wants to share information in a consistent way.
[0082] XML, a formal recommendation from the World Wide Web Consortium (W3C), is similar to the language of today's Web pages, the Hypertext Markup Language (HTML). Both XML and HTML contain markup symbols to describe the contents of a page or file. HTML, however, describes the content of a Web page (mainly text and graphic images) in terms of how it is to be displayed and interacted by a user. For example, a <P> starts a new paragraph. XML describes the content in terms of what data is being described. For example, a <PHONENUM> could indicate that the data that followed it was a phone number. This means that an XML file can be processed purely as data by a program or it can be stored with similar data on another computer or, like an HTML file, that it can be displayed. For example, depending on how the application in the receiving computer wanted to handle the phone number, it could be stored, displayed, or dialed.
[0083] XML is “extensible” because, unlike HTML, the markup symbols are unlimited and self-defining. XML is actually a simpler and easier-to-use subset of the Standard Generalized Markup Language (SGML), the standard for how to create a document structure. XML markup, for example, may appear within an HTML page. Early applications of XML include Microsoft's Channel Definition Format (CDF), which describes a channel, a portion of a Web site that has been downloaded to the user hard disk and is then is updated periodically as information changes. A specific CDF file contains data that specifies an initial Web page and how frequently it is updated. Applications related to banking, e-commerce ordering, personal preference profiles, purchase orders, litigation documents, part lists, and many others are anticipated.
[0084] Although not limited to, the following are some noted advantages of the present invention. The system 100 provides the technical capability that enables health and human service providers to share protected health information of their clients/patients—through an electronic central data repository. The system 100 is designed to be the public sector outpatient component of a comprehensive regional electronic health information infrastructure that facilitates standards-based electronic communication and real-time sharing of electronic health information records-across multiple providers. Access to a complete set of client/patient information at point of care has been demonstrated to reduce medical errors, and improve both cost and treatment effectiveness. The system 100 has been intentionally developed using originally authored and public domain open-source computer code, and current commercially available software technologies. Business rules demonstrating a commitment to non-proprietary and non-vended products facilitate greater opportunity for interoperability with multiple systems, and greater accessibility to public health and human service safety net providers.
[0085] Some other noted, and not to be limited by, characteristics are: mobile device support for WAP/WML and Pocket Browser devices, clean code/html content separation using server controls, pages that are constructed from dynamically-loaded user controls, configurable output caching of portal page regions, and multi-tier application architecture. The system 100 also provides ADO.NET data access using SQL stored procedures, data content tracking and logging, XML serialization and schema support, SOAP support, SMTP and POP3 email support, Microsoft's Windows authentication—username/password in Active DS or NT SAM, and forms authentication using a database for usernames/passwords. Also provided is role-based security to control user access to portal content, user-based security to control user access to application objects, Web Services for interoperability support, Web Services for better usability, SQL Server Reporting Services, and IIS 5.0 and SQL compatibility. The system 100 also uses Microsoft's Server 2000 Applications, Microsoft's Windows 2000 Advanced Server Operating System, system tape backup with remote storage of tapes, Cisco Systems' VPN encryption for secure connections, HIPAA Privacy and Security rule compliance, SNOMED CT integration, and HL7 version 3 standards compliance.
[0086] Although not limited to, it is further noted that there are also specific unique components of the system 100 that provide significant advantages over comparable current state of the art products. First, the system 100 is developed for use in an outpatient setting, which is where over 80% of health care services are provided. Second, the system 100 maintains health information records both individually and as a part of a household unit. This is particularly useful for clients/patients whose eligibility for service is tied to household factors such as income, and clinically useful for providers who are working with multiple members of one family. Third, the system 100 has a system of role-based access, which readily facilitates multiple user access to a health information record while protecting access to certain kinds of information as required by federal and state law such as HIPAA. Fourth, each bit of data resident in the system 100 is time, date, and user stamped to insure security and facilitate accountability among multiple users of a central record, while insuring that the records can be readily and routinely updated. All data changes are logged and stored in tables on the server. This further facilitates restoration of data precluding the need to refer to tape back ups and it provides the ability to report log changes.
[0087] While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | A method and health information exchange system for health and human care providers providing shared community health information records on individuals and their related household members in a secured relational database that is fully HIPAA compliant are disclosed. The system gathers a broad range of medical, epidemiological, and demographic information on individuals and their related household members visiting disjointed and unassociated health and human services providing care in a predefined region. The database is accessible to authorized subscribers via a secure private web site in real time, and allows for the tracking of service utilization of the individuals and their related household members in the predefined region to help ensure that the individuals and their related household members are receiving the necessary care from the variety of disjointed and unassociated health and human services. | 6 |
1. Field of the Invention
This invention relates to improvements in tube twisting apparatus and more particularly, but not by way of limitation, to an automated tube twisting apparatus for producing in succession multiple twisted tubes of a controlled helical corrugation pattern and of uniform overall length with uniformity between substantially any desired number of twisted tubes.
2. Description of the Prior Art
Finned tubes have long been utilized in the heat exchanger industry, and the like, for improving the dissipation of heat. Many of the tubes in use today comprise a cylindrical tube having a plurality of longitudinally spaced radially extending fins secured to the outer periphery thereof, and in some instances the tubes are provided with a continuous helical fin secured to the outer periphery of the tube. The inner periphery of these tubes is normally smooth and whereas the fins on the outer periphery of the tube improve the operation of the heat exchanger, the inner periphery does not provide any material increased effect in the efficiency of the tube. It has been found that twisting of the walls of the tube itself in order to deform the tube into a helical corrugated configuration along the length thereof provides an event more efficient heat dissipation in a heat exchanger in that both the inner and outer peripheries of the tube are deformed.
Many devices have been developed for twisting cylindrical tubes to provide the desired helical corrugations therealong, such as those shown in the Humphrey U.S. Pat. No. Re. 24,783, issued February, 1960; the Humphrey U.S. Pat. No. 3,015,355, issued January, 1962, and the Bunnell U.S. Pat. No. 3,533,267, issued October 1970. These devices have certain disadvantages however, in that it is difficult to control the uniformity of the corrugations along the length of the tube and the overall length of the completed tube, and thus it is very difficult to produce a plurality of tubes of uniform diametric and longitudinal dimensions. As a consequence, it becomes difficult, if not impossible, to assemble a plurality of the tubes in a heat exchanger, or the like, since the variations in tube size creates a problem in the installation of the tubes. Usually time must be consumed in sorting through a plurality of the tubes to find those of substantially identical dimensions, or a plurality of the tubes must be discarded as unusable in a particular installation. This procedure is time consuming and expensive.
SUMMARY OF THE INVENTION
The present invention contemplates an automatic apparatus for twisting tubes to provide a helical corrugation extending substantially throughout the length of the tube and which has been particularly designed and constructed for overcoming the foregoing disadvantages. The novel apparatus comprises a lathe-type machine having a head stock or collet for receiving one end of the tube therein in order to rotate the said end about the longitudinal axis of the tube, and a tail stock member spaced from the head stock and movable in alternate forward and reverse directions with respect thereto. A suitable sensor is provided for detecting the advance of the corrugations along the length of the tube during the twisting operation, and is operable connected with the head stock and tail stock through a suitable clutching mechanism for stopping the forward movement of both the tail stock and rotation of the head stock when the corrugations have reached a preselected point along the length of the tube and initiating a reverse movement for both the tail stock and head stock for a controlled unwinding and stretching of the twisted tube. A first sensor device is provided for response to the reverse movement of the tail stock for releasing the engagement of the tail stock with the tube upon a preselected length of reverse movement of the tail stock, and a second sensor device is provided for detecting the continued reverse movement of the tail stock and stopping all machine operation when the tail stock has reached a predetermined position along the bed of the machine whereby the apparatus is ready for the next succeeding tube twisting operation. Means is also provided for automatically inserting a mandrel through the tube prior to the twisting of the tube, and the position of the mandrel is controlled by suitable limit switch means. In this manner substantially any desired number of twisted tubes having a common diametric helical and longitudinal dimension may be produced. The novel apparatus is simple and efficient in operation and economical and durable in construction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of an apparatus embodying the invention, with portions thereof eliminated for purposes of illustration.
FIG. 2 is a view taken on line 2--2 of FIG. 1.
FIG. 3 is a view taken on line 3--3 of FIG. 1.
FIG. 4 is a view taken on line 4--4 of FIG. 3.
FIG. 5 is a side elevational view, partly in section, of a typical cylindrical tube as prepared to be twisted by the apparatus of the invention.
FIG. 6 is a view taken on line 6--6 of FIG. 5.
FIG. 7 is a view of a tube as twisted by the apparatus of the invention.
FIG. 8 is a schematic view of an operating circuit for an apparatus embodying the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in detail, reference character 10 generally indicates an automated tube twisting apparatus embodying the invention and comprising a suitable frame 12, preferably generally similar to a lathe, having a tail stock assembly 14 mounted thereon for movement in alternate forward and reverse directions, and a head stock or collet assembly 16 secured thereon in spaced relation to the tail stock 14. The frame 12 includes a substantially horizontally disposed bed 18 supported by suitable spaced legs 20. A pair of suitable gear reduction units 22 and 24 are mounted on the upper surface of the bed 18 in any suitable or well known manner. The gear reduction units 22 and 24 are provided with a common input shaft 26 which may either be a single shaft extending between the two units, or may comprise a pair of shafts disposed in axial alignment and suitably coupled together in end-to-end relation for simultaneous rotation thereof about the longitudinal axis. The shaft 26 is supported above the bed 18 by suitable pillow block bearings 28, which may be secured to the bed in any well known manner, such as by channel members 30 as shown in FIG. 1.
The input shaft 26 is driven by a suitable revisible motor 32, such as a hydraulic motor but not limited thereto, which is secured to the bed 18 in any well known manner and is operably connected with the shaft 26 by a belt 34 and pully 36 for rotation of the shaft 26. The gear reduction unit 22 is provided with an output shaft 38 which is operably connected with a lead screw 40 by an endless belt 42 extending between and around pulley members 44 and 46 for rotation of the lead screw 40 about its own longitudinal axis as is well known and as will be hereinafter set forth in detail. The gear reduction unit 24 is also provided with an output shaft 48 preferably disposed in substantial axial alignment with the shaft 38 and operably connected with the set screw 40 through an endless belt 50 and a pair of spaced pulleys 52 (only one of which is shown in the drawings) for transmitting rotation to the lead screw 40 as will be hereinafter set forth. The input shaft 26 is operably connected with the head stock assembly 16 through an endless belt 54 and a pair of spaced pulleys 56 and 58 for rotation of the head stock as will be hereinafter set forth. In addition, a suitable reversible clutch means 59, preferably an air actuated clutch but not limited thereto, is operably connected between the motor 30 and lead screw drive mechanisms in any well known manner for controlling the direction of movement of the tail stock assembly 14 during operation of the apparatus 10.
As more particularly shown in FIG. 3, the head stock or collet assembly 16 comprises an outer housing 60 having a centrally disposed bore 62 extending longitudinally therethrough for receiving a flanged sleeve 64 through one end thereof. A suitable bushing sleeve, or the like, 66 is interposed between the inner periphery of the bore 62 and the outer periphery of the sleeve 64 for wedging the sleeve 64 securely within the housing 60 whereby the housing and sleeve may be rotated about the common longitudinal axis thereof by the pulley 58. The outer pulley 58 may be keyed or otherwise secured to the outer periphery of the housing 60 for transmitting said rotation thereto during operation of the apparatus 10.
The outer end of the sleeve 64 is journalled within an apertured cap member 68 by suitable bearings 70, and an apertured end plate 72 is suitably secured to the outer end of the cap for retaining the flanged sleeve 64 in position with relation thereto. A substantially inverted U-shaped bracket 74 (FIG. 4) surrounds the outer periphery of the cap member 68 and is pivotally secured to the frame 12 in any suitable manner, such as by a pin member 76 extending between the spaced lower legs of the U-bracket 74. The cap 68 is pinned or otherwise secured to the legs of the U-bracket 74 as shown at 78 in FIG. 4, and an apertured flange 80 extends outwardly from the cross member of the U-bracket 74 for pivotal connection at 82 with a suitable solenoid 84, or cylinder having a reciprocal actuator arm 86. The cylinder 84 is pivotally secured to the frame 12 in any suitable manner such as pivot pin 88. When the cylinder 84 is activated for extension of the arm 86, the U-bracket 74 is pivoted in a counter clockwise direction about the pivot pin 76, as viewed in FIG. 3, for pulling the sleeve 64 in one direction within the bore 62 for providing said wedging engagement between the sleeve and the housing 60, and upon retraction of the arm 86, the pivotal movement of the U-bracket 74 is reversed for moving the sleeve 64 in an opposite direction within the housing 60 for releasing the wedging engagement therebetween, for a purpose as will be hereinafter set forth.
An annular shoulder 90 is provided on the outer periphery of the housing 60 for receiving the pulley 58 against one side thereof and for supporting a suitable bearing housing 92 on the opposite side thereof. The bearing housing 92 is secured in position around the outer periphery of the housing 60 in any well known or suitable manner, and the outer periphery of the bearing housing 90 is rigidly secured to the frame 12 in any suitable manner, such as the support plates 94 and 96 as shown in FIG. 2. The housing 60 is thus secured to the frame 12 for free rotation about its own longitudinal axis upon actuation by the pulley 58. In addition, the bore 62 is reduced at 98 and is of a suitable cross-sectional configuration for slidably receiving a tapered sleeve member 100 therein. The inner end of the sleeve 100 is threadedly secured to the inner end of the sleeve 64 as shown at 102 in FIG. 3, and the outer portion of the sleeve 100 is preferably provided with a plurality of longitudinally extending slits (not shown) through the sidewall thereof. The outer end of the sleeve 100 is provided with a centrally disposed longitudinally extending bore 104, and upon movement of the sleeve 100 in one direction with respect to the bore 60, the wall segments of the sleeve 100 formed by the circumferentially spaced slits permits the sidewalls of the sleeve 100 to expand slightly for a slight increase in the diameter of the bore 102, and movement of the sleeve 100 in an opposite direction with respect to the bore 60 securely wedges the outer periphery of the sleeve in the reduced bore portion 98 and reduces the diameter of the bore 100.
The tail stock assembly 14 comprises an outer housing 106 having a centrally disposed bore 108 extending longitudinally therethrough for receiving a flanged sleeve 110 therein. An annular shoulder 112 is provided on the inner periphery of the sleeve 110 and is threaded for receiving a guide sleeve 114 there through. The bore 108 is of a reduced diameter at 116 and is outwardly tapered at the outer end thereof for cooperating with a wedging sleeve 118 generally similar to the sleeve 110. The sleeve 118 is provided with a centrally disposed bore 120 similar to the bore 104, and the sidewall of the sleeve surrounding the bore 120 is provided with a plurality of circumferentially spaced longitudinally extending slits whereby movement of the sleeve 118 in one direction within the bore 108 will permit the wall to flex slightly outwardly for increasing the diameter of the bore 120, and movement of the sleeve 118 in an opposite direction will wedge the sleeve within the bore 116 and reduce the diameter of the bore 120. The inner end of the sleeve 118 is threadedly secured to the inner end of the sleeve 110 as shown at 122 whereby the sleeves 110 and 118 move as a unit within the bore 108.
The outer end of the sleeve 110 is preferably provided with a bracket 124 generally similar to the U-bracket 74 and having a pivot pin 126 pivotally connecting the bracket 124 with a flange 128 which is rigidly secured to a support means 130, which in turn is rigidly secured to the outer periphery of the housing 106. The opposite side of the bracket 124 is pivotally secured at 132 to an extendable arm 134 of a solenoid or cylinder 136, and the cylinder is pivotally secured at 138 to an outwardly extending flange 140 secured to the outer periphery of the housing 106. When the cylinder 136 is activated for extending the arm 134, the sleeve 110 is moved in one direction with respect to the bore 108 for increasing the size of the bore 120, and when the arm 134 is moved to a retracted position with respect to the cylinder 136 the sleeve 110 is moved in a direction for decreasing the size of the bore 120, for a purpose as will be hereinafter set forth.
The guide sleeve 114 is provided with an internal bore 142 in substantial alignment with the bore 120 and extending longitudinally from the bore into communication with a corresponding bore 144 provided in an end plug 146 which is inserted through the outer end of the bore 108 as shown in FIG. 3. During operation of the apparatus 10, a mandrel 148 is inserted through the guide sleeve 114 and therebeyond in a direction toward the head collet assembly 16. An outwardly extending nipple, flange, or the like, as shown at 150 for engagement with a sensor device 152 in order to limit the movement of the mandrel in the direction toward the head collect 16.
The support means 130 is rigidly secured to a plate member 154 which is reciprocally secured to a movable plate member 156 by means of a dove-tail connection therebetween as particularly shown at 158 in FIG. 2. The flange 128 is pivotally secured at 160 to the extendable arm 162 of a suitable solenoid or cylinder 164, and the cylinder 164 is pivotally secured at 166 to a flange 168 which is secured to the plate 156. In this manner, alternate extension and retraction of the arm 164 moves the plate 154 reciprocally with respect to the plate 156 for moving the tail stock assembly 14 reciprocally with respect to the plate 156 for a purpose as will be hereinafter set forth.
The plate 156 is slidably secured to a pair of spaced mutually parallel guide rods 170 and 172 by suitable support bushings 174 and 176 whereby the plate 156 may be freely reciprocated along the guides 170 and 172, as is well known. The guide rods 170 and 172 are rigidly secured to the frame 12 in any suitable or well known manner and extend longitudinally substantially throughout the length of the bed 18, but preferably terminate in spaced relation to the belt and pulley drive assemblies. A suitable sensor device means 180, such as a micro-switch or the like, is movably secured to the frame 12 in any suitable manner for engagment by the plate 156 during movement thereof in a direction away from the head collet assembly 16. The switch 180 is operably connected with the cylinders 84 and 136 for opening of the respective bores 104 and 120 upon engagement of the switch 180 by the plate 156. Still another sensor device 182 is secured to the frame 12 in the proximity of the outer end thereof remotely disposed from the belt and pulley drives for limiting or stopping the movement of the plate 156 in the direction away from the head collet, thus placing the tail stock in a position for commencing a next succeeding tube twisting operation.
During a tube twisting operation, cylindrical tube 184 to be twisted is positioned between the tail stock assembly 14 and the head stock assembly 16, with one end of the tube being inserted within the bore 104 and the opposite end of the tube being inserted within the bore 120. The tube 184 is provided with a plurality of circumferentially spaced dimples 186 in the sidewall thereof and spaced at a preselected distance inboard of one end of the tube, as particularly shown in FIG. 5. As one end of the tube 184 is rotated while the opposite end thereof is held against rotation, the walls of the tube begin to twist, forming a helical corrugation 188 along the length of the tube 1. The corrugations begin at the dimples 186, and it is thus important to position the dimples inboard of the respective tube end at a distance wherein it is desired to initiate the corrugations on the tube. As the twisting operation continues, the corrugations travel along the length of the tube and a suitable sensor means 190, such as an electric photo cell, is provided in the proximity of the undimpled end of the tube and is activated the moment the corrugations reach the preselected position in line with the sensor. The sensor 190 is operably connected with the clutch 59 and motor 30 for reversing the operation of the head collet and rotation of the lead screw 40 for a purpose as will be hereinafter set forth.
A roller assembly generally indicated at 192 is provided in the proximity of the outboard or rearward end of the tail stock 14 and is engageable with the outer periphery of the mandrel 148 for moving the mandrel in alternate forward and reverse directions during operation of the apparatus 10. In the forward direction, the mandrel is inserted through the tail stock assembly 14 and forwardly through the head stock 16. In the reverse direction, the mandrel is withdrawn from the head collet and tail stock.
In use, the operation of the apparatus 10 is substantially entirely automated. The operator of the machine or apparatus 10 initially sets the machine for the particular end results required, as is well known, adjusts the position of the sensor devices in accordance with the dimensions of the tubes to be twisted and the desired end product. Subsequent to the initial "set up", the dimpled end of the tube 184 is inserted into the bore 120 of the tail stock assembly, and the cycle start switch or buttom 194 is engaged. The operational cycle begins by actuation of the cylinder 136 for closing of the bore 120 against the outer periphery of the tube 184. The assembly 192 then inserts the mandrel 148 into the bore 144, through the tube 184 and through the sleeve 64 of the head stock 16. When the projection member 150 engages the sensor device 152, the forward movement of the mandrel is stopped. The cylinder 164 is then activated for moving the tail stock assembly 14 in a forward direction along the dove-tail connection 158. This forward distance through which the tail stock 14 moves is selected in accordance with the distance required for inserting the outer or free end of the tube 184 into the bore 104 of the head stock 16, whereupon the cylinder 84 is activated for closing the bore 104 around the outer periphery of the tube 184. The motor 30 is then activated for rotating the head collet and initiating the twisting of the tube 184 and the feed screw clutch 59 is engaged for rotating the feed screw 40 and advancing the plate 156 in a direction toward the head collet 16. This moves the tail stock assembly 14 in a forward direction, or toward the head stock 16.
The twisting of the tube 184 causes the wall of the tube to begin forming into a helical corrugation at the dimples 186, and upon a continued rotation of the head stock 16, the corrugation moves forwardly along the length of the tube. The mandrel 148 extending through the length of the tube 184 prevents a collapse of the walls of the tube and limits the inner diameter of the corrugations being formed in the walls of the tube. As soon as the corrugation moves to a position of alignment with the sensor 190, the clutch 59 is activated for reversing the direction of rotation of the lead screw 40 and reversing the direction of the motor 30. At this time, the tube 184 is untwisted to release the mandrel and the length of the twisted tube is stretched through a preselected distance, whereupon the sensor device 180 is engaged by the plate 156. This actuates the cylinders 84 and 136 for releasing the clamping engagement of the bores 104 and 120 with the tube 184, and activates the assembly 192 for withdrawing the mandrel 148 from the tube and tail stock. The tail stock continues to move in the rearward direction, or away from the head collet 26 until the plate 156 engages the rearmost sensor device 182, whereupon the tail stock is in a position for commencing the next succeeding tube twisting operation. It will be readily apparent that substantially any desired number of twisted tubes of substantially identical dimensions and configurations may be produced by the apparatus, thus greatly facilitating the ultimate use of the twisted tubes.
Whereas the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications, apart from those shown or suggested herein may be made within the spirit and scope of this invention. | An automated apparatus for forming helical corrugations in a cylindrical tube and comprising a tail stock movable in alternate forward and reverse directions, a head stock disposed in spaced relation with respect to the tail stock whereby the tube may be supported therebetween in a manner for rotating one end of the tube about its own longitudinal axis while holding the opposite end against rotation for twisting the wall of the tube to form the corrugations, a sensor device for detecting the progression of the corrugations along the length of the tube whereby forward movement of the tail stock and forward rotation of the head stock is stopped in accordance with a predetermined position in the twisting operation and the tail stock and head stock are actuated in reverse directions for a controlled unwinding and stretching of the twisted tube, a first sensor device responsive to the reverse movement of the tail stock for releasing the engagement of the twisted tube for permitting removal of the tube from the apparatus, a second sensor device responsive to the continued reverse movement of the tail stock for stopping the operation of the apparatus in preparation for a next succeeding tube twisting operation, and an automated apparatus for inserting a mandrel through the tube prior to the twisting operation for control of the inner diameter of the corrugations. | 1 |
This is a division of application Ser. No. 009,349, filed Jan. 30, 1989.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a recording apparatus which includes a process of forming electrostatic latent images on a changed recording medium by means of irradiation of laser beams, and more particularly, to a recording apparatus which is capable of recording multi-colored information on the recording medium with a plurality of laser beams.
2. Description of the Prior Art
A recording apparatus of the above kind includes, as shown, for instance, in FIG. 73, a drum-shaped photosensitive body 100 as the recording medium. In the periphery of the photosensitive body 100 there are arranged successively along the direction of rotation shown by the arrow, a first charger 101, a first exposure unit 102, a first developing unit 103, a second charger 104, a second exposure unit 105, a second developing unit 106, a transfer-stripping charger 107, a cleaner 110, and a discharger 109. One cycle of process is completed by electrically charging the photosensitive body 100 uniformly with the first charger 101, forming a second electrostatic latent image by the second exposure section 105, visualizing a second color by the second developing unit 106, carrying out a control processing if needed to equalize the amount of charges by the two color toners, though not shown, transferring dichromatic information onto a transfer material 108 with the transfer-stripping charger 107, cleaning with the cleaner 110 the toner that remains on the photos ensitive body 100 after transfer, and erasing the latent images with the discharger 109.
However, the existing apparatus has the second developing unit 106 which is of contact development type so that even when there is formed a first toner image 103a which is brought out to be visible, for example, by the first developing unit 103 as shown in FIG. 74(A), there may occur a case in which a portion of the first toner image 103a is scraped off by the second developing unit 106 as shown in FIG. 74(B). Then, in response to the exposure condition of the second exposure section 105, second toner 106a may be piled up by the second developing unit 106 over the first toner image 103a as shown in FIG. 74(C).
On the other hand, when the first toner 103a that was scraped off by the second developing unit 106 is sent into the inside of the second developing unit 106 to be mixed with the second toner 106a as shown in FIG. 75, the life of the developer (consisting of a carrier and a toner) will undergo a sharp reduction.
Further, in the case of the dichromatic printing process in which both of the first developing unit 103 and the second developing unit 106 are operated in the normal development mode, the changes in the surface potential of the photosensitive body 100, the conditions of the toner on the photosensitive body 100, and so forth will change as illustrated in FIG. 76(A).
Namely, due to charging by the first charger 001, the surface potential of the photosensitive body 100 is raised, and when the normal exposure is given using the first exposure section 102, only the information zone which is irradiated by the laser beam is maintained at a high potential to form an electrostatic latent image, leaving the outside of the information zone at a low potential. The electrostatic latent image is brought out to be visible using a negatively charged toner by the first developing unit 103. When the photosensitive body 100 is charged again in this state by the second charger 104, the surface potential of the photosensitive body 100 returns to nearly the level of the first charged state and the surface toner on the electrostatic latent image is transformed to a state in which it is charged positively by the appended charges.
Next, when the photosensitive body 100 is exposed normally by the second exposure section 105, there is formed an electrostatic latent image with high potential in the information zone, and at the same time there remains the image that was visualized in the past by the first developing unit 103. Further, an electrostatic latent image is brought out visible by the second developing unit 106 in a second exposure using negatively charged toner. A small amount of the toner is attached also to the electrostatic latent image due to the first exposure
The electrostatic latent image that is brought out to be visible in this manner by the two normal development modes is transferred onto the transfer material 108.
In addition, in the case of the dischromatic printing process in which the first developing unit 103 is operated in the inverted development mode and the second developing unit 106 is operated in the normal development mode, the surface potential of the photosensitive body 100 due to charging by the first charger 101 is raised, and an inverted exposure is carried out by the first exposure section 102 as shown in FIG. 76(B), bringing the information zone alone in low potential to form an electrostatic latent image, with the area outside of the information zone maintained at high potential. The electrostatic latent image is brought out to be visible by the first developing unit 103 due to positively charged toner. When the photosensitive body 100 is charged in this state again by the second developing unit 104, the surface potential of the photosensitive body 100 returns to approximately the level of the first charging.
Next, when the photosensitive body 100 is exposed normally by means of the second exposing section 105, the information zone becomes an electrostatic latent image with high potential, and the image that was brought out visible by first developing unit 103 remains as is. Then, the electrostatic latent image due to the second exposure is brought out visible by the second developing unit 106 with negatively charged toner, and a small amount of the toner is attached also to the electrostatic latent image due to the first exposure After carrying out a pre-transfer charging with a charger which is not shown in order to give the same polarity to the electrostatic latent images that are brought out visible in this manner by the inverted development mode and the normal development mode, each of the electrostatic latent images that are brought out to be visible is transferred onto the transfer material 108.
In the case of the conventional dichromatic printing process by the combination of the normal-normal development modes or the dichromatic printing process by the combination of the inverted-normal development modes, there is necessarily involved a process of charging a toner with the charge that has the polarity that is opposite to the polarity of the toner.
In particular, in the dichromatic printing process by the combination of the inverted-normal development modes, the polarity of the toner used varies for each development mode so that there is an inconvenience in that in order to transfer simultaneously both electrostatic latent images that are brought out to be visible onto the transfer material 108, there has to be given a pre-transfer charging to invert the polarity of one of the toners. Moreover, when the dichromatic printing process is employed in which development is carried out in the inverted mode after development in the normal mode, there also arises the necessity of carrying out a pre-transfer charging.
Furthermore, in the dichromatic printing process of the combination of the normal-normal development modes, the toner
is the same in each of the developing units. However, it is inevitable to have the opposite charge on the toner, at the time of recharging with the second charger 104, as shown in FIG. 76(A).
When the opposite charge appears on the toner, although each image is transferred later with corona of respective polarity, it is clear that the efficiency for each is lower than that for the ordinary monochromatic transfer.
However, when a high resistance is given to the toner in order to enhance the transfer efficiency and to secure a stable development in a humid atmosphere, there arises a problem that the toner which sits on the photosensitive body inverts the polarity so that it is difficult to invert the polarity even with the reversed charging.
In addition, when the thickness of the toner layer on the photosensitive body is large, the toner layer is laminated in multiple layers rather than in a single layer. In such a case, when the top layer in particular is inverted, it prevents the transfer of the opposite charge to the inner toner layers, so that there is a problem that the toner polarity in the lower layers is difficult.
Moreover, the existing color copier in practice is of the type in which an image is transferred onto a transfer paper or an intermediate transfer drum for each color, and this process is repeated, to complete the full color print, so that this method can also be applied to the recording apparatus of the type under consideration.
However, in that case, the copying speed will have to be reduced sharply since a sheet of copy is obtained by repeating the process similar to the above.
Furthermore, in the existing recording apparatus of the above kind, when printing is done in only one color, if, for instance, while the apparatus is in printing operation in a first color, a second color is designated, then the printing operation in the second color will be initiated by temporarily interrupting the rotational driving of the photosensitive body simultaneous with the completion of printing operation in the first color. Therefore, the copying speed will have to be reduced in some cases.
SUMMARY OF THE INVENTION
The object of the present invention which was conceived in view of the above circumstances, is to provide a recording apparatus which is capable of maintaining a high copying speed always.
In order to achieve the above object, the recording apparatus of the present invention is characterized in that, while the apparatus is in printing operation in one monochromatic printing mode which was accepted by the apparatus in the past, when there is given an indication that demands another monochromatic printing mode from within or without the apparatus, the apparatus accepts the indication upon completion of the printing operation in the monochromatic printing mode that was accepted in the past. In addition, the apparatus includes switching means which switches the electrostatic latent image formation means and the development means so as to respond to the other monochromatic printing made mentioned above, and control means which controls, when making a transition to the control which carries out a predetermined printing operation in response to the switching operation of the switching means, the rotational drive of the photosensitive body in continuation to the monochromatic printing mode that was accepted in the past.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram which shows an outline of the recording apparatus of the present invention,
FIG. 2 is a diagram which shows an overall schematic configuration of the system for an example of the dichromatic LBP to which is applied the recording apparatus of the present invention,
FIG. 3 is a schematic transitional diagram in accordance with the processes, for the changes in the surface potential of the photosensitive body, the toner condition on the photosensitive body, and the like, in the LBP to which is applied the present invention,
FIG. 4 an overall configurational diagram for the image formation unit in the LBP to which is applied the present invention, FIG. 5 and FIG. 6 is a configurational diagram for the first developing unit,
FIG. 7 a curve for development characteristic of the first developing unit,
FIG. 8, FIG. 9, FIG. 10 are diagrams for illustrating the configuration in installing a first developing unit to the dichromatic LBP,
FIGS. 11A and 11B are an explanatory diagram for the modes of accessing and removing the first developing unit from the photosensitive unit,
FIG. 12 is a perspective diagram for the developing unit driving mechanism,
FIG. 13 is a configurational diagram for the schorotron charger that is applied to the second charger.
FIG. 14 is a characteristic curve for the schorotron charger,
FIG. 15 is a diagram for illustrating the configuration of the second developing unit,
FIG. 16 is a diagram which shows schematically the development conditions of the second developing unit,
FIG. 17 is a characteristic curve for reversed attachment of a first image to the second developing unit,
FIG. 18 is an explanatory diagram for the configuration of the pretransfer charger,
FIG. 19 is a view from the top of the optical system in the dichromatic LBP,
FIG. 20 is a top sectional diagram of the polygonal scanner unit,
FIG. 21 is a transverse sectional view of the polygonal scanner unit,
FIG. 22 is a diagram which shows the arrangement of the first and the second laser units,
FIG. 23 is a diagram which shows the surroundings of the beam detector,
FIG. 24 is diagram which shows the incidence of the first and the second beams to the photosensitive body,
FIG. 25 is an explanatory diagram for the configuration of the cylindrical spacer attached to the beam detector,
FIG. 26 is a transverse sectional view of the optical system,
FIG. 27 is a detailed diagram of the prism holder for the two-beam adjustment,
FIG. 28 is a sectional diagram of the holder,
FIG. 29 is a diagram for showing the installation of the holder,
FIG. 30 is an explanatory diagram for the operation of the holder,
FIG. 31 is a detailed diagram for another embodiment of the holder,
FIGS. 32A & 32B are a diagram for illustrating the arrangement of the double-beam generating section,
FIG. 33 is an explanatory diagram for the correction conditions of the prism,
FIGS. 34, 35A and 35B show explanatory diagrams for the operation of the correction conditions,
FIGS. 36A, 36B and 37 are explanatory diagrams for the measurement of the thickness of polygonal mirror surface,
FIG. 38 is a perspective diagram which shows a schematic configuration of the double-beam laser optical system,
FIGS. 39A & 39B are a diagram which shows the changes in the scanning speed of the optical system,
FIG. 40 is a diagram for showing the efficiency of optical system for the first and the second beams,
FIGS. 41A & 41B are a transitional diagram which shows schematically the conditions on the photosensitive body, for the case of the first development alone and of the second development alone, in accordance with the process, in the dichromatic LBP to which is applied the present invention, FIGS. 42A and 42B are a curve which shows the surface potential characteristic of the photosensitive body,
FIG. 43 is a curve which shows the case of compensating the surface potential characteristic without taking temperature into account,
FIG. 44 is a curve which shows the case of compensating the surfade potential characteristic by taking temperature into account,
FIG. 45 is a block diagram which shows the configuration of the control in the dichromatic LBP that employs the present invention,
FIGS. 46A & 46B are a diagram which shows the content of the ROM data table,
FIG. 47 is a diagram which shows the details of the interface signal between the interface circuit and a host system,
FIG. 48 is a diagram for illustrating the relationship between the interface signal and the data writing position,
FIGS. 49A & 49B are a detailed explanatory diagram for the command and the status that are used for the dichromatic LBP,
FIG. 50 is a block diagram which shows various kinds of detectors in detail,
FIG. 51 is a block diagram which shows the details of the driving circuits and the output elements,
FIG. 52 is a block diagram which shows the details of the process control circuits and its input-output terminals,
FIG. 53 is a block diagram which shows the details of the laser modulation circuits and the semiconductor lasers,
FIG. 54 is a circuit diagram which shows the details of the beam detector circuit and the beam detector,
FIG. 55 is a diagram which shows the relationship between the range of one scanning of the laser beam and each of the positions of the beam detector position and the data writing position,
FIG. 56 is a diagram for showing the positional relationship of the data writing positions for the entire paper,
FIG. 57 is a circuit diagram which shows the details of the printing data writing circuit,
FIG. 58 is a timing chart for the printing data writing control signal in the dichromatic printing mode,
FIG. 59 is a timing chart for one line portion of the data writing control signal,
FIG. 60 is a timing chart for the process control signal in the dichromatic printing mode,
FIG. 61 is a timing chart for the process control signal in a first color printing mode,
FIG. 62 is a timing chart for the process control signal in a second color printing mode,
FIGS. 63A to 67B are flow charts for showing the overall operation of the dichromatic LBP,
FIGS. 68A, 68B, 69A and 69B are flow charts for showing subroutine for setting the page top counter, page end counter, left margin counter, right margin counter, and two-beam scanning length correcting valve,
FIGS. 70A and 70B are a flow chart showing the subroutine for the potential control during the warming-up and the potential control prior to the first printing,
FIGS. 71A to 72 are flow charts showing the subroutine for the charged potential control,
FIG. 73 is an explanatory diagram for the configuration of the conventional recording apparatus,
FIGS. 74A, 74B, 74C and FIG. 75 are diagrams that show respectively examples of the problem in the existing apparatus, and
FIGS. 76A & 76B are a transitional diagram which shows schematically the conditions of the conventional photosensitive body in accordance with the processes.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, an embodiment of the present invention will be described in detail.
FIG. 1 is a block diagram which shows an outline of a recording apparatus of the present invention.
The recording apparatus has in the periphery of a photosensitive body 1, charging means 2, the combination of electrostatic latent image formation means 3a and development means 3b for a first color, and the combination of electrostatic latent image formation means 4a and development means 4a for a second color.
When an acceptance approval signal is issued from control means 6 to switching means 5, if there comes in an indication for demanding a monochromatic printing mode of a first color alone from, for example, outside or inside, a monochromatic acceptance signal A for the first color is applied from the switching means 5 to the control means 6. By this arrangement, the control means 6 activates the electrostatic latent image 3a, the development means 3b, and others to carry out the printing operation with the first color.
When there is given an indication, during printing operation with the first color, that requests a monochromatic printing mode with the second color alone that comes from the outside or from the inside of the apparatus, by the issuance of an acceptance approval signal from the control means 6 to the switching means 5 upon completion of the printing operation according to the monochromatic printing mode with the first color alone, there is supplied a monochromatic printing acceptance signal B with the second color from the switching means 5 to the control means 6. Then, the control means 6 controls driving means 7, when printing operation is to be carried out with the second color by activating the electrostatic latent image formation means 4a, the development means 4b, and others, so as to drive to rotate the photosensitive body 1 in continuation of the monochromatic printing mode with the first color.
Further, when there is given to the switching means 5 an indication to request a multi-color printing mode from the outside or from the inside, and when the indication is accepted by the switching means 5, a multi-color printing acceptance signal C is supplied to the control means 6. Based on this, the control means 6 carries out the control of activation states simultaneously for the electrostatic latent image formation means 3a, 4a and the development means 3b 4b for the first color and the second color.
FIG. 2 is a diagram which shows a schematic configuration for the entire system of an example of a dichromatic LBP to which is applied the recording apparatus of the present invention.
The dichromatic LBP 199 is joined to a host system 500 (an external apparatus such as an electronic computer and a word processor) via a transmission controller (interface circuit or the like) which is not shown. In this arrangement, the system receives two kinds of dot image data from the host system 500, modulates two laser beams to carry out writing on the photosensitive body. The two kinds of dot image data that are written are developed independently and they are transferred onto a recording paper.
Namely, in the interior of the dichromatic LBP 199 there are provided various components shown in FIG. 1 as the fundamental components for image formation. In the figure, 200 is a drum-shaped photosensitive body. In the periphery of the photosensitive body 200, along the direction of rotation indicated by the arrow there are arranged successively a first charger 201, a first surface potential sensor 202, a first developing unit 203, a second charger 204, a second surface potential sensor 205, a second developing unit 206, a pretransfer charger 207, a transfer charger 208, a stripping charger 209, a cleaner 210, and a discharger 211. A first exposure is carried out by irradiating the photosensitive body 200 with a first laser beam 309 between the first surface potential sensor 202 and the first developing unit 203. In addition, the system has a configuration in which a second exposure is carried out with a second laser beam 310 between the second surface potential sensor 205 and the second developing unit 206.
In addition, from the viewpoint of eliminating the problems that exist in the conventional development mode which is a combination of the development modes, a dichromatic printing process which is activated by two inverted development modes is employed in the present invention. In this case, changes in the surface potential of the photosensitive body 200, conditions of the toner on the photosensitive body 200, and others vary as shown in FIG. 3.
Namely, the surface potential of the photosensitive body 200 is raised by the charging with the first charger 201, and by the irradiation with the first laser beam 309, an inverted development is carried out to create an electrostatic latent image in the information zone which is brought to low potential while the outside of the information zone is maintained at high potential. The electrostatic latent image is brought out to be visible by the first developing unit 203 with a positively charged toner. When the photosensitive body 200 is charged again in this state with the second developing unit 204, the surface potential of the photosensitive body 200 returns approximately to the level of the first charging. Next, when the photosensitive body 200 is invertedly exposed by the irradiation of the second laser beam 310, this information zone becomes an electrostatic latent image with low potential, and the image that was brought out to be visible previously by the first developing unit 203 remains as is. Then, the electrostatic latent image due to the second exposure is brought out to be visible with a positively charged toner by the second developing unit 206. In that case, the image that was brought out to be visible by the first development will not be affected by the second development since it is formed by a positively charged toner.
Both of the electrostatic latent images that are brought out to be visible by the two inverted development modes are toner images of positive polarity so that it is possible to transfer them onto a transfer material as they are. In that process of transfer, there will be generated a difference in the transfer efficiency because of the differences in the charges of the two kinds of toner and in the potentials of the photosensitive body on the rear of the toner images. However, there is no difference in the polarity, in contrast to the case of the prior art where there is one in the mutual relation of the toner images, so that the practical problem is only slight.
Of course, it is possible match the transfer conditions of two kinds of toner image by the execution of a pretransfer charging after the completion of the second development with the pretransfer charger 207.
FIG. 4 is a configurational diagram which shows the entirety of the image formation unit in a dichromatic LBP which is an embodiment of the present invention
In the embodiment, similar to FIG. 2, there are arranged successively in the circumference of the photosensitive body 200, along the direction of rotation shown by the arrow, a first charger 201, a first surface potential sensor 202, a first developing unit 203, a second charger 204, a second surface potential sensor 205, a second developing unit 206, a pretransfer charger 207, a transfer charger 208, a stripping charger 209, a cleaner 210, and a discharger 211.
In addition, 212 is a polygonal scanner unit, 213 is a paper feeding device, 214 is an upper paper feeding cassette, 215 is an upper paper feeding roller, 216 is a first transportation route, 217 is a preresist pulse sensor, 218 is a pair of resist rollers, 219 is a second transportation route, 220 is an adsorption belt, 221 is a fixing unit, 222 is a paper ejection switch, 223 is a pair of paper ejection rollers, and 224 is a tray for ejected paper.
Of the various parts enumerated in the above, the photosensitive body 200 has an outer peripheral surface of Se--Tc layer. Because of this, the first charger 201 is made as a corona charger with positive polarity. The first charger gives a charged potential of 600 V or 1,000 V to the photosensitive body 200.
The first surface potential sensor 202 detects the charged condition of the photosensitive body 200 by the first charger 201.
In the stage following the first surface potential sensor 202, the photosensitive body 200 undergoes a first exposure under the irradiation of the first laser beam 309 that is reflected from the polygonal scanner unit 212 to form an electrostatic latent image on the photosensitive body 200 due to the first exposure.
The first developing unit 203 which develops the electrostatic latent image due to the first exposure, is a nonmagnetic single component developing unit with sectional view as shown in FIG. 5 and external appearance as shown in FIG. 6.
In the first developing unit 203, a development sleeve 405 is moved at an approximate relative speed of zero with respect to the photosensitive body 200. On the development sleeve 405, a toner layer is coated by a coating blade 406, and the electrostatic latent image on the photosensitive body 200 due to the first exposure is brought out to be visible by the toner layer.
Between the photosensitive body 200 and the development sleeve 405, there is given a predetermined gap. The gap has an appropriate size in response to the case of using a DC power supply alone for the bias power supply and to the case of using a superposed power supply of AC and DC power supplies. Namely, for the case of using a DC power supply alone, it is appropriate to choose the gap in the range of 50 to 300 μm while it is appropriate to choose it in the range of 80 to 500 μm in the case of a superposed power supply. In the present embodiment, a gap size of 150 μm was chosen for the case of a DC power supply alone, and a size of 200 μm for the case of a superposed power supply.
In FIG. 5, 402 is a mixer, 406 is a coating blade, and 408 is a toner.
Further, in FIG. 6, 403 is a supply roller, 407 is a holder, 410 is a blade, 411 is a gap adjusting ring, 412 is a side seal, 413 is a toner color display window, and 414 is a toner color detection section.
Moreover, nonmagnetic single-component development characteristic in the case of a DC bias power supply is as shown in FIG. 7(A), and nonmagnetic single-component development characteristic in the case of a superposed bias power supply of AC and DC is as shown in FIG. 7(B).
Next, the structure for installing the first developing unit 203 on a dichromatic LBP 199 will be described in detail by making reference to FIG. 8, FIG. 9, FIG. 10, and FIG. 11.
To begin, the first developing unit 203 is inserted into an aperture 418 in a frame 417 of the dichromatic LBP 199. A shaft 415 spans the frame 417 and a frame on the opposite side (not shown), and supports the rotation of the first developing unit 203. The first developing unit 203 is inserted by hooking it to a guiding plate 416 with the shaft 415 as the guiding shaft. The guiding plate 416 is rotated together with a handle 419. After insertion of the first developing unit 203, when the handle 419 is turned in the direction of the arrow A, the guiding plate 416 is also moved in the same direction, and the first developing unit 203 is moved with the shaft 415 as the center of turning. As a result, the gap adjusting ring 411 makes a contact with the photosensitive body 200. As the guiding plate 416 is rotated, a lever 420 is moved to be fitted in a notch 424, and is fixed in a predetermined position. A developing unit pressing lever 421 is moved by a spring 422 interlocked with the lever 420. As a result of this action, the lever 421 gives the first developing unit 203 a force to press the photosensitive body 200. When the handle 419 is turned in the direction opposite to that of the arrow A, the guiding plate 416 is turned also in the same direction, and further, the levers 420 and 421 are turned in the counterclockwise direction by the force of a spring 423 which is attached to the lever 420. As a result, the energizing force to the developing unit is removed, and the first developing unit 203 is removed from the photosensitive body 200 by the guiding plate 4.
FIG. 11(A) illustrates the situation in which the first developing unit 203 is to be attached or to be removed, while FIG. 11(B) illustrates the contact of the first developing unit 203 with the photosensitive body 200.
FIG. 12 shows the driving section for the developing unit. The driving force from a developing unit driving motor 425 is transmitted to clatches 426(a) and 426(b). Choice between the first developing unit 203 and the second developing unit 206 is decided by the color of the printing. When the first developing unit 203 is selected, a clatch 426(a) is activated to turn the development sleeve 405(a) of the first developing unit 203. When the second developing unit 206 is activated, a clatch 426(b) is activated to turn the development sleeve 405(b) of the second developing unit 206.
Next, the photosensitive body 200 is charged again by the second charger 204. In this process, unevenness in the potential created on the surface of the photosensitive body 200 generated in the various processes up to the first developing is returned to a uniform potential. In the present embodiment, use is made of a schorotron. In the schorotron, a charging wire 160 is applied a voltage of 6 kV, a shielding wire is kept at the ground potential, and a grid 1,200 V is impressed with a voltage of 1,200 V. Reference numerals 161 and 163 are a high tension power supply and a grid power supply, respectively.
Further, in FIG. 14 is shown the result of an experiment that illustrates the situation in which the effect of uniformizing the unevenness of potential is obtained by the schorotron. The figure illustrates the variations after passage of the second charger, with the grid voltage as a constant, for the surface potentials 0 V, 600 V, and 1,000 V for curves A, B, and C, respectively.
Here, by comparing curve A with curve B, the way in which the unevenness in the potential of the photosensitive body 200 generated by the first exposure is uniformized after passage of the second charger, will be seen clearly. Namely, when a superposed development of AC and DC is employed for the first development, the unevenness in the potential of the photosensitive body 200 can be made less than several tens of volts if the grid voltage of the second charger is kept greater than 800 V.
Further, comparing curve A with curve C (the case of using a DC development as the first development), the potential difference can be made less than several tens of volts if the grid voltage is greater than 1,300 V. In the present embodiment, a grid voltage of 1,300 V was adopted because of the use of a DC noncontact single component development for the second development, as will be described later. In that case, the voltage after the second development was about 1,120 to 1,180 V for both of the first image information portion and other portions.
The second surface potential sensor 205 detects the charged state of the photosensitive body 200 due to the second charger 204.
In the stage following the second surface potential sensor 205, analogous to the first exposure, second laser beam 310 that is reflected by the polygonal scanner unit 212 is illuminated on the photosensitive body 200 to carry out a second exposure and to form an electrostatic latent image due to second exposure on the photosensitive body 200.
The second developing unit 206 which develops the electrostatic latent image due to the second exposure has a sectional form as shown in FIG. 15. If a nonmagnetic single-component toner 401 is present in its interior, the nonmagnetic single-component toner 401 is sent in to the gap between a baffle 40 and a supply roller 403 by means of a mixer 402 and the supply roller 403. The outer peripheral surface of the supply roller 403 is of soft material made of polyester-based polyurethane foam, and is made porous by separate bubbles. Since the supply roller 403 is rotated in the direction opposite to that of the development sleeve 405 by making contact with it, the supply roller 403 scrapes off toner 108 that remains on the development sleeve 405 without contributing to the development, and attaches fresh toner 401 on the development sleeve 405. The development sleeve 405 is formed by sand blasting, for example, the surface of an aluminum sleeve, and then by giving an effective fabrication. Reference numeral 406 is a development blade which is made of a thin stainless steel plate of thickness 0.15 mm. In the state fixed to a holder 407, the development blade 406 gives a force of 1,000 g/mm to the development sleeve 405 that makes contact with it. Toner 401 which is attached to the development sleeve 405 is made into a thin layer and is charged uniformly by passing the gap between the development sleeve 405 and the development blade 406. Here, between the development sleeve 405 and the photosensitive body 200, there is applied a voltage of the bias power supply 409.
The bias power supply 409 is a DC bias. In applying the DC bias, the following three conditions have to be satisfied, Namely,
(a) It should be sufficient to develop the image information portion (the portion of potential erasure in the second exposure).
(b) It should not spoil the portion outside of the image (the unexposed portion in the second exposure).
(c) It should not attract the toner of the first image after the second charging.
FIG. 16 illustrates schematically the state of the toner motion in order to show potentials that are suitable and potentials that are unsuitable for satisfying these conditions.
First, condition (a) corresponds to the toner motion as indicated by "development" in FIG. 16. This is due to the difference on the photosensitive body of the potential at the development portion (potential of the development sleeve) and the potential at the laser beam irradiation portion. Its development characteristic for the case of development with a DC bias is shown in FIG. 16 to have a characteristic similar to that shown in FIG. 7(A). It was found that a potential difference greater than 900 V is required in order to obtain a sufficiently high image density.
Next, it will be clear from FIG. 7(A) that the result of subtraction of (the potential for the area outside of the image information portion) from (the potential of the developing unit) should be less than 250 V in order to avoid the generation of a fog.
Further, the relation between the potential of the second developing unit and the potential of the first image portion is the same as the relation for a fog, in the aspect of color mixing of the image. The color mixing in the developing unit corresponds to the toner motion which is opposite to that in the above, and the result of the experiment is as shown in FIG. 17. From the figure, it will be seen that the result of subtraction of (the potential of the second developing unit) from (the potential of the first developing unit) has to be less than 200 V.
Consequently, it was found that the following relationships among various potentials have to be satisfied in order to obtain satisfactory superposed images that have no color mixing.
(Potential of the second developing unit)
(Potential of the second image information portion) 900 V.
(Potential of the second developing unit)
(Potential of the nonimage information portion of the second image) >250 V.
(Potential of the second developing unit)
(Potential of the first image portion) >250 V.
(Potential of the first image portion)
(Potential of the second developing unit) <200 V.
The potential of the first image portion after a recharging by the second charger may be higher or may be lower than the potential of the second developing unit depending upon the conditions such as the toner concentration.
Next, in the present embodiment, pretransfer charging is carried out for the photosensitive body 200 using a pretransfer charger 207 as was mentioned in conjunction with FIG. 3.
An effect required by the pretransfer charging process is to equalize the potentials of the first and second images. Then,.it is possible to make the transfer conditions of the two images nearly equal and obtain a satisfactory dichromatic image as a result of carrying out transfers with almost no difference under identical transfers.
Another effect required is to improve the detachability in removing a transfer paper from the photosensitive body 200. This is required because, in the case of inverted development, the charge polarity on the photosensitive body and the polarity of the transfer corona are opposite each other. Accordingly, the attractive force between the photosensitive body and the transfer paper becomes greater than in the case of the normal development, with a result that the detachability of the transfer paper becoming deteriorated. Namely, the attractive force between the photosensitive body and the transfer paper is arranged to be reduced by lowering the surface potential of the photosensitive body before the transfer.
Now, for reducing the surface potential of the photosensitive body, one may think of discharge using light. However, although the detachability of the transfer paper can surely be improved by this method, it will also generate an inconvenience that the toner image will be spread.
The above phenomenon arises as a result that in the inverted development, the polarity of the potential on the photosensitive body and the polarity of the toner are the same fundamentally, so that the sticking force of the toner to the photosensitive body is weak. When the charges on the photosensitive body is brought to zero by means of the light, the effect of enclosing the toner by the charges of the same polarity in the surrounding will be multified, with a result that the toner image is dispersed by the repulsive force of the toner itself, making it impossible to obtain a satisfactory image quality. For that reason, the pretransfer process has to be able to achieve the following effects.
(a) It reduces the potential of the photosensitive body to a predetermined level.
(b) It lowers the potential of the first image portion close to the predetermined level.
(c) It raises the potential of the second image portion close to the predetermined level.
As a charger which is capable of realizing these effects, use was made of a superposed charger of an AC high voltage and a DC high voltage as shown in FIG. 18. To the charging wire 164 there is impressed a high voltage which is the superposition of AC and DC as represented by an AC high voltage power supply 166 and a DC high voltage power supply 167. The shield 165 is grounded.
Next, the function of the charger will be described. The most important point of the charger is that the potential of the portion which has higher potential than a predetermined value is lowered while at the same time the potential of the portion which has lower potential than the predetermined value is raised.
What has been described in the above is based on the effects of charge removal in the high tension AC discharge. For instance, when use is made of ACP-P5KV, if the surface potential is called Vx, the flow of the positive corona component, of corona ions that are generated by the charging wire to which is applied an AC high voltage, moves in proportion to the potential difference (25 k V -V X ). On the contrary, the flow of the negative corona component moves in proportion to the potential difference (V X +2.5 kV). Consequently, when V X >0, motion of the negative component is larger, whereas when V X <0, motion of the positive component is larger, converging in both cases close to 0 V. (To be more specific, negative corona is easy to be generated than positive corona, so that the converging potential is not 0 V but is somewhat negative.)
Next, when a DC with the voltage value of V DC is superposed, potential differences that cause the positive and negative ions are (2.5 kV+V DC -V X ) and (V X -V DC -+2.5 kV), and hence, it converges close to V DC according to the idea similar to above. (In fact, it is V DC α.) From what has been described above the effects (a) to (c) mentioned earlier can be realized. It is to be noted that the schorotron charger also possesses the effect of smoothing the unevenness in the surface potential to a constant value. A distinct difference of this charger from a charger which is a superposition of AC and DC is that in this charger it is not possible to lower a higher potential to match a lower potential, so that it is only possible to equalize the potential to a value which is greater than the maximum potential in the unevenness of the potential. For this reason, the charger tends to have a problem in the detachability of the transfer material mentioned in the foregoing. In order to achieve the same effects by the use of a schorotron, one may lower the surface potential once to a level not quite equal to 0 V, and then lower it to a constant value with the schorotron.
Further, in a superposed charger of AC and DC, the detachability and quality of transferred images were best in the present embodiment when the potential after the passage was in the range of 100 to 800 V. The voltages corresponding to this situation were 4.0 to 6.0 kV for AC and 100 to 750 V for DC.
Next, the optical system for the dichromatic LBP in the present embodiment will be described in detail. In an optical system in which are involved a plurality of laser beams, configuration and shape of lenses to be used will vary depending upon a variety of combinations such as the case where there is a simple optical scanner or the case where there are a plurality of them, in scanning lasers, the case, when the optical scanner consists of polygonal mirrors, where light i made to be incident upon the same surface or the case where light is incident upon different surfaces, the case where the form of the laser beams incident upon the optical scanner is parallel beams incident upon the optical scanner is parallel beams or the case where they are convergent beams, and the case where the incident beams are mutually parallel or the case where they are not parallel.
In the present embodiment description will be given in conjunction with the case of a dichromatic LBP in which there are involved two laser beams and one polygonal mirror where each of the incident beam is a parallel light and the two beams are mutually parallel.
In the existing optical system with a plurality of laser beams there were problems in factors that affect the image quality, namely, unevenness in the image quality due to the differences in the beam diameter on the photosensitive body, scanning speed, and so on, installation, adjustment, and the like of a plurality of beams, and so forth.
First, as shown by the sectional diagram for the image formation unit shown in FIG. 4 and the view from top o the optical system shown in FIG. 19, by fixing a polygonal scanner unit 212 which includes the lasers, fθ lens(es), and the like, reflecting mirrors 311, 312, 314, 315, 316, and 307? for directing the scanned laser beam to a predetermined position, transparent glasses 313 and 137 for dust prevention, a beam detector (not shown), and so forth, on a single base 318, it is possible to minimize the difference in the beam diameter on the photosensitive body and the difference in the scanning speed due to errors in the optical path lengths for each laser beam. In addition, mutual adjustment for each laser beam can be achieved readily prior to or after incorporating the optical system in the body of the apparatus. Although the present embodiment treats specifically the case of two laser beams, situation is similar for the case when an optical system with more than two laser beams are involved.
FIG. 20 is an upper sectional diagram of the polygonal scanner unit 212. In a prior system a polygonal mirror 300, f8 lens 301, and each laser are either fixed to a base or are fixed via separate casings, so that a difficulty existed in aligning optical axis or the like. In the present embodiment shown in FIG. 20, the polygonal scanner unit 212 consists mainly of an octagonal mirrors 300, fθ lens 301, first and second semiconductor lasers 302 and 303, collimator lenses 304 and 305, prism 306, and a casing 336, where the fθ lens 301 is mounted with screws on a flange 327 fixed to the casing with screws.
Further, a first and a second laser units 321 and 322 which include the first and the second semiconductor lasers 302 and 303, collimator lenses 304 and 305, and have adjustment mechanisms, are fixed to a holder 325 that has cylindrical built-in prism holder 324 to which is fixed a prism 322, with fixing set screws 334 and 335 shown in FIG. 21 and FIG. 22, via a plastic spacer 323. The first and the second laser units 321 and 322 are arranged orthogonally each other in a horizontal plane free to rotate and fixable at any point in the plane. The laser beam 309 of the first laser unit 321 is adjusted by the prism 306 so as to be incident upon the polygonal mirror 300.
The holder 325 is fixed to the casing 336 by being screwed to the spacer 326.
As in the above, the polygonal scanner unit 212 includes adjustment of the laser optical axis so that it contributes to the miniaturization and enhancing the accuracy of the optical system, and also to a reduction of the number of assemblage processes.
Although two laser are involved in the present embodiment, a plurality of three or more lasers may be used, lenses in the laser units 321 and 322 may be a lens system other than the collimator lenses, and the laser beams from a plurality of laser units need not be incident upon the same surface of the polygonal mirror 300.
Next, the relationship between the polygonal mirror 300 and the laser units 321 and 322 will be described. First, laser beam 309 which is emitted from the first laser unit 321 is bent orthogonally by the prism 306 which has coatings on the incident plane 306a and the exit plane 306b as shown in FIG. 20 and FIG. 21, and is adjusted in a horizontal plane to be parallel to the second beam that will be described later. After it is incident at a point with a distance h 1 below the central axis of the polygonal mirror 300 and past the fθ lens 301, it passes through the 1-1 and 1-2 reflecting mirrors 311 and 312, as shown in FIG. 4, and the transparent glass 313, and scans and exposes the photosensitive body 200 in the direction from the front to the rear of the plane of the paper. Further, laser beam 310 which is emitted from a second laser units 322 is incident upon a point a distance h 2 above the central axis of the polygonal mirror 300 is scanned on the photosensitive drum in the same direction as in the first laser beam after passing, similar to the first laser beam, the 2-1, 2-2, and 2-3 reflecting mirrors 314, 315, and 316 and the transparent glass 317.
The optical parts are arranges for the laser beams 309 and 310 that are radiated from the first and the second semiconductor lasers 302 and 303, respectively, so as to have approximately equal efficiency of the respective optical system before they are scanned and exposed on the photosensitive drum 200, as shown in FIG. 40.
With this arrangement, the outputs of each semiconductor laser can be adjusted with a single volume, which contributed to simplification of adjustment and bringing down the cost of the apparatus.
Moreover, regarding the dispersion in the laser powers due to dispersion in the sensitivity of the photosensitive drum 200, there will not arise a situation in which powers of some lasers out of a plurality of lasers are insufficient, so that it will contribute also to improve the reliability as a printer.
As shown in FIG. 21, the first and the second laser units 231 and 322 are mounted on the holder 325 keeping a distance of h 1 +h 2 , and the second laser beam 310 passes in the holder 325 over the prism 306 which is used by the first laser beam 309 to be incident upon the polygonal mirror 300. In this case, the distance h 1 +h 2 is determined by the beam diameters of the parallel beams after passing the collimator lenses 304 and 305. The prism 306 and the prism holder 324 are arranged so as not to obstruct the first laser beam 309. The laser units 321 and 322 that have the first and the second semiconductor lenses 302 and 303 are fixed to the casing 326 via a holder 325 in a plance of the optical axis before its incidence on the polygonal mirror 300 which is parallel to the base 318.
When the optical axes before incidence on the polygonal mirror 300 of the first and second laser units 321 and 322 are arranged to come to lie in a plane perpendicular to the plane of the base 318, the protective effect by the insulating spacer 323, and moreover, vibration-proof, connector fabrication, and others will become difficult.
In the present embodiment, two lasers are used. However, a plurality of three or more beams may be used, and a plurality of beams may be incident on the same plane of the polygonal mirror 300.
In addition, as shown in FIG. 21 and FIG. 22, the first and the second laser units 321 and 322 are arranged so as to have the lines that connect the optical axis points of the first and the second laser units 321 and 322 and each of the incident points on the reflecting planes of the polygonal mirror 300 to be parallel to the plane of the base 318. By so doing, laser beams can be made to be incident upon the polygonal mirror 300 in the simplest manner and with the shortest distance, and also, to improve the reliability.
Next, as shown in FIG. 24, the angles -α and -β formed by the normal vectors to the photosensitive drum at the incident points 336 and 337 of the first and the second laser beams 309 and 310 and the directions of the laser beams at the incident points as the reference directions, are chosen to satisfy -α≈-β. If |α≈|β|, the inner beam diameters on the photosensitive drum 200 may bechanged even if the beam diameters of the first and the second laser beams 309 and 310 are equal, and the image quality will be affected. Further, even for the variation in the change in the optical path length due to distortion in the scanning line, the relative error between the first beam and the second beam will be decreased.
In other words, in the present embodiment, the condition |α|=|β| on the incidence angles is of no problem, namely, either one or both of the first and second laser beams 309 and 310 may have negative values. Further, although the description of the present embodiment was given in conjunction with the use of two lasers, the present invention can be applied also to the case of three or more lasers. In addition, the photosensitive drum may be of drum-shape, for example, of beltlike, or the photosensitive body may be a unified body of a plurality of photosensitive bodies instead of a single photosensitive body.
Next, periphral mechanisms of the beam detector 308 which generates horizontal synchronized signal that is indispensable for the printing control by the laser printer will be described.
In FIG. 4, the first laser beam 309 which is scanned by the fθ lens 301 is led to the beam detector 308 by the reflecting mirror 307 in the range of scanning of the first laser beam 309. FIG. 19 is a diagram which shows the surroundings of the beam detector 308 in the optical system as seen from the top, and FIG. 23 is its detailed diagram.
In FIG. 23, the first laser beam 309 which is scanned by the f0 lens 301 is reflected by the reflecting mirror 307 and impinges upon the beam detector 308 which is placed at a distance that is approximately equal to the photosensitive drum 200.
The reflecting mirror 307 is held by a flat spring 340 is fixed on the base 318 via a bracket 328. The flat spring 340 is adjusted by an adjusting screw 339 to have an optimum beam incidence on the beam detector 308. The angle between the flat spring 340 and the reflecting mirror 307 is designed so as to have the beam incident upon the beam detector 308 when the adjusting screw 339 sticks out from the bracket 328 by a distance of a, and a structure that can withstand vibrations or shocks is obtained by the pressure of the spring. In addition, the angle φ between the base 318 and the reflecting mirror 307 in its adjusted state, is chosen to be less than 90°, namely, arranging its reflecting surface pointing downward. With the bracket 328 and the angle φ, the reflecting mirror 307 becomes relatively free from stains or dusts, which keeps the laser beam that is led to the beam detector 308 stably for the long time.
Moreover, the beam detector 308 is mounted on a PC plate 342 for beam detection which keeps the beam detector 308 fixed on a bracket 341 with a fixed distance by means of a spacer 343. Further, on the bracket 341 there is fixed a cylindrical spacer 331 that includes a cylindrical lens section 344 made of methyl metacrylate, fitted to, and coaxial with, the beam detector 308. This arrangement stabilizes out-of-focus or insufficiency of light in the beam on the beam detector 308, tilt of the surface of the polygonal mirror 300, and the horizontal synchronized signal against vibrations or shocks.
FIG. 25 shows the details of the cylindrical spacer 331. The cylindrical spacer 331 consists of a cylindrical lens section 344 and a holder section 345 that are united into a body, and the portion (hatched portion in the figure) masking the cylindrical lens section is coated in black color. This is done so because the laser beam that is led to the beam detector 308 by the reflecting mirror 307 has a certain width so that light that impinges upon the surroundings of the cylindrical lens section 344 also enters the beam detector by refraction or the like, which generates noises in the horizontal synchronized signal and causes a large defect in the image quality. With a processing mentioned above, it becomes possible to provide images of high quality easily and at low cost. Of course, treatments for prevention of light transmission other than black coating will be equally effective, and the material for the cylindrical spacer 331 may be one with high light transmissivity other than methyl metacrylate such as polycarbon.
FIG. 26 is a diagram which shows cover to the optical system and the mounting of the reflecting mirror. For the first laser beam 309, the 1-1 and 1-2 reflecting mirrors 311 and 312, respectively, are fixed by a pair of bracket 352 and fixing flat spring 354, and the bracket 352 are fixed to the base 318. The 1-2 reflecting mirroe 312 is supported on three points by three optical path adjusting screws 354 (one of them is not shown in the figure) so as to be capable of being adjusted. In addition, the first transparent glass 313 for dust prevention is fixed to the base by bracket 346, and a first cover 319 to the first laser beam 309 is fixed to the base 318 so as not to obstruct the first and the second laser beams 309 and 310 between the polygonal scanner unit 212 and the 2-1 reflecting mirror 314. Further, between the fθ lens 301 and the first cover 319 is covered with a sealing material 350 of MORUTOPUREN?.
Further, the polygonal scanner unit 212 is covered with a third cover 367. In the past, the entirety of the optical system including the polygonal scanner unit 212 was made into a sealed structure. With the above construction, however, exchange of the polygonal scanner unit 212 became facilitated by simply opening the third cover 367 without affecting other optical parts.
For the second laser beam 310, after it is reflected by the 2-1 reflecting mirror 314, it is reflected by the 2-2 and 2-3 reflecting mirrors 315 and 316 that are mounted on a pair of brackets 348. Of these two, the 2-3 reflecting mirror 316 are supported on three points by three adjusting screws 351' (one of them is not shown in the figure) so that it can be used for adjusting the light path. In addition, the second transparent glass 317 for dust prevention is fixed to a bracket 370. The second laser beam 310 is covered with the first cover 319 until it is reflected by the 2-1 reflecting mirror 314 and traverses the base 318 downward, and is covered thereafter with a second cover 320. Further, the second cover 320 that has a laser scanning window section 357 and the bracket 348 are sealed with a sealing material such as MORUTOPUREN?.
FIG. 27 is a detailed diagram for the prism 306 and the prism holder 324 shown in FIG. 20, and FIG. 28 shows the P--P cross section of FIG. 27. As shown in the figures, the prism 306 is fixed to the cylindrical prism holder 324 with a plastic spacer 358 and a pressing flat spring 359, without the intermediary of screws or the like. The prism holder 324 is placed in the hollow portion of the holder 325, as shown in FIG. 22 or FIG. 29, and is attached to the holder 325 with a fixing screw 360. The prism holder 324 can be rotated by means of two angle adjusting screws 361 and 361' as shown in FIG. 29, permitting an easy and sure adjustment of the incidence angle of the first laser beam 309 to the polygonal mirror 300. FIG. 30 illustrates such adjustments. Further, the prism 306 may be replaced by a reflecting mirror which is shown in FIG. 31 where a reflecting mirror 355 is utilized in place of the prism 306.
FIG. 32(A) is a conceptual diagram which illustrates the positional relationship between the incident lasers of a two-bundle optical system of the present embodiment upon the polygonal mirror 300. FIG. 32(B) illustrates an example in which a reflecting mirror 355 is used in place of the prism 306. In FIG. 32(A), the first and the second semiconductor lasers 302 and 303 should be parallel ideally after passing the collimator lenses 304 and 305. However, in a semiconductor laser there exists a deviation (astigmatism) in the beam radiate point for the vertical and gorizontal directions, and hence the beam does not become parallel in practice. Accordingly, there will arise a difference in the actual beam inner diameters on the photosensitive drum 200 between the laser first beam 309 that propagates through the prism 306 and the second laser beam 310 that is not affected by the prism 306, unless the first laser beam 309 is given a path length longer by than the second laser beam 310 before impinging upon the polygonal mirror 300, as shown in FIG. 33. For that reason, in the present embodiment, the first and the second laser 302 and 303 are arranged to satisfy the relation ##EQU1## (where n' is the index of refraction of the prism, θ is the
angle with the optical axis, and nsinθ=n'sinθ')
With the above arrangement, it becomes possible to remove discrepancy between the diameters of the first and the second beams.
Further, although the correction for the case of using collimator lenses for the lens system is described in the present embodiment, similar correction will be required also for an optical system by which the beam is condensed on the reflecting surface of the polygonal mirror 300.
In FIG. 32(B), a reflecting mirror 355 is used in place of the prison 306 so that it is not necessary to give a correction such as is needed for the case of using the prism. However, because of the presence of the astigmation in the semiconductor laser as mentioned earlier, the distances from the semiconductor lasers 302 and 303 to the reflecting surface of the polygonal mirror 300 are chosen to satisfy approximately the relation
2'=1a'+1b'
By so doing, it is possible to keep the beam diameters of the first and the second laser beams on the image surface at a predetermined value. Needless to say, similar situation will hold for the case of a lens system which condenses the beam light on the reflecting surface of the polygonal mirror 300.
Although the case of using two laser beams was described in the present embodiment, an optical system with a plurality of more than two lasers may also be employed.
FIG. 34 shows a diagram which shows the laser units 321 and 322 from the rear. The laser units 321 and 322 are made in identical manner, and are fixable via insulating spacer 323 to the holder 325 at any angular position by the pressing screws 334 and 345. Accordingly, although the beam spot 362 of the semiconductor laser on the photosensitive drum 200 has an elliptic form of a×b as shown in FIG. 35(A), when the laser units are rotated by an angle θ as shown in FIG. 34, the beam spot on the photosensitive drum 200 becomes a'×b' with the spreads in the main and auxiliary scanning directions a' and b', respectively. Therefore, by varying the inclination angle θ, it becomes possible to obtain desired beam diameters.
As a result, the difference in the beam diameter due to the radiation angle of the semiconductor laser may be given such an adjustment as equalizing the beam diameters in the main and auxiliary scanning directions on the photosensitive drum 200, by varying θ for each laser unit 321 and 322 according to each beam diameter.
Further, in a laser printer of a single light flux, some dispersion in the beam diameter becomes a dispersion between the individual apparatus, and for a specific printer, the dispersion of the beam diameter will not be much of a problem provided that the dispersion is within the designed range. However, for a multiple light flux laser printer with two or more light fluxes, dispersion in the beam diameter between the beams will appear directly as a defect in the image quality of that printer. Although two lasers are utilized in the present embodiment, the situation is equally applicable to an apparatus that employs more than two lasers. In addition, each of the laser units 321 and 322 employs identical system so that the entire apparatus is simplified and can contribute to a reduction of the number of parts used.
FIG. 36 is a diagram which illustrates that the laser beams which pas the collimator lenses 304 and 305 impinge upon the polygonal mirror 300. FIG. 36(A) shows the case in which the major axes of each of the laser beams 363 and 364 coincide with the horizontal direction of the polygonal mirror 300, and FIG. 36(B) shows the situation in which the laser beams are 10 inclined by the adjustment of the beam diameter by θ 1 and θ 2 to give beams 363' and 364', respectively.
In FIG. 36(A), a 1 , b 1 and a 2 , b 2 show the beam diameters for both beams. In this case, the thickness of the polygonal mirror 300 can be determined by the beam diameters of each laser beam as ##EQU2## where h becomes the pitch Th=h 1 +h 2 of the first and second laser beam, and h satisfies the following inequality ##EQU3## Hence, by substituting Eq. (2) into Eq. (1) there is obtained ##EQU4## where the third term "+1" is included there to take into account of DARE? of both end surfaces 365 and 366 of the polygonal mirror. In the above is given the result for the thickness of the polygonal mirror 300 of the present embodiment which utilizes two light flux. The situation is analogous for the case of a plurality of beams of more than two, and for the general case of n beams, as shown in FIG. 37, there is obtained
t>[b.sub.n cos45°]+1. (3)
Further, the relation given by Eq. (3) is applicable also to the case which employs an optical system that has a focal point on the polygonal mirror 300 analogous to the case of the present embodiment where parallel light impinges upon the polygonal mirror 300. In this way, it is possible to provide a design value for the thickness which is minimum as well as economical of the polygonal mirror for a plurality of beams.
FIG. 38 is a perspective view for illustration an outline in carrying out recording of information in the photosensitive body 200 by means of two laser beams.
In the laser beam scanning of this kind, there are two problems that affect the image quality. Namely, if the starting point and the end point of scan in the main scanning direction on the photosensitive body 200 by the beam 309 that is radiated from the first semiconductor laser 302 are called S 1 and E 1 , respectively, and similarly, the starting point and the end point of scan by the second semiconductor laser 303 are called S 2 and E 2 , respectively, there arise problems as shown in FIGS. 39(A) and 39(B).
FIG. 39(A) represents the case the starting points Sl and S 2 of both scans are not flush having an error of d, and as the causes for which one may think of the following two cases.
(1) The case in which the optical axes in the horizontal plane of the laser beams 309 and 310 from the first and the second semiconductor lasers 302 and 303 were not parallel prior to their incidence upon the polygonal mirror 300.
(2) The case in which, when there is provided a beam detector 308 for each of the laser beams 309 and 310, there are errors in the fixing positions of the two beam detectors 308.
For the above problems, electrical measures were taken in the past.
FIG. 39(B) represents the case when the scanning lengths 1 and 2 in the main scanning direction of the laser beams 309 and 310 of the first and the second semiconductor lasers 302 and 303 are different. This situation arises when there is a difference in the optical path lengths of the laser beams 309 and 310 after each of them passed the f8 lens 301 and before carrying out exposure.
Further, in FIG. 38, 202 and 205 shows the first and the second surface potential sensors, respectively. In the past, the surface potential sensors 202 and 205 were set in the nonimaging portion of the photosensitive drum 200, which led to a drawback in that the photosensitive drum 200 had to be made long in its longitudinal direction. In the present embodiment, the surface potential sensors 202 and 205 are set at approximately the center of the photosensitive drum 200 so that it can contribute to a reduction in the length of the photosensitive drum, miniaturization and space sawing of the apparatus.
Next, referring to FIG. 4, the paper feeding system of the transfer paper will be described.
On one side area of photosensitive body 200, there are provided upper and lower paper feeding devices as a paper feeding device 213 in a forwarding section. In what follows, the upper paper feeding device will be described.
The upper paper feeding device includes a cassette 214 for housing transfer papers A which is taken out one by one by a paper feeding roller 215. A transfer paper A thus taken out is transported toward the photosensitive body 200 via a first transporting route 216 as a first forwarding section. In midpoints of the first transporting route 216, there are arranged a first detector 217 and resist rollers 218 along the transporting direction of the transfer paper A. In addition, on the transporting route 216, along the transporting direction of the transfer paper A there are arranged successively a stripping charger 200, an adsorption belt 220, a fixing unit 221, a second detector 222, and paper ejection rollers 223.
To describe image formation, a transfer paper A is taken out from the paper feeding cassette 214, and its position is put in order by being pushed against the resist rollers 218. The transfer paper A is detected by the first detector 217, sent to the transfer charger 208 by re-starting the resist rollers 218 by synchronizing the timing with the image on the photosensitive body 200, and the image is transferred on one side of the paper. The transfer paper to which image transfer is completed, is removed of static electricity that was accumulated on the paper, detached from the drum, sent to the fixing unit 221 where the image is fixed. The transfer paper A with image fixing completed, is ejected to a tray for ejected paper 224 via rollers 223 after passing the fixing unit 221.
Now, in the configuration of dichromatic LBP that has been described in FIG. 2 to FIG. 40, there occur frequently the necessity of making a print in one color only.
In that case, the following conditions have to be satisfied. Namely,
(a) there will occur no problem for development and transfer of the color desired to be output.
(b) There should be no mixing of the color of one of the developing unit with the color of the other developing unit, and the color of the other developing unit should not be mixed in an image on the photosensitive body.
(c) There should not occur unnecessary allover extended development in the area on the photosensitive body where there are no image information.
For these reasons, for the case of a monochromatic printing in a first color alone, the same process as in the dichromatic printing that was described in accordance with FIG. 3 is given up to the first development, and the process from re-charging (second charging) to the second development is discontinued, as shown in FIG. 41(A).
Further, in the dichromatic LBP configuration described in connection with FIG. 2 to FIG. 40, the surface potential of the photosensitive body 200 varies due to (a) difference in the solid material used for the photosensitive body, (b) fatigue caused by continued copying operation, and (c) changes in temperature.
In order to eliminate such variations in the surface potential of the photosensitive body 200, there is carried out a surface potential feedback as will be described below.
In FIG. 42 are shown examples of surface potential change due to fatigue caused by continuous use and surface potential change due to temperature. Generally speaking, dark attenuation is accelerated by fatigue due to continuous use, and the surface potential at the development position is lowered because of that.
As for the changes due to temperature, dark attenuation is generally faster for higher temperature so that the surface potential at the development position is reduced.
The data shown in the graphs were those obtained by a surface potentiometer which is located at the development position that is separated from the charging position by a predetermined angle that is determined by the arrangement for machine processing. The potential of the photosensitive body which is charged to a predetermined level at the charging position decreases due to dark attenuation during the time the photosensitive body is turned from the charging position to the development position. The potential at the development position is referred to as the surface potential which affects greatly the development conditions and influences the copied image directly. Accordingly, it is important to keep the surface potential at the development position at a constant value.
In the present invention, there are provided two charging devices (the first charging and the second charging), and both images, after exposure, are brought out to be visible by the first and the second developing units. Further, in order to set the surface potentials at the positions of both developing units at respectively predetermined values there are provided respective surface potential sensors between the first charging and the first development positions as well as between the second charging and the second development positions. The first charging and the second charging are controlled respectively by the outputs of these sensors. In particular, to set the potential at the second development section at a predetermined level through the control on the second charging is important in dichromatic printing in connection with prevention of color mixing on the photosensitive body and on the second developing unit sleeve.
There may be thought of a variety of ways for controlling the charging units. In the present invention use were made of a KOROTORON? for the first charging unit and a SUKOROTORON? for the second charging unit. It was arranged in the present invention to control the DC high tension to be applied to the wire by the KOROTORON? and to control the grid voltage by the SUKOROTORON?.
Next, the method of their control will be described.
A first method as shown in FIG. 43 is to measure the surface potential with a sensor that is located between the position of the charging unit and the position of the developing unit to control the potential at that position to be at a constant value. In comparison to large variations in the surface potential that varied due to the difference in the dark attenuations between the charging position and the development position in the case of without control, it becomes to vary due to the difference in the dark attenuations between the sensor position and the development position when there is introduced the control, so that the amplitude of variations becomes smaller because of the shortening of the attenuation time.
Although the variations in the surface potential may be lessened by the first method, a complete correction becomes difficult to achieve especially for photosensitive bodies with large temperature changes or fatigue due to continuous copying. In such a case a second method that follows may be adopted.
It is a method of lessening the variations in the surface potential at the development position that is required in practice, by changing the converging value of the potential at the sensor position in the rear, for different condition, by estimating the variations from the characteristics of the photosensitive body. First, the method of giving more accurate correction for variations due to temperature.
FIG. 44 is a diagram for illustrating the method of controlling the surface potential for the case of a photosensitive body which has a slow dark attenuation at low temperatures and a faster dark attenuation at high temperatures. In this method, the potential is kept at a constant value at the development position by setting the surface potential at the sensor position to be low for low temperatures and high at high temperatures. The situation is similar for fatigue due to continuous copy, so that the potential at the sensor position needs only be controlled by estimating the changes in the dark attenuation during continuous copying.
These situations may be summarized that, by calling the time for the photosensitive body to travel between the sensor position and the development position T, dark attenuation V during the time T varies according to the temperature conditions and the conditions for continuous copying, so that the potential at the sensor position is given by
V+V
where V is the necessary potential at the development position.
To make a correction to the changes due to temperature, it can be achieved by detecting the temperature of the photosensitive body with a temperature detection element to change automatically the valur of V.
To make a correction to the changes due to continuous copying, it can be achieved by counting the number of copies to vary the value of V.
Next, a detailed description of an embodiment of the present invention will be given based on its electrical comfiguration.
FIG. 45 is a block diagram which shows the configuration of the control section of the dichromatic LBP.
The control section of the dichromatic LBP includes basically a ROM 502 which houses a system program with CPU 501 as the control center, a ROM 503 which houses a data table, a ROM 504 which is used as a working memory, a timer 505, an I/O device 506 for I/O data, a writing control circuit 513 for printing data, and an interface circuit 519.
As shown in FIG. 46, the contents of the data table housed in the ROM 503 consist of top margin control data for a first color stored in addresses (4000) and (4001), top margin control data for a second color stored in addresses (4002) and 4003), and left margin control data stored in addresses (4004) and (4005).
Further, in addresses (4006) and (4007) there are stored bottom margin control data in the case of paper size of A3, and in addresses (4008) and )4009) right margin control data for the same size of the paper are stored. In a similar manner, tables corresponding to various sizes of the paper are stored up to the address (4083).
in addresses starting with (4090) there are stored coarse adjustment data for top margin, in addresses starting with (40B0) there are stored fine adjustment data for top margin, in addresses starting with (40D0) there are stored coarse adjustment data for left margin, in addresses starting with (4100) there are stored fine adjustment data for left margin, and in addresses starting with (4120) there are stored data for correcting scanning length for two beams, each of the foregoing data corresponding to switches from 1 to n.
These margin control data, coarse adjustment data, and fine adjustment data will be used as the setting data a margin controlling counter and a binary counter, of a printing data write control circuit 513 that will be described later.
In addresses (6000) and (6001) there is stored a first development bias data for red toner, and in addresses (6002) and (6003) there is stored a second development data for the same color. Similarly, first and second development bias data for blue toner, green toner, and black toner are stored in the addresses up to (600F). These will be used as the setting data for development bias control for a process control circuit 522 that will be described later.
In addresses (6100) and (6101) there are stored target surface potential table data for a first charging potential control, having a reference value of 25° C.
n addresses (6102) and (6103) there are stored error table data in convergence, which represents a tolerance control range for the target surface potential. In the addresses (6104) and (6105) there are stored output table data for a first time control, which will be used as a setting value for a first corona charger which is output for the first time during the warning up.
In the addresses (6106) and (6107) there are stored minimum correction table data.
In addresses (6108) and (6109) there are stored surface potential limits table data, in addresses (610A) and (610B) there are stored control output upper limits table data, an in addresses (610C) and (610D) there are stored control output lower limits table data. The surface potential limits table data, the control output upper limits table data, and the control output lower limits table data will be used for self diagnosis of the control system.
Following them tables that correspond to second charging potential control are stored in addresses up to (611B). In addresses starting with (6120) there are stored charge transition temperature correction table data for a temperature range of 10° C. to 40° C., which serves as a temperature correction data for the target surface potential table data of 25° C.
The time 505 is a general purpose timer and generates fundamental timings for controlling the paper transportion processes around the photosensitive body, and so forth.
The I/O device 506 carries out outputting of display data to a scan display section 507, inputting of various kinds of switch data or the like, inputting to each of the detector in the control section, outputting to driving circuits for driving elements such as motor clatches, solenoids, outputting to a driving circuit 511 for driving a laser scan motor 512 that scans the two laser beams, and inputting and outputting to and from a process control circuit 522 that controls the output of a high tension power supply 523 and others in response to the inputs of detected signals such as potential sensors, temperature sensors, and so forth.
The printing data write control circuit 513 controls the driving of a first laser modulation circuit 514 for optically modulating the first semiconductor laser 302 for image data writing of the first color and a second laser modulation circuit 521 for optically modulating the second semiconductor laser 303 for image data writing of the second color, and controls the writing of the printing data of video image sent from a host system 500 in a predetermined position on the photosensitive body. In this case, a beam detector 518 which makes use of pin diode of luminous response, detects one of the two light beams that are scanned by a laser scanning motor, horizontal synchronized pulses are generated by a beam detector 517 by digitizing analog signals from the beam detector 518 with a luminous comparator, and the detector 517 sends out the pulses to the printing data write control circuit 513.
An interface circuit 519 carries out outputting of status data to the host system 500 as well as receiving of command data and printing data from the host system 500.
In addition, there is provided a power supply 520 to supply power to each of these control sections.
In what follows a detailed description will be given for the major blocks in FIG. 45.
FIG. 47 is a diagram for illustrating the details of the interface signals that are transferred between the interface circuit 519 and the host system 500. In the figure, D7-D0 is an 8-bit both-way data bus, IDSTA is a selection signal for the data bus, which will be used for selecting which one is to be used between a status data bus to the host system 500 and a command data bus from the host system 500. Further, ISTB is a strobe signal for latching the command data within the interface circuit, and IBSY is a signal for approving the sending of a strobe signal ISTB and for approving the reading of the status data.
A signal IHSTN1 is a horizontal synchronized signal of the first color which requests sending of one line of printing data.
A signal IVCLK1 is a video clock signal of the first color which requests sending of one dot of printing data.
A signal IPEND1 is a page end signal which informs the completion of one line of printing.
The host system 500 sends out a video data signal IVDAT1 for the dot image data of the first color, based on IHSYN1 and IVCLKl signals, and discontinues the sending upon receipt of an IPENDl signal.
Similarly, IHSYN2 is a horizontal synchronized signal of the second color, IVCLK2 is a video clock signal for the second color, and IPEND2 is a page end signal for the second color. The host system sends out a video data signal IVDAT2 of dot image data for the second color based on IHSYN2 and IVCLK2, and discontinues its sending upon receipt of an IPEND2. These video data signals IVDAT1 and IVDAT2 are sent to the printing data write control circuit. The relationship described in the above is shown in FIG. 48.
A signal IPRDY is a signal that informs that the dichromatic LBP 199 is a ready state, IPREQ is a signal which approves sending of a print starting signal IPRNT from the host system 500, IPRME is a prime signal which brings the dichromatic LBP 199 to an initial state, IPOW is a signal which informs that the dichromatic LBP 199 is the on-state.
Next, details of the command and status used for the dichromatic LBP 199 in FIG. 49(A) and FIG. 49(B), respectively.
In FIG. 49(A), SRl to SR7 are status request command which correspond to statuses 1 to 7 in FIG. 49(B), CSTU is a command indicating paper feeding for the upper part of the cassette, CSTL is a command indicating the same for the lower part, VSYNC is a command indicating the start of sending printing data from the host system 500, SP1, SP2 and DP1 are commands indicating the printing mode, where SP1 is the printing operation with the first color alone, SP2 is the printing operation with the second color alone, and DP1 is a mode which indicates the printing operations of both of the first color and the second color. Finally, ME1 to ME9 are command indicating manual modes of various kinds.
In FIG. 49(B), "paper in transportation" is a status which shows that paper is fed and it is in transportation within the dichromatic LBP 199, VSYNC request is a status which indicates that the dichromatic LBP 199 received a print start position and that receipt of printing data is now possible, "manual" is a status which indicates that the paper feeding mode is in the manual state, "cassette top/bottom" is a status which indicates the state of cassette selection of the cassette paper feeding, "printing mode-first color mode, second color mode, two color mode" is a status which indicates the printing mode state that is selected, "cassette size (top)" and "cassette size (bottom)" are status that show the size code of cassette installed, "toner color (first color)" and "toner color (second color)" as status that show the toner color code of the developing unit installed, "test/maint" is a status that indicates that it is in the test/maintenance state, "data re-sending request" is a status which shows that re-printing is necessary due to jamming of a paper or the like, "during wait" is a status which indicates that the dichromatic LBP is in the warming-up state of the fixing unit, and "operator call" indicates an occurrence of a factor for an operator call of status 5. "Serviceman call" indicates that a factor for serviceman call of status 6 occurred. "Toner pack exchange" indicates that the toner is full in the toner pack. "No paper" indicates that there remains no paper in the cassette indicated. "Paper jam" indicates that a paper is jammed in the apparatus. "No first color toner" indicates that no toner exists in the first developing unit, "no second color toner" indicates that no toner exists in the second developing unit, "first laser failure" indicates that the first laser diode is not reaching a prescribed output yet or that the beam detector cannot detect the beam, "second laser failure" indicates that the second laser diode is not reaching a prescribed output yet. "Scan motor failure" indicates that the scan motor does not reach a prescribed speed of rotation even after elapse of a predetermined length of time or it deviates for some reason from the prescribed speed of rotation after reaching the prescribed speed of rotation. "First potential sensor failure" and "second potential sensor. failure" show respectively that the surface potential of the photosensitive body cannot be detected, and "re-sending page number" indicates the number of pages for re-printing when there occurred a data re-sending request status.
FIG. 50 is a detailed block diagram for various kinds of detectors 508 shown in FIG. 45. In FIG. 50, signals from various kinds of detectors are input to the I/O port 506. Reference numeral 530 represents upper cassette size detection switches which consist of four switches where various paper sizes are represented by combinations of these switches. Reference numeral 531 represents lower cassette size detection switches with configuration which is similar to the upper cassette size detection switch Reference numeral 532 is a no paper in upper cassette switch which is turned on when there is no paper in the upper cassette Reference numeral 533 is a no paper in lower switch. Reference numeral 534 is a pre-resist roller bus sensor detects presence or absence of the papers sent from the paper feeding cassette Reference numeral 535 is a manual feed switch which detects a paper which is fed through manual feeding guide, and 537 is a paper ejection switch which is located in the fixing roller section. Reference numeral 538 first developing unit toner color detection switches that consist of three switches and designate toner colors by their combinations. Reference numeral 539 are second developing unit toner color detection switches whose configuration is similar to the first developing unit toner color detection switches. Reference numeral 540 is a no toner in first developing unit switch which detects that there exists no toner in the first developing unit, 541 is a no toner in second developing unit switch which detects that there exists no toner in the second developing unit, and 542 is a toner full detection switch which is activated when the toner pack is filled with toner.
Reference numeral 543 is a door switch which is turned on or off by opening and closing of the front cover, and 544 is a jam reset switch which is provided in the front cover. The am reset switch is a switch which is turned on to confirm that a paper jamming is taken care of or that the toner pack is replaced when a paper jamming occurred or there is generated an operator call for filling of the toner. Accordingly, the operational display for a jam or filling the toner will not be cleared unless this switch is closed.
FIG. 51 is a block diagram which shows the details of a driving circuit 509 and an output element 510 shown in FIG. 45. In FIG. 51, 551 is a motor for developing units for which use is made of a Hall motor which is DC driven. Reference numeral 550 is a driver of the motor for the developing units, and is PLL controlled. Reference numeral 553 is a motor for the fixing units, and use is made of a Hall motor of DC drive. Reference numeral 552 is a driver of the motor for the fixing units, and is PLL controlled. Reference numeral 555 is a fan motor for cooling the interior of the apparatus for which use is made of a Hall motor driven by DC. Reference numeral 554 is a driver for the cooling fan motor, but is not PLL controlled as in the developing units and the fixing units. Reference numeral 557 is a driving motor for the photosensitive drum 200 which makes use of a four-phase pulse motor. Reference numeral 556 is a driver for the drum motor which makes use of a constant current 1-2 phase excitation type. Reference numeral 559 is a resist motor for driving the resist rollers 218 and manual feeding roller, which makes use of a four-phase pulse motor. Reference numeral 558 is a driving motor for the resist motor for which use is made of a constant voltage two-phase excitation type. Further, if the resist motor 559 is rotated in the forward direction, it rotates the resist rollers and if it is rotated in the reverse direction, it rotates the manual feeding roller.
Reference numeral 561 is a paper feeding motor which drives the lower paper feeding roller and the upper feeding roller, and makes use of a four-phase pulse motor. Reference numeral 560 is a driver for the paper feeding motor, and makes use of a constant voltage two-phase excitation type similar to the resist motor driver 558.
Reference numeral 563 is a solenoid for collecting toner, and when it is turned on, the blade 210 is pushed against the photosensitive body 200. Reference numeral 562 is a driver for the blade solenoid.
Reference numeral 565 is an electromagnetic clatch for first developing unit, and when the developing units are turned on in the state of turning-on of the clatch, the sleeve in the first developing unit is arranged to be rotated. Reference numeral 564 is a driver for the first electromagnetic clatch for the first developing unit. Reference numeral 567 is an electromagnetic clatch for the second developing unit, and when the motor 551 for developing units is turned on while the clatch is in on-state, the sleeve in the second developing unit is rotated. Reference numeral 566 is a driver for the electromagnetic clatch for the second developing unit.
FIG. 52 is a block diagram which shows the details of the process control circuit 522 and its input-output elements 523 shown in FIG. 45. In FIG. 52, 201 is a first charger for charging with its corona discharge wire connected to the output terminal of the high tension power supply 575 for first charging. The input terminals of the high tension power supply for first charging are connected to the output of a D/A converter 576 which changes the high tension output current and to a signal from the I/O port which carries out ON/OFF of the high tension output. The input of the D/A converter 576 is connected to the I/O port 506, and CPU 501 controls the output current of the high tension power supply 575 for fist charging via the D/A converter 576. Reference numeral 570 is a drum temperature sensor which detects the temperature in the neighborhood of the photosensitive body 200, and its output is input to an A/D converter 593. The output of the A/D converter 593 is input to the 1/0 port 506 and is processed in the CPU 501. Reference numeral 202 is the first potential sensor which detects the surface potential of the photosensitive body 200, and its output is input to the A/D converter 593. Reference numeral 309 is the beam of the first semiconductor laser, 203 is the first developing unit, the sleeve of the developing unit is connected to the output terminal of the high tension power supply 577 for first development bias, and the input terminals of the high tension power supply 577 for first development bias are connected to the output of a D/A converter which changes the high tension output voltage and to a signal from the I/O port which carries out ON/OFF of the high tension output. The output of the high tension power supply for first development bias is an output of AC+DC.
Reference numeral 204 is a second charger for charging, and the corona discharge wire of the charger are connected to the output terminal of a high tension power supply 579 for second charging wire, and the grid of the charger is connected to the output terminal of the high tension power supply 581 for second charging. To the input terminals of the high tension power supply 579 for second charging wire are input the output of a D/A converter 580 which varies the high tension output voltage and a signal from the I/O port which carries out ON/OFF of the high tension output. To the input terminals of the high tension power supply 581 for second charging grid are input the output of a D/A converter 582 which varies the high tension output voltage and a signal from the I/O port which carries out ON/OFF of the high tension output. For the chargers except for the second charger for charging, use are made of general and charger.
Reference numeral 205 is the second potential sensor which detects the surface potential of the photosensitive body 200, and its output is input to the A/D converter 593. Reference numeral 310 is the beam of the second semiconductor laser, 206 is the second developing unit, the sleeve of the developing unit is connected to the output terminal of the high tension power supply 583 for second development bias, and the input terminals high tension power supply 583 for second development bias are connected to the output of a D/A converter 584 which varies the high tension output voltage and a signal from the I/O port which carries out ON/OFF of high tension output. The output of the high tension power supply for second development bias is a DC output. Reference numeral 207 is the pre-transfer discharging charger which is connected to the output terminal of a high tension power supply 585 for pre-transfer discharger, and the input terminals of the high tension power supply 585 for pre-transfer discharge are connected to the output of a D/A converter 586 which varies the high tension output voltage and a signal from the I/O port which carries out ON/OFF of the high tension output.
Reference numeral 208 is the transfer charger which is connected to the output terminal of a high tension power supply 587 for transfer, and the input terminals of the high tension power supply 587 for transfer are connected to the output of a D/A converter 588 which varies the high tension output voltage and a signal from the I/O port which carries out ON/OFF of the high tension output.
Reference numeral 209 is the stripping charger which is connected to the output terminal of a high tension power supply 589 for stripping, and the input terminals of the high tension power supply 589 for stripping are connected to the output of a D/A converter 590 which varies the high tension output voltage and a signal from the I/O port which carries out ON/OFF of the high tension output.
Reference numeral 211 is the discharging lamp which is connected to a power supply 573 for discharging lamp, and the input terminals of the power supply 573 for discharging lamp are connected a D/A converter 574 which varies the amount of output light of the discharging light and a signal from the I/O port which carries out ON/OFF of the output of the discharging lamp.
FIG. 53 is a detailed circuit diagram for the first laser modulation circuit 514, the first semiconductor laser, the second laser modulation circuit 521, and the second semiconductor laser. First, the first laser modulation circuit 514 and the first semiconductor laser 302 will be described.
In FIG. 53, 302 is a first semiconductor laser diode which consists of a light-emitting laser diode 812a and a photodiode 811a for monitoring the output beam intensity from the laser diode.
Reference numeral 809a is a high frequency transistor, a resistor R29a which carries out optical modulation for the first laser diode 812a is a current detecting resistor, 810a is a transistor for lowing a bias current in the first laser diode 812a, R30a is its current limiting resistor, R27a a base current limiting resistor for the transistor 810a, and 817a is an inverter. To the input of the inverter 817a there is input a first laser diode enable signal LDON10, and when the signal becomes LOW level, the transistor 810a is turned on and a bias current flows in the first laser diode 812a. Reference numerals 807a and 808a are luminous analog switches for giving modulations to the first laser diode 812a, and each of the analog switches becomes on-state when a HIGH level signal is applied to the gate (G) and the resistance between the drain (D) and the source (S) becomes low. On the contrary, when a LOW level signal is applied to the gate, the resistance becomes high and the switch becomes off-state. Reference symbol R21a is a short-circuit protective resistor during ON-OFF changes of the analog switches 807a and 808a, and 813a and 814a are date drivers for the analog switches 807a and 808a. Reference symbols C02a and C03a are capacitors for speeding up, and R24a and R25a are input resistors for the gate drivers 813a and 814a. Reference symbols 815a and 816a are EXCLUSIVE-OR gates which can be changed by the output of a 2 AND gate 820a. The output of the 2 AND gate 820a becomes LOW level when either one of its inputs becomes LOW level, then the output of the EXCLUSIVE-OR gate 815a becomes LOW level, the analog switch 807a is turned on, and the first laser diode 812a becomes on-state. The condition for bringing the output of the AND gate 820a to LOW level is either the first video data signal VDAT10 is on LOW level or a first sample signal SAMP10 is on LOW level. When both of the inputs to the 2 AND gate are HIGH level, the output of the EXCLUSIVE-OR gate 816a becomes LOW level, the analog switch 808a is turned on, and the first laser diode 812a becomes off-state.
Reference numeral 806a is an operational amplifier and forms a voltage follower circuit. DOl is a Zener diode which regulates the output of the first laser diode 812a within the maximum rated value. Further, a resistor R19a and the capacitor COla constitute an integration circuit, and R20a is a discharge resistor to discharge the charges on the capacitor C01a at a fixed rate. Reference numeral 804a is an analog switch whose gate (G) is connected to the inverter 805a, and the input of the inverter 805a receives the first sample signal SAMP10. Reference numeral 803a is a transistor for level transformation, R22a is a base current limiting resistor for the transistor 803a, and R18a acts as a current limiting resistor during charging of the capacitor C01a. Reference numeral 802a is a comparator which is endowed with a hysteresis characteristic by the action of resistors R14a and R15a.
To the + input side of the comparator 802a there is impressed through a resistor R14a the output voltage of a first laser monitoring amplifier 801a. The amplifier 801a amplifies the output of a photodiode 811a which detects the light output from the first laser diode 812a. Resistors R12a, R13a, and VR01a regulate the degree of amplification of the operational amplifier 801a. Accordingly, the degree of amplification of the operational amplifier 801a can be varied by varying VRO1a. Reference numeral R11a is an effective loading resistor for the output of the photodiode within the first laser diode, and between the ends of the resistor there is obtained a voltage which is proportional to the output current of the photodiode 811a. Since the output current of the photodiode 811a is proportional to the light output of the laser diode 812a, the light output of the laser diode can be adjusted by varying the volume VRO1a.
Reference numeral 818a is a comperator for confirming 10 whether the first laser diode is emitting light, and to the side input there is impressed the output voltage of the operational amplifier 801a. To the + side input there is impressed a voltage that is divided by resistors R16a and R17a. Accordingly, when the first laser diode 812a emits light and its output becomes greater than the voltage that is divided by the resistors R16a and R17a, the output level of the comparator 818a changes from HIGH level to LOW level, and a first laser ready signal LRDY10 is output.
Further, to the - side input terminal of the comparator 802a there is impressed a setting voltage for laser light quantity. The setting voltage used is the output of a voltage follower 819. To the + input terminal of the voltage follower 819 is input a voltage that is divided by an exposure adjusting volume 821 and a resistor R31 so that it is possible to vary the output voltage of the voltage follower 819 by varying the exposure adjusting volume 821.
Next, the operation of a first laser modulation circuit 514 and a first laser diode 512 will be described. First, when the first laser diode enable signal LDON10 becomes LOW level, a bias current flows in the first laser diode 812a. Next, when the first sample signal SAMP10 becomes LOW level, the output of a voltage follower 806a becomes 0 V and a modulating transistor 809a is not turned on, since the analog switches 804a and 805a are turned on but the capacitor CO1a is not charged. Consequently, there is flowing a current in the first laser diode 812a to an extent in which it will not radiate. At this time, there is no current in the first photodiode 811a so that the output of the comparator 802a is on LOW level and the transistor 803a is turned off, and hence, the capacitor CO1a is charged through resistors R18a and R19a. The time constants of the resistors R18a and R19a and the capacitor CO1a for the charging are chosen in the range of 20 to 50 msec.
If the values of the time constants are too small, response of the stabilizing circuit is too fast and the variations in the light output level of the laser become large. On the contrary, if they are too large, the response becomes poor and it takes long time before the light output becomes stabilized. Due to charging of the capacitor CO1a, the output voltage of the voltage follower 806a is raised gradually. Accordingly, a collector current begins to flow in response to the rise in the base voltage of the laser modulating transistor 809a.
In the first laser diode 812a there flows a resultant of the bias current from the transistor 810a and the collector current from the transistor 809a, and when the resultant current exceeds the threshold current for the first laser diode 812a, the first laser diode 812a emits light. Through the emission from the first laser diode 812a, a current flows in the first photodiode 811a for monitoring, the voltage of the + input terminal of the operational amplifier is raised, and the amplifier outputs a voltage which is an amplification of the input voltage. When the output voltage of the operational amplifier 801a becomes greater than the voltage divided by the resistors R16a and R17a, the output of a comparator 818a, namely, the first laser ready signal LRDY10, changes from HIGH level to LOW level. When the output voltage of the operational amplifier 801a exceeds the voltage at the input terminal of the comparator 802a, namely, the set voltage for the first laser light quantity, the output of the comparator 802a changes from LOW level to HIGH level, the transistor 803a is turned on, and the condenser CO1a is discharged through the resistor R19a. Accordingly, the base voltage of the modulating transistor 809a is also lowered and the light output of the first laser diode is lowered. When the light output of the first laser diode is lowered, the voltage of the + input terminal of the comparator 802a also becomes lower than the set voltage for the light quantity of the first laser, so that the transistor 803a is turned off again and the capacitor CO1a is charged again through the resistors R18a and R19a. In this manner, when the light output of the first laser diode 812a reaches the set voltage at the - terminal for light quantity of the first laser, the comparator 802a thereafter repeats gradually ON and OFF in the neighborhood of the set voltage for light quantity of the first laser, and the light output of the first laser diode 812a is stabilized.
When the CPU 501 confirms via the I/O port that the first laser ready signal LRDY10 becames LOW level, the sample timer that will be described later is started to operate, the first sample signal SAMP10 is kept on LOW level for a fixed length of time in the region outside of printing for each line, to stabilize the laser light quantity by turning on the analog switches 804a and 807a.
Next, when the dichromatic LBP 199 becomes in the printable state and the first video data signal VDAT10 is sent out from the host system 500, the analog switches 807a and 808a repeat ON and OFF in response to the first video data signal VDAT10, the first laser diode 812a is modulated by the modulating transistor 809a, and writes a dot image data on the photosensitive body 200.
In the above, the first laser modulation circuit 514 and the first semiconductor laser 302 were described in detail. The second laser modulation circuit 521 and the second semiconductor laser 303 have similar configurations. However, to the light quantity setting voltage of the second laser diode 812b, namely, to - input terminal of the comparator 802b, is applied the output of the voltage follower 819. Hence, by varying the exposure adjustment volume 821, the output voltage of the voltage follower 819 is varied, so that the - voltages at the - input terminals of comparators 802a and 802b are varied simultaneously. Therefore, by varying the exposure volume 821, the light output of the first laser diode 812a and the light output of the second laser diode 812b can be adjusted at the same time.
FIG. 54 is a detailed circuit diagram for the beam detection circuit 517 and the beam detector 518 shown in FIG. 45. In FIG. 54, 518 is a beam detector for which use is made of a PIN diode with very fast response. The beam detector 518 serves also as a reference pulse in writing printing data in the photosensitive body 200 so that the generating position of the pulse has to be kept stable all the time.
The anode side of the beam detector 518 is connected to the - side input terminal of a high speed comparator 825 via load resistor R41 and a resistor R44. Further, to a resistor R43 there is connected in parallel a capacitor C10 for noise removal. In addition, R46 is a resistor for positive feedback to provide the hysteresis characteristic and C11 is a capacitor for feedback to improve the output waveform by producing a fast feedback.
Next, the operation of the beam detector 518 and the comparator 825 will be described. When a laser beam passes the beam detector 518 at high speed, there flows a pulsed current in the beam detector 518, generating a positive pulsed voltage at the - input terminal of the comparator 825. The pulsed voltage is compared with the voltage at the + input terminal, and a negative pulse HSYO is output from the comparator 825.
FIG. 55 is a diagram which shows the range of one scanning of taser beam on the photosensitive body 200, and the positional relationship between beam detection position, data write position, and so on within the range.
In FIG. 55, 900 is a beam scan starting point, and 901 is a beam scan end point, and a beam which arrived the beam scan end point 901 starts the next cycle of beam scan from the beam scan starting point 900 by the next surface of the polygonal mirror, with time zero. Reference numeral 902 is a beam detection starting point of the beam detector 518, 903 is the left side-surface of the photosensitive body, and 910 is its right side-surface. Reference numeral 904 is the left end surface of the paper, 909 is the right end surface of the paper size A3, and 907 is the right end surface of the paper size A6. Reference numeral 905 is the data write starting point, 908 is the data write end point of the paper size A3, and 906 is the data write end point of the paper size A6.
Reference symbol d2 is the distance from the beam detection starting point 902 to the write starting point, d3 is the distance from the beam detection starting point to the write end point for A6 size, and d4 is the corresponding distance for A3 size. Further, dl is the range of one scan of the beam.
The distances d5 and d6 are effective printing ranges for sizes A6 and A3. As may be seen from the figure, the papers for the present printer is fed always with the left end surface as the reference so that the distance the beam detection starting point 902 to the print starting point 905 is the same for papers of all sizes. Therefore, data writing needs be started after elapse of time that corresponds to the distance between the point the beam detector detected the beam and the write starting point. FIG. 56 shows the entire sizes of papers and their printing areas, not only their horizontal dimensions as shown in FIG. 55.
In FIG. 56, 917 and 918 represent A6 paper and A3 paper, respectively. Reference numerals 904, 905, 906, 907, 908, and 909 are the same positions as shown in FIG. 55.
Reference numeral 911 is the front end of the paper, 913 is the data write starting point in the vertical direction of the paper, 912 is the rear end of an A3 size paper, and 916 is represents the data write end point for an A3 size paper. Reference numeral 915 is the rear end of an A6 size paper and 914 represents the data write end point for an A6 size paper.
FIG. 57 is a detailed circuit diagram for the printing data write control circuit 513 in FIG. 45. The principal functions of the printing data write control circuit 513 includes to send two printing data to the laser modulation circuits 514 and 521 in order to write them in predetermined areas on the photosensitive body 200 in response to the size of the paper to be printed. In addition, it sends necessary signals to the laser light output stabilizing circuits of the laser modulation circuits 514 and 521. Further, it sends timing signals necessary for sending of printing data to the host system 500.
In FIG. 57, 830 is an I/O port which carries out sending and receipt of signals necessary for control of the laser modulation circuits 514 and 521 and the printing data write control circuit 513. Reference numeral 831 consists of counter/timer which carry out control of printing data write control, laser light output sampling, and so forth, and the setting of the operational mode and the setting of the pre-set values for the counter/timer can be done programmably in the CPU 501.
Reference numeral 865 is a laser light output sampling timer, and to its gate input G6 there is input a beam detection signal HSYO which is the output of a beam detection circuit 517. The timer is started when the beam detection signal HSYO is shifted from LOW level to HIGH level, and the completion of the timer operation is arranged to coincide with the completion of the operation of the beam detector 518 to be ready to the next detection operation.
Consequently, every time when a beam detection signal HSYO is input to the input G6, the timer 865 is activated. To the clock input CK6 of the timer 865, there is input a clock of 1500 kHz. The output SMPTO of the timer 865 is input to one input of a 2 OR gate 877 whose output is sent via two 2 NAND gates 886 and 887 to the first laser modulation circuit 514 and the second laser modulation circuit 517 as first sample signal SAMP10 and second sample signal SAMP20, respectively. The other input of the 2 NAND gate 886 receives the first laser diode enable signal LDON21 which is output from the I/O port 830 so that it is possible to forbid independently the first sample signal SAMP10 and the second sample signal SAMP20. Further, to the other input of the 2 0R gate 877, there is input the laser test signal LDTSl output from the I/O port 830, and it is possible to set the first semiconductor laser 515 and the second semiconductor laser 516 in the forced emission state. To the I/O port 830 there are input the first laser ready signal LRDY10 and the second laser ready signal LRDY20 so that by judging the forced emission state of each of the first and the second ready signal it is possible to confirm whether or not each laser is emitting.
Reference numeral 866 is a D-type F/F which generates a line start signal LSTl, and it is set by a beam detection signal HSYO and is reset by the rising of a sample timer output SMPTO. Reference numeral 867 is a D-type F/F which generates a beam detection ready signal LDOTl is input to the I/O port 830. The D-type F/F's 866 and 867 can also be reset by the output of the 2 OR gate 869. The inputs to the 2 0R gate 869 are the first and the second laser diode enable signals.
Reference numeral 832 is a crystal oscillator with oscillation frequency of about 1 Hz which generates reference clocks for image clock pulses. Reference numerals 834 and 835 are J-F/F which form quartervary counter and generate a first video clock VCKX21 (about 8 MHz) that corresponds to the minimum modulation unit, one dot, of the laser beam, by dividing the output of the crystal oscillator 832 into four.
Reference numerals 837 and 838 are J-F/F similar to 834 and 835, and forms a quarternary counte. To the J-K input of the J-K F/F 837 there is input the carry out CO of an n-bit binary counter 845 via an inverter 846. The Q outputs of the J-K F/F 834, 835, 837, and 838 carry out toggle operation synchronized with the clock input CK when the J-K inputs are on HIGH level, and discontinue the toggle operation when the J-K inputs are on LOW level. As a result, the second video clock signal VCKY21 which is the output of the last stage J-K F/F 838 becomes, when the pulse separation in the ordinary operation is called "1", during the time of generation of carry out signal CO of the n-bit binary counter 845, "11/4", prolonged by a quarter clock. The preset inputs D 0 to D n are connected to the outputs Q 0 to Q n of the n-bit latch 847, and their set values can be given values that correspond to DIP-OW or the like of the CPU 501. These set values are for setting the carry out numbers of the n-bit binary counter 845 during one line (that is, during the time when LST1 is on HIGH level), and eventually set the clock generation number of "11/4". An inverter 839, a shift register 840, 2 NOR gates 841 and 842 are circuits for giving a predetermined operation to the n-bit binary counter 845.
The second video clock signal VCKY21 is used for correcting the difference between the scan length 1 and 2 of the two laser beams shown in FIG. 39 (B). For that purpose, one needs only to designate the first video clock signal VCKX21 to the longer scan length 1 of the laser beam and the second video clock signal VCKY21 to the shorter laser beam 2. Reference numeral 848 is a selector to carry out the designation with the output CHGCK of the I/O port 830.
Next, the correction method will be described by making reference to an example. For instance, if the laser beam with longer scan length is 200 mm and the laser length 2 with shorter scan length is 199 mm, the difference in the scan length is 1 mm. If the resolving power is 12 lines per 1 mm, 12 sot clocks of the video clock signal VCKY 21 for laser beam 2 with shorter scan length need be prolonged per 2,400 dot clocks (200×12). In this case, correction of 1/4 dot clock has to be carried out for a number of 12×4=48 times for 2,400 dots since 1/4 dot clock is prolonged in one correction.
Accordingly, in the n-bit binary counter 845 for which the clock input CP is 1/4 dot clock, 48 carry outs need be output during clock counts of 9,600 (namely, 2,400×4). In other words, it needs be preset so as to generate one carry for every 200 counts.
Reference numeral 836 is a binary counter whose Q2 output HCT31 outputs an 8-dot clock (about 1 MHz) which is obtained by dividing the first video clock VCKX21 into eight parts. Reference numeral 863 is a left margin counter which sets the data write starting point based on the beam scan starting point. Reference numeral 864 is a right margin counter which sets the data write end point based on the beam scan starting point. To the gate input G4 of the left margin counter 863 and the gate input G5 of the right margin counter 864 there is input the line start signal LST1, and to the clock input CK4 of the left margin counter 863 and the clock input CK5 of the right margin counter 864 there is input the 8-dot clock HCT31. Both counter with a single counter for each can give corrections for the variations in the data write starting point and the data write end point due to mechanical errors in attaching the beam detector 518, simultaneously for the two laser beams. The reason for giving corrections to the errors are that both deviations in the 8 -dot clock unit position and the data write end position remain in the tolerable range provided that the setting for both counter is changed in response to DIP-SW or the like, and that adjustment of the errors beyond the above value can be carried out easily. The set value for the right margin counter is varied for different size of the paper.
Reference numeral 875 is a 2 AND gate to whose one input receives the output LMCTO of the left margin counter 863 and the other input receives the output RMCTO of the right margin counter 864 via an inverter 874, so that the output of the 2 AND gate 875 represents the horizontal printing region.
The output of the 2 AND gate 875 is shifted for 4 dot portion by a shift register 868 whose Q output provides a horizontal printing region signal HPEN 1.
The horizontal printing region signal HPEN 1 is input to the CE input of an n-bit binary counter 850 and to the shift register 854. The n-bit binary counter 850, a 2 NAND gate 849, an n-bit latch, and a J-K F/F 852 has a configuration which can shift the data write starting point by one dot unit, and the output of the J-K F/F 852 outputs a horizontal printing region signal HPENB 1. The preset inputs Do to Dn of the n-bit binary counter 850 that are connected to the outputs of the n-bit latch 851, sets the number of shifts to the right, and the set value can be set by CPU 501 to values in response to DIP-SW or the like. The shift registers 854 and 855, inverter 853 form a circuit which shifts the horizontal printing region signal HPEN 1 by 2 dot clocks to the right, and the output of the shift register 855 outputs a second horizontal region signal HPENA 1. This is arranged in this manner because the first horizontal printing region signal HPENB 1 is shifted to the right by 2 dot clocks even for a minimum setting value.
The output of an AND gate 857 is a first video clock signal VCLKB which shows the video clock signal for the first horizontal region. One of the inputs to the AND gate 857 is the first horizontal region signal HPENB 1, and the other input is the Y1 output of the selector 848. Further, the output of an AND gate 856 is the second video clock signal VCLKA 1 that shows the video clock signal for the portion of the second printing region, and one of the inputs to the AND gate 856 is the second horizontal printing region signal HPENA 1 and the other is the Y2 output of the selector 848.
As described in the above, a signal that can adjust the data write starting point in the unit of 1 dot, the first horizontal region signal HPENB 1, and the first video clock signal VCLKB 1 are used for correcting the error in the scan starting point of two laser beams as shown in FIG. 39(A). In this case, the error may be adjusted by designating the second horizontal printing region signal HPENA 1 and the second video clock signal VCLKA 1 to a laser beam S2 whose scan starting point comes earlier and by designating the first horizontal printing region signal HPENB 1 and the first video clock signal VCLKB 1 for a laser beam S1 whose scan starting point comes later.
A selector 858 is the selector for carrying out the above designation which is carried out by the output CHG 12 of the I/O port 830.
Reference numerals 859 to 862 are counters for setting the data write starting point and the data write end point for the vertical direction (direction of motion of the paper), where 859 is a first page top counter for setting the data write starting point for the first color, 860 is a first page end counter for setting data write end point for the first color, 861 is a second page top counter for setting data write starting power for the second color, and 862 is a second page end counter for setting data write end point for the second color.
The gate inputs Go to G3 for the counters 859 to 862 are connected to a page top signal PTOP 1 which is an output of the I/O port and is activated by VSYNC command.
The clock inputs CK0 to CK3 of the counters 859 to 862 are connected to the line start signal LST 1, and as a result, it becomes possible to count with one line of scan as the unit (one dot as the unit). The method of setting each counter will be described later.
Reference numeral 871 is a 2 AND gate whose one input is the output PTCT 10 of the first page top counter 859 and the other input is the output PECT 10 of the first page end counter 860 via an inverter 870. Accordingly, the output of the 2 AND gate 871 becomes a vertical printing region signal VPEN 11 for the first color.
Reference numeral 873 is a 2 AND gate whose one input the output PTCT 20 of the second page top counter 861 and the other input is the output PECT 20 of the second page end counter which is input via an inverter 872. Accordingly, the output of the 2 AND gate 873 represents a vertical printing region signal VPEN 21 for the second color.
The output PECT 10 of first page end counter and the output PECT 20 of the second page end counter are input to the 1/0 port 830, and after the completion of each counting operation send a first page end signal IPEND 10 and a second page end signal IPEND 20 to the host system 500.
Reference numerals 878 and 879 are 2 NND gates that send a horizontal synchronized signal IHSYN 10 for the first color and a horizontal synchronized signal IHSYN 20 for the second color, respectively, to the host system 500.
Reference numerals 887 and 881 are 2 NAND gates that send a video clock signal IVCLK 10 for the first color and a video clock signal IVCLK 20 for the second color, respectively, to the host system 500.
Reference numeral 884 is a 3 NAND gate which sends a video data signal IVDT 10 for the first color from the host system 500 to the first laser modulation circuit 514 as a first video data signal VDAT 10.
Reference numeral 885 is a 3 NAND gate which sends a video data signal IVDT 20 for the second color from the host system 500, to the second laser modulation circuit 521 as a second video data signal VDAT 20.
Reference numeral 888 is an inverter which sends a first laser diode enable signal LDON 10 to the first laser modulation, and 889 is an inverter which sends a second laser diode enable signal LDON 20 to the second laser modulation circuit 521.
A timing chart for the principal signals for a portion of one page and for one line in the dichromatic printing mode are shown in FIG. 58 and FIG. 59, respectively.
Next, the operation of each component which is activated in response to control command issued from the control section of the dichromatic LBP 199 will be described in detail by making reference to the flow charts shown in FIG. 63 to FIG. 72.
FIG. 63 to FIG. 67 are flow charts that illustrate the overall operation of the dichromatic LBP.
In FIG. 63 are shown a self-diagnosis and warm-up processings for the dichromatic LBP.
In FIG. 63, when the operator closes a power supply 520, the system program housed in the ROM 502 is started, first the self-diagnostic processing of steps A101 to A104 are executed, and when the door switch is ON (negation of step A101), it goes to door opening processing (step A105), and becomes jam processing (step A106) through paper ejection switch ON, manual stop switch ON, and bus sensor ON.
Then, if it is not in the test print mode nor in the maintenance mode (negation of step A107 and negation of step A108), the heater lamp, which heats the fixing unit 221 that takes a relatively long time before the apparatus becomes ready, is turned on (step A111) to start warm-up processing. Next, the motor and the scan motor 512 of the fixing unit 221 is turned on (step A112). Here, if it is in the test print mode (affirmation of step A107), the test print processing is given (step A109), and if it is further in the maintenance mode, the maintenance processing is carried out (step A110).
When the scan motor 512 becomes in the ready state by being turned on (affirmation of step A113), the blade solenoid is turned on (step A114). Further, if the scan motor 512 does not become ready state even after 30 seconds from the turning-on of the motor (negation of step A113 and affirmation of step A115), the failure processing of the scan motor 512 is executed (step A116).
After a subsequent delay processing (step A117), each of the drum motor of the photosensitive body 200, the motor 425 for the developing units, the clatch for the first driving unit 203, the clatch for the second developing unit 206, and the lamp of the discharger 211 is turned on (step A118), and after a delay processing (step A119), each of the first laser unit 321, the second laser unit 322, the laser test device, the pre-transfer charger 208 is turned on (step A120).
After an ensuing delay processing (step A121), failure is checked of the first laser unit 321 and the second laser unit 322 by the use of the monitors (steps A122 and A123), and if they are found to be normal (affirmation of step A122 and affirmation of step A123), it is checked with the horizontal synchronized signals HSYNC whether their beam detection is ready or not (step A126). Further, if the first laser unit 321 has a failure (negation of step A122), a failure processing for the first laser (step A124) is carried out, and if the second laser unit 322 is in failure negation of (step A123), a failure processing for the second laser (step A125) is carried out. In addition, if beam is not detected with a horizontal synchronized signal HSYNC (negation of step A126), there is carried out a beam detection failure processing (step A127).
After an ensuing delay processing (step A129), the stripping charger 209 is turned on (step A130), a potential control during warm-up such as shown in FIG. 70, via a delay processing (step A131) is carried out (step A132). Here, step A132 is a processing for preparing the apparatus as soon as possible for the first printing.
After an ensuing delay processing (step A133), it proceeds to the processings of step A134 to step A140. Namely, in step A134, each of the pre-transfer charger 207, the transfer charger, and the stripping charger 209 are turned off. In step A136, the motor 425 for the developing units, the clatch of the first developing unit 203, the clatch of the second developing unit 206, the first charging unit 201, and the second charging unit 204 are turned off. in step A136, the motor 425 for the developing units, the clatch for the first developing unit 203, the clatch for the second developing unit 206, the first charger 201, and the second charger 204 are turned off. In step A138, the drum motor of the photosensitive body 200, the discharger 211, the first laser unit 321, the second laser unit 322, and the motor for the fixing unit 222 are turned off. In step A140, the blade solenoid is turned off. Further, the steps A134 to A140 may be carried out at the same time en bloc. However, from the viewpoint of avoiding to have steps of potential in one sheet of transfer paper, delay processings are provided in steps A135, A137, and A139.
Thereafter, with the fixing unit 221 in ready state (affirmation of step A141), each step of the self-diagnosis and warm-up are completed, and it proceeds to the routine shown in FIG. 64.
In FIG. 64, there are shown processings of reporting the condition of each part of the dichromatic LBP 199 to the host system, and outputting the print request when there are received normal judgment about the condition of each parts from the host system 500.
In FIG. 64, judgment is obtained first from the host system about the contents of status 5 read from the table housed in the ROM 503 (steps A142 to A145). Namely, in step A142, whether or not the toner bag is to be exchanged is judged. If it is necessary to be exchanged (affirmation of step A142), after waiting for the exchange of the toner bag (step A146), and after completion of exchange (affirmation of step A146, and step A147), it proceeds to step A143. In step A143, whether there exists a no toner state of the first color is judged by ON/OFF of the empty step of the first developing unit 203. If there is no first color toner (affirmation of step A143), whether or not it is in the second color mode is checked by status 1 (step A148), and if it is in the first color mode and in the two color mode (negation of step A148), and proceeds to step A144 after completion of refilling of the first color toner of the first developing unit (affirmation of step A149 and step A150). In step A144, whether or not the second color toner is in empty state is judged by the ON/OFF of the empty switch of the second developing unit 206. If there is no second color toner (affirmation of step A144), whether or not it is in the first color mode is checked by status 1 (step A151), and if it is in the second color mode and two-color printing mode (negation of step A151), it proceeds to step A145 with the completion of refilling of the second color toner for the second developing unit (affirmation of step A152, and step A153). If it is in the first color mode (affirmation of step A151), it proceeds to step A145 by skipping steps A152 and A153.
In this way, a command acceptance approval is issued (step A145) from the host system 500 if there exist no abnormality in the conditions of the toners of the first developing unit 203 and the second developing unit 206.
Because of the above, if there is a command which indicates the first color printing mode (affirmation of step A154), the first color mode is set for status 1 (step A 157), and if there is a command which indicates the second color printing mode (affirmation of step A155), the second color mode is set in status 1 (step A158).
Further, if there is a command which indicates the two-color printing mode (affirmation of step A156), the two-color mode is set in status 1 (step A159).
Then, when in the ensuing step A160, a processing is carried out which turns on IPRDY and IPRE, there is carried out a processing which judges whether or not IPRNT is in the on-state. If it remains in off-state (negation of step A161), it goes back to step A142, and if it is in on-state (affirmation of step A161), completes the acceptance of a print request (step A162), and it proceeds to the printing
In FIG. 65, processings similar to the routine warm-up processings are executed in step A163 to step A174.
In the ensuing step A177, whether or not it is in the second color mode is checked by status 1. If it is not in the second color mode (negation of step A177), the clatch of the first developing unit 203 is turned on to drive the second developing unit 203 (step 178), and then it proceeds to step A179. If it is in step second color mode (affirmation of step A177), it proceeds to step A179 by shipping step A178.
In step A179, whether or not it is in the first color mode is checked by status 1. If it is not in the first color mode (negation of step A179), the clatch of the second developing unit 206 is turned on to drive the second developing unit 206 (step A180), and proceeds to step A181. If it is in the second color mode, it proceeds to step A181 by shipping step A180.
In step 181, the bias table data about the toner color of the first developing unit 203 is read, and in the ensuing step A181, the bias table data read is set in the D/A converter 578. In the next step A183, the bias table data about the toner color of the second developing unit 206 is read, and in the ensuing step A184, the bias table data that is read is set in the D/A converter 584.
After an ensuing delay processing (step A185), a potential control before a first printing as shown in FIG. 70 is carried out (step A186).
In an ensuing step A187, whether or not it is in the second color mode is checked by status 1. If it is not in the second color mode (negation of step A187), the development bias 409 of the first developing unit 203 is turned on (step A18) before proceeding to step A190. If it is in the second color mode (affirmation of step A187), it proceeds to step A190 by skipping step A188, and at the same time, a control on the potential by second charging as shown in FIG. 71 and FIG. 72 is carried out (step A189).
In step A191 that follows a delay processing of step 190, whether or not it is in the first color mode is checked by status 2. If it is in the second color mode (negation of step A191), the development bias 409 of the second developing unit is turned on (step A192) and proceeds to step A194. If it is in the first color mode (affirmation of step A191), it proceeds to step A194 by skipping step A192, and at the same time, a control on the potential by the first charging as shown in FIG. 71 and FIG. 72 is carried out (step A193).
In step A194, whether the paper feeding cassette is in the top or in the bottom is judged by status 1. When it is judged to be the top one, the paper feeding motor is driven to be rotated in the forward direction to feed a paper in the top cassette (step A195) to proceed to step A199, and at the same time, the paper feeding motor is turned off (step A109) after a delay processing of step A208. On the hand, if it is judged to be the bottom one, skips step A195, and after a delay processing (step A196), the paper feeding motor is rotated in the reverse direction to feed a paper in the bottom cassette (step A197) before proceeding to step A199, and at the same time, after a delay processing of step A208 it turns off the paper feeding motor (step A209).
In step A199, whether or not it is in the second color mode is confirmed by status 1. If it is in the first color mode (negation of step A199), it proceeds to step A202 after a delay processing of step A200, and if it is in the second color mode (affirmation of step A199), it proceeds to step A202 after a delay processing of step A201.
In step A202, it confirms that beam detection is ready by a horizontal synchronized signal HSYNC before proceeding to step A204. If on the other hand beam detection is not ready (negation of step A202), it carries out a beam detection failure processing.
In step A204, the page top counter, page end counter,
margin counter, right margin counter, and a two-beam scan length correction value are set.
In the ensuing step A205, a vertical synchronized signal VSYNC request of status 1 is set. At the same time, it waits for a scan command by a vertical synchronized signal VSYNC (step A206), and when there is issued a command (affirmation of step A206), a vertical synchronized signal request of status 1 is reset (step A207).
In an ensuing step A210 of FIG. 66, counting by the top/bottom counter is started to write an image. Following that, whether or not it is in the dichromatic printing mode is confirmed by status 1 (step A211). If it is in the first color mode or in the second color mode (negation of step A211), it proceeds to step A213, and if it is in the dichromatic mode (affirmation of step A211), it proceeds to step A213 as well as repeats the control on the potential by the first charging as shown in FIG. 71 and FIG. 72 for five times (step A212).
In the ensuing step A213, whether or not it is in the second color mode is confirmed by status 1. If it is not in the second color mode (negation of step A213), after a delay processing of step A214 it proceeds to step A216, and if it is in the second color mode (affirmation of step A213), after a delay processing of step A215 it proceeds to step A216.
When in step A216 the resist motor is turned on and the total counter is turned on, after a delay processing (step A217) it proceeds to step A221 by turning off the total counter, and at the same time, after a delay for the portion of the paper size (step A219) the resist motor is turned off (step A220).
In step A221, it is confirmed again whether or not it is in the second color mode. If it is not in the second color mode (negation of step A221), the first color image writing is completed when the first page end is detected (affirmation of step A222) and an IPEND 1 pulse is output (step A223).
In this case, if status 1 is the first color mode (affirmation of step A224), with the first color toner in the first developing unit 203 (negation of step A231), when there is an indication command for the first color printing mode affirmation of step A247) after judgment by step A238→step A239→step A246, the development bias 409, and its clatch, of the second developing unit 206 are turned off (step A244), the second developing unit 204 is turned off (step A245a) by an interruption of the charged potential control of the second developing unit 204, the first color mode of status 1 is set (step 245b), and a print request IPREQ is turned on (step A248), as shown in FIG. 67.
Here, if there is no first color toner in the first developing unit 203 (affirmation of step A231), and further, there is no second color toner in the second developing unit 206 (affirmation of step A232), the print ready signal IPRDY is turned off (step A252) as shown in FIG. 67.
Further, even if there is no first color toner in the first developing unit 203 (affirmation of step A231), when there is the second color toner in the second developing unit 206 (negation of step A232) and both of the first color and the second color have the same color (affirmation of step A233), the development bias 400 of the first developing unit 203 and its clatch are turned off (step A235) at the time when there is issued an indication command for the second color printing mode (affirmation of step A234. Then, the first charger 201 is turned off by an interruption of the control on charged potential of the first charger 201 (step A236), the second color mode of status is set (step A237), and through negation of step A246 and a following step A247, a print request IPREQ is turned on (step A248).
In contrast to the above, with status 1 being the first color mode in step A224 and the second color toner in the second developing unit 206 (affirmation of step A238), if there is an indication command for the second color printing mode (affirmation of step A239), the development bias of the first developing unit 203 and its clatch are turned off (step A235), the first charging unit 201 is turned off by an interruption of the control on the charged potential of the first charger 201 (step A236), the second color mode of status 1 is set (step A237), and through the judgments of step A246 and step A247 or a judgment of step A246, a print request IPREQ is turned on (step A248).
On the other hand, when it is judged that it is second color mode, in step A221 and step A224, the second color image write is completed with the detection of the second page end (affirmation of step A225), and a IPEND 2 pulse is output (step A226).
In this case, even if status 1 is no second color toner (affirmation of step A240), when the first color is in the first developing unit 203 (negation of step A241) and both of the first color and the second color are the same color (affirmation of step A243), the development bias of the second developing unit 206 and its clatch are turned off (step A244) at the time when an indication command for the first color printing mode is issued (affirmation of step A243) and the second charger 204 is turned off by an interruption of control on the charged potential of the second charger 204 (step A245). After a first color mode of status 1 is set (step A245a), a print request IPREQ is turned on as shown in FIG. 67 (step A248).
Further, in step A227 if status is other than the second color mode, whether or not "no first color toner" is judged by status 5 (step A228), and whether or not "no second color toner" is judged by status 5 (step A229). Then, if there is no toner in both of step A228 and step A229, the print ready IPRDY is turned off (step A252).
In addition, if there are toners of the first color and the second color exist (negation of step A228 and negation of step A229), it proceeds to step A248. At the same time, control on the potential by second charge is carried out twice as shown in FIG. 71 and FIG. 72 (step A230).
Moreover, by deleting the judgments of step A233 and step A242 from the routine of step A221 through step A248, it is possible to carry out continuous development by switching development even when the toners of the first developing unit 203 and the second developing unit 206 are not the same color.
In FIG. 67, after the processing of turning on a print request IPREQ in step A248, a judgment processing is carried out by waiting 5 seconds from turning-on of the print request IPREQ (steps A249 and A250). If there is the print request IPREQ (affirmation of step A249), the print request IPREQ is turned off (step A251) to judge whether or not the printing mode is changed (step A266).
If the printing mode is changed (affirmation of step A266), it returns to step A177, and the first developing unit 203 or the second developing unit 206 is brought to the developable state, by watching satus 1 and status 2 between step A177 and step A194.
If the printing mode is not changed (negation of step A266), it returns to step A194, and the processings between step A177 through step A194 are omitted.
However, in the case of either printing mode, processings are carried out for both cases without having the processing of step AlOl through step A174, so that the recording operation can be continued without temporarily interrupting the dichromatic LBP 199.
In contrast, when the judgment processing of waiting the print request IPREQ for 5 minutes (step A249 and A250), if 5 seconds elapsed (affirmation of step A250), after an interruption processing of step A253 to step A265, it goes back to step A101 and goes into the waiting state which is waiting for a command from the host system 500.
Further, when the print ready IPREQ is turned off (step A252), the printing operation becomes unnecessary so that after the interruption processing of step A253 through step A265 it returns to step AlOl and goes into the state waiting for a command from the host system 500.
FIG. 68 and FIG. 69 are flow charts that show step A204 shown in FIG. 65.
The subroutine shown in FIG. 68 and FIG. 69 can be classified into a top margin coarse adjustment setting processing of step B101 to step B107, a top margin fine adjustment setting processing of step B114 to step B119, a bottom margin fine adjustment setting processing of step B120 to step B123, a left margin coarse adjustment setting processing of step B124 to step B128, a right margin coarse adjustment setting processing of step B129 to step B131, a right margin fine adjustment setting processing of step B132 to step B136, and a two-beam scan length correction setting processing of step B137 to step B141, and their details are as shown in the figures.
FIG. 70 is a flow chart which shows the potential control during warm-up and the potential control before first print.
In the potential control during warm-up, the value CHDT1 of the first time controlled output by first charging is read from the table data (step C101), and set the value that is read in the D/A converter 576 (step C102). Further, the value (CHDT2) of the first time controlled output by second charging is read from the table data (step C103), and the value that is read is set in the D/A converter 582 (step C104).
When the first charger is turned on in the ensuring step C105, a control on the potential by first charging is carried out (step C106) as shown in FIG. 71 and FIG. 72. After an ensuing delay processing (step C107), a control on the potential by second charging is carried out (step C109).
.Then, the number of times of the potential control, n, is incremented (step C110), and the steps from C105 to Clll are repeated until the number n of the potential control reaches three. When the control is repeated for three times, the first charger 201 and the second charger 204 are turned off (step 112), the potential control in warm-up is completed.
For the potential control before first print, if status 1 is not the second color mode (negation of step 101), the first charger 201 is turned on (step D102) to carry out the first charge potential control (step D103), as shown in FIG. 71 and FIG. 72. If it is the first color mode only (affirmation of step D104), the pre-first-print potential control is completed.
In addition, if it is to carry out the second color mode also (negation of step D104), after a delay processing (step D105), the second charger is turned on to carry out a second charged potential control (step D107) as shown in FIG. 71 and FIG. 72, completing the pre-first-print potential control.
Moreover, if status 1 is the second color mode in the initial step D101, the second color mode alone is executed so that the second charger 204 is turned on (step D106) to carry out a second charged potential control (step D107) as shown by FIG. 71 and FIG. 72, completing the pre-first-print potential control.
FIG. 71 and FIG. 72 are flow charts that show details of the charged potential control processing.
In the subroutine shown in FIG. 71 and FIG. 72, first, the drum temperature detector 570 is selected by the A/D converter (step E101), and when temperature measurement of the photosensitive body 200 is carried out (step E102), either of the first charged potential control or the second charged potential control is selected (step E103), and based on the data table of the ROM 503, processings in step E104 through step E109 are executed in the case of the first charged potential control, and processings of step E113 through step E118 are executed in the case of the second charged potential control.
Then, in step E110 and step E119, the first target surface potential data (VOS 1) and the second target surface potential data (VOS 2) are corrected so as to correspond to the actual temperature of the photosensitive body 200, to obtain the corresponding correction data VOS 1' and VOS 2', respectively.
In the ensuing steps Elll and step E120, operational processings as shown are carried out in order to store the values obtained in step E104 through step E110 and the values obtained in step E113 through step E119, respectively, in a common register.
In the next step E112 and step E121, the first potential sensor 202 and the second potential sensor 205, respectively, are selected by the A/D converter 593.
Next, for both cases of the first charged potential control and the second charged potential control, processings that follow step E 122 are carried out.
First, a delay processings for the times corresponding to the path length between the first and second chargers 201, 204 and the first and second surface potential sensors 202, 205, are carried out to measure the surface potential Vs from the first and second surface potential sensors 202 and 205 (steps E122 and E123).
In the following steps, processings are carried out based on the data obtained in step Elll and step E120.
Namely, in step E124, self-diagnosis is carried out to see whether the read value is greater than Va in accordance with the formula
VS≧=Vos+Vomax
If it is greater (affirmation of step E124), a processing for potential control error is carried out (step E125). If it is smaller (negation of step E124), it proceeds to step E126.
In step E126, it is judged whether or not the read value is in coincidence with the target value and the control width of the error table according to the formula
Vs=Vos±Voz
If they do not coincide (negation of step E126), how far the read data is away from the target data, for example, 200 V, 100 V, and 50 V, is examined (steps E127, E128, and E129). Then, processings of setting the control value to be equal to X1 or X2, 2 times, 4 times, or 6 times (steps E130, E131, E132, and E133).
After these settings, it proceeds to step E134 to set the charged output. In the ensuing step E135, whether or not the charged output is greater than its maximum value is checked, and in the next step E136 whether or not the charged output is smaller than its minimum value is checked. If it is greater or smaller (affirmation of step E 135 or affirmation of step E136), there is carried out a potential control error processing (step E137).
Then, if the charged output is within the control width (negation of step E135 and negation of step E136) it proceeds to step E138 where it is judged which of the first charger 201 or the second charger 204 the actual object of the potential control is.
If the result of judgment is the first charger 201, after setting
CH.sub.DT1Y =CH.sub.DT
(step E139), a processing of setting CH DT1 in the D/A converter 576 is carried out before proceeding to step E145.
If the result of the judgment is the second charger 204, after setting
CH.sub.DT2Y =CH.sub.DT
(step E141), a processing of setting CH DT2 in the D/A converter 582 is carried out before proceeding to step E145.
In step E145, the number of times of the charged potential control is incremented, and proceeds to the routine of step E146 and the following steps shown in FIG. 72.
Namely, if it is a pre-first-print potential control (affirmation of step E146), with the number of times of potential control, m, to be equal to 3 (affirmation of step E151), nonconvergence by the potential control is completed, whereas it goes back to step E122 when m is less than 3.
Further, if it is the potential control in warm-up (step E147), after the number of times of potential control, m, equals to (affirmation of step E151), a potential control error is carried out (step E153), whereas it goes back to step E 122 when m is less than 10.
Moreover, if status 1 is not the two-color mode (negation of step E148), it goes back to step E122. However, if status is the two-color mode (affirmation of step E148), inquiry is made to see the object of the potential control is the first charger 201 or the second charger 202. If it is the first color mode, the potential control is completed with 5 times of potential control (affirmation of step E150), whereas if it is the second color mode, the potential control is completed with 2 times of potential control (affirmation of step E154).
As in the foregoing, in an embodiment of a dichromatic LBP 199 of the present invention, as may be seen from the flow charts in FIG. 63 to FIG. 67 that show the overall operation of the dichromatic LBP, if there is an indication to request another monochromatic printing mode comes in (corresponding to affirmation of step A221) from outside (namely, a host system) or from within (CPU 501), while the printer is in the printing operation according to the monochromatic printing mode that was accepted in the past, the indication is accepted after completion of the printing operation of the monochromatic printing mode that was accepted in the past (corresponding to step A251). In addition, corresponding to the switching operation of switching means that carries out switching operation of the electrostatic latent image formation means and the development means to those that correspond to another monochromatic printing mode (corresponding to step A266), it goes back to step A177 without transiting to the interruption mode for the photosensitive body 200 and others (step A253 through step A265), and drives to rotate the photosensitive body by control means in continuation to the monochromatic printing mode that was accepted in the past. Accordingly, for instance, while it is in a continuous monochromatic recording, it is desired to print the original information in another color, or it is desired to change both of the recording information and the recording color, it is possible to continue the recording operation of the dichromatic LBP without temporarily interrupting the operation of the apparatus.
Further, the embodiment has a configuration which consists of printing mode discrimination means which discriminates between a multi-color printing mode and a monochromatic printing mode (corresponding to step A221 and step A224), selection means which selects one combination out of a plurality of image formation processes required for the printing operation, based on the printing mode discrimination means, as shown in step A221 through step A248, and a control means which controls the printing operation according to the combination of the image formation processes that is selected by the selection means.
Accordingly, if there is an indication command of a first color printing mode (negation of step A247), the development bias of the second developing unit 206 and its clatch are turned off (step A244), and the second developing unit 204 (step A245) is turned off. Then, if there is an indication command for the second color printing mode (step A239), the bias 409 of the first developing unit 203 and its clatch are turned off to turn off the first charger 201 (step A236).
Further, the development means is equipped with the means of generating toner color information corresponding to the toner color of the development means, and the means of detecting the quantity of the toner of the development means corresponding to step A231 and step A232, step 240 to step A249, and step A228 and step A229). Moreover, it has means of comparing step A233 and step A242) toner color information of unused development means with that of development means which is currently in printing operation or which is set after completion of the printing operation, when the toner detection means of the development means detected that there is no toner, switching means (corresponding to step A234 and step A243) which, when there is information about coincidence of colors as a result of comparison of the comparison means, switches the usage mode to other development means and other electrostatic latent image formation means according to an indication from the outside (host system 500 or the CPU 501) after completion of the printing operation (corresponding to step A223), and control means for printing operation which carries out a predetermined printing operation by the switching means (step A221 through step A248), so that even if the toner is used up during a continuous monochromatic recording, for example, when there is the toner in other developing unit (in the flow chart of the present embodiment, only the case of having toner of the same color is described), it is possible to continue the recording operation without carrying out toner refilling by a temporary interruption of the apparatus operation.
Furthermore, as may be clear from the routine in step A101 through step A265, the monochromatic printing mode has a shorter time for one cycle of recording than in the multi-color printing mode.
As described in the foregoing, according to a recording
.even if a second color is apparatus of the present invention, indicated during the printing operation with a first color, for example, it is possible to continue the rotational drive of the photosensitive body at the time when the printing operation with the first color is completed, so that the copying speed can always be maintained at a high level. | A recording apparatus according to the present invention in which a data is recorded by charging a driven recording medium, scanning laser beams on the driven recording medium to form electrostatic latent images thereon, and developing and transferring the electrostatic latent image, comprises a charger for charging the driven recording medium; and at least two image forming device disposed around the recording medium for recording multi-colored and/or uni-colored data in a plurality of print modes. In the recording apparatus, the print modes is controlled so as to drive the second image forming device corresponding to the second print mode after the operation of the first print mode is closed, when the second print mode is designated in the operation of the first image forming means corresponding to the first print mode. And, the driver for driving the recording medium is controlled so as to continuously drive the recording medium when the first print mode is switched to the second print mode by the switching device. The image forming device comprises device for forming an electrostatic latent image on the recording medium by scanning laser beams in accordance with the recording data and device for developing the electrostatic latent image. | 6 |
This application is a divisional application of U.S. Utility patent application Ser. No. 11/930,811 entitled “MODULAR TAPER ASSEMBLY DEVICE” which was filed on Oct. 31, 2007 by Larry G. McCleary, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD OF THE INVENTION
The present invention relates generally to the field of orthopedics, and more particularly, to an implant for use in arthroplasty.
BACKGROUND OF THE INVENTION
Patients who suffer from the pain and immobility caused by osteoarthritis and rheumatoid arthritis have an option of joint replacement surgery. Joint replacement surgery is quite common and enables many individuals to function properly when it would not be otherwise possible to do so. Artificial joints are usually comprised of metal, ceramic and/or plastic components that are fixed to existing bone.
Such joint replacement surgery is otherwise known as joint arthroplasty. Joint arthroplasty is a well-known surgical procedure by which a diseased and/or damaged joint is replaced with a prosthetic joint. In a typical total joint arthroplasty, the ends or distal portions of the bones adjacent to the joint are resected or a portion of the distal part of the bone is removed and the artificial joint is secured thereto.
There are known to exist many designs and methods for manufacturing implantable articles, such as bone prostheses. Such bone prostheses include components of artificial joints such as elbows, hips, knees and shoulders.
During performance of a joint replacement procedure, it is generally necessary to provide the surgeon with a certain degree of flexibility in the selection of a prosthesis. In particular, the anatomy of the bone into which the prosthesis is to be implanted may vary somewhat from patient to patient. Such variations may be due to, for example, the patient's age, size and gender. For example, in the case of a femoral prosthesis, the patient's femur may be relatively long or relatively short thereby requiring use of a femoral prosthesis, which includes a stem that is relatively long or short, respectively. Moreover, in certain cases, such as when use of a relatively long stem length is required, the stem must also be bowed in order to conform to the anatomy of the patient's femoral canal.
Such a need for prostheses of varying shapes and sizes thus creates a number of problems in regard to the use of a one-piece prosthesis. For example, a hospital or surgery center must maintain a relatively large inventory of prostheses in order to have the requisite mix of prostheses needed for certain situations, such as trauma situations and revision surgery. Moreover, since the bow of the stem must conform to the bow of the intramedullary canal of the patient's femur, rotational positioning of the upper portion of the prosthesis is limited thereby rendering precise location of the upper portion and hence the head of the prosthesis very difficult.
In addition, since corresponding bones of the left and right side of a patient's anatomy (e.g. left and right femur) may bow in opposite directions, it is necessary to provide (left) and (right) variations of the prosthesis in order to provide anteversion of the bone stem, thereby further increasing the inventory of prostheses which must be maintained.
As a result of these and other drawbacks, a number of modular prostheses have been designed. As its name implies, a modular prosthesis is constructed in modular form so that the individual elements or figures of the prosthesis can be selected to fit the needs of a given patient's anatomy. For example, modular prostheses have been designed which include a proximal neck component which can be assembled to any one of numerous distal stem components in order to create an assembly which fits the needs of a given patient's anatomy. Such a design allows the distal stem component to be selected and thereafter implanted in the patient's bone in a position that conforms to the patient's anatomy while also allowing for a limited degree of independent positioning of the proximal neck component relative to the patient's pelvis.
One issue that arises as a result of the use of a modular prosthesis is the locking of the components relative to one another. In particular, firm reproducible locking of the proximal neck component to the distal stem component is critical to prevent separation of the two components subsequent to implantation thereof into the patient. The need for the firm locking is particularly necessary if the design does not provide for positive locking with weight bearing. As such, a number of locking mechanisms have heretofore been designed to lock the components of a modular prosthesis to one another. For example, a number of modular prostheses have heretofore been designed to include a distal stem component, which has an upwardly extending post, which is received into a bore defined distal neck component. A relatively long fastener such as a screw or bolt is utilized to secure the post with the bore. Other methods of securing modular components include the impacting of one component onto the other. This method has highly variable results
Current designs of modular stems include designs in which the modular connection utilizes a tapered fit between the two components. For example, the proximal body may include an internal taper, which mates with an external taper on the distal stem. Such a taper connection may be used in conjunction with additional securing means, for example, a threaded connection or may be used alone. It is important that the tapered connection be secure. For example, the proper amount of force must be applied to the tapered connection to properly secure the tapered connection so that the connection can withstand the forces associated with the operation of the stem.
Current attempts to provide a device to adjoin components of a modular joint prosthesis are fraught with several problems. For example, the device may not provide sufficient mechanical advantage to securely lock the components. Further, the ergonomics available to lock the components may not be optimal. Additionally, a device relying solely on the displacement for a taper connection may not provide sufficient force as there may not be an accurate correspondence of displacement to the clamping force. Also, utilizing a displacement method may make it possible to overtighten and damage the components. Further, prior art solutions may be difficult to manufacture or expensive to make.
Once a modular prosthesis, for example, a modular hip stem prosthesis, has its relative components positioned properly, the components must be firmly secured to each other. It is possible when the components are secured together that relative motion between the components may occur causing their relative position in particular their angular orientation to be disturbed. In other words, when the first and second components of the modular hip stem are drawn together, one component may rotate about the other one causing their version or orientation to be compromised. Further, whatever device is used to angularly position the components of the modular prosthesis into the proper orientation may need to be removed and an assembly device positioned on the prosthesis to secure the components to each other. Such removal of the alignment device and installation of the assembly device adds cost and complexity to the procedure, as well as, increasing the operating room time.
There is thus a need to provide for an assembly and disassembly tool capable of alleviating at least some of the aforementioned problems.
US Patent Application Publication No. 20040122439 entitled “ADJUSTABLE BIOMECHANICAL TEMPLATING & RESECTION INSTRUMENT AND ASSOCIATED METHOD”, US Patent Application Publication No. 20040122437 entitled “ALIGNMENT DEVICE FOR MODULAR IMPLANTS AND METHOD”, US Patent Application Publication No. 20040122440 entitled “INSTRUMENT AND ASSOCIATED METHOD OF TRIALING FOR MODULAR HIP STEMS”, US Patent Application Publication No. 20040267266 published Jun. 25, 2003 entitled “MODULAR TAPERED REAMER FOR BONE PREPARATION AND ASSOCIATED METHOD”, and US Patent Application Publication No. 20040267267 published Dec. 30, 2004 entitled “NON-LINEAR REAMER FOR BONE PREPARATION AND ASSOCIATED METHOD” are hereby incorporated in their entireties by reference.
Prior attempts to provide instruments to assemble modular prostheses have had problems due to the large and bulky nature of such instruments. These large and bulky instruments are difficult for the surgeon to use and provide problems in performing minimally invasive orthopedic implant surgery. Furthermore, prior art tools provide a tool designed for only one modular prosthesis. The tool may not be suitable for prostheses with other sizes and shapes. The present invention is directed to alleviate at least some of the problems with the prior art.
SUMMARY OF THE INVENTION
According to one embodiment of the present invention, an assembly tool for assembly of a first component of a prosthesis to a second component of the prosthesis for use in joint arthroplasty is provided. The tool includes a housing for contact with the first component. The housing defines a housing longitudinal axis thereof. An internal component is also provided and is connected to the second component. The internal component includes an actuating device and an actuator rod. The actuator rod defines an internal component longitudinal axis that is coexistent with the housing longitudinal axis. The housing and the internal component are adapted to provide for the assembly of the first component of the prosthesis to the second component of the prosthesis. The internal component is adapted to provide relative motion of the internal component with respect to the housing when the actuating device of the internal component is moved relative to the housing in at least a direction transverse to the internal component longitudinal axis and the actuator rod of the internal component is moved relative to the housing in a direction parallel to the internal component longitudinal axis for assembly of the first component of the prosthesis to the second component. The relative motion of the internal component with respect to the housing is utilized to effect the relative motion of the first component with respect to the second component to urge the second component into engagement with the first component.
According to another embodiment of the present invention, a kit for use in joint arthroplasty is provided. The kit includes a first component of a prosthesis, a second component of the prosthesis, and an assembly tool for assembling the first component to the second component. The tool includes a housing for contact with the first component and an internal component connected to the second component. The internal component includes an actuating device and an actuator rod. The actuating device having at least one scissor arm. The housing and the internal component are adapted to provide for the assembly of the first component of the prosthesis to the second component of the prosthesis. The internal component is adapted to provide relative motion of the internal component with respect to the housing when the at least one scissor arm is moved relative to the housing, the relative motion of the internal component with respect to the housing being utilized to effect the relative motion of the first component with respect to the second component to urge the second component into engagement with the first component.
According to yet another embodiment of the present invention, a method for providing joint arthroplasty is provided. The method includes providing a first component and a second component removably attachable to the first component. An instrument having a housing operably associated with the first component is provided. The housing defines a longitudinal axis. The housing also includes an internal component operably associated with the second component. The internal component includes the actuating device and an actuator rod. The internal component is operably associated with the housing for relative motion there between for assembly of the first component of the prosthesis to the second component. The first component is assembled to the second component and the internal component of the tool is connected to the second component. The actuating device of the internal component is moved relative to the housing, such that the movement is at least in a direction transverse to the longitudinal axis. The actuator rod of the internal component is moved relative to the housing, the movement being along the longitudinal axis, the movement securing the first component to the second component.
Other technical advantages of the present invention will be readily apparent to one skilled in the art from the following figures, descriptions and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a plan view partially in cross-section of an embodiment of the present invention in the form of an assembly tool including a threaded connection in operation with a prosthesis;
FIG. 2 is a perspective view of another embodiment of the present invention in the form of an assembly tool with a spiral cam and follower mechanism shown in engagement with a prosthesis;
FIG. 3 is a cross section view of FIG. 2 along the line 3 - 3 in the direction of the arrows;
FIG. 4 is a plan view of a two pieced modular hip stem than may be assembled with the assembly tool of FIG. 2 ;
FIG. 5 is an exploded plan view of the modular hip stem of FIG. 4 ;
FIG. 6 is a flow chart of a method of using the assembly tool of the present invention according to another embodiment of the present invention;
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention and the advantages thereof are best understood by referring to the following descriptions and drawings, wherein like numerals are used for like and corresponding parts of the drawings.
According to the present invention and referring now to FIG. 1 , assembly tool 10 according to the present invention is shown. The assembly tool 10 is used for assembly of a first component 12 of a prosthesis 14 to a second component 16 of the prosthesis 14 for use in joint arthroplasty. The tool 10 includes a housing 18 operably associated with the second component 16 . The housing 18 defines a housing longitudinal axis 20 of the housing 18 . The tool 10 also includes an internal component 22 operably associated with the second component 16 . The internal component 22 defines an internal component longitudinal axis 24 of the internal component 22 . The internal component 22 includes an actuating device 26 and an actuator rod 28 connected to the actuating device. The actuator rod defines a transverse axis 30 that is perpendicular to the internal component longitudinal axis 24 . The internal component 22 is adapted to provide relative motion of the internal component 22 with respect to the housing 18 when the actuator rod 28 is rotated relative to the housing 18 about the transverse axis 30 .
The assembly tool 10 is suited for use with the prosthesis 14 when, for example, the prosthesis 14 includes the first component 12 and the second component 16 which are engaged and disengaged by relative motions along an axis. For example, the assembly tool 10 is suitable when the prosthesis 14 includes components, which are connected by a tapered connection. For example, as shown in FIG. 1 , the first component 12 includes an internal taper 32 that mates with an external taper 34 located on the second component 16 .
As shown in FIG. 1 , the first component 12 is engaged with the second component 16 when the first component 12 moves in the direction of arrow 36 and/or when the second component 16 moves in the direction of arrow 38 . As shown in FIG. 1 , the housing 18 is operably associated with the first component 12 while the internal component 22 is operably associated with the second component 16 . To provide for the operable association of the components, it should be appreciated that the housing 18 includes a housing operating feature 40 , which is operably associated with a first component operating feature 42 of the first component 12 . Similarly, the internal component 22 includes an internal component operating feature 44 , which cooperates with a second component operating feature 46 of the second component 16 .
For simplicity, since the housing 18 and the first component 12 are merely required to prevent motion of the two components toward each other, the housing 18 and the first component 12 may be designed such that the housing operating feature 40 may be in the form of a bottom and/or surface 41 ( FIG. 3 ). Similarly, the first component operating feature 42 may be in the form of a top surface 43 ( FIG. 3 ) of the first component 12 .
The internal component operating feature 44 and the second component operating feature 46 may be any features capable of urging the second component 16 upwardly in the direction of arrow 38 . For example, for simplicity, the internal component operating feature 44 may be in the form of internal threads 47 ( FIG. 3 ) formed on the second component operating feature 46 , which may mate with external threads 45 ( FIG. 3 ) formed on the second component 16 .
The housing 18 and the internal component 22 may have any shape or configuration capable of providing relative motion along housing longitudinal axis 20 and internal component longitudinal axis 24 . For example, and as shown in FIG. 1 , the housing 18 may be in the form of a hollow component or tube. Similarly, the internal component 22 may be in the form of a rod or cylinder, which may slideably fit within the housing 18 .
Turning now to FIG. 2 , in which a plan view of the instrument 10 is shown, the parts of the instrument 10 and their operation will be described in more detail. As shown, the housing 18 includes an outer housing 48 and the housing operating feature 40 . The outer housing 48 also includes apertures 49 for coupling the outer housing 48 to the internal component 22 .
The internal component 22 includes an actuating device 50 and an actuator rod 52 . The actuating device 50 includes a screw 53 and four scissor members 54 a , 54 b , 54 c , 54 d . The scissor members 54 a , 54 b , 54 c , 54 d each include two legs 56 a , 56 b . The legs 56 a , 56 b are connected via a pin 58 . One pair of scissor members 54 a , 54 b are also connected via the pin 58 . The other pair of scissor members 54 c , 54 d are connected via the corresponding pin 58 . The two pins 58 also connect the screw 53 to the scissor members 54 a , 54 b , 54 c , 54 d . Thus, when the screw 53 is rotated about the transverse axis 30 , the four scissor members 54 a , 54 b , 54 c , 54 d expand and contract (like a car jack). The scissor members 54 a , 54 b , 54 c , 54 d are connected to the outer housing 48 via pins 59 . The pins 59 extend through the apertures 49 in the outer housing 48 .
The bottom portion of all four legs 56 b are connected with a connecting member 62 that includes an aperture 64 for receiving a rod 66 that is a part of the actuator rod 52 . The rod 66 extends longitudinally through the outer housing 48 of the housing 18 . The bottom of the rod 66 includes the internal component operating feature 44 , which in the illustrated embodiment is a threaded aperture 68 . Surrounding and connected to the rod 68 is a cylinder 70 . When a user turns the cylinder 70 , the rod 66 also rotates. This can be used to connect the internal component operating feature 44 to the second component operating feature 46 (as shown in FIG. 1 ). The use of the scissor members 54 a , 54 b , 54 c , 54 d provide a greater mechanical advantage to the tool. By increasing the mechanical advantage through the use of the screw 53 and the scissor arms 54 a , 54 b , 54 c , 54 d , the amount of force that the user has to apply to the screw is greatly decreased from prior art designs.
Referring now to FIG. 3 , the engagement of the assembly tool 10 with the prosthesis 14 is shown in greater detail. As shown in FIG. 3 , the second component 16 includes a second component operating feature in the form of external threads 45 . The external threads 45 are matingly fitted to, for example, internal threads 47 formed on internal component 22 . The first component 12 includes an operating feature in the form of, for example, a top surface 43 which mates with bottom surface 41 of the housing 18 of the tool 10 . In some embodiments, the threads may be Acme threads.
Since the housing 18 is in contact with the first component 12 , when the first component is moved in the direction of arrow 80 relative to the first component 12 , the internal component 22 is moved in the direction of arrow 82 relative to the housing 18 . Thus, the relative motion of the internal component 22 with respect to the housing 18 in the direction of arrow 82 corresponds to the relative motion of the second component 16 with respect to the first component 12 in the direction of arrow 80 .
Referring now to FIG. 4 , the prosthesis 14 is shown in greater detail. The prosthesis 14 as shown in FIG. 4 includes a taper connection 31 . As shown in FIG. 4 , the taper connection consists of the external taper 34 formed on the distal stem 16 that engages with internal taper 32 formed on the first component in the form of the proximal body 12 .
It should be appreciated that the prosthesis for use with the assembly tool 10 of FIGS. 1 and 2 , respectively, may include the first component 12 (in this case a proximal body) and the second component 16 (here a distal stem) which have an interference connection that is, for example, an interference connection of a cylindrical bore to a cylindrical stem, as well as, a splined non-uniform cross-section stem to a splined or non-uniform cross-section opening. It should further be appreciated that proximal body and distal stem of the prosthesis 14 for use with the assembly tool of the present invention may include a taper connection in which the distal stem has an internal taper and the proximal body has an external taper.
Again referring to FIG. 4 , the prosthesis 14 as shown may include external threads 45 formed on the distal stem 16 . The proximal body 12 may include a neck 84 to which a head 86 may matingly be fitted. As an additional precaution in assuring that the proximal body 12 remains secured to the distal stem 16 , the prosthesis 14 may further include a nut 88 that threadably engages the external threads 45 of the distal stem 16 .
Referring now to FIG. 5 , the prosthesis 14 is shown with the proximal body 12 disassembled from the distal stem 16 . The external taper 34 of the distal stem 16 is defined by an included angle β 1 . In order that the proximal body 12 fits securely to the distal stem 16 , the proximal body 12 includes the internal taper 32 defined by included angle β 2 . The angles β 1 and β 2 may be generally the same. Alternatively the taper angle may be divergent. The angles β 1 and β 2 should be chosen, such that the fit of the proximal body 12 to the distal stem 16 is secure.
In one embodiment, the instrument is made of stainless steel, however it is contemplated that other sterilizable metals may also be used.
Turning now to FIG. 6 , a flow chart describing the operation of the assembly tool 10 according to one embodiment will be described. At step s 100 , a first component and a second component are provided. The second component is removably attachable to the first component. An assembly tool or instrument is also provided, the assembly tool including a housing and an internal component. The internal component includes an actuating device and an actuator rod (step s 101 ). The first component is assembled to the second component at step s 102 . At step s 104 , the user connects the housing of the tool to the first component. The user also connects the internal component of the tool to the second component (step s 106 ). At step s 108 , the user moves the actuating device of the internal component in a direction transverse to a longitudinal axis relative to the housing. The actuator rod of the internal component is then moved along the longitudinal axis relative to the housing to secure the first component to the second component (step 110 ).
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions, and alterations can be made therein without departing from the spirit and scope of the present invention as defined by the appended claims. | A kit for use in joint arthroplasty that includes a first component of a prosthesis, a second component of the prosthesis, and an assembly tool for assembling the first component to the second component. The tool includes a housing for contact with the first component and an internal component connected to the second component. The internal component includes an actuating device and an actuator rod. The actuating device has at least one scissor arm. The housing and the internal component are adapted to provide for the assembly of the first component of the prosthesis to the second component of the prosthesis. The internal component is adapted to provide relative motion of the internal component with respect to the housing when the at least one scissor arm is moved relative to the housing, the relative motion of the internal component with respect to the housing being utilized to effect the relative motion of the first component with respect to the second component to urge the second component into engagement with the first component. | 0 |
This application is a continuation, of application Ser. No. 08/365,130 filed on Dec. 28, 1994, now abandoned.
The present invention relates to a procedure and an apparatus for determining the position of an elevator car.
As an example of known technology, a deviation detector producing a linear function of the output deviation is mounted in a vertical position on the, car threshold while the magnets used as its counterparts are mounted on the landing thresholds. When the magnet lies at the middle of the measurement range of the detector, the thresholds are in exact alignment relative to each other.
In a normal situation, the movement of the elevator car is monitored by means of a tachometer and a pulse counter, and the position of the elevator car is obtained by comparing the counter value to a floor table stored in memory. In an abnormal situation, e.g. after a power failure, it is necessary to verify the correctness of the initial value of the pulse counter. This can be done by performing a so-called synchronizing drive, which means driving the elevator to a certain floor. Floor-specific codes are generally not provided for all floors, in which case the elevator is driven e.g. to the bottom floor, where a separate switch is provided. This method is slow because the driving distance may be quite long.
In the case of automatic doors, the doors are opened by applying an advance opening system and fine adjustment after the doors have been opened. To ensure safe operation, so-called door zone signals are used, usually two signals for each floor; in other words, each floor is provided with two non-safety switches providing information about the car position. In the description below, these signals are referred to as door zone I and door zone II.
The object of the invention is to develop a new procedure for determining the position of an elevator car. The procedure of the invention is characterized in that the code data contained in code units mounted in the building is read by means of a code data detector unit in such manner that a code unit containing floor data and door zone data is mounted essentially close to the threshold of the landing door on each floor and that the detector unit reading the floor data and door data is mounted essentially close to the threshold of the car.
A solution according to the invention is characterized in that a linear transducer generating position data for accurate levelling is fitted in the detector unit.
Another solution according to the invention is characterized in that the floor data is encoded in a magnetic code plate.
A solution according to the invention is characterized in that the detector units are implemented using magnetic detectors which read the code plates.
A solution according to the invention is characterized in that the detector unit is also used for checking a position counter contained in a processor.
The apparatus of the invention is characterized in that a code unit containing floor data and door zone data is mounted essentially close to the threshold of the landing door on each floor and that a detector unit for reading the floor data and door zone data is mounted in the car essentially close to the threshold of the car.
Another embodiment of the invention is characterized in that a base plate carrying the magnets of a linear position transducer and coding magnets containing the floor data and a door zone magnet array is mounted in the shaft near a landing, and that a detector unit mounted near the threshold of the car correspondingly contains a magnetic linear position transducer, code detectors and door zone detectors.
The advantages achieved by combining the floor-specific positioning devices into a single assembly that is easy to install include the following:
the elevator stops exactly at the level of the landing
oscillator switches and vane lines can be left out, and so can the associated installation work
position adjustment can be used during an accurate levelling drive
installation costs are reduced and installation becomes easier
installation time is reduced and no readjustment is needed
adjustment errors resulting from rope elongation can now be taken into account
instead of a single high-quality detector, two simple detectors can be used
the data is carried by a current signal, which is less sensitive to interference than a voltage signal
positioning devices can now be mounted on the car and landing thresholds
when a linear position transmitter is used, more accurate feedback for adjustment is obtained at the end of the deceleration phase.
In the following, the invention is described in detail by the aid of some examples of its embodiments by referring to the attached drawings, in which
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 presents the layout of a code plate containing magnets and the detectors responding to the magnets in the elevator system,
FIG. 2 presents the positions of the magnets on the code plate, made of an iron plate,
FIG. 3 illustrates the principle of the door zone I detector,
FIG. 4 presents the current signal of door zone I,
FIG. 5 presents door zone II, implemented using a series of magnets carrying the code of the floor
FIG. 6 presents the current signal obtained from a linear position transmitter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an elevator car 1, a counterweight 2 and a rope 6 running over a traction sheave 5. The position of the elevator car 1 is determined by means of a magnetic code plate 3 in which a code identifying the floor is encoded. The code plate functions as a code unit. It is fastened with two screws below the landing and is placed in the threshold of the landing door. The detector unit used is a unit 4 sensitive to a magnetic field and it contains a linear position transmitter 12 in the car, detectors 13a and 13b and detectors 22, 23 and 24. The detector unit 4 is placed in the threshold of the car door. Door zone I receives information from an elongated magnet as shown in FIG. 3 by means of detectors 13a and 13b, and door zone II receives information from the code magnets in FIG. 5 via detectors 24. A common method to produce door zone signals is to use magnetic or inductive switches.
In FIG. 2, the magnets are placed on an iron backplate 7. The magnet array for door zone I is indicated by number 8. The coding of door zone II is done with magnets 9. Magnets 10 are the magnets of the linear position transmitter 12. The magnets are placed symmetrically with respect to the midline 11. Magnetic detectors are used for the reading of the code plate. The linear transducer consists of a linear position transmitter 12 and the code unit consists of a code plate.
FIG. 3 illustrates the operation of the detector of door zone I. The code plate contains magnets 8 placed on a back-plate 7. Each magnet 8 consists of three separate magnets so arranged that there is a shorter magnet at each end and a longer one between them. The detector unit 4 contains two direction sensing detectors 13a and 13b which are so placed that the switching point or 0-point of the detectors 13 is independent of the distance between the magnet 8 and the detectors 13. This zero point lies within the curve pattern comprising curves d and d' in FIG. 3, which represent the distances between the magnet 8 and the detectors 13. In express zones, the elevator position is monitored using so-called ghost floors, which have no door zone magnets. Therefore, the opening of the doors at a ghost floor is inhibited. `Express zones` means floors in a high-rise building which the elevator passes by without stopping. The elevator may only stop at the top and bottom floors and pass by the floors in between. These intermediate floors are called an express zone.
FIG. 4 presents the current signal 14 of door zone I. The coding of the door zone into a current signal is effected by transmitting the following information through a wire in the car cable:
elevator is in door zone 15 (i>i 1 ); purpose: to bypass the safety circuit during accurate levelling and advance opening
elevator is within the operating range 17 (i 3 >i>i 2 ) of the linear position transmitter, detectors 13a and 13b are both active
elevator is below 16 the operating range of the linear position transmitter (i 2 >i>i 3 ), only detector 13a is active
elevator is above 18 the operating range of the linear position transmitter (i 4 >i>i 3 ), only detector 13b is active
elevator is in door zone (walk-through car) and door zones overlap 19 (i>i 4 ).
The expression `door zones overlap` means that the building consists e.g. of a new part and an old part and the elevator is placed between them. The floors in the old part may lie at different levels than the floors in the new part, in which case the elevator is first driven e.g. to the level of a floor in the new part and then maybe some 300 mm downwards to a floor in the old part. The data regarding the operating range 17 of the linear position transmitter can also be used as a so-called interior door zone 20. The interior door zone is used for accurate levelling (according to US regulations).
In FIG. 5, door zone II is implemented using a magnet array 21 in which the floor code is encoded. With this system, no synchronizing drive is needed after a power failure. The door zone data itself, which indicates that the elevator is in door zone II, is obtained via an OR gate 25 from detectors 24, which are independent of the polarities of the magnets 21. In FIG. 5, the floor code is obtained with nine detectors 22 and 23. The outermost detectors 23 give a triggering signal to an &-gate 26 which is used to transfer the floor code provided by the seven intermediate detectors 22 into memory 27. A converter 28 transmits the door zone data II and the floor code in the form of a current signal 29 to a control processor. The floor code is encoded as a binary number in the magnetic code plate 3 by changing the polarity.
FIG. 6 presents the current signal of the linear position transmitter (not shown in the figures) or linear transducer in the detector unit 4. The current is zero when there is no magnet near 31 the position transmitter. When a magnet appears in the range of the position transmitter, the signal is activated 30. The current signal 14 of door zone I provides the required information regarding the linear operating range 17 of the position transmitter. At the zero point of the position transmitter, the processor is given an interrupt 32, which is used to check the value of the position counter in the processor. The processor calculates the car position by means of its position counter. An interrupt means that the operation of the processor can be interrupted by a signal. The zero point is so defined that its value is 12 mA. This is an example frequency, called the standard signal.
It is obvious to a person skilled in the art that different embodiments of the invention are not restricted to the examples described above, but that they may instead be varied within the scope of the claims presented below. The invention may be implemented using different types of magnets, e.g. plastic magnets, and the polarities of the magnets can be changed, as well as capacitive and optic detectors. | A procedure for determining the position of an elevator car in which the code data contained in code units mounted in the building is read by means of a code data detector unit (4) in such manner that a code unit containing floor data and door zone data is mounted essentially close to the threshold of the landing door on each floor and that the detector unit reading the floor data and door data is mounted essentially close to the threshold of the car. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to sharps disposal containers, and pertains particularly to an improved closure having a temporary close position and a permanent close position.
The safe and efficient disposal of sharps such as surgical knives, blades, hypodermic needles and the like is a tremendous problem for medical and other healthcare facilities.
Disposable containers have been developed in recent years which provide a reasonably high degree of security for disposable sharps articles and materials from hospitals and clinics. Many of these articles, such as needles and surgical blades known as sharps, and other similar articles and materials, must be disposed of in a manner to keep them out of the hands of unauthorized persons and to keep them from being reused.
The containers are normally designed to prevent the removal of materials from the container under ordinary circumstances until permanently closed. The permanent closure is normally present on the container and often used as a temporary cover until the container is filled and ready for permanent closure. However the permanent closure is frequently unintentionally placed in the permanent position prior to completely filling the container. This results in unnecessary waste of containers and unnecessary cost. Therefore, it is desirable that the container be completely filled prior to permanent closure for disposal.
One secure container of the aforementioned type is that disclosed in prior U.S. Pat. No. 4,502,606, issued Mar. 5, 1985, and directed to a locking closure for disposable containers. These containers, have usually been provided with a permanent closure that is available to use as a temporary closure until ready for permanent closure. However, the closure is frequently mistakenly place in the permanent locking position prior to filling the container.
There is a need for a closure that may be safely used as a temporary closure without the danger of unintentionally placing it in the permanent closure position.
SUMMARY OF THE INVENTION
It is the primary object of the present invention to provide an improved closure that may be safely used as a temporary closure without the danger of unintentionally placing it in the permanent closure position.
In accordance with a primary aspect of the present invention, a disposable container closure assembly, comprises wall means for defining an opening for a substantially rigid container, a closure adapted to fit and close said opening, said closure having a first position for releasably engaging said wall means and closing said opening, and a second position for engaging said wall means and permanently closing said opening, and flexible tethering means secured at a first end to said frame means and detachably secured at a second end to said closure for retaining said closure in said first position, said tethering means being detachable from said closure for enabling positioning said closure in said second position.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
The above and other objects and advantages of the present invention will become apparent from the following description when read in conjunction with the accompanying drawings wherein:
FIG. 1 is a top plan view of a closure assembly in accordance with a preferred embodiment of the invention;
FIG. 2 is a top plan view like FIG. 1, showing the closure in the open position;
FIG. 3 is a view taken on line 3--3 of FIG. 2;
FIG. 4 is a top plan view like FIG. 1, showing the closure in the permanent closed position;
FIG. 5 is a perspective view showing details of the temporary latch; and
FIG. 6 is a perspective view showing details of the permanent latch.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and to particularly FIGS. 1 and 2, there is illustrated a top view of a container closure assembly, designated generally by the numeral 10, and comprises a closure frame 12 for mounting on an upwardly extending peripheral rim normally defining an upwardly directed opening of a substantially rigid container. The top support or frame member 12, in the illustrated embodiment has a generally rectangular configuration for mounting on and covering the upwardly opening mouth or open top of a container (not shown). This top is permanently attached to a plastic disposable container of the type typically used for the disposal of syringes, sharps and the like. These type containers are disclosed in a number of patents, such as mentioned above.
The frame or container top 12 has a central recess 14 formed with a downwardly depending wall 16 and with a circular opening 18 for receiving a circular closure member designated generally at 20. The closure member 20 is tethered or secured to the container by a hinge assembly or member designated generally at 22. The closure is designed to pivot or hinge about the side edge of the top frame or cover 12 to an open position, as seen in FIG. 2, to enable the insertion of articles to be disposed of into the container. The closure may then be swung down to the temporary closed position, as shown in FIG. 1, until time to insert other articles. At this time, the closure may be pulled up and swung over as shown in FIG. 2 to expose the opening for the insertion of articles. When the container is full, the closure is disconnected from the hinge member and then rotated 60° and pressed downward until it engages permanent latching means for permanently latching the closure into the opening. The container may then be disposed of in the usual manner.
Referring to FIG. 2, the container top or closure frame is molded of a thin sheet of plastic and has a recessed center portion 14, as shown, with a central circular opening 18 formed with a downwardly depending circular wall 24 having alternate guide and latching projections molded into it. As shown in FIG. 2 the wall defining the central circular opening, has six guide projections 26, 28, 30, 32, 34. and 36, extending outward toward the center of the opening from the wall. Disposed between alternate sets of the guide projections are temporary latch projections 38, 40 and 42. These projections have a substantially triangle or inverted V shape in side view. This provides a slope shaped upper and lower surface for detent-like temporary engagement with latch means on the closure, as will be described.
Also disposed between alternate pairs of the guide members are permanent latching members 44, 46 and 48. As will be appreciated, the permanent locking projections and the temporary locking projections are disposed at 60° intervals from one another about the axis along the periphery of the circular wall defining the opening. The permanent locking projections slope downward and outward to a lower straight horizontal surface that serves as a permanent latch for loops on the closure member, as will be described. The temporary latching members extend outward with an upwardly sloping lower surface for a detent like latching of the closure member in position.
As will be appreciated from FIGS. 1, 2 and 3, the closure member 20 is molded of a thin sheet of circular plastic in the form of a peripheral or circular rim with a downturned lip 50 having extended projections 52 for reinforcement purposes. The center of the closure is recessed downward in semi-circular areas forming a central circular hub 54 with three radial ribs 56, 58 and 60 extending outward to the circular rim. A central transverse cross-bar 62 is formed in the central circular hub providing a hand grip. The central hub is molded with raised surfaces for reinforcement and to provide a grasping area.
The closure member is formed with three downwardly depending latching tabs having slots forming latching loops 64, 66 and 68. These latching loops extend downward from the peripheral edge of the depressed semi-circular areas on the underside of the closure. These latching loops are equally positioned around the circumference of the closure member to selectively register with and engage with the respective temporary and permanent latch projections, as shown in FIGS. 5 and 6. These latching loops 64, 66 and 68 are positioned to selectively engage the temporary latching projections 38, 40 and 42 (FIGS. 2 and 5) when the closure is in a first angular orientation about its center axis as seen in FIG. 1. The loops are positioned to engage the permanent latching projections 44, 46 and 48 (FIGS. 2 and 6) when the closure is in a second angular orientation about its axis as seen in FIG. 4.
A tethering or hinge member in the form of a generally rectangular open frame designated generally at 22 is hinged at one end to the closure frame 12 and detachably connected at the other to the closure. The hinge member 22 is formed with a central body 72 with arms 76 and 78 extending outward to and integral with a cross bar 80. A pair of generally cylindrical connector pins 82 and 84 are adapted to register with and frictionally engage a pair of sockets or bores 86 and 88 on ribs 58 and 60 on top of the closure to temporally connect them together in the position as shown in FIGS. I and 2. This is the temporary latching position of the closure as discussed above.
The pins of the hinge are removable from the sockets as shown in FIG. 4. to enable the closure to be rotated to the permanent latching position. This pin and socket combination temporarily connects the closure to the hinge or tethering member which is hinged to the side of the closure frame. The hinge member is formed with closing hooks 82 and 84 and shoulders 86 and 88 which engage a transverse pivot pin or rod 90 formed with stand-off arms 92 and 94 as a bracket on the rim of the closure frame. When the closure is secured to the hinge member as shown in FIGS. 1 and 2, the orientation is such that the latch tabs orient with and engage the temporary latching projections as shown in FIG. 5. This enables the closure to be positioned and fixed in that position by the hinge to enable one to temporarily close the opening in the container and to later open it for the insertion of disposable items.
The closure is provided with indicia means in the form of an arrow 96 on a top portion thereof opposite the hinge and small diamond shaped or triangle shaped markers 98 and 100 molded into the top of the closure frame. When these are properly oriented, the closure may be pressed down into its permanently locked or latched position. The container is then ready for total disposal as in the usual manner.
As shown in FIG. 1, the closure is formed with indicia means in the form of an arrow 96 on top of rib 56 which points straight ahead in the temporary close position. The hinge 22 maintains the closure in its orientation as long as it is connected as illustrated.
Once the container is completely filled, the closure member may be disconnected from the orienting tether or hinge 22 member by simply grasping and pulling up on the bar 80 between the pins of the hinge member removing the pins from the sockets in the top of the closure member. The closure member may then be lifted and rotated 60° orienting the arrow 96 with indicia in the form of triangles 98 and 100 on the closure frame and pressed down to a permanent latching position.
While I have illustrated and described my invention by means of specific embodiments, it is to be understood that numerous changes and modifications may be made therein without departing from the spirit and scope of the invention as defined in the appended claims. | A disposable container closure assembly, comprises a wall defining a circular opening for a substantially rigid container, a closure adapted to fit and close the opening, the closure having a first position for releasably engaging the wall and closing the opening, and a second position for engaging the wall and permanently closing the opening, and a flexible tether secured at a first end to the frame and detachably secured at a second end to the closure for retaining the closure in the first position, the tether being detachable from the closure for enabling positioning the closure in the second position. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 09/898,850, filed Jul. 3, 2001 now U.S. Pat. No. 7,106,794, which claims priority to and benefit from U.S. Application Ser. No. 60/224,733, filed Aug. 11, 2000. The above-identified applications are hereby incorporated herein by reference in their entirety.
INCORPORTATION BY REFERENCE
The above-referenced U.S. provisional application Ser. No. 60/224,733 is hereby incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
N/A
BACKGROUND OF THE INVENTION
Current data communication systems rarely approach highest possible rate, i.e., the rate corresponding to Shannon channel capacity. For example, voiceband modems complying with ITU-T recommendation V.90 employ uncoded modulation for downstream transmission. The nominal downstream rate of 56 kbit/s is thereby almost never achieved, although under practical channel conditions the capacity rate can exceed 56 kbit/s.
The difference between the signal-to-noise ratio (SNR) required to accomplish a given rate with a given practical coding and modulation scheme and the SNR at which an ideal capacity-achieving scheme could operate at the same rate is known as “SNR gap to capacity”. At spectral efficiencies of 3 bit per signal dimension or higher, uncoded modulation with equiprobable PAM (pulse amplitude modulation) and QAM (quadrature amplitude modulation) symbols exhibit an SNR gap of 9 dB at a symbol error probability of 10 −6 . In the case of V.90 downstream transmission, the SNR gap can correspond to a rate loss of up to 12 kbit/s.
This overall 9 dB gap is generally comprised of a “shaping gap” portion and a “coding gap” portion. The “shaping gap” portion (approximately 1.5 dB) is caused by the absence of constellation shaping (towards a Gaussian distribution). The remaining “coding gap” portion (approximately 7.5 dB) stems from the lack of sequence coding to increase signal distances between permitted symbol sequences.
Two different techniques are used, generally in combination, to reduce the overall 9 dB gap. The first technique addresses the “coding gap” portion, and uses one of several coding techniques to achieve coding gains. One of these techniques is trellis-coded modulation. More recent techniques employ serial- or parallel-concatenated codes and iterative decoding (Turbo coding). These latter techniques can reduce the coding gap by about 6.5 dB, from 7.5 dB to about 1 dB.
Once a coding gain is achieved, the second technique, referred to as shaping, can be used to achieve an even further gain. This type of gain is generally referred to as a shaping gain. Theoretically, shaping is capable of providing an improvement (i.e., shaping gain) of up to 1.53 dB.
Two practical shaping techniques have been employed in the prior art to achieve shaping gains, namely, trellis shaping and shell mapping. With 16-dimensional shell mapping, such as employed in V.34 modems, for example, a shaping gain of about 0.8 dB can be attained. Trellis shaping can provide a shaping gain of about 1 dB at affordable complexity. Accordingly, between 0.5 and 0.7 dB of possible shaping gain remains untapped by these prior art shaping methods.
Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of such systems with the present invention as set forth in the remainder of the present application with reference to the drawings.
BRIEF SUMMARY OF THE INVENTION
Aspects of the present invention may be found in a method of communicating data in a communication system. The method generally comprises accepting and randomizing (scrambling) data from a source of user data, such as a computer, for example. The randomized data are accumulated until a Huffman codeword is recognized, at which time the Huffman codeword is mapped into a channel symbol. Then the channel symbol is applied to an input of a communication channel. In the field of source coding, the above operation is known as Huffman decoding.
The encoding operation described above may be combined with further channel encoding operations such as, for example, trellis coded modulation or some form of serial- or parallel-concatenated coding to achieve coding gain in addition to shaping gain. In addition, channel symbols can be modulated in various ways before they are applied to the input of the communication channel.
In one embodiment of the invention, the channel encoding operation described above is performed in combination with a framing operation to achieve transmission of data at a constant rate.
Next, on the receiver side of the communication channel, a channel symbol is received from an output of the communication channel after suitable demodulation and channel decoding. Once obtained, the channel symbol is converted into the corresponding Huffman codeword. The data sequence represented by concatenated Huffman codewords is de-randomized (descrambled) and delivered to a sink of user data.
In one embodiment of the invention, a deframing operation is performed, which provides for data delivery to the data sink at constant rate.
The method of the present invention results in a symbol constellation and a probability distribution of symbols in this constellation that exhibits a shaping gain of greater than 1 dB. The shaping gain may be, for example, 1.35 dB or 1.5 dB, depending on the specific design
In general, a communication system according to the present invention comprises a communication node that performs a “Huffman decoding” operation to generate channel symbols with a desired probability distribution.
These and other advantages and novel features of the present invention, as well as details of an illustrated embodiment thereof, will be more fully understood from the following description and drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a block diagram of a generic communication system that may be employed in connection with the present invention.
FIG. 2 illustrates additional detail regarding the transmitters of FIG. 1 according to the present invention.
FIG. 3 shows shaping gain versus rate for PAM and QAM sq constellations of different sizes, in accordance with the present invention.
FIG. 4 plots shaping gains versus rate for square and lowest-energy 1024-QAM constellations, in accordance with the present invention.
FIG. 5 depicts the mean and standard deviation of the rate in bit/dimension and the shaping gain accomplished for a nominal rate of R=4 bit/dimension with QAM le constellations of different sizes, in accordance with the present invention.
FIG. 6 illustrates a 128-QAM le constellation with Huffman shaping for a nominal rate of 3 bit/dimension, in accordance with the present invention.
FIG. 7 illustrates one embodiment of a generic method for achieving constant rate and recovering from bit insertions and deletions.
FIG. 8 illustrates the probability of pointer overflow as a function of framing buffer size in accordance with the present invention.
FIG. 9 illustrates one embodiment of the design of a Huffman code in accordance with the present invention.
FIG. 10 is a block diagram of one embodiment of a communication system that operates in accordance with the method of present invention.
FIG. 11 is another embodiment of the design of a Huffman code in accordance with the present invention, when a framer/deframer is utilized.
FIG. 12 is a block diagram of another embodiment of a communication system that operates in accordance with the method of present invention, utilizing a framer/deframer.
FIG. 13 illustrates one operation of a system that employs Huffman shaping in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a block diagram of a generic communication system that may be employed in connection with the present invention. The system comprises a first communication node 101 , a second communication node 111 , and a channel 109 that communicatively couples the nodes 101 and 111 . The communication nodes may be, for example, modems or any other type of transceiver device that transmits or receives data over a channel. The first communication node 101 comprises a transmitter 105 , a receiver 103 and a processor 106 . The processor 106 may comprise, for example, a microprocessor. The first communication node 101 is communicatively coupled to a user 100 (e.g., a computer) via communication link 110 , and to the channel 109 via communication links 107 and 108 .
Similarly, the second communication node 111 comprises a transmitter 115 , a receiver 114 and a processor 118 . The processor 118 , like processor 106 , may comprise, for example, a microprocessor. The second communication node 111 is likewise communicatively coupled to a user 120 (again a computer, for example) via communication link 121 , and to the channel 109 via communication links 112 and 113 .
During operation, the user 100 can communicate information to the user 120 using the first communication node 101 , the channel 109 and the second communication node 111 . Specifically, the user 100 communicates the information to the first communication node 101 via communication link 110 . The information is transformed in the transmitter 105 to match the restrictions imposed by the channel 109 . The transmitter 105 then communicates the information to the channel 109 via communication link 107 . The receiver 114 of the second communication node 111 next receives, via communication link 113 , the information from the channel 109 , and transforms it into a form usable by the user 120 . Finally, the information is communicated from the second communication node 111 to the user 120 via the communication link 121 .
Communication of information from the user 120 to the user 100 may also be achieved in a similar manner. In either case, the information transmitted/received may also be processed using the processors 106 / 118 .
FIG. 2 illustrates additional detail regarding the transmitters of FIG. 1 according to the present invention. The functions of transmitter 201 may be decomposed into those of a source encoder 203 and a channel encoder 205 . Generally, the source encoder 203 is a device that transforms the data produced by a source (such as the user 100 or user 120 of FIG. 1 ) into a form convenient for use by the channel encoder 205 . For example, the source may produce analog samples at a certain rate, such as, for example, 8000/s, as in a telephone application. The source encoder 203 then may perform the function of analog-to-digital conversion, converting each analog sample into an 8-bit binary code. The output of the source encoder 203 then would be a binary sequence of digits presented to the input of the channel encoder 205 at a rate of 8×8000=64,000 bit/s. The output of the source encoder 203 is passed to the channel encoder 205 , where the data are transformed into symbols that can be transmitted on the channel. For example, the data may be transformed using pulse-amplitude modulation (PAM), whereby successive short blocks of data bits of length N are encoded as analog pulses having one of 2 N allowable amplitudes.
In most communication systems, the data presented to the channel encoder are assumed to be completely random. This randomness is normally assured by the inclusion of a scrambler designed into the system. In the previous example of PAM, random data would lead to each 2 N of the allowable amplitudes being equally likely. That is, each of them occurs with probability 2 −N . It turns out that employing equally likely pulse amplitudes leads to a small inefficiency in the use of the power in the signal that is transmitted into the channel. In fact, as mentioned above, if the amplitude distribution can be made more nearly Gaussian, then up to 1.53 dB of transmitted power can be saved for the same level of error performance at the receiver.
Accordingly, a shaping function is provided in FIG. 2 by a shaper 207 , which alters the statistical distribution of the values presented to modulator 209 . Shaping the transmitted signal generally means controlling the distribution of transmitted signal values to make the signal appear more Gaussian in character. The shaper 207 comprises a Huffman decoder 211 and a mapper 213 . The design of the Huffman decoder 211 depends upon the characteristics of the channel.
In the Huffman decoder 211 , the sequence of scrambled binary data bits is parsed into Huffman codewords. The codewords are then mapped into modulation symbols. The Huffman code is designed to let the modulation symbols assume approximately a sampled Gaussian distribution.
Unlike trellis shaping or shell mapping, Huffman shaping is not a constant-rate-encoding scheme. Moreover, decoding errors can lead to bit insertion or deletion in the decoded binary data sequence. This may be acceptable for many systems, such as, for example, those in which variable-length packets are transmitted in burst mode with an Ethernet-like medium access protocol. In some cases, continuous transmission at constant rate is desirable, such as, for example, those involving variable-rate encoded voice and video streams over constant rate channels. A constant rate and recovery from bit insertions and deletions may be achieved, and the framing overhead may be kept to a value equivalent to a SNR penalty of ≈0.1 dB, for example, utilizing the method of the present invention.
The following mathematical foundation of Huffman shaping is based upon M-ary PAM data transmission, but the concept clearly applies to two- and higher-dimensional modulation as well.
Let A M be a symmetric M-ary PAM constellation of equally spaced symbols. Adjacent symbols are spaced by 2, and M may be even or odd (usually M will be even):
A M ={a i =−( M −1)+2 i, 0≦ i≦M −1}
e.g.: A 8 ={−7, −5, −3, −1, +1, +3, +5, +7}, A 5 ={−4, −2, 0+2, +4} (1)
If symbols are selected independently with probabilities p={p i , 0≦i≦M−1}, the symbol entropy H(p) (=rate) and the average symbol energy E(p) become:
H
(
p
)
=
-
∑
i
=
0
M
-
1
p
i
log
2
p
i
bit
/
symbol
(
p
i
=
1
M
∀
i
:
H
(
p
)
=
H
M
=
log
2
M
)
,
(
2
)
E
(
p
)
=
∑
i
=
0
M
-
1
p
i
a
i
2
(
M
-
PAM
,
p
i
=
1
M
∀
i
:
E
(
p
)
=
E
M
=
M
2
-
1
3
)
.
(
3
)
Shaping gain G S (p) expresses a saving in average symbol energy achieved by choosing symbols from A M with probabilities p rather than selecting equiprobable symbols from a smaller constellation A M′ , where M′=2 H(p) (M′<M, ignoring that M′ may not be an integer):
G
s
(
p
)
=
E
M
′
E
(
p
)
=
2
2
H
(
p
)
-
1
3
×
E
(
p
)
.
(
4
)
The maximum shaping gain is obtained by the probability distribution p={tilde over (p)}, which minimizes E(p) subject to the constraints R=H(p) and
∑ i = 0 M - 1 p i = 1.
Differentiation of
J ( p ) = ∑ i = 0 M - 1 p i a i 2 + λ 1 ( - ∑ i = 0 M - 1 p i log 2 p i - R ) + λ 2 ( ∑ i = 0 M - 1 p i - 1 ) ( 5 )
with respect to the probabilities p i yields the conditions
∂ J ( p ) ∂ p i ❘ p = p ~ = a i 2 - λ 1 ln 2 ( ln p ~ i + 1 ) + λ 2 = 0 , for 0 ≤ i ≤ M - 1. ( 6 )
The parametric solution of (6), with the Lagrange multipliers λ 1 , λ 2 transformed into the new variables α, s, becomes
p
~
i
=
exp
(
-
1
+
ln
2
λ
1
(
a
i
2
+
λ
2
)
)
=
α
exp
(
-
s
a
i
2
)
,
0
≤
i
≤
M
-
1.
(
7
)
The optimum distribution {tilde over (p)} is thus found to be a Gaussian distribution sampled at the symbol values of A M . This solution can also be obtained by maximizing the rate R=H(p) subject to the constraints
E ( p ) = S and ∑ i = 0 M - 1 p i = 1.
The value of α follows from
∑ i = 0 M - 1 p i = 1.
The value of s may be chosen to achieve a given rate R≦log 2 (M) or a given average symbol energy S≦E M .
If M and R are increased, the optimum shaping gain tends towards the ultimate shaping gain G s ∞ =πe/6=1.423 (1.53 dB). This gain can be derived as the ratio of the variance of a uniform density over a finite interval and the variance of a Gaussian density, both with the same differential entropy.
One can see that (7) does not only hold for regular symmetric PAM constellations, but gives the optimum shaping probabilities for arbitrary one- and higher-dimensional symbol constellations as well.
In general, given a sequence of M-ary source symbols which occur independently with probability distribution p, a traditional Huffman coding approach encodes the source symbols into binary codewords of variable lengths such that (a) no codeword is a prefix of any other codeword (prefix condition), and (b) the expected length of the codewords is minimized.
An optimum set of codewords is obtained by Huffman's algorithm. More particularly, let a i be a source symbol that occurs with probability p i . The algorithm associates a i with a binary codeword c i of length l i such that 2 −l i ≈p i . The algorithm guarantees that
∑ i = 0 M - 1 2 - l i = 1
(Kraft's inequality is satisfied with equality), and that the expected value of the codeword length,
L = ∑ i = 0 M - 1 p i l i ,
approaches the entropy of the source symbols within one bit [10]:
H ( p )≦ L<H ( p )+1. (8)
In the limit for large H(p), the concatenated Huffman codewords yield a binary sequence of independent and equiprobable zeroes and ones with rate R=L≅H(p) bit per source symbol. However, for certain probability distributions L may be closer to H(p)+1 than H(p) because of quantization effects inherent in the code construction. If H(p) is small, the difference between L and H(p) can be significant. The rate efficiency may be improved by constructing a Huffman code for blocks of K>1 source symbols. Then, (8) takes the form H(p)≦L(K)/K=L≦H(p)+1/K, where L(K) is the expected length of the Huffman codewords associated with K-symbol blocks. The code comprises M K codewords and the rate expressed in bit per source symbol will generally be within 1/K bit from H(p).
With the Huffman shaping method of the present invention, the traditional encoding approach is reversed. A Huffman code is generated for the optimum probability distribution {tilde over (p)} of the modulation symbols in a given M-ary constellation. In the transmitter, the sequence of data bits is suitably scrambled so that perfect randomness can be assumed. The scrambled sequence is buffered and segmented into Huffman codewords, as in traditional Huffman decoding. A codeword c i is encountered with probability 2 −l i ≈{tilde over (p)} i and mapped into modulation symbol a i . In the receiver, when a symbol a i is detected codeword c i is inserted into the binary output stream.
For the general case of K-dimensional modulation (K=1: PAM, K=2: QAM), it is appropriate to express rates and symbol energies per dimension, while a i , {tilde over (p)} i , and l i relate to K-dimensional symbols.
The mean value R h and the standard deviation σ R h of the number of bits encoded per symbol dimension become
R
h
=
1
K
∑
i
=
0
M
-
1
2
-
l
i
l
i
bit
/
dimension
(
≈
1
K
H
(
p
~
)
)
,
(
9
)
σ
R
h
=
1
K
∑
i
=
0
M
-
1
2
-
l
i
(
l
i
-
KR
h
)
2
.
(
10
)
The average symbol energy per dimension S h and the shaping gain G s h of the Huffman-shaped symbol sequence are given by
S
h
=
1
K
∑
i
=
0
M
-
1
2
-
l
i
a
i
2
energy
per
dimension
(
≈
1
K
E
(
p
~
)
)
,
(
11
)
G
s
h
=
2
2
R
_
h
-
1
3
×
E
h
.
(
12
)
The corresponding quantities obtained with optimum shaping probabilities {tilde over (p)} will be denoted, respectively, by {tilde over (R)} and σ {tilde over (R)} (bit/dimension), {tilde over (S)} (energy per dimension), and {tilde over (G)} s (optimum shaping gain).
For numerical evaluations, uncoded modulation with M-PAM (M=2 m) and M-QAM (M=4 m) constellations have been considered. The M-QAM constellations are either square constellations M-QAM sq =√{square root over (M)}−PAM×√{square root over (M)}−PAM, or lowest-energy constellations M-QAM le comprising the M points in the set {(1+2i , 1+2k), i, k εZ} nearest to the origin. The symmetries of the symbol constellations are enforced on the Huffman codes. In the PAM case, m codewords are constructed for positive symbols and then extended by a sign bit. Similarly, in the QAM case m codewords are constructed for symbols in the first quadrant and extended by two quadrant bits. The results of different numerical evaluations are depicted in FIGS. 3 , 4 , and 5 .
FIG. 3 shows shaping gain versus rate for PAM and QAM sq constellations of different sizes, in accordance with the present invention. The solid curves indicate the shaping gains obtained with the optimum shaping probabilities {tilde over (p)}. Every rate in the interval 1≦R≦log 2 (M)/K can be accomplished (bit per dimension). The shaping gains vanish at R=1 (constellations reduced to BPSK or QPSK) and R=log 2 (M)/K (equiprobable M-QAM). The optimum shaping gains practically reach the ultimate shaping gain of 1.53 dB at R=4 bit per dimension for ≧32-PAM and ≧1024-QAM sq constellations. With the Huffman shaping method of the present invention, not every rate can be realized because of quantization effects in the construction of Huffman codes. For PAM, shaping gains of up to ≈1.35 dB are achieved at some rates above 3 bit per dimension. The effects of quantization are significantly reduced in the QAM cases. With ≧256-QAM sq constellations shaping gains within 0.1 dB from the ultimate shaping gain of 1.53 dB are consistently obtained at rates above 3 bit per dimension.
FIG. 4 plots shaping gains versus rate for square and lowest-energy 1024-QAM constellations, in accordance with the present invention. Minor differences occur in the region of diminishing shaping gains, at rates above 4.5 bit/dimension. The shaping gain of equiprobable 1024-QAM le (R=5 bit/dimension) is 0.2 dB.
FIG. 5 depicts the mean and standard deviation of the rate in bit/dimension and the shaping gain accomplished for a nominal rate of R=4 bit/dimension with QAM le constellations of different sizes, in accordance with the present invention. The nominal rate is at least closely achieved with Huffman shaping (with optimum shaping it is exactly achieved). The standard deviation increases with increasing constellation size to a final value of ≈1 bit/dimension. The optimum shaping gain and the Huffman shaping gain increase rapidly when the initial 256-QAM constellation is enlarged. The respective final shaping gains of ≈1.5 dB and ≈1.4 dB are practically achieved with M=512 (512-QAM le : 1.495 dB and 1.412 dB, 1024-QAM le : 1.516 dB and 1.432 dB).
FIG. 6 illustrates a 128-QAM le constellation with Huffman shaping for a nominal rate of 3 bit/dimension, in accordance with the present invention. The codeword lengths ranging from 5 to 12 bits are indicated for the first-quadrant symbols. R h =2.975 (σ R h =0.919) bit/dimension and G s h =1.378 dB ({tilde over (G)} s =1.443 dB) are achieved. The symbol energies, optimum shaping probabilities, codeword probabilities and lengths, and the codewords of the first quadrant symbols are listed below. The codewords for the first-quadrant symbols end with 00.
TABLE 1
Huffman code words tabulated against
their index
i
|a i | 2
{tilde over (p)} i
p i h = 2 −l i
l i
c i
0
2
0.03872
0.03125
5
00000
1
10
0.02991
0.03125
5
10000
2
10
0.02991
0.03125
5
01100
3
18
0.02311
0.03125
5
11100
4
26
0.01785
0.01563
6
010000
5
26
0.01785
0.01563
6
001100
6
34
0.01379
0.01563
6
110000
7
34
0.01379
0.01563
6
101100
8
50
0.00823
0.00781
7
1010000
9
50
0.00823
0.00781
7
0101100
10
50
0.00823
0.00781
7
0101000
11
58
0.00636
0.00781
7
1101100
12
58
0.00636
0.00781
7
1101000
13
74
0.00379
0.00391
8
10101100
14
74
0.00379
0.00391
8
10101000
15
82
0.00293
0.00195
9
001001000
16
82
0.00293
0.00195
9
001000100
17
90
0.00226
0.00195
9
001010100
18
90
0.00226
0.00195
9
001010000
19
98
0.00175
0.00195
9
001011100
20
106
0.00135
0.00098
10
0010011100
21
106
0.00135
0.00098
10
0010011000
22
122
0.00081
0.00049
11
00100000100
23
122
0.00081
0.00049
11
00100000000
24
130
0.00062
0.00049
11
00101101000
25
130
0.00062
0.00049
11
00101100100
26
130
0.00062
0.00049
11
00101100000
27
130
0.00062
0.00049
11
00100001100
28
146
0.00037
0.00024
12
001000010100
29
146
0.00037
0.00024
12
001000010000
30
162
0.00022
0.00024
12
001011011000
31
170
0.00017
0.00024
12
001011011100
FIG. 7 illustrates one embodiment of a generic method for achieving constant rate and recovering from bit insertions and deletions. Data frames of N b bits are embedded into symbol frames of N s modulation symbols. Every sequence of bits transmitted within a symbol frame begins with a S&P (synch & pointer) field of n sp =n s +n p bits, where n s is the width of a synch subfield enables and n p is the width of a pointer subfield. The synch subfield enables the receiver to acquire symbol-frame synchronization. In principle, sending a known pseudo-random binary sequence with one bit (n s =1) in every S&P field is sufficient (as in T1 systems). The pointer subfield of the n th symbol frame expresses the offset in bits of the n th data frame from the S&P field.
With reference to FIG. 7 , in the 1 st symbol frame, the 1 st data frame follows the S&P field with zero offset. The S&P field and 1 st data frame are parsed into Huffman codewords, which are then mapped into modulation symbols indexed by 1, 2, 3, . . . N s . The end of the 1 st data frame is reached before the N s th modulation symbol has been determined. The data frame is padded with fill bits until the N s th modulation symbol is obtained. The 2 nd data frame follows the S&P field of the 2 nd symbol frame again with zero offset. Now the last symbol of the 2 nd symbol frame is found before the 2 nd data frame is completely encoded. The S&P field of the 3 rd symbol frame is inserted and encoding of the remaining part of the 2 nd data frame is then continued, followed by encoding the 3 rd data frame. The pointer in the S&P field indicates the offset of the 3 rd data frame from the S&P field. The 3 rd data frame can again not completely be encoded in the 3 rd symbol frame. The 4 th data frame becomes completely encoded in the 4 th symbol frame and is padded with fill bits, and so on. The pointer information in the S&P fields enables a receiver to recover from bit insertion and deletion errors.
To determine the overhead in framing bits per symbol, first let B n be the number of bits that are encoded into the N s symbols of the n th symbol frame. As mentioned above, the mean and standard deviation of the number of bits encoded per symbol dimension are R h and σ R h , respectively, as given by (9) and (10). Then B=N s KR h is the mean and σ B =√{square root over (N s K)}σ R h the standard deviation of B n . For large N s , the probability distribution of B n will accurately be approximated by the Gaussian distribution
Pr
(
B
n
=
x
)
≅
1
2
π
σ
B
exp
(
-
(
x
-
B
)
2
2
σ
B
2
)
,
x
=
0
,
1
,
2
,
3
,
…
(
13
)
Next, let P n be the pointer value in the S&P field of the n th symbol frame. The pointer values will remain bounded if B>n sp +N b . Equivalently, the average number of fill bits per frame, n fill , is nonzero:
n fill =B− ( n sp +N b )>0. (14)
Moreover, in a practical implementation the pointer values remain limited to the values that can be represented in the n p -bit pointer subfield, i.e. 0≦P n ≦2 n p −1. Parameters are chosen such that the probability of P n >2 n p −1 becomes negligible. From FIG. 7 , one can verify the recursive relation
P n = { 0 if n sp + P n - 1 + N b ≤ B n - 1 n sp + P n - 1 + N b - B n - 1 otherwise . ( 15 )
The temporal evolution of the pointer probabilities then becomes
Pr ( P n = 0 ) = ∑ x ≥ 0 Pr ( P n - 1 = x ) Pr ( B n - 1 ≥ n sp + N b + x ) , ( 16 ) Pr ( P n = y ) = ∑ x ≥ 0 and x ≥ y - n sp - N b Pr ( P n - 1 = x ) Pr ( B n - 1 = n sp + N b + x - y ) , y = 1 , 2 , 3 , … . ( 17 )
(equation (17) changed to fit within page margins)
The steady-state distribution Pr(P=x)=Pr(P n→∞ =x) can be determined numerically (mathematically speaking, Pr(P=x) is the eigensolution of (16) and (17) associated with eigenvalue one). Pr(P=x) and Pr(P≧x) are plotted in FIG. 8 for the following case.
Lowest-energy 512-QAM, nominal rate R=4 bit/dimension Huffman code design: R h =4.015, σ R h =0.927 bit/dimension; shaping gain G s h =1.412 dB. Assume N s =512 QAM symbols/symbol, N b =4094 bit/data frame, n sp =12 (n s =1, n p =11) B=4111.36, σ B =29.66, n fill =5.36 bit/symbol frame.
The pointer field allows for a maximum pointer value of 2047. FIG. 6 shows that Pr(P>2047) is well below 10 −10 . The pointer values exhibit a Paréto distribution, i.e., log(Pr(P≧x)) decreases linearly for large x.
A framing overhead of (n sp +n fill )/N s =0.034 bit/QAM symbol is found, which is equivalent to an SNR penalty of 0.102 dB. The final net shaping gain becomes 1.412−0.102=1.310 dB.
Based on the above mathematical foundation of Huffman shaping, in one embodiment of the invention, the method of the present invention may generally comprise two parts. The first is related to the design of the Huffman code to be employed on a given channel, and the second is related to the operation of the Huffman shaper in the transmitter. While the above mathematical foundation of Huffman shaping assumes a PAM implementation; extension to higher-dimensional modulation are also possible.
FIG. 9 illustrates one embodiment of the design of a Huffman code in accordance with the present invention. The modulation scheme is characterized by parameters M, α, and s (see (7) and accompanying text above) acquired in block 901 , from which are derived the constellation levels {a i ;i=0, 1, . . . , M −1} also in block 901 . The probability p i is then calculated for each a i in step 903 for i=0, 1, . . . , M −1. Finally, a Huffman code for the symbols {a i } and their corresponding probabilities {p i } is constructed in block 905 .
FIG. 10 is a block diagram of one embodiment of a communication system that operates in accordance with the method of present invention. Upon completion of the construction of the Huffman code in FIG. 9 , a Huffman shaper is employed. Referring to FIG. 10 , Huffman shaper 1001 is loaded with information from a table similar to Table 1 above. The Huffman shaper information comprises one entry for each valid Huffman codeword and a corresponding entry for the channel symbol into which that Huffman codeword is mapped. The information is also sent to the receiver, using means available in the training procedure for the system. Then Huffman shaping proceeds during data transmission.
Specifically, referring again to FIG. 10 , data source 1003 generates (typically binary, but this is not required) data symbols at an adjustable rate controlled by the Huffman shaper 1001 . The data symbols are converted to pseudo-random form in a scrambler 1005 . The Huffman shaper 1001 generally comprises two parts, namely, a Huffman parser 1007 and a mapper 1009 . The Huffman parser 1007 accumulates outputs from the scrambler 1005 , symbol by symbol (e.g., bit by bit), until it accumulates a valid Huffman codeword. This codeword forms the input to the mapper 1009 . The mapper 1009 generates the channel symbol that corresponds to the Huffman codeword and passes the channel symbol to modulator 1011 , under the control of the modulator clock 1013 . The modulator clock 1013 defines the timing of the system. If required by the modulator clock 1013 , the Huffman shaper 1001 controls the rate at which it accumulates output symbols from the scrambler 1005 , in order to meet the demands of the modulator clock 1013 .
Slicer/decision element 1015 maps the symbol received from the channel 1017 into its best estimate of the channel symbol transmitted by the remote transmitter. The Huffman encoder 1019 maps the estimated received channel symbol into a Huffman codeword, which is passed to the descrambler 1021 . The descrambler 1021 inverts the operation of the scrambler 1005 , and the resulting received sequence of data symbols is passed to the user 1023 .
The Huffman shaper 1001 is modeled as being able to control the rate at which data are input to the shaper (see reference numeral 1025 of FIG. 10 ). More colloquially, present-day communication systems often operate in an environment where a large buffer of data are available for transmission, and data can be removed from that buffer at any rate appropriate for the transmission medium. Therefore, ascribing an adjustable rate capability to the Huffman shaper 1001 does not burden the method of the present invention with functionality that is not already present in practical situations.
As described above, a system that employs Huffman shaping carries a variable number of bits per modulation symbol. Therefore channel errors can introduce data in the receiver that is incorrect bit-by-bit, and that actually may contain the wrong number of bits as well. That is, referring to FIG. 10 , if a channel symbol different from the one introduced at the input to the modulator 1011 is received at the output of the slicer/decision element 1015 , then both the bits and the number of bits passed to the Huffman encoder 1019 may be incorrect. To compensate for this potential effect, a framer/deframer may be introduced.
FIG. 11 is another embodiment of the design of a Huffman code in accordance with the present invention, when a framer/deframer is utilized. Again, a PAM implementation is assumed, but extensions to higher-dimensional modulation are also possible. Referring to FIG. 11 , the modulation scheme is characterized by parameters M, α, s, N b , N s , n s , and n p acquired in block 1001 , from which are derived the constellation levels {a i ; i=0, 1, . . . , M −1}(block 1101 ). Parameters N b , N s , n s , and n p define, respectively, the number of data bits, the number of modulation symbols, the number of synch bits, and the number of pointer bits in each symbol frame. The probability p i then is calculated for each a i in block 1103 for i=0, 1, . . . , M −1. Finally, a Huffman code for the symbols {a i } and their corresponding probabilities {p i } is constructed in block 1105 .
FIG. 12 is a block diagram of another embodiment of a communication system that operates in accordance with the method of present invention, utilizing a framer/deframer. Upon completion of the construction of the Huffman code in FIG. 11 , a Huffman shaper is employed. Referring to FIG. 12 , Huffman shaper 1201 is loaded with information from a table similar to Table 1 above. The Huffman shaper information consists of one entry for each valid Huffman codeword and a corresponding entry for the channel symbol into which that Huffman codeword is mapped. A framer 1203 is loaded with parameters N b , N s , n s , and n p . The information is also sent to the receiver using means available in the training procedure for the system. In the receiver a deframer 1205 is loaded with the same parameters, N b , N s , n s , and n p . Then Huffman shaping proceeds during data transmission.
Specifically, referring to FIG. 12 , data source 1207 generates data symbols at an adjustable rate controlled by the Huffman shaper 1201 . The data symbols are converted to pseudo-random form in a scrambler 1209 . The scrambler 1209 output is collected in the framer 1203 , which arranges transmitted data in groups of N b bits per symbol frame, N s modulation symbols per symbol frame, n s synch bits per frame and n p pointer bits per frame as discussed above. The Huffman shaper 1201 generally comprises of two parts, a Huffman parser 1211 and the mapper 1213 . The Huffman parser 1211 accumulates outputs from the framer 1203 , symbol by symbol, until it accumulates a valid Huffman codeword. This codeword forms the input to the mapper 1213 . The mapper 1213 generates the channel symbol that corresponds to the Huffman codeword and passes the channel symbol to the modulator 1215 under the control of the modulator clock 1217 . The modulator clock 1217 defines the timing of the system. If required by the modulator clock 1217 , the Huffman shaper 1201 controls the rate at which it accumulates output symbols from the scrambler 1209 in order to meet the demands of the modulator clock 1217 (see reference numeral 1218 in FIG. 12 ).
The slicer/decision element 1219 maps the symbol received from the channel 1221 into its best estimate of the channel symbol transmitted by the remote transmitter. The Huffman encoder 1223 maps the estimated received channel symbol into a Huffman codeword. In this embodiment, switch 1225 is in position A. The deframer 1205 is able to distinguish individual received modulation symbols by means of the demodulator clock 1227 signal from the demodulator 1229 . It uses the received symbol frame as well as the synch and pointer bits to construct a serial data stream corresponding to the output of the scrambler 1209 . This output is passed to the descrambler 1231 , which inverts the operation of the scrambler 1209 , and the resulting received sequence of data symbols is passed to the user 1233 .
In still another embodiment of the invention, the Huffman code constructed in a slightly modified fashion. This embodiment uses a one-dimensional form of the Huffman code described above. Specifically, a Huffman code is constructed for only the positive modulation symbols. After a Huffman code word has been collected in the transmitter by the Huffman decoder, the decoder uses its next input bit to define the sign of the modulation symbol corresponding to the collected Huffman code word. An inverse procedure is applied in the receiver. Again, a PAM implementation is assumed, but extension to higher-dimensional modulation is also possible.
Referring to FIG. 11 , the modulation scheme is characterized by parameters M, α, s, N b , N s , n s , and n p acquired in block 1101 , from which are derived the constellation levels {a i ; i=0, 1, . . . , M −1} (block 1101 ). Parameters N b , N s , n s , and n p define, respectively, the number of data bits, the number of modulation symbols, the number of synch bits, and the number of pointer bits in each symbol frame. The probability p i is then calculated for each nonnegative a i in block 1103 for i=0, 1, . . . , M −1. Finally, a Huffman code for the nonnegative symbols {a i } and their corresponding probabilities {p i } is constructed in block 1105 .
Upon completion of the construction of the Huffman code in FIG. 11 , a Huffman shaper is employed. Referring to FIG. 12 , Huffman shaper 1201 is loaded with information from a table similar to Table 1 above. The Huffman shaper information consists of one entry for each valid Huffman codeword and a corresponding entry for the channel symbol into which that Huffman codeword is mapped. The framer 1203 is loaded with parameters N b , N s , n s , and n p . The information is also sent to the receiver using means available in the training procedure for the system. In the receiver the deframer 1205 is loaded with the same parameters, N b , N s , n s , and n p . Then Huffman shaping proceeds during data transmission.
Specifically, data source 1207 generates data symbols at an adjustable rate controlled by the Huffman shaper 1201 . The data symbols are converted to pseudo-random form in scrambler 1209 . The scrambler 1209 output is collected in the framer 1203 , which arranges transmitted data in groups of N b bits per symbol frame, N s modulation symbols per symbol frame, n s synch bits per frame and n p pointer bits per frame, as discussed above. The Huffman shaper 1201 generally comprises two parts, the Huffman parser 1211 and the mapper 1213 . The Huffman parser 1211 accumulates outputs from the framer 1203 , symbol by symbol, until it accumulates a valid Huffman codeword. The Huffman parser 1211 then accumulates one additional input bit and appends it to the Huffman codeword. This Huffman codeword with the appended bit forms the input to the mapper 1213 . The mapper 1213 generates the channel symbol that corresponds to the Huffman codeword, and uses the appended bit to define the sign of the channel symbol. It then passes the channel symbol to the modulator 1215 under the control of the modulator clock 1217 .
The slicer/decision element 1219 maps the magnitude of the symbol received from the channel 1221 into its best estimate of the magnitude of the channel symbol transmitted by the remote transmitter. It also estimates the sign of the received symbol. The channel symbol magnitude is passed to the Huffman encoder 1223 , which maps the estimated received channel symbol magnitude into a Huffman codeword and presents the output at the A input of switch 1225 . The sign of the received symbol is presented at the B input of switch 1225 by means of connection sign information 1235 . Switch 1225 , normally in the A position; is switched to the B position after each received Huffman code word, in order to accept the sign information 1235 from the slicer/decision element 1219 . The deframer 1205 is able to distinguish individual received modulation symbols by means of the demodulator clock 1227 signal from the demodulator 1229 . It uses the received symbol frame as well as the synch and pointer bits to construct a serial data stream corresponding to the output of the scrambler 1209 . This output is passed to the descrambler 1231 , which inverts the operation of the scrambler 1209 , and the resulting received sequence of data symbols is passed to the user 1233 .
FIG. 13 illustrates one operation of a system that employs Huffman shaping in accordance with the present invention. A transmitter 1301 accepts user data (block 1303 ). The transmitter 1301 may also perform a framing operation ( 1307 ) to provide a means to recover from possible errors that may be introduced in the channel.
The transmitter 1301 then implements Huffman shaping. Specifically, the transmitter 1301 accumulates source data until a Huffman codeword is recognized (block 1309 ), and then maps the resulting Huffman codeword into a channel symbol (block 1311 ). The transmitter then performs a modulation operation (block 1313 ), which optionally includes sequence coding to increase the signal distances between permitted symbol sequences. Finally, the modulated signal is applied to the input of the communications channel (block 1315 ).
The receiver 1317 accepts the received signal from the channel output (block 1319 ), and demodulates it (block 1321 ). Demodulation generally includes such operations as timing tracking and equalization. The received signal is then subjected to a decision operation, which may optionally include sequence decoding (block 1323 ). The Huffman shaping (blocks 1309 and 1311 ) is inverted by applying the received signal to the input of a Huffman encoder (block 1325 ). The receiver 1317 then performs a deframing operation (block 1327 ), and communicates the received data to the user (block 1331 ).
Based on the foregoing discussion, it should be apparent that in one embodiment of the invention, once data is received from a data source, the sequence of binary data bits is randomized by a scrambling operation and bits are mapped into channel symbols such that the channel symbols occur with a probability distribution suitable for achieving shaping gain. This is accomplished by accumulating scrambled data bits until a Huffman codeword is recognized, at which time the Huffman codeword is mapped into a channel symbol. Then the channel symbol is applied to the input of a communication channel. The probability of recognizing in the scrambled data sequence a particular Huffman codeword of length L bits is 2 −L . Hence, the channel symbol associated with that particular Huffman codeword will be transmitted with probability 2 −L . Note that this channel encoding operation via Huffman codes corresponds in the field of source coding to Huffman decoding.
In one embodiment of the invention, the channel encoding operation described above is performed in combination with a framing operation to achieve transmission of data at a constant rate. In addition, channel symbols can be modulated in various ways before they are applied to the input of the communication channel.
Next, on the receiver side of the communication channel a channel symbol is obtained at the demodulator output. The channel symbol is converted into the corresponding Huffman codeword. The sequence of bits represented by concatenated Huffman codewords is descrambled and delivered to the data sink. The described channel decoding operation corresponds in the field of source coding to Huffman encoding.
In one embodiment of the invention, a deframing operation is performed, which provides for data delivery to the data sink at constant rate. In addition, the deframing operation limits the effect of channel demodulation errors, which can cause a temporal shift of the received binary data sequence. This shift can occur when a channel symbol is erroneously decoded whose associated Huffman codeword differs in length from the Huffman codeword associated with the correct channel symbol.
The method of the present invention results in a symbol constellation and a probability distribution of symbols in this constellation that exhibits a shaping gain of greater than 1 dB. The shaping gain may be, for example, 1.35 dB or 1.5 dB, depending on the specific design. More specifically, for PAM constellations, shaping gains of up to ≈1.35 dB are achieved for some rates. For QAM constellations, shaping gains within 0.1 dB from the ultimate shaping gain are consistently obtained for rates of >3 bit per dimension.
In general, a communication system according to the present invention comprises a communication node that performs a Huffman decoding operation to generate channel symbols with a desired probability distribution.
Many modifications and variations of the present invention are possible in light of the above teachings. Thus, it is to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as described hereinabove. | In a communication system, Huffman coding techniques are used to obtain shaping gains for an improvement in data transmission rates. More particularly, a novel method of Huffman shaping is described that achieves a shaping gain of greater than 1 dB. The shaping gain results in a higher data rate transmission in a communication system where transmitted power is constrained. | 7 |
BACKGROUND OF THE INVENTION
Numerous handgun grip arrangements have been proposed including the use of resilient grip panels with and without internal stiffening members embedded in such panels. Rubber grip panels and wood grip panels of various sizes and shapes have been used over the years.
None of the prior grip arrangements has provided satisfactory gripping by the operator together with an acceptable appearance, versatility and simplicity of design, combined with ease of manufacture.
SUMMARY OF THE INVENTION
Broadly, the present invention provides a novel grip arrangement for handguns in which elastomer grip elements are positioned on each side of the handle frame. The elastomer grip elements have recesses formed in them to receive non-deformable externally inserted stiffening elements. Fasteners are used to secure the elastomer grip elements and externally inserted stiffening elements to each other and to the handle frame.
It is a feature of the invention that the externally inserted stiffening elements are shaped and sized to be capable of being gripped by the handgun operator to move these externally inserted stiffening elements toward the handle frame thus deforming the resilient grip elements and providing a firm and comfortable grip for the handgun operator. The externally inserted stiffening elements further add to the functionality and appearance of the firearm, and the grips so constructed offer the advantages of superior cushioning against recoil and comfortable gripping surfaces for the shooter.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a left side partial elevational view of a revolver including the present invention;
FIG. 2 is a right side partial elevational view of the revolver;
FIG. 3 is a right side elevational view of the handle of the revolver;
FIG. 4 is a rearward elevational view of the handle of the revolver;
FIG. 5 is a sectional view taken along the line 5--5 of FIG. 3;
FIG. 6 is a sectional view taken along the line 6--6 of FIG. 3;
FIG. 7 is a sectional view taken along the line 7--7 of FIG. 3;
FIG. 8 is a sectional view taken along the line 8--8 of FIG. 4;
FIG. 9 is a view taken along line 9--9 of FIG. 4;
FIG. 10 is an exploded perspective view of the revolver including the handle;
FIG. 11 is a right hand elevational view of a first modification of the invention as applied to a revolver;
FIG. 12 is a sectional view taken along the line 12--12 of FIG. 11;
FIG. 13 is a view taken along the line 13--13 of FIG. 11;
FIG. 14 is a sectional view taken along the line 14--14 of FIG. 11;
FIG. 15 is a sectional view taken along the line 15--15 of FIG. 11;
FIG. 16 is a second modification of the present invention as applied to a revolver;
FIG. 17 is a sectional view taken along the line 17--17 of FIG. 16;
FIG. 18 is a sectional view taken along the line 18--18 of FIG. 16;
FIG. 19 is a view taken along the line 19--19 of FIG. 16;
FIG. 20 is a sectional view taken along the line 20--20 of FIG. 16;
FIG. 21 is a view taken along the line 21--21 of FIG. 16;
FIG. 22 is a third modification of the invention as applied to an automatic pistol;
FIG. 23 is a view taken along the line 23--23 of FIG. 22;
FIG. 24 is a sectional view taken along the line 24--24 of FIG. 22;
FIG. 25 is a sectional view taken along the line 25--25 of FIG. 22;
FIG. 26 is a sectional view taken along the line 26--26 of FIG. 22;
FIG. 27 is a left-hand elevational view of the handle of the automatic pistol;
FIG. 28 is a fourth modification of the invention as applied to another automatic pistol;
FIG. 29 is a rearward elevational view of the automatic pistol of FIG. 28;
FIG. 30 is a frontal elevational view of the automatic pistol of FIG. 28;
FIG. 31 is a sectional view taken along the line 31--31 of FIG. 28;
FIG. 32 is a sectional view taken along the line 32--32 of FIG. 28;
FIG. 33 is a sectional view taken along the line 33--33 of FIG. 28;
FIG. 34 is an enlarged view of a portion of FIG. 31;
FIG. 35 is a left-hand side elevational view of a fifth modification as applied to a revolver;
FIG. 36 is, on its left half, a rearward view of the revolver of FIG. 35 and on its right half a sectional view;
FIG. 37 is a sectional view taken along the line 37--37 of FIG. 36;
FIG. 38 is a sectional view taken along line 38--38 of FIG. 35;
FIG. 39 is a partial left-hand side elevational view of a sixth modification as applied to a revolver;
FIG. 40 is a sectional view taken along line 40--40 of FIG. 41;
FIG. 41 is a rearward elevational view of the revolver of FIG. 39;
FIG. 42 is a partial elevational left-hand view of the revolver of FIG. 39;
FIG. 43 is a sectional view taken along line 43--43 of FIG. 42;
FIG. 44 is a sectional view taken along line 44--44 of FIG. 42; and
FIG. 45 is a sectional view taken along line 45--45 of FIG. 42.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning to FIGS. 1-3, revolver 10 includes frame 11, barrel 12, cylidner 13, hammer 14, trigger 16, trigger guard 17, left grip panel 18, right grip panel 19, left grip panel insert 21 and right grip panel insert 22. Also shown are left panel depression are 23 and grip panel fastener 24.
In FIGS. 4-10, it is seen that each panel 18, 19 is made of an elastomer or otherwise deformable material and sized and shaped including notches 20 to abut along narrow abutment surface 25 and to thereby surround handle frame 26. Grip panels 18, 19 each has in it a recess 27, 28 respectively. Recesses 27, 28 each extend a substantial distance up and down and a substantial distance across each panel 18, 19 and each recess 27, 28 receives a grip panel insert 21, 22 respectively. Panel inserts 21, 22 are made of a stiff material such as wood to provide more rigidity and a more pleasing appearance to the handle system which includes handle frame 11, grip panels 18, 19, panel inserts 21, 22 and the fastener arrangement 24 to hold them together The size and shape of the recesses 27, 28 and the inserts 21, 22 housed in them may be varied to control the resilience, stiffness, and appearance of a particular handle system.
Alignment of panel inserts is further controlled by the tolerance between the recess edges 27a, 28a and the sides of the panel inserts 21, 22. In addition, alignment of both panels 18, 19 and inserts 21, 22 is aided by alignment recess holes 30 in the panels 18, 19 and insert openings 31 in the inserts 21, 22 which holes and openings receive stud 32 affixed to handle frame 26 (see FIG. 10). Stud 32 prevents turning or twisting of the grip elements around fastener arrangement 24.
Handle frame 26 is preferably substantially smaller than the grip panels 18, 19 permitting substitution of smaller or larger panels as desired. Where larger panels are used which extend below the frame handle 26, the size and shape of the insert design will permit obtaining the desired flexibility-to-stiffness of the system. For example, a man with a large hand and a strong grip may wish a larger or stiffer insert as compared to a woman with a smaller hand and a less strong grip.
Handle frame 26 and panels 18, 19 are shaped to provide space 33 in front of and behind handle frame 26 (see FIGS. 7, 8). Hammer strut 34, hammer spring 36 and springloaded trigger guard latch mechanism 37 is also shown (FIG. 8 ). Fastener 24 includes bolt 39, nut 41 and washer 42.
Turning to FIGS. 11-15, the second embodiment of the invention includes revolver 40 in which the grip panels 18', 19' do not engage but instead are separated by the handle frame 26'. Further the grip panels 18', 19' each include a second inner recess 43, 44 (positioned opposite outer recesses 27', 28') to provide for right and left spaces 46, 47 between the panels 18', 19' and the handle frame 26'. The purpose and function of inserts 21', 22', fasteners 24' and aliqnment stud 32' are the same as in the earlier described embodiment.
With attention to FIGS. 16-21, the third embodiment is shown adapted for another style of revolver known as the "single action" type. This embodiment shows revolver 50 in which second inner recesses 43', 44' are slightly larger than in the earlier second embodiment. Handle frame 26' includes frame opening 49. All other aspects of the invention are similar to the second embodiment.
With attention now to FIGS. 22-27, an automatic pistol is shown with handle 61 including handle frame 62, flexible grip members 63, 64 and rigid inserts 72, 73. Fasteners 68 pass through holes 69 in the grip members 63, 64 and through holes 71 and the grip inserts 72, 73 for threaded engagement in threaded holes 74 in grip handle frame 62 to avoid interference with the magazine 77. Fasteners 68 are recessed in inserts 72, 73. Also shown is barrel 79, bolts 80 and 81 handle frame release lever.
Turning to FIGS. 28-34 a fifth embodiment is seen in which pistol 90 carries the same handle grip construction as pistol 70 except the flexible grip panels 81, 82 are secured to grip handle frame 83 by lower fasteners 84 which engage notches 86, 87 in the lower ends of panels 81, 82, respectively. The handle construction of pistol 90 further differs in that rigid inserts 88, 89 carry tapered end portions 91, 92 which fit into complementary panel notches 93, 94.
FIGS. 35-38 illustrate another embodiment as shown in which revolver 100 has a handle construction similar to that illustrated in FIG. 11 in that the new grips extend over the revolver's handle with generally the same external contours as the handle. This basic handle style is used on many kinds of revolvers, and FIGS. 35-38 illustrate that this new grip arrangement is adaptable to many guns, such as those manufactured by Smith and Wesson, Colt, Charter Arms, Llama, Taurus, Rossi and others. Also shown are hammer spring 91 and spring anchor piece 92.
Finally, with respect to FIGS. 39-45, revolver 110 includes grip panels 111, 112; inserts 113, 114; grip handle 116 and exposed lower grip handle section 117. Support pin 118 engages grip panels 111, 112 (see FIG. 43). Inserted fastener assembly 121 engages panels 111, 112 to urge them toward frame 116 (FIG. 45). Elastomer element wraps around the rear portion of the grip frame only giving resiliency to that portion and sides only. The front area comprises the grip frame itself. | A grip for a handgun including a deformable elastomer grip part positioned on each side of the handgun handle. One or more of the grip parts has a recess in its outside to receive a non-deformable stiffening element. The size and shape of the recess and stiffening element can be varied to accomplish the desired flexibility-to-stiffness of the handle grip. | 5 |
RELATED APPLICATIONS
This application is a continuation-in-part of patent application Ser. No. 368,921 filed April 16, 1982, which is a continuation-in-part of patent application Ser. No. 197,853, now abandoned and a continuation-in-part of No. 360,523 filed respectively Oct. 17, 1980, and Mar. 22, 1982 now U.S. Pat. No. 4,465,495.
BACKGROUND
A high fuel value coal-wter slurry which can be injected directly into a furnace as a combustible fuel can supplant large quantities of expensive fuel oil presently being used by utilities, factories, ships, and other commercial enterprises.
For many years, coal-water slurries have been successfully transported long distances by pipeline to point of use, such as a utility. Since practical, cost effective pipeline slurries do not possess the requisite characteristics for efficient use as fuels, present practice is to dewater, grind the dried coal cake to finer particle sizes, and spray the dried solid particles into the combustion chamber.
Pipline and fuel coal-water slurries differ markedly in required characterisitics because of their different modes of use.
For efficient, low-cost service, slurries which are pumped through pipelines for long distances should have the lowest possible viscosities and rheology which is preferably Newtonian with zero or negligible yield point. In practice, these requirements are achieved by coal concentrations which are considerably smaller than those desired in the fuel slurry. Particle sizes in the upper end of the size distribution range are excessively large for efficient combustion. A typical long-distance pipeline slurry containing no dispersant has a coal concentration of about 40 to 50% and a particle size distribution of 8 M×0 (U.S. Standard Sieve) with about 20% being -325 M.
A great deal of work has been done to make possible higher loadings in pipeline slurries by adding a suitable organic dispersant which reduces viscosity and improves particle dispersion. A dispersant which has been of particular interest is an anionic compound in which the anion is a high molecular weight organic moiety and the cation is monovalent, e.g., an alkali metal, such as Na or K. The anion attaches to the coal particles to give them a high negative charge or zeta potential, which causes repulsion sufficient to overcome Van der Waal's attraction and, thereby, prevents flocculation with concomitant reduction in viscosity. In accordance with DLVO theory, small monovalent cations maximize the desired negative zeta potential. This phenomenon is discussed in Funk U.S. Pat. No. 4,282,006, which also advises against the use of multivalent cations because they act as counterions which disadvantageously reduce zeta potential. The monovalent salt dispersants have been found to give essentially zero yield points. Pipeline slurries, including those containing the anionic alkali metal organic dispersants, when at rest, tend to separate gravitationally in a short period of time into supernantant and packed sediment which is virtually impossible to redisperse.
For efficient practical use as a fuel, the slurry must have several essential characteristics. It must have long-term static stability so that it can be stored for extended periods of time by suppliers or at the point of use. During such storage, they must remain uniformly dispersed or, at most, be subject to some soft subsidence which can be easily redispersed by stirring. By subsidence is meant a condition in which the particles do not segregate, as in sedimentation, but remain dispersed in the carrier fluid in a gel or gel-like formation. Uniform dispersion is essential for reliably constant heat output. Coal loadings must be sufficiently high, e.g., up to 65 to 70% or higher, to produce adequate fuel value despite the presence of the inert water carrier. The coal particles must be small enough for complete combustion in the combustion chamber. The slurry must also be sufficiently fluid to be pumped to and sprayed into a combustion chamber. However, the low viscosities required for pipelinable slurries are not required for a fuel slurry. Such fuel slurries have hitherto eluded the commercial art.
It is obvious that a process which can convert coal directly into a fuel slurry or transform pipeline slurry at its terminal into a fuel slurry having the aforedescribed characteristics without requiring dewatering the coal to dryness would be most advantageous.
Coal-water slurries which have the aforesaid requisite properties for effective use as fuels which can be used as a substitute for fuel oil, are disclosed in copending Robert S. Scheffee patent applications Ser. No 197,853 now abandoned and No. 360,523, the teachings of which are hereby incorporated by reference. These applications teach the use of alkaline earth metal organosulfonate dispersants to form stable coal-water fuel slurries which have coal-loading capacity as high as 70% or more and particular bimodal particle size distributions. The divalent metal salt acts both as dispersant and slurry stabilizer. The fuel slurries are thixotropic or Bingham fluids which have yield points; become fluid and pourable under relatively small stresses to overcome the yield point; and have the long-term static stability required for a practical fuel. The viscosities of these slurries, though not excessively large for handling and use, are considerably higher than those obtained with ammonium salts alone.
Fuel slurries, such as those prepared in accordance with the present invention, which have substantially lower viscosities than those obtained with the divalent salts alone, while retaining the same long-term static stability and other properties required for use as a fuel, have important advantages in terms of ease of handling and power consumption. Application Ser. No. 368,921 discloses that the use of anionic monovalent cation salt organic dispersant, such as the alkali metal salts together with anionic alkaline earth metal salt organic dispersant, produces these highly desirable results. It has been found that use of the ammonium salt as the cationic monovalent salt provides the desired results and has the additional advantage of not producing slag as a combustion product.
Generally, the prior art has focused on reducing viscosity and, thereby, increasing loadings and pumpability of pipeline slurries. The art has taught the use of anionic ammonium, alkali metal, or alkaline earth metal organic dispersants as equivalents for these objectives, and has shown the monovalent cationic salt dispersants to be superior. None of the references teach or suggest the unique capability of the alkaline earth metal salts as long-term static stabilizers or their combination with monovalent cation salts such as alkali metal or NH 4 salt derivatives, to produce the stable fuel slurries of the present invention. References of interest include Wiese et al. U.S. Pat. No. 4,304,572 and Cole et al. U.S. Pat. No. 4,104,035 which disclose the use of ammonium, alkali metal or alkaline earth metal salts of organosulfonic acids to improve slurry loading and pumpability. In both cases the data show the monovalent salts to be superior for the stated objectives.
SUMMARY
Fuel slurries comprising up to about 70% or higher of coal stably dispersed in water are produced by admixing finely-divided coal, water, a minor amount of anionic ammonium salt organic dispersant, and a minor amount of anionic alkaline earth metal salt organic dispersant.
The coal particle sizes should be within efficient combustion size range. Given the present state of the art, 100% of the coal is desirably about -40 M (420μ) and at least about 40% is -200 M. Preferably, at least about 50% is -200 M. A suitable coal size distribution is prepared from a bimodal mixture comprising about 10 to 50 wt. %, preferably 10 to 30 wt. % on slurry, of particles having a size up to about 30μ MMD (mass median diameter), preferably about 1 to 15μ MMD, as measured by a forward scattering optical counter, with the rest of the coal being larger particles having a size range of about 20 to 200μ MMD. Crushed coal can be ground in known manner to produce the particle sizes required for preparation of the fuel slurries.
The actual degree of coal loading is not critical so long as it is sufficient to provide adequate heat output. The maximum concentration of coal successfully incorporated into a given slurry may vary with such factors as particle size distribution, the particular dispersants used and their total and relative concentrations.
As disclosed in Ser. No. 197,853, the alkaline earth metal salt organic dispersant is added to the slurry in an amount sufficient to impart a substantial yield point and to maintain the slurry in stable dispersion for extended storage periods without separation of the coal particles into packed sediment.
The NH 4 salt organic dispersant is added to the slurry in an amount sufficient to impart substantially reduced viscosity, as compared with that imparted by the alkaline earth metal salt organic dispersant alone without destabilizing the slurry. As will be seen from the Examples, the slurries containing only the ammonium salt generally have a minimal yield point. Also as disclosed in Ser. No. 197,853, the long-term static stability requires a thixotropic or Bingham fluid with an appreciable yield point. The optimum amount of the combination of alkaline earth metal and ammonium salt organic dispersants which will accomplish the desired long-term stability results without excessive increase in yield point or viscosity can readily be determined by routine tests to determine yield point and viscosity in which the amounts and ratios of the ammonium and alkaline earth metal salt dispersants are varied.
It is believed that the relative proportions of the available ammonium and alkaline earth metal cations provided by the respective dispersants play an important role in imparting stability and determining yield point and viscosity. However, so many other factors, such as the particular coal, the particular particle size distribution, and the particular dispersant anions, also affect rheological properties in varying and generally unquantifiable degree, that it is difficult to specify generically an optimum ratio of the mono- and divalent cations which would necessarily apply to different specific slurries. In general, increasing valency of the cationic charge by increasing the ratio of the divalent to monovalent cations, e.g., Ca++:NH 4 +, produces increasingly stable soft gels, with increase in yield point and viscosity as the proportion of multivalent ions increases.
The anionic ammonium and anionic alkaline earth metal (e.g., Ca, Mg) organic dispersants preferably have organic moieties which are multifunctional and high molecular weights, e.g., about 1,000 to 25,000. Examples of useful dispersants include organosulfonates, such as the NH 4 lignosulfonates, NH 4 napthhalene sulfonates, Ca lignosulfonates, and Ca naphthalene sulfonates, and organo carboxylates, such as NH 4 lignocarboxylate. The ammonium and alkaline earth metal organosulfonates are preferred. The total amount of the two types of dispersant used is minor, e.g., about 0.1 to 5 pph coal, preferably about 0.5 to 2 pphc.
In some cases, it may be desirable to add an inorganic salt or base to control pH of the slurry in the range of about pH4 to 11. This may improve aging stability, pourability, and handling characteristics of the slurry. A salt, such as ammonium phosphate, or a base, such as NH 4 OH, NaOH or KOH, is used in minor amounts sufficient to provide the desired pH, e.g., about 0.1 to 2% based on the water. Other additives which may be included are biocides and anti-corrosion agents.
The finely-divided coal particles, water, and dispersants are mixed in a blender or other mixing device which can deliver high shear rates. High shear mixing, e.g., at shear rates of at least about 100 sec -1 , preferably at least about 500 sec -1 , as disclosed in patent application Ser. No. 197,853 is essential for producing a stable slurry free from substantial sedimentation.
The slurries can generally be characterized as thixotropic or Bingham fluids having a yield point. When at rest, the slurries may gel or flocculate into nonpourable compositions which are easily rendered fluid by stirring or other application of relatively low shear stress sufficient to overcome the yield point. They can be stored for long periods of time without separation into packed sediment. They may exhibit some soft subsidence which is easily dispersed by stirring. Slurries embodying these characteristics are included in the term "stable, static dispersions" as employed in the specification and claims. The slurries can be employed as fuels by injection directly into a furnace previously brought up to ignition temperature of the slurry.
In addition to preparing the stable fuel slurry directly from dry coal ground to the desired particle sizes as aforedescribed, the invention can be employed to convert a pipeline slurry at its destination into a fuel slurry and, thereby, eliminate the present costly requirement for complete dewatering. The process of the invention is highly versatile and can be applied to a wide variety of pipeline slurries.
The details of the conversion process are determined by the make-up of the particular pipeline slurry. As aforedescribed, pipeline slurries generally have lower coal concentrations and larger particle sizes than are required for effective fuel use and may or may not include a viscosity-reducing monovalent cation salt organic dispersant.
In the case of pipeline slurries which do not contain dispersant, the following procedures can be used:
Coal concentration can be increased to fuel use requirements by partial dewatering or by addition of coal. After such adjustment, the slurry is passed through a comminuting device, such as a ball mill, to reduce the coal particles to the desired fuel size. It should be noted that increasing concentration by coal addition can be done after ball milling, but preferably precedes it.
Addition of the ammonium and alkaline earth metal organic dispersants can be done after the milling. Preferably at least some to all of the ammonium or alkaline earth metal dispersant or some to all of both are added to the coal-water slurry prior to milling. When only a portion of the dispersant(s) is added during milling, the remainder is added subsequently, together with any other additives such as biocides, buffer salts, bases and the like. The slurry mixture is then subjected to high shear mixing, as aforedescribed. The amount and ratio of total ammonium and alkaline earth metal dispersants added for optimum stability, viscosity, and yield point are determined by routine tests as aforedescribed.
In the case of pipeline slurries which include an ammonium salt organic dispersant to reduce viscosity and increase coal concentration, the following procedures can be used:
If the coal concentration is inadequate for fuel use, it can be adjusted by partial dewatering or addition of coal. If coal concentration in the pipeline slurry is adequate, this step can be omitted. Generally, coal particle sizes are larger than desired for fuel use for reasons of reducing viscosity, so that the slurry requires passage through a milling device. The slurry contains its original ammonium salt organic dispersant which assists in the milling procedure. Some or all of the alkaline earth metal dispersant can also be added to the wet milling process.
After determination of the concentration of ammonium salt dispersant in the pipeline slurry, the optimum amount of alkaline earth metal dispersant and any additional ammonium dispersant required is determined by routine test. After addition of dispersant and any other desired additives, such as biocides, buffer compounds, bases, and anti-corrosion agents, the slurry mixture is subjected to high shear mixing.
The fuel slurries made from the long-distance pipeline slurries are substantially the same as those produced directly from dry coal.
DETAILED DESCRIPTION
Example 1
A series of slurries containing 65% by weight of West Virginia bituminous coal was prepared with 1.0 pphc (parts per hundred of coal), (0.65% slurry) of a mixture of NH 4 and Ca lignosulfonates and with 1.0 pphc of the NH 4 or Ca dispersant only. The coal was a bimodal blend comprising 70% of a coarse fraction having an MMD of 37μ and a maximum size of about 300μ and 30% of a fine fraction having a 7.8μ MMD (45.5 and 19.5% respectively by weight of slurry). MMD of the blend was 16μ.
The larger particle sizes were determined by sieving. Sub-sieve particle sizes were determined by a forward scattering optical counter which is based on Fraunhofer plane diffraction.
The coarse fraction was prepared by dry ball milling and sieving through a 50 mesh screen. The fine grind was prepared by wet ball milling for 2 hours. The wet ball milling was done with 60% of total dispersant. The remaining 40% was added during mixing. Preferably, though not essentially, the coal is milled with water so that the very fine particles are in water slurry when introduced into the mixer. At least some of the dispersant is included in the ball milling operation to improve flow and dispersion characteristics of the fine particle slurry.
The fuel slurry blends were prepared by mixing the coarse fraction, the fine ball-milled fraction, additional dispersant, and water in the amounts required for the desired slurry composition. Each of the slurries also contained 0.2 pphc NH 4 OH, to provide a slightly basic pH. The amounts of the NH 4 and Ca dispersants were changed to vary the ratio of the NH 4 + and Ca++ cations. The weight ratio of NH 4 to Ca dispersant was varied from 1:0 to 0:1 pphc. While the total dispersant content was maintained constant at 1 pphc, the total product of valence times cation molar content was held constant at 2.4 charges per unit weight of coal. Thus the valency was systematically varied from monovalent to divalent while maintaining constant total charge. The particular dispersants used were an ammonium lignosulfonate containing 4.4 wt % NH 4 and a calcium lignosulfonate containing 5% Ca.
The slurries were prepared by premixing the dry-milled and wet-milled grinds and the remaining dispersant, base, and water in a planetary baker's type low-shear mixer, followed by high-shear mixing (Oster) at a shear rate of about 1000 sec -1 . The "low-sheared" and "high sheared" samples were evaluated for pH, yield point, and viscosity, and were stored at room temperature (70° F.) for observations of stability. Yield point and viscosity were measured using a Brookfield rotational viscometer with cylindrical spindles.
Results are summarized in Table 1.
It will be seen that none of the low-sheared mixes was stable, demonstrating that high shear mixing is an essential processing step for stability.
The ammonium dispersant alone imparts very low viscosity and negligible yield point, which makes it suitable for pipeline use, and no appreciable static stability, which makes it unfit for use as a fuel. The Ca dispersant alone imparts substantially higher viscosity and yield point, which makes it unfit for practical use as a pipelinable slurry, and long-term static stability, which makes it suitable for use as a fuel.
The data also show that as valency of the cation charge is increased by reducing NH 4 concentration and increasing Ca content, viscosity, yield point, and stability increase until, at an NH 4 /Ca dispersant ratio of 0.2/0.8, the slurry is substantially as stable as the Ca only slurry and has substantially lower viscosity and yield point, namely 3.7 p and 1.0 dyne/cm 2 vs. 5.9 p and 7.5 dynes/cm 2 . The NH 4 /Ca slurry, like the Ca-only slurry, is still stable after static storage for up to 2 weeks.
It can be seen that the monovalent NH 4 dispersant can be added to the highly stable Ca dispersant slurries to reduce viscosity and yield point without sacrificing the long-term static stability essential for a storage fuel slurry.
Example 2
A series of slurries containing 65% by weight (bone dry) of West Virginia bituminous coal was prepared by charging a ball mill with crushed coal, additives, and water, and milling to a size consist of 100% -100 M and 90-95% -200 M. The coal feed had been crushed to a size consist of 10 M×0 (<2000μ), and as in Example 1, the additives were NH 4 and Ca lignosulfonates at a constant dispersant content of 1 pphc, and 0.2 pphc NH 4 OH. Upon being discharged from the mill, the slurries were mixed in a high shear mixer at a shear rate of about 1000 sec -1 . Samples of sheared and unsheared slurry were stored at room temperature for observation of stability, after having been evaluated for pH and viscosity. These evaluations were carried out as described previously in Example 1. The results of these tests are summarized in Table 2.
As in Example 1, the NH 4 dispersant alone imparts low viscosity, negligible yield point, and inadequate static stability. Ca dispersant alone imparts relatively high viscosity and yield point and good long-term static stability. As the ratio of NH 4 /Ca in the mixed dispersants drops, viscosity, yield point, and stability increase. At NH 4 /Ca ratios of 0.4/0.6 and 0.2/0.8, despite substantially lower viscosity and yield point as compared with the 0.1 ratio, long term static stability is substantially the same, namely at least two weeks.
Example 3
A 65 wt. % pipeline bituminous coal-water slurry was prepared by mixing 45.5 parts of a coarse fraction crushed to 10 M (2000μ)×0 with an MMD of 530μ; 19.5 parts of a fine coal fraction wet ball milled to 50 M (300μ)×0 and an MMD of 18μ; 0.65 parts of an ammonium lignosulfonate containing 2.4 mmol NH 4 per 100 g coal, and a total of 33.35 parts water.
The coal, water, and NH 4 dispersant were mixed in a Hobart mixer. Viscosity of the mix was 1.25 p. Although the slurry was exceedingly unstable at rest, the very low viscosity obtained with the NH 4 lignosulfonate dispersant makes it useful as a long-distance pipeline slurry.
0.65 parts of a calcium lignosulfonate were added to the above slurry, which was then charged to an 8 5/8 inch diameter ball mill and milled 45 minutes. The resulting slurry was fluid and had a size consist of 99.6% -140 M with 96% -200 M, which is well within the desired particle size range for efficient combustion. It was then subjected to high shear mixing at about 6000 rpm in an Oster blender. After the blending, viscosity at 10 sec -1 was 4.8 p. The slurry was fluid and stable. At rest, it was a soft non-pourable gel with slight supernatant and very slight sediment after seven days. It became fluid and pourable with easy stirring.
TABLE 1__________________________________________________________________________ NH.sub.4 /Ca Molar Ratio, Rheological ConstantsLignosulfonate mmoles High Viscosity Yieldcontent, pphc per 100 Shear Poise Point Stability @ 1 Day Stability @ ˜ 1-2 weekNH.sub.4 Ca gm coal Mixed at 10 sec.sup.-1 dynes/cm.sup.2 pH Super. Sub. Sed. Super. Sub. Sed.__________________________________________________________________________1.0 0 2.4/0 No 3.8 .7 8.6 Yes Pkd -- Yes 1.3 .3 8.2 Yes Pble Pkd Yes Pkd0.6 0.4 1.4/.48 No 7.3 0.5 9.0 Yes Pkd Yes 2.0 0.7 9.0 Yes Pble Sl Yes Pkd0.5 0.5 1.2/.6 No 7.1 0.5 9.0 Yes Pkd Yes 2.4 0.3 9.0 Sl Pble Sl Yes Pkd0.4 0.6 .96/.72 No 7.3 0.7 9.1 Yes Pkd Yes 3.0 0.7 9.0 Sl Pble Sl Yes Pkd0.2 0.8 .48/.96 No 4.7 0.9 9.1 Yes Pkd Yes 3.7 1.0 9.0 No Pble No Sl V.Soft No0 1.0 0/1.2 No 6.4 0.9 8.8 Yes Pkd Yes 5.9 7.5 9.0 No Pble No Sl Soft No__________________________________________________________________________ Abbreviations: Super. = superate Sl. = slight Sub. = subsidence Pble = pourable Sed. = sediment Pkd = packed
TABLE 2__________________________________________________________________________ NH.sub.4 /Ca Molar Ratio, Rheological ConstantsLignosulfonate mmoles High Viscosity Yieldcontent, pphc per 100 Shear Poise Point Stab. @ 1 day @ ˜ 1 week @ ˜ 2 weeksNH.sub.4 Ca gm coal Mixed at 10 sec.sup.-1 dynes/cm.sup.2 pH Super. Sub. Sed. Super. Sub. Sed. Super. Sub. Sed.__________________________________________________________________________1 0 2.4/0 Yes 1.4 0.08 Yes Pble Soft Yes Pble Pkd Yes Pble Pkd0.6 0.4 1.4/.48 No 2.7 0.05 9.3 Yes Pble Pkd -- Yes 3.1 0.05 Yes Pble No Yes Pble Pkd Yes Pble Pkd0.4 0.6 .96/.72 No 4.1 0.23 9.4 Yes Pble Pkd Yes Non- Pkd Pble Yes 3.8 0.1 No Pble No Sl Pble No Sl Soft No0.2 0.8 .48/.96 No 4.2 0.13 9.4 Yes Pble Pkd Yes Pble Pkd Yes Pkd Yes 4.2 0.10 No Soft No Sl Soft No Yes Soft Sl0 1.0 0/1.2 Yes 8.3 13 9.4 No Soft No Sl Soft No Yes Soft No__________________________________________________________________________ to the desired reduced size consist; and high shear mixing. In this case the 65% pipeline coal concentration was adequate for efficient use as a fuel. It should be understood that if coal concentration in the pipelinable slurry is inadequate, it can be increased by partial dewatering or addition of dry coal. If the pipeline slurry does not contain dispersant, the ammonium salt organic dispersant can be added prior to milling, or before or after high shear mixing, preferably before.
This example also demonstrates the importance of high shear mixing in preparation of the stable fuel slurry.
While the present invention has been described by specific embodiments thereof, it should not be limited thereto, since obvious modification will occur to those skilled in the art without departing from the spirit of the invention or the scope of the claims. | Coal-water fuel slurries having long-term storage stability and improved viscosities and comprising finely-divided coal within efficient combustion size range, water, and minor amounts of ammonium salt organic dispersant and alkaline earth metal salt organic dispersant, and process for making such slurries. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a two-stage fuel injector equipping the combustion chambers of gas turbines.
[0003] 2. Discussion of the Background
[0004] It improves devices such as that described in French patent 2 832 492, the structure and operation of which can be summarized as follows. Two valves are arranged in series in an outer bushing of the injector and are biased separately into closed positions by respective springs. The fuel fed into the injector by a pump passes through a filter and weighs on the first valve, which is a primary valve biased by a weak spring. A moderate pressure is therefore enough to open said valve, and the fuel passes through it and then flows along a primary path which leads it out of the injector. The primary path comprises an annular portion between the outer bushing and an inner body, in which the other valve or secondary valve is housed in a sliding manner. The fuel also weighs on the secondary valve, which is biased by a much stronger spring than the previous spring. It therefore does not move until a pressure is reached which is greater than that necessary to displace the primary valve and to open the primary fuel path, but once it too has been opened it opens up a secondary fuel path which branches from the primary fuel path and passes through the secondary valve. The flow of fuel delivered by the injector is then increased by the additional flow which flows through this secondary fuel path. This secondary flow is used in certain regimes of the engine in which the injector is employed.
[0005] The idea here is to enrich the mixture delivered by the injector, i.e. to increase the fuel flow, but only in the primary flow regime. This enrichment might be required in order to improve the ignition capacity during high-altitude flight and also on the ground. It will concern only some of the injectors of the engine. The temptation will therefore be to modify existing injectors instead of using a completely new design or a different model. It will in particular be advantageous if the injector sought is identical to the existing injector with regard to the parts governing the secondary flow.
SUMMARY OF THE INVENTION
[0006] According to the invention, this is achieved by means of a two-stage fuel injector comprising two valves arranged in series and biased towards closed positions, namely a primary valve arranged on a primary fuel path and a secondary valve arranged on a secondary fuel path, the primary fuel path and the secondary fuel path branching downstream of the primary valve, and an inner body in which the secondary valve slides and which delimits the primary path, the secondary path comprising a central cavity of the secondary valve and at least one hole passing radially through the secondary valve between its periphery and the central cavity, characterized in that it comprises at least one orifice passing through the inner body between the primary fuel path and the secondary valve and opening into the hole when the secondary valve is in the closed position.
[0007] In order to achieve perfect enrichment of only the primary flow, it is advantageous if the orifice passing through the inner body opens into an end portion of the hole, in a direction towards the upstream end of the secondary fuel path.
[0008] In many customary injectors, however, the piercing of the orifice will produce an excessive primary flow. It will then be useful to replace, over part of its length, the annular portion of the primary flow path with another orifice which can be calibrated to the required diameter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Other characteristics and advantages of the invention will become apparent from the following detailed description, particularly when considered in conjunction with the drawings in which:
[0010] FIG. 1 shows a cross-section view of the injector according to an exemplary embodiment of the present invention with the primary flow alone;
[0011] FIG. 2 shows a cross-section view of the injector according to the embodiment of FIG. 1 , with the primary flow and secondary flow; and
[0012] FIG. 3 shows a flow curve obtained as a function of fuel pressure for an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] The invention will now be described in connection with FIGS. 1 and 2 , which show an injector according to the invention in states with the primary flow alone and with the primary flow and secondary flow, respectively.
[0014] The injector in FIGS. 1 and 2 comprises a cylindrical outer bushing 1 which is hollowed out in places between its two end faces. It contains at the upstream end a strainer-type fuel filter 2 and opens via a fuel inlet orifice 3 . The fuel filter 2 bears against a diaphragm 4 with a central orifice 5 which is designed to regulate the flow of fuel in the face of size variations produced during manufacture, according to the teaching of French patent 2 832 492 already cited at the start of this text. A bearing seat 6 for a primary valve 7 extends further downstream in the outer bushing 1 . A weak spring 28 biases the primary valve 7 against the seat 6 towards the upstream end of the injector. When the force of the spring 8 is overcome by the pressure of the fuel, the primary valve 7 moves downstream and allows the fuel to pass around it.
[0015] The outer bushing 1 also comprises an inner body 8 with a piercing 9 in which there slides a secondary valve 10 which is biased by a spring 11 towards the upstream end as far as a stop position, which can be produced by a collar 12 of the secondary valve 10 which is located at the downstream end and which bears against a corresponding seat portion of the inner body 8 . The secondary valve 10 comprises a central cavity 13 , although this does not pass all the way through it, and holes 14 of radial orientation which allow the central cavity 13 to communicate with the peripheral surface of the secondary valve 10 and which open in front of the wall of the piercing 9 of the inner body 8 . Slots 15 are cut on the secondary valve 10 so as to extend the holes 14 towards the downstream end in order to give the desired fuel flow in the secondary regime as a function of its pressure and the degree of closing of the secondary valve 10 .
[0016] The downstream end of the injector comprises a system of concentric conduits, the end of which penetrates into the outer bushing 1 . A downstream body 16 is housed therein and connects to the inner body 8 already mentioned. The downstream body 16 is pierced by a secondary fuel discharge conduit 17 , in the centre of which there is a primary fuel discharge conduit 18 .
[0017] After having passed the primary valve 7 , the fuel takes a primary flow path which passes around the primary valve 7 and then around the inner body 8 , into an annular slot 19 located between the inner body and the outer bushing 1 , and then around the downstream body 16 into an extension of this slot and finishing in the primary discharge conduit 18 . The fuel also flows around the secondary valve 10 and in its central cavity 13 , and it weighs against the secondary valve but does not displace it until it has reached a higher pressure. The state shown in FIG. 2 is then reached: the holes 14 or the slots 15 meet the end of the piercing 9 of the inner body 10 and a secondary flow circuit is opened up which is established through the central cavity 13 , the holes 14 and the slots 15 , and a chamber 20 formed by the downstream body 16 below the inner body 8 ; the fuel finally reaches the secondary flow conduit 17 .
[0018] The characteristic elements of the invention will now be considered. An orifice 21 is pierced through the inner body 8 and extends from one of the holes 14 to the annular slot 19 in the state shown in FIG. 1 . The primary fuel flow path therefore comprises a branching which passes through the central cavity 13 and the orifice 21 and gives rise to the desired enrichment in this regime. It must be emphasized that the orifice 21 opens immediately downstream of a solid portion of the secondary valve 10 in this position in which it rests against its seat. Thus, as shown clearly in FIG. 2 , the orifice 21 is closed off by the secondary valve 10 as soon as it is displaced when the secondary flow is established, so that the enrichment then ceases.
[0019] Contrary to a previous design, the annular slot 19 is interrupted by a collar 23 of the inner body 8 which extends as far as the outer bushing 1 ; the primary fuel flow path is re-established by an orifice 22 passing through this collar 23 and joining the two portions of the annular slot 19 ; it is possible to calibrate said orifice to a very precise diameter, just like the orifice 21 , so as to perfectly control the primary fuel flow.
[0020] FIG. 3 shows the flow curve obtained as a function of the pressure of the fuel, with a first portion 24 representative of the flow rate in the primary regime obtained with the known injection, a second portion 25 representative of the primary flow obtained with the injector of the invention, and a portion 26 which is obtained in the secondary flow regime and which, according to the object of the invention, is identical for the new injector and for the old injector. | This injector with two valves ( 7, 10 ) which open at different fuel pressures so as to establish a primary flow regime and then a secondary flow regime is characterized in that the primary regime is enriched with fuel via an orifice ( 21 ) which adds a branch to the primary flow path of the fuel, but which is closed when the secondary valve is displaced so as to prevent enrichment of the fuel in the secondary regime. This invention applies in particular to certain aircraft engines. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a process for preparing hydroxylammonium salt through catalytic reduction of nitrate ions in an acidic medium and in the presence of an activated catalyst. The catalyst comprises carrier particles with metal particles containing palladium and platinum.
2. Description of the Related Art
An important application of hydroxylammonium salts is in the preparation of oximes from ketones or aldehydes, for instance, the preparation of cyclohexanone oxime from cyclohexanone. Cyclohexanone oxime can be rearranged into caprolactam, from which nylon is prepared. Consequently, the synthesis of hydroxylammonium salts is commonly coupled with other known processes, such as the preparation of cycloalkanone oxime. Hydroxylammonium salts are also used in the production of antioxidants, dyeing auxiliaries, and photographic chemicals.
In the synthesis of hydroxylammonium, nitrate ions or nitrogen oxides, for example, are converted into hydroxylammonium ions with the aid of hydrogen according to the following reaction:
2H.sup.+ +NO.sub.3.sup.- +3H.sub.2 →NH.sub.3 OH.sup.+ +2H.sub.2 O.
Oximes can be prepared by a cyclic process in a reaction medium buffered with an acid (e.g., phosphoric acid and/or sulphuric acid) and buffer salts derived from the acid (e.g., alkali salts and/or ammonium salts). The cyclic process involves two synthesis zones. In a hydroxylammonium salt synthesis zone, the nitrate ions or nitrogen oxides are converted with hydrogen to hydroxylamine. The hydroxylamine reacts with free buffer acid to form the corresponding hydroxylammonium salt, which is then transported to an oxime synthesis zone where the hydroxylammonium salt reacts with a ketone to form the corresponding oxime, with release of acid. After separation of the oxime from the reaction medium, the reaction medium is returned to the hydroxylammonium salt synthesis zone and fresh nitrate ions or nitrogen oxides are added to the reaction medium.
Catalysts for the preparation of hydroxylammonium salts are commercially available, for example, from Johnson Matthey and Degussa. However, the activity and selectivity of these catalysts can be improved. An improved catalyst would make the process of preparing hydroxylammonium salts more efficient.
SUMMARY OF THE INVENTION
An objective of this invention is to provide a process with better selectivity and/or activity for the production of hydroylammonium salts by using an improved catalyst. The improved catalyst is provided as metal particles, the metal particles comprising the noble-metals palladium and platinum, deposited on carrier particles; the concentrations of palladium and platinum are substantially the same among different metal particles. This is not the case with present commercial catalysts. The concentration of palladium is not necessarily substantially the same in each metal particle as the concentration of platinum; instead,"substantially the same" means the concentrations of the relevant noble metal has a narrow distribution among different metal particles.
Hydroxylammonium salt is prepared through catalytic reduction of nitrate ions in an acidic medium, in the presence of an activated catalyst. The catalyst is provided as a metal particle comprising palladium and platinum; the platinum concentration among different metal particles has a standard deviation of less than about 4% absolute, preferably less than about 3.5%, and more preferably less than about 3%. Standard deviation (% absolute) is calculated by dividing the standard deviation of platinum concentrations of different metal particles by the average platinum concentration. The platinum concentration in each metal particle is the same as the weight percentage in each metal particle. In addition, the palladium:platinum ratio in each metal particle may be between about 7:3 and about 9.9:0.1. Preferably, the size of the metal particle may be between about 0.5 nm and about 20 nm; more preferably, the size of the metal particle is between about 1 nm and about 15 nm. The particle size of the carrier may be between about 0.1 μm and about 50 μm, and the carrier material may consist essentially of active carbon or graphite. The metal particles may be deposited on the walls of the pores of the carrier particles.
The advantages of the improved catalyst include increased activity in the reduction of nitrate ions, even at modest pressures, and increased selectivity for hydroxylamine. The improved catalyst increases the efficiency of producing hydroxylammonium salts by increasing the yield of hydroxylamine relative to unwanted products (e.g., nitrous oxide, nitrogen monoxide) and/or by operating the process at lower pressures, thus, lowering operational costs.
DETAILED DESCRIPTION OF THE INVENTION
Nitrate ions in an acidic medium are reduced to hydroxylammonium salt in the presence of an activated catalyst. The catalyst is provided as metal particles, each particle containing the noble-metals palladium and platinum, deposited on carrier particles; the concentrations of the palladium and the platinum in each metal particle are substantially the same."Substantially the same" is defined as a standard deviation of the platinum concentrations of the palladium-platinum alloy particles of at most about 4% absolute. Preferably the standard deviation of the concentration thus defined is smaller than about 3.5%; more preferably, the standard deviation is smaller than about 3%. The absolute error in the palladium concentration is the same as the absolute error in the platinum concentration.
The weight ratio of the palladium and the platinum may lie between about 6:4 and 9.9:0.1. Preferably the weight ratio lies between about 7:3 and 9.5:0.5. The weight ratio of platinum between different metal particles is also substantially the same.
In principle, any material that is stable in the reaction medium can be used as the carrier, for example active carbon or graphite. Silica is another possible carrier material.
The average particle size of the carrier is usually smaller than 50 μm. "Average particle size" is understood to mean that 50 vol. % of the particles is larger than this diameter. However, a carrier with at least 90 vol. % of the total number of particles having a diameter of less than about 20 μm has also proved to be suitable. In view of the smallness of such carrier particles, removing the catalyst through filtration may prove difficult. Normal filtration may be achieved without adversely affecting the catalyst's activity by adding an amount of inert material, for example carrier material without metal particles, having a particle diameter that exceeds that of the carrier particles of the catalyst, for example about 20-100 μm. An amount of about 0.3-10 g of inert material per gram of catalyst material is suitable.
Usually the average carrier particle size exceeds about 0.1 μm. If a cross-flow filtration technique is used, such as described in U.S. Pat. No. 5,362,398, the carrier particle size preferably exceeds about 1 μm, in particular it exceeds about 5 μm. If a more conventional filtration technique is used, the carrier particle size preferably exceeds about 10 μm .
The catalyst must be activated; the catalyst may be activated by the presence of one or more catalyst activators. Catalyst selectivity for different hydroxylamines depends on the specific element used as an activator. The catalyst activator may be an element from the group comprising Cu, Ag, Au, Cd, Ga, In, Tl, Ge, Sn, Pb, As, Sb and Bi. Compounds containing the elements in question may also be used as catalyst activators, for example oxides, nitrates, phosphates, sulphates, halogenides, tartrates, oxalates, formiates and acetates. The elements or their compounds can be directly applied to the catalyst as described in U.S. Pat. No. 3,767,758 or they can be added to the reaction medium. A suitable result can be obtained for a catalyst with a surface area of between 5-10 m 2 /g catalyst if about 0.01-5 mg, preferably about 0.02 mg to about 4 mg, of catalyst activator is present per gram of catalyst. The larger/smaller the surface of the catalyst, the more/less activator is needed.
The H 2 pressure at which this reaction takes place is generally between about 1 bar and about 50 bar, preferably between about 5 bar and about 25 bar. The total pressure of the reaction may be controlled by mixing an inert gas with the hydrogen. The H 2 used may or may not be purified. Purification may be aided by the presence of, for example, active carbon to remove organic components, a palladium catalyst to remove oxygen and/or zinc oxide to remove sulphur, and ruthenium to promote the conversion of CO and CO 2 . If helium is mixed with the H 2 , the helium can be purified with active carbon. Other inert gases like argon, nitrogen or methane are also suitable for mixing with the hydrogen gas.
Hydroxylammonium salts can be prepared at a pH between about 1 and about 6, preferably between about 1 and about 4. The pH of the reaction may be maintained by addition of a strong mineral acid, such as hydrochloric, nitric, sulphuric, or phosphoric acid or salts thereof. Nitric acid is a preferred source of nitrate ions.
The temperature may vary between about 20° C. and about 90° C.; preferably a temperature of between about 30° C. and about 70° C. is used.
Suitable reactor designs are described in"Ullmann's Encyclopedia of Industrial Chemistry", vol. A5, VCH Wienheim, page 36 (1986).
This process for preparing hydroxylammonium has been disclosed in Belgian patent application 9500936, filed Nov. 10, 1995, the entire contents of which are hereby incorporated by reference and relied upon. Moreover, all journal articles, texts, and patents cited in this specification are incorporated by reference in their entirety.
The invention will be further elucidated with reference to the following examples, without being limited thereto.
EXAMPLES AND COMPARATIVE EXPERIMENTS
The examples and comparative experiments were carried out in a thermostatted pressure reactor made of chrome-nickel steel, having an internal diameter of 80 mm and a volume of about 300 ml, according to the following process: the reactor was fitted with four 8-mm-wide baffles and a 6-blade turbine stirrer with a cross-section of 40 mm and blades of 10×10 mm. The reactor was operated as a three-phase slurry reactor with a continuous throughput of the liquid and gas phases, while the solid, powdered catalyst was retained in the reactor with the aid of a Teflon R membrane filter in the liquid outlet. A liquid feed containing 3.2 mol/l nitric acid dissolved in an aqueous 3.3 mol/l phosphoric acid buffer plus 0.1 mol/l NaOH was fed to the reactor with the aid of a pump. The volume of the liquid phase in the reactor was kept at a constant value of 115 ml. Hydrogen was also fed to the reactor. The reactor pressure was kept at a constant level with the aid of a pressure regulator in the gas outlet; the off-gas was cooled before the pressure regulator, while the total off-gas flow rate was measured after the pressure regulator. The hydrogen partial pressure was varied at a constant total pressure by mixing with helium to achieve the partial pressures listed in the Examples and Comparative Experiments. The total pressure used below was 40 bar.
The reactor was operated at a constant pH of 1.8. To maintain this pH, the supply of H + via the feed was adjusted to the amount consumed in the reaction via a pH measurement in the liquid outlet and adjustment of the feed flow rate.
All the products were analyzed on-line. The concentrations of the N 2 , NO and N 2 O gases in the off-gas were measured with the aid of a gas chromatograph. The concentrations of hydroxylamine and NH 4 + , in addition to the remaining H + , were determined by an automatic titrator. The catalysts were fed into the reactor; the concentrations may be inferred in the following Tables from the activity expressed per gram noble metal. The aim was to ensure constant activity in the reactor, which means that more or less catalyst was used, depending on the catalyst's activity. Then the reactor was closed and inertised with the aid of helium. After the inertisation, a pressure of 40 bar H 2 gas was introduced to the partial pressure listed in the Examples and Comparative Experiments, and the reactor was filled with 115 ml of liquid having the composition of the product solution (i.e., hydroxylamine, phosphoric acid, nitrate, and nitric acid). Then the reaction was started by introducing feed via the pump. The temperature was 55° C. and the stirring rate was 1300 rpm (rotations per minute); the reaction was run for two weeks.
The catalyst was activated with the aid of Ge, as a solution of GeO 2 in water or dissolved in the feed, which was introduced in steps during the course of the experiment. The first dose was added within a few minutes (between 1 and 10 minutes) after the start in each reaction.
Activation of catalyst was as follows: a first dose of approx. 0.0625 ML (monolayer) of Ge, followed by the same amount after 24 hours, to a total of 0.125 ML; then 0.0625 ML of Ge every 48 hours, to a total of 0.31 or 0.375 ML. The amount of Ge added in the Examples and Comparative Experiments is given below.
"Monolayer" is defined as follows: a complete monolayer of Ge corresponds to the number of Pd and/or Pt atoms on the surface of the metal particles. This number can be determined with the aid of CO chemisorption, on the assumption that every atom of noble-metal on the surface adsorbs one CO molecule.
Activation was effected in steps because the amount of catalyst activator that should be added is not known beforehand. In determining how much catalyst activator should be added, the objective to achieve maximal catalyst selectivity. When selectivity is maximized, the activity of the catalyst is also high and the yield can be greater than 90%. Ge was added in steps to maximize catalyst selectivity. In the Tables, the activity and selectivity are measured at the Ge dose resulting in maximum selectivity for hydroxylamine. The amount of Ge added to activate a commercial catalyst was the same as the amount added to activate the catalyst of the invention.
Temperature, pH, hydrogen pressure, nitrate concentration, hydroxylamine concentration, and stirring rate can also affect activation of the catalyst.
The feed flow rate was between 0.9 and 5 ml/min, depending on the catalyst's activity, the hydroxylamine concentration each time being typically 0.9-1.0 mol/l. Feed flow rate is adjusted according to pH of the reaction: constant pH indicates a constant hydroxylamine concentration. The hydroxylamine concentration can be maintained at a constant level during the reaction by means of a constant pH.
The activity A, expressed in mmol of NO 3 - /g met . hr, was calculated as the sum of the product yields according to equation (1):
A =Y-hyam +Y--NH.sub.4.sup.+ +Y--N.sub.2 +Y--NO+Y--N.sub.2 O(1)
where Y stands for yield, and hyam stands for hydroxylamine. The amount of metal in the catalyst in grams is g met .
The yield of the products in the liquid phase was calculated on the basis of the standardized concentrations c in mol/l, the liquid flow rate Q feed in ml/min and the amount of noble-metal introduced with the catalyst, expressed in grams (g met ), according to (2):
Y(x)=c(x)*Q.sub.feed *60/g.sub.met (2)
where x may be hydroxylamine or NH 4 + . Q feed was calculated from the weighed decrease in the feed (in grams) with time and the density of the liquid (grams/ml) that was measured before use.
The yields of the products in the gas phase were calculated from the concentrations c in vol. % measured by the gas chromatograph, the off-gas flow rate Q gas in Stl/hr and the amount of noble-metal (g met ):
Y(y)=a* c(y)/100!*Q.sub.gas *1000/(24.04*g.sub.met) (3)
where y stands for N 2 , NO or N 2 O and where
a=1 in the case of NO
a=2 in the case of N 2 and N 2 O
The factor 24.04 is the molar gas volume in L at 1 atm., 20° C.
Q gas was calculated by summing the measured supplied feed gases and the calculated gaseous products formed, after subtraction of the calculated summed H 2 consumption for all products.
The selectivity S, expressed in %, of each catalyst was calculated with the aid of the previously determined yield Y and the activity A according to:
S(z)=100*Y(z)/A (4)
where z stands for one of the products hydroxylamine, NH 4 + , N 2 , NO or N 2 O.
Thus, the selectivities were compared based on converted NO 3 - and were calculated on the basis of measurements of the above products.
The weight ratio of the palladium to the platinum in an individual metal particle was determined with the aid of transmission electron microscopy (TEM) and elemental determination by energy-dispersive X-ray analysis (EDX). The apparatus used was a VG HB-5 STEM R from Vacuum Generators, equipped with a Field Emission Gun (FEG) as described in the special issue of Electron Optics Bulletin (November 1993) published by Philips Electron Optics.
The catalyst was first embedded in polymethylmethacrylate (PMMA), from which 70-nm-thick sections were cut. Then five representative carrier particles were selected and five individual metal particles were measured per carrier particle: four metal particles at the edge of the carrier particle and one metal particle at the center of the carrier particle. The sections were then irradiated in a transmission electron microscope (TEM) with a stream of electrons. The acceleration voltage was 120 kV. This led to the generation of element-specific X-ray radiation by the metal particles, which was detected with the aid of a Tracor-ExplorerR EDX detector in 500 seconds. The Pd/Pt ratio was calculated from the measured amount of X-ray radiation on the basis of 100% standardization to the sum of the Pd+Pt concentrations. The EDX technique is described in "Scanning Electron Microscopy and X-Ray Microanalysis" (Ed. J. I. Goldstein et al.), Plenum, N.Y. (1992). The load is measured separately by means of neutron activation analysis (NAA). The concentration of each noble metal in the metal particles is shown as Pd and Pt loads for the carrier particle, in percent by weight.
Example I and Comparative Experiments A-C
In the first series of experiments, catalysts were tested at 40 bar H 2 pressure. The catalysts had a 80-20 Pd/Pt ratio. The catalyst with a standard deviation Pt! in the Pd/Pt alloy of 2.5 showed both higher selectivity and higher activity, as is shown in Table 1. 0.31 ML Ge was added to the reactions.
TABLE I__________________________________________________________________________ standard deviation maximum Pd Pt Pt! of the selectivity activity load load metal particle towards mol NO.sub.3.sup.- /Type wt. % wt. % % abs. hyam % N g.sub.met · hr yield__________________________________________________________________________Example IExp. Cat. 8.3 1.9 2.5 85.5 4.75 4.06Exp. AEF10RIW 7.5 1.9 11 81.5 2.85 2.32DegussaExp. BEF1055R/W 8.0 1.9 7 83 3.25 2.70DegussaExp. C10R464 8.1 2.0 5 83.5 2.4 2.00JohnsonMatthey__________________________________________________________________________
Example II and Comparative Experiment D
In these two experiments, the catalysts previously used in Comparative Experiment C and Example I were used at a H 2 pressure of 12 bar. The use of a lower H 2 pressure caused a decrease in activity and selectivity. It was unexpectedly found that the selectivity of the catalyst according to the invention decreases much less. The results are shown in Table II. 0.375 ML Ge was added to the reactions.
TABLE II__________________________________________________________________________ standard deviation maximum Pd Pt Pt! of the selectivity activity load load metal particle towards mol NO.sub.3.sup.- /Type wt. % wt. % % abs. hyam % N g.sub.met · hr yield__________________________________________________________________________Example II Exp. Cat. 8.3 1.9 2.5 81 2.4 1.94Exp. D 10R464 8.1 2.0 5 76 1.05 0.80 Johnson Matthey__________________________________________________________________________
Examples III-V and Comparative Experiment E
Catalysts with a 90-10 Pd/Pt ratio supplied by Engelhard (custom synthesized for DSM) and a commercial catalyst with a 80-20 Pd/Pt ratio supplied by Johnson Matthey were tested at 10 bar H 2 . A high selectivity was obtained at an acceptable activity for the catalysts of the invention as compared with Experiment E. The results are shown in Table III. 0.31 ML Ge was added to the reactions.
TABLE III__________________________________________________________________________ standard deviation maximum Pd Pt Pt! of the selectivity activity load load metal particle towards mol NO.sub.3.sup.- /Type wt. % wt. % % abs. hyam % N g.sub.met · hr yield__________________________________________________________________________Example III Q086-31 9.3 0.85 2.4 81.0 1.7 1.38Example IV Q086-44 9.2 1.05 2.3 84.5 1.15 0.97Example V Q086-55 8.8 0.95 1.3 84 1.75 1.47Exp. E 10R464 8.1 2.0 5 74.5 1.1 0.82 Johnson Matthey__________________________________________________________________________
Examples VI-VII and Comparative Experiment F
Catalysts with a 90-10 Pd/Pt ratio supplied by Engelhard (custom synthesized for DSM) and a commercial catalyst with a 80-20 Pd/Pt ratio supplied by Johnson Matthey were tested at 10 bar H 2 . The results given in Table IV show that selectivity was much improved for the catalysts of the invention as compared with Experiment F. 0.375 ML Ge was added to the reactions.
TABLE IV__________________________________________________________________________ standard deviation maximum Pd Pt Pt! of the selectivity activity load load metal particle towards mol NO.sub.3.sup.- /Type wt. % wt. % % abs. hyam % N g.sub.met · hr yield__________________________________________________________________________Example VI Q086-46 9.0 0.98 2.5* 81 0.6 0.49Example VII Q086-44 9.2 1.05 2.3 83.3 0.85 0.71Exp. F 10R464 8.1 2.0 5 76 1.05 0.80 Johnson Matthey__________________________________________________________________________ *estimation
Examples VIII-XI and Comparative Experiment G
Catalysts with a 90-10 and a 80-20 Pd/Pt ratio supplied by Engelhard (custom synthesized for DSM), and a commercial catalyst with a 80-20 Pd/Pt ratio supplied by Johnson Matthey were tested at 10 bar H 2 . Selectivity was again much improved for the catalysts of the invention as compared with Experiment G, see the results shown in Table V. 0.25 ML Ge was added to the reactions.
TABLE V__________________________________________________________________________ standard deviation maximum Pd Pt Pt! of the selectivity activity load load metal particle towards mol NO.sub.3.sup.- / Type wt. % wt. % % abs. hyam % N g.sub.met · hr yield__________________________________________________________________________Example VIII Q085-55 8.8 0.95 1.3 79.1 1.96 1.55Exmaple IX Q086-46 9.0 0.98 2.5* 81.3 1.14 0.92Example X Q086-44 9.2 1.05 2.3 81.4 1.2 0.98Example XI 40748 8.8 0.95 1.7 84.2 0.9 0.75 EngelhardExp. G 10R464 8.1 2.0 5 70.5 1.57 0.71 Johnson Matthey__________________________________________________________________________ *estimation
Examples XII and Comparative Experiment H
Catalysts were tested at 5 bar H 2 . Selectivity improvements for the catalysts of the invention as compared with Experiment H are shown in Table VI. 0.25 ML Ge was added to the reactions.
TABLE VI__________________________________________________________________________ standard deviation maximum Pd Pt Pt! of the selectivity activity load load metal particle towards mol NO.sub.3.sup.- /Type wt. % wt. % % abs. hyam % N g.sub.met · hr yield__________________________________________________________________________Example XII Q086-46 9.0 0.98 2.5* 79 0.8 0.63Exp. H 10R464 8.1 2.0 5 73 1.0 0.73 Johnson Matthey__________________________________________________________________________ *estimation
While the present invention has been described in connection with what is presently considered to be practical and preferred embodiments, it is understood that this invention is not to be limited to the disclosed embodiments of a process for preparing hydroxylammonium salts, but on the contrary is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
Thus, it is to be understood that variations in the present invention can be made without departing from the novel aspects of this invention as defined in the appended claims. | The invention relates to a process for the preparation of a hydroxylammonium salt through catalytic reduction of nitrate ions in an acid medium, in the presence of an activated catalyst, which catalyst comprises carrier particles with a plurality of metal particles containing palladium and platinum, the relative concentrations of the palladium and the platinum in each metal particle being substantially the same. In particular, the distribution of platinum concentrations among different metal particles has a standard deviation of less than 4% absolute. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method of manufacturing a semiconductor device having memory cell transistors such as a mask ROM (Read Only Memory), and more particularly, to a method of manufacturing a semiconductor device having memory cell transistors by a reduced number of manufacturing steps.
[0003] 2. Description of the Related Art
[0004] [0004]FIG. 1A is a plan view of a mask ROM in a flat cell structure, and FIG. 1B is an equivalent circuit diagram of the mask ROM.
[0005] In the conventional flat cell type mask ROM, a plurality of N + diffusion layers are formed in a line-and-space pattern at a surface of a semiconductor substrate (not shown). A plurality of gate electrodes 2 are formed perpendicularly to the N + diffusion layers 1 also in a line-and-space pattern. The N + diffusion layer 1 and the gate electrode 2 are insulated from each other by an insulating film (not shown). There is a gate insulating film (not shown) between the gate electrodes 2 and the semiconductor substrate. Thus, a memory cell transistor having the gate electrode 2 , the gate insulating film and two N + diffusion layers is formed. The surface region of the semiconductor substrate under the gate insulating film corresponds to the channel of the memory cell transistor.
[0006] A channel selected based on a request (requested design) by a customer is, for example, implanted with boron ions. The threshold value of the memory cell transistor having the channel increases. Thus, the mask ROM coding is performed. As a result, as shown in FIGS. 1A and 1B, a transistor 4 a having a low threshold value and a transistor 4 b having a high threshold value are formed. A mask used for implanting the boron ions is provided with an opening 3 designed based on the request by the customer as shown in FIG. 1A. The opening 3 is formed in a position in alignment with the channel of the transistor 4 b having a high threshold value.
[0007] A conventional method of manufacturing the mask ROM will be now described in conjunction with FIGS. 2A to 2 D. FIGS. 2A to 2 D are sectional views showing steps in the conventional method of manufacturing the mask ROM in the order of steps. Note that FIGS. 2A to 2 D are sectional views taken along line X-X in FIG. 1A.
[0008] The semiconductor substrate 5 is defined to a region A having memory cell transistors, and a region D having a peripheral circuit for writing/reading data to/from the memory cell transistors. The region D has a region B having an N-channel MOS transistor, and a region C having a P-channel MOS transistor.
[0009] As shown in FIG. 2A, in the region A, an N + diffusion layer 1 is formed at the surface of the semiconductor substrate 5 . A gate oxide film (not shown) and a gate electrode 2 are formed on the semiconductor substrate 5 . In the region B, an N-type diffusion layer 16 is formed at the surface of the semiconductor substrate 5 , and a gate oxide film (not shown) and a gate electrode 2 are formed on the semiconductor substrate 5 . In the region C, a P-type diffusion layer 7 is formed at the surface of the semiconductor substrate 5 , and a gate oxide film (not shown) and a gate electrode 2 are formed on the semiconductor substrate 5 . The gate oxide films or the gate oxide films are each formed at a time in some cases. Thereafter, an interlayer insulating film 6 is formed on the entire surface. The interlayer insulating film 6 is provided with a contact hole 6 a extending to the N-type diffusion layer 16 and a contact hole 6 b extending to the P-type diffusion layer 7 .
[0010] As shown in FIG. 2B, phosphorus ions are implanted through the contact holes 6 a and 6 b. As a result, an N + diffusion layer 17 is formed at the surface of the N-type diffusion layer 16 and the P-type diffusion layer 7 , and an N-channel transistor 11 a is thus formed.
[0011] As shown in FIG. 2C, a photoresist film 8 to expose only the region C is formed. Boron ions are then implanted. As a result, a P + diffusion layer 9 is formed at the surface of the P-type diffusion layer 7 in place of the N + diffusion layer 17 , and a P-channel transistor 11 b is thus formed.
[0012] Then, the photoresist film 8 is removed, and a photoresist film 18 covering the region D is formed as a ROM code mask instead. As shown in FIG. 2D, the photoresist film 18 is provided with openings 3 a corresponding to the openings 3 in FIG. 1A. More specifically, the openings 3 a are formed based on the design of the openings 3 . Then, boron ions are implanted through the openings 3 a. As a result, code implantation layers 10 are selectively formed at the surface of the semiconductor substrate 5 in the region A. At the time, boron ions are not implanted into the transistors 11 a and 11 b.
[0013] Thereafter, the photoresist film 18 is removed, metal interconnections, bonding pads (not shown) and the like are formed to complete a semiconductor device.
[0014] In the mask ROM, the flat cell structure is mainly used as a cell corresponding to high density integration.
[0015] According to the above method (first prior art), cell transistors with a low threshold value are formed, and after the interlayer insulating film 6 is formed, a ROM code mask (photoresist film 18 ) having the openings 3 a is formed according to the design. The ROM code mask is formed after the gate electrodes 2 are formed in some cases.
[0016] However, the patterns of the ROM code masks are different depending upon the code content. The pattern density, i.e., the density of the openings 3 a is different among chips in a single product. Therefore, if the opening 3 a has a pattern size as designed in a location with a low mask pattern density, the pattern size of the opening 3 a in a location with a high mask pattern density becomes larger than the designed value. In the mask ROM shown in FIG. 1A, for example, a transistor 4 a with a low threshold value located in the second row from the top and the second column from the left is surrounded by eight transistors 4 b with a high threshold value, and therefore the size of the opening 3 a for the transistor 4 b is larger than designed. As a result, code implantation layers (P-type diffusion layers) 10 are formed wider than the designed value, so that the threshold value of the transistor 4 a surrounded by the transistors 4 b is larger than designed. Consequently, the transistor 4 a adjacent to the transistor 4 b with a high threshold value and the transistor 4 a adjacent to the transistor 4 a with a low threshold have different threshold values.
[0017] This is more noticeable as the distance between the memory cell transistors is reduced with the reduction of the element size. As the element size has been reduced, a fine pattern is necessary for the ROM code mask, so that a relatively expensive, high precision reticle requiring a long manufacturing period is necessary.
[0018] In the field of the mask ROM, reduction in TAT (Turn Around Time) is a significant object and the use of such a high precision reticle requiring a long manufacturing period is not desirable. Therefore, there is a demand for a new type ROM code mask.
[0019] A method directed to a solution to the difference in the size of the opening caused depending upon the pattern density of the ROM code mask is disclosed, for example, by Japanese Patent Laid-Open Publication No. Hei. 5-283653. The manufacturing method (second prior art) will be now described in conjunction with FIGS. 3A to 3 E. FIGS. 3A to 3 E are sectional views showing steps in the conventional method (second prior art) of manufacturing a mask ROM in the order of steps. FIGS. 3A to 3 E are sectional views taken along line X-X in FIG. 1A.
[0020] As shown in FIG. 3A, in the region A, an N + diffusion layer 1 is formed at the surface of the semiconductor substrate 5 and a gate oxide film (not shown) and a gate electrode 2 are formed on the semiconductor substrate 5 . In the region B, an N-type diffusion layer 16 is formed at the surface of the semiconductor substrate 5 , and a gate oxide film (not shown) and a gate electrode 2 are formed on the semiconductor substrate 5 . In the region C, a P-type diffusion layer 7 is formed at the surface of the semiconductor substrate 5 , and a gate oxide film (not shown) and a gate electrode 2 are formed on the semiconductor substrate 5 . Note that the oxide films or the gate electrodes are each formed simultaneously in some cases. Then, an interlayer insulating film 6 is formed on the entire surface. The interlayer insulating film 6 is provided with a contact hole 6 a extending to the N-type diffusion layer 16 and a contact hole 6 b extending to the P-type diffusion layer 7 . The interlayer insulating film 6 is also provided with a contact hole 6 a in alignment with the channel region in the region A.
[0021] As shown in FIG. 3B, phosphorus ions are implanted through the contact holes 6 a, 6 b, and 6 c. As a result, an N + diffusion layer 17 is formed at the surface of the N-type diffusion layer 16 and the P-type diffusion layer 7 , and an N-channel transistor 11 a is thus formed.
[0022] As shown in FIG. 3C, a photoresist film 8 to expose only the region C is formed. Boron ions are then implanted. As a result, a P + diffusion layer 9 is formed in place of the N + diffusion layer 17 at the surface of the P-type diffusion layer 7 , so that a P-channel transistor 11 b is formed.
[0023] The photoresist film 8 is then removed and a photoresist film 18 covering the region D is formed as a ROM code mask. As shown in FIG. 3D, the photoresist film 18 is provided with openings 3 a corresponding to the openings 3 in FIG. 1A. Boron ions are then implanted through the openings 3 a. As a result, code implantation layers 10 are selectively formed at the surface of the semiconductor substrate 5 in the region A. At the time, boron ions are not implanted into the transistors 11 a and 11 b.
[0024] The photoresist film 18 is then removed and a photoresist film 19 covering the region D is formed. As shown in FIG. 3E, the photoresist film 19 is patterned to expose contact holes 6 c. An insulating film 12 is then deposited by liquid phase growth to fill the contact holes 6 c. Then, using the photoresist film 19 as a mask, the insulating film 12 is etched back, so that the surface level of the insulating film 12 coincides with the surface level of the interlayer insulating film 6 .
[0025] The photoresist film 19 is then removed, metal interconnections, bonding pads (not shown) and the like are formed and a semiconductor device is thus completed.
[0026] According to the second conventional example, not only the photoresist film 18 but also the interlayer insulating film 6 serves as a ROM code mask. Therefore, ion implantation can be achieved through equal size openings.
[0027] According to the second conventional example, however, there must be four masks in total for the ROM coding and the following steps. In other words, there must be a mask for the ROM coding (photoresist film 18 ), a mask for filling the contact hole 6 c with an insulating film (photoresist film 19 ), a mask for forming metal interconnections (not shown), and a mask for forming pads (not shown). This increases the number of steps and the manufacturing cost as well.
SUMMARY OF THE INVENTION
[0028] It is an object of the present invention to provide a method of manufacturing a semiconductor device having memory cell transistors with a reduced number of masks and reduced variation in the threshold values.
[0029] According to the present invention, a method of manufacturing a semiconductor device having memory cell transistors comprises: forming a plurality of diffusion layers extending in a first direction at a surface of a semiconductor substrate in a cell region to be provided with the memory cell transistors; forming a plurality of gate electrodes extending in a second direction perpendicular to the first direction on the semiconductor substrate in the cell regions; forming an interlayer insulating film on the semiconductor substrate; forming a first resist film on the interlayer insulating film; forming a second resist film provided with openings previously designed in an arbitrary manner on the first resist film; and implanting ions in the cell region using the first and second resist films as a mask. The first resist film is provided with openings in positions in alignment with regions between adjacent diffusion layers among the plurality of diffusion layers.
[0030] According to the present invention, variation in the threshold values can be suppressed regardless of the density of mask patterns.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] [0031]FIG. 1A is a plan view of a flat cell type mask ROM;
[0032] [0032]FIG. 1B is an equivalent circuit diagram of the mask ROM;
[0033] [0033]FIGS. 2A to 2 D are sectional views showing steps in a conventional method of manufacturing a mask ROM (first prior art) in the order of steps;
[0034] [0034]FIGS. 3A to 3 E are sectional views showing steps in a conventional method of manufacturing a mask ROM (second prior art) in the order of steps;
[0035] [0035]FIGS. 4A to 4 E are sectional views showing steps in a method of manufacturing a mask ROM according to a first embodiment of the present invention in the order of steps; and
[0036] [0036]FIGS. 5A to 5 D are sectional views showing steps in a method of manufacturing a mask ROM according to a second embodiment of the present invention in the order of steps.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] The preferred embodiments of the present invention will be now described in detail in conjunction with the accompanying drawings. FIGS. 4A to 4 E are sectional views showing steps in a method of manufacturing a mask ROM according to a first embodiment of the present invention in the order of steps. FIGS. 4A to 4 E are sections taken along line X-X in FIG. 1A.
[0038] As shown in FIG. 4A, an N + diffusion layer (impurity diffusion layer as a source/drain) 1 is formed at the surface of a semiconductor substrate 5 in a region A, and a gate oxide film (not shown) and a gate electrode 2 are formed on the semiconductor substrate 5 . In a region B, an N-type diffusion layer (impurity diffusion layer as a source/drain) 16 is formed at the surface of the semiconductor substrate 5 , and a gate oxide film (not shown) and a gate electrode 2 are formed on the semiconductor substrate 5 . In a region C, a P-type diffusion layer (impurity diffusion layer as a source/drain) 7 is formed at the surface of the semiconductor substrate 5 , and a gate oxide film (not shown) and a gate electrode 2 are formed on the semiconductor substrate 5 . The gate oxide films or the gate electrodes may each be formed simultaneously. Then, an interlayer insulating film 6 is formed on the entire surface. The interlayer insulating film 6 is provided with a contact hole 6 a extending to the N-type diffusion layer 16 and a contact hole 6 b extending to the P-type diffusion layer 7 .
[0039] As shown in FIG. 4B, phosphorus ions, for example, are implanted through the contact holes 6 a and 6 b. As a result, an N + diffusion layer 17 is formed at the surface of the N-type diffusion layer 16 and the P-type diffusion layer 7 , and an N-channel transistor 11 a is formed.
[0040] As shown in FIG. 4C, a photoresist film 8 to expose only the region C is formed. Boron ions, for example, are implanted. As a result, a P + diffusion layer 9 is formed in place of the N + diffusion layer 17 at the surface of the p-type diffusion layer 7 , and a P-channel transistor 11 b is formed.
[0041] Then, the photoresist film 8 is removed, and a photoresist film (first resist film) 13 is deposited on the entire surface. The photoresist film 13 may be composed of, for example, photo-curing resin. As shown in FIG. 4D, openings 13 a in alignment with channel regions in the region A are formed in the photoresist film 13 by patterning. The photoresist film 13 is cured by heating and ultraviolet-ray.
[0042] Then, a photoresist film (second resist film) 20 covering a region D is formed as a ROM code mask on the photoresist film 13 . As shown in FIG. 4E, the photoresist film 20 is provided with openings 3 a corresponding to the openings 3 in FIG. 1A. Boron ions, for example, are implanted through the openings 3 a. As a result, code implantation layers 10 are selectively formed at the surface of the semiconductor substrate 5 in the region A. At the time, boron ions are not implanted into the transistors 11 a and 11 b.
[0043] Then, the photoresist films 20 and 13 are removed at a time, and metal interconnections, bonding pads (not shown) and the like are formed and a semiconductor device is completed.
[0044] According to the first embodiment, not only the photoresist film 20 but also the photoresist film 13 serves as a ROM code mask. More specifically, the opening 3 a allows the opening 13 a to be selectively exposed, while variation in the size of the opening 3 a does not affect the element characteristics. Since the opening 13 a is formed on the channel regions of all the memory cell transistors, the density is uniform. Therefore, there is little variation in the size of the opening 13 a. As a result, variation in the size of the code implantation layer 10 is extremely scarce. The transistors 4 a with a low threshold value have a threshold value substantially uniform regardless of whether it is surrounded by the transistors 4 b with a high threshold value or not.
[0045] The steps required by the second prior art, i.e., the steps of forming an opening 6 c in the interlayer insulating film 6 , filling the opening 6 c with an interlayer insulating film 12 , and etching back the interlayer insulating film 12 are not necessary according to the present embodiment. Therefore, according to the present embodiment, the number of steps can be smaller than that of the second prior art. The number of masks is reduced by one as well. As a result, the TAT can be reduced.
[0046] Furthermore, the photoresist film 13 as an underlying mask for the ROM code mask and the photoresist film 20 as the ROM code mask can be removed at a time, and therefore the number of steps can be prevented from increasing.
[0047] A second embodiment of the present invention will be now described. FIGS. 5A to 5 D are sectional views showing steps in a method of manufacturing a mask ROM according to the second embodiment of the present invention in the order of steps. FIGS. 5A to 5 D are sectional views taken along line X-X in FIG. 1A.
[0048] As shown in FIG. 5A, an N + diffusion layer 1 is formed at the surface of a semiconductor substrate 5 in a region A, and a gate oxide film (not shown) and a gate electrode 2 are formed on the semiconductor substrate 5 . In a region B, an N-type diffusion layer 16 is formed at the surface of the semiconductor substrate 5 , and a gate oxide film (not shown) and a gate electrode 2 are formed on the semiconductor substrate 5 . In a region C, a P-type diffusion layer 7 is formed at the surface of the semiconductor substrate 5 , and a gate oxide film (not shown) and a gate electrode 2 are formed on the semiconductor substrate 5 . Note that the gate oxide films or the gate electrodes may each be formed simultaneously. An interlayer insulating film 6 is then formed on the entire surface. The interlayer insulating film 6 is provided with a contact hole 6 a extending to an N-type diffusion layer 16 and a contact hole 6 b extending to the P-type diffusion layer 7 .
[0049] As shown in FIG. 5B, phosphorus ions, for example, are implanted through the contact holes 6 a and 6 b. As a result, an N + diffusion layer 17 is formed at the surface of the N type diffusion layer 16 and the P-type diffusion layer 7 , and an N-channel transistor 11 a is formed.
[0050] Then, as shown in FIG. 5C, a photoresist film (first resist film) 14 is formed on the interlayer insulating film 6 . The photoresist film 14 may be, for example, composed of photo-curing resin. Openings 14 a are formed in the photoresist film 14 in alignment with the channel regions in the region and the photoresist film 14 in the region C is removed by patterning. As a result, the contact holes 6 b is exposed. Boron ions, for example, are then implanted. A P + diffusion layer 9 is formed at the surface of the P-type diffusion layer 7 in place of the N + diffusion layer 17 as a result, and a P-channel transistor 11 b is formed. At the time, the channel region in the region A is covered with the gate electrode 2 and the interlayer insulating film 6 , so that boron ions are not implanted into the channel region in the region A. Then, the photoresist film 14 is cured by heating and ultraviolet-ray.
[0051] A photoresist film (second resist film) 15 covering a region D is then formed as a ROM code mask on the photoresist film 14 . As shown in FIG. 5D, the photoresist film 15 is provided with openings 3 a corresponding to the openings 3 in FIG. 1A. Boron ions, for example, are implanted through the openings 3 a. As a result, code implantation layers 10 are selectively formed at the surface of the semiconductor substrate 5 in the region A. At the time, boron ions are not implanted into the transistors 11 a and 11 b.
[0052] Thereafter, the photoresist films 15 and 14 are removed simultaneously, metal interconnections, bonding pads (not shown) and the like are formed to complete a semiconductor device.
[0053] According to the second embodiment described above, not only the photoresist film 15 but also the photoresist film 14 serves as a ROM code mask, so that the same effects as those by the first embodiment can be provided. In addition, the photoresist film 14 may serve as a mask for ion implantation in the region C and therefore the number of masks can be reduced by one. | A plurality of diffusion layers extending in a first direction is formed at a surface of a semiconductor substrate in a cell region to be provided with the memory cell transistors. A plurality of gate electrodes extending in a second direction perpendicular to the first direction is formed on the semiconductor substrate in the cell regions. An interlayer insulating film is formed on the semiconductor substrate. A first resist film is formed on the interlayer insulating film. The first resist film is provided with openings in positions in alignment with regions between adjacent diffusion layers among the plurality of diffusion layers. a second resist film provided with openings previously designed in an arbitrary manner is formed on the first resist film. Then ions are implanted in the cell region using the first and second resist films as a mask. | 8 |
This is a continuation of application Ser. No. 287,348 filed Dec. 21, 1988, now U.S. Pat. No. 5,088,977.
BACKGROUND OF THE INVENTION
This invention relates generally to an electrical transdermal drug device delivering a drug to the patient for systemic distribution by blood flow using principles of electrokinetic phenomena, such as electrophoresis and electroosmosis, and more particularly to an electrical transdermal drug applicator delivering counteracting substances locally to the patient's skin and/or electrically inducing the skin to produce endogenous compounds which extend the period of therapeutic drug delivery and thereby increase usefulness of the drug applicator. Reference to or disclosure of devices for transdermal delivery of drugs by application of electrical current through the skin of a person or animal are shown in the following United States patents:
______________________________________ 385,556 4,243,052 486,902 4,325,367 588,479 4,367,745 2,493,155 4,419,019 2,267,162 4,474,570 2,784,715 4,406,658 3,163,166 4,314,554 3,289,671 4,166,457 3,547,107 4,239,052 3,677,268 4,290,878 4,008,721 4,164,226 4,141,359 4,362,645 4,239,046 4,273,135______________________________________
The following foreign patents refer to or disclose transdermal drug delivery devices:
EPA No. 0060452
DE No. 290202183
DE No. 3225748
EPA No. 0058920
UK No. 2104388
Thus, it is evident, that transdermal delivery of drugs by application of an electrical current is not unknown. Yet, except for experimental and developmental purposes, such electrical transdermal drug applicators are not presently commercially available for use by medical professionals or by individuals.
A problem with transdermal patches, especially electrically powered patches, is that such devices exhibit a rate of drug delivery which decays with passage of time despite a steady state condition for the applied electrical current and steady state drug concentrations within the drug reservoir of the device. This phenomenon has been reported in scientific journals, for example, an article, IN VIVO TRANSDERMAL DELIVERY OF INSULIN, Chien et al, Annals of New York Academy of Sciences, pages 38-47 (1987).
Therein, changes in blood glucose level are recorded versus time after insulin is delivered transdermally to laboratory animals, using an electrical current. Several parameters are varied. For example, it is reported that a pulsed DC current has a greater and more enduring effect in reducing blood glucose levels in laboratory animals, than does a pure continuous DC current. The actual quantity of insulin, which is delivered, is not measured. Rather, the effect of the drug in reducing blood glucose levels is measured. It is found that one repetition rate of DC pulses is more effective than another pulse repetition rate in reducing blood glucose levels measured both in magnitude and time duration. A square waveform provided better results than did a sinusoidal waveform or a trapezoidal waveform.
The authors of the paper analogize the skin electrically with resistances and capacitance in parallel as an equivalent circuit. They theorize that the DC current charges the capacitance of the skin which, once charged, can accept no more current and accordingly limits drug delivery. Using DC pulses rather than steady state current allows time for the skin capacitance to discharge, such that on the next pulse, additional current, capacitor charging, and drug delivery can occur.
However, an anomalous situation arises when at a favorable pulse repetition rate, and with the same current delivery level as in prior tests, the duty cycle is varied. It would be expected that the greater the duty cycle, that is, the greater the current ON time versus the current OFF time ratio, the greater amount of insulin would be delivered transdermally and the measured effects on blood glucose level would be correspondingly more favorable and more enduring. Contrary to expectations, as the duty cycle increases from a one-to-one ratio toward an eight-to-one ratio, the reduction in blood glucose level becomes less, rather than more, although duration of this reduction is somewhat extended.
In summary, application of current over a longer period of time, that is, consumption of more energy for delivering drugs transdermally, results in what appears to be less delivery of drug as measured by the effect on blood glucose level.
That publication graphically illustrates the problem with prior art transdermal drug applicators and delivery methods using electrical current to carry drugs through the skin, that is, the effectiveness of the delivered drug is insufficient in duration of effect and the rate of drug delivery falls off as the delivering current is continuously applied over extended periods of time.
What is needed is an electrical transdermal drug applicator and method which provide enhanced drug delivery to the patient with regard to quantity of systemically delivered drug and duration of drug effectiveness.
SUMMARY OF THE INVENTION
Generally speaking, in accordance with the invention, an electrical transdermal drug applicator having enhanced drug flow to the bloodstream of the subject is provided. The applicator, in addition to delivering a primary drug into a subject's circulatory system for therapeutic purposes, delivers from a reservoir a non-therapeutic counteracting agent to the skin of the patient which induces flow enhancement and allows delivery of the primary drug systemically over a longer period of time and in greater quantity than heretofore appeared possible using electric current. Construction of the electrical transdermal drug applicator with electrochemical flow enhancement by introduction of a counteracting agent to the skin and/or specific electrical wave shapes is based on applicant's appraisal of known phenomena as described above.
However, charging of skin capacitance is not considered to be the primary factor in reducing drug delivery capability as current application time and magnitude of current are increased. The efficiency of administration of insulin may be partially vitiated by adsorption and degradation within the skin tissues or by restricted blood circulation in the skin. The passage of current and/or dissociated water ions and/or certain drugs through the human skin causes a series of events related to reduction in magnitude of negative net surface charge exhibited by living mammalian cells. A most important consequence of reduction in magnitude of the negative charge on the cells is triggering of an avalanche-like coagulation process which forms thrombi, that is, blood clotting, which in turn stops blood flow through capillaries. Passage of current from a transdermal applicator tends to reduce the negative charge on cells of the skin proximate the applicator reservoir, where drugs are delivered, causing blood clotting in the capillaries which not only stops local blood flow, but also stops drug flow into the circulatory system of the subject. A drug transdermally delivered locally is not effective systemically when the capillaries of the skin contain coagulated blood.
In addition, especially in the anodic (+) region of current delivery through the skin, an immediate contraction of small blood vessels, especially arteries, takes place causing a complete interruption of blood flow to said vessels. Thus, as with blood clotting, contraction of the small blood vessels prevents drugs delivered through the skin by the transdermal applicator from being delivered into the circulatory system.
Electroosmosis, which is an important factor in delivery of drugs from the applicator reservoir through the skin and into the blood circulation system, is affected by the existence of fixed negative charges on the cellular walls within the skin. A reduction of such net negative charge, as caused by passage of even small electric currents or of the water ions through the skin, inhibits electroosmosis.
Blood clotting, blood vessel contraction, and reduced electroosmotic effects, as described above, can combine synergistically to slow down or completely stop system transdermal delivery of primary drugs, especially from electrically powered transdermal applicators. This occurs even when the drug is successfully transferred from the applicator through the skin into the local skin tissue.
To counteract the current or drug induced loss of negative charge on the cellular walls within the skin, the electrical transdermal drug applicator with electrochemical flow enhancement, in accordance with the invention, delivers into the skin, in addition to the primary drug having therapeutic purpose, counteractive substances known to increase the negative charge on cell surfaces.
A negative charge on cell surfaces is generally accepted as a fundamental factor in preventing the clotting of blood on that surface. Negative charge (Coulombic repulsion) is also considered to be part of the mechanism for the coagulation of platelets. Additionally, overcoming negative charge is also believed to be a crucial aspect of fibrin formation, part of the avalanche of reactions in the clotting of blood (thrombosis). Without being bound by theory, for the reasons given above, it is known at a minimum, that providing a negative charge on natural or artificial surfaces in contact with animal blood helps prevent clotting or thrombosis.
One may add to the negative charge on a cell surface by reaction with or adsorption of anionic moieties compatible with animal cells such as salicylates, nitrates, methylcarboxylates, sulfonates, chlorosulfonates, phosphonates, gluconates, maleates, citrates, phthalates, or sulfates. These moieties bonded to or adsorbed on a cell surface inhibit adherence of animal blood, maintain the fluidity of animal blood, and help prevent clotting of blood in motion.
Specific drugs known as anticoagulants, antiplatelets, or antifibrotics also are negatively charged and are illustrated in the Table. Among these are heparin (a mixture containing mucosaccharide sulfonates), salicylates, protamine sulfate, potassium aminobenzoate, and nitroprusside--a source of sodium nitrate. Not only are these substances direct action drugs, they are also agents for increasing the negative charge on cell surfaces and artificial surfaces in contact with animal blood. The chemicals may be chemically bonded to, adsorbed to, or absorbed in the surface.
Another class of entities for increasing the negative charge on cell surfaces or acting to inhibit either platelet formation or coagulation of animal blood are natural substances produced by the metabolism of the animal or man. Among these natural biochemical factors are: prostacyclin, thrombomodulin, Ecto-ADPase, urokinase, tissue plasminogin activators (TPA), streptokinase, antithrombin III, protein C, protein S, prostaglandins I 2 and E 1 , sulfated glycosaminoglycans, N-acetylcysteine with nitroglycerin, nicoumalone, phosphatidyl inositol, hydrophilic ganglioside GM-1, cyclic GMP, S-nitrothiols, dodecapeptide gamma F1B, 400-411, and guanosine 3 1 , 5 1 -monophosphate, their metabolic precursors and reaction products.
Additional natural vasodilators are kinins and histamines.
Such substances, if included in the reservoir of the transdermal drug delivery applicator, move through the skin and react with the cells at the same time that the primary therapeutic drug is delivered through the skin. By maintaining a more negative condition of charge on cell surfaces, blockage of flow through local blood vessels is reduced or prevented, allowing drugs delivered transdermally to be further delivered into the systemic flow. Generally, the counteractive substance has no therapeutic value, although in special instances a substance may serve a dual purpose.
Maintaining a more negative condition of charge on cell surfaces could be achieved simultaneously and/or alternatively by precharging the cell surface with a negative charge prior to electroosmotic drug delivery in cases where such delivery takes place from the positive drug reservoir. The precharging and the discharging voltage levels are monitored and maintained within preset limits by electronic means.
In situations where one polarity of voltage delivers the primary drug and the opposite polarity delivers the counteractive substance, arrangements can be made for simultaneous delivery of both substances, or alternatively, alternating delivery can be provided.
To prevent formation of thrombi of platelets, that is, blood coagulation, adjacent the applicator/skin interface, antithrombotic agents are delivered from the applicator reservoir, either as a preconditioner or during drug delivery or alternately. Such counteractive substances would include, for example, heparin or aspirin. To counteract contraction or constriction of blood vessels adjacent the applicator interface, vasodilators can be used in the reservoir. Nitroglycerin is one such dilator. Alternatively or concomitantly, specific electrical pulses, such as square wave pulses of 0.4 ms and a frequency of 80 Hz at an intensity which could produce a tingling sensation may be used for repetitive periods of up to two hours a day to maintain vasodilation.
Accordingly, it is an object of the invention to provide an improved transdermal drug applicator and method which provide enhancement of drug flow into the system of the subject by means of delivery of counteractive agents.
Another object of the invention is to provide an improved transdermal drug applicator and method which provide, in addition to the primary therapeutic drug, a counteractor which works to make local cell charges relatively more negative.
Yet another object of the invention is to provide an improved transdermal drug applicator and method which enhance flow of primary therapeutic drug through the skin by addition of a vasodilator in the applicator reservoir.
A further object of the invention is to provide an improved transdermal drug applicator and method which provide an anticoagulant in the primary drug reservoir for delivery with the primary drug into the skin of the user.
Another object of the invention is to provide an improved transdermal drug applicator and method which captures mobile ions such as H + and OH - and thereby prevents such ions from reaching the skin tissues and causing production of thrombi, vaso-constriction and extreme changes of the cellular negative charge.
A still further object of the invention is to provide an improved transdermal drug applicator and method for the stimulation and systemic release of endogenous substances which have a natural therapeutic effect.
Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification.
The invention accordingly comprises the several steps and the relation of one or more of such steps with respect to each of the others, and the apparatus embodying features of construction, combinations of elements and arrangement of parts which are adapted to effect such steps, all as exemplified in the following detailed disclosure, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention, reference is had to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a cross-section of human skin showing pathways for transdermal drug delivery in accordance with the invention.
FIG. 2 is an electrical transdermal drug applicator in accordance with the invention including a single reservoir holding both a primary drug and a counteractor.
FIG. 3 is an electrical transdermal drug applicator in accordance with the invention including a parallel arrangement of reservoirs; one holding a primary drug; the others holding a counteractor.
FIG. 4 is an electrical transdermal drug applicator in accordance with the invention including two reservoirs electrically in series.
FIGS. 5-8 illustrate alternative arrangements of reservoirs and circuitry in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the FIG. 2, an electrical transdermal drug applicator 10 in accordance with the invention includes a reservoir 12 containing a primary drug 14 and a counteractor 16, both being dispersed in a suspension, for example, a gel 18 as disclosed in any of the above-referenced patents by the inventor here (as examples). A surface 20 of the reservoir 12 rests against the surface 22 of the user's skin 23 and is maintained in position, for example, by an adhesive (not shown). An electrode 24 connects to another surface 26 of the reservoir 12 and this in turn is connected to a DC source 28 by way of an electrical current conditioner 30 and a single pole switch 32. The other terminal of the DC source 28 connects to the skin surface 22 by way of a return electrode 36 which directly contacts the skin and is maintained in position, for example, by an adhesive (not shown). A single pole switch 34 is intermediate the electrode 36 and the DC source 28.
As discussed more fully hereinafter, the counteractor 16 acts locally on the blood vessels, for example, blood capillaries, whereas, as described in the Sibalis patents cited above, the primary drug is delivered systemically into the body's circulatory system.
It should be understood that the skin 23 is illustrated in FIGS. 1, 2 with simplified representations and the electrical transdermal drug applicator is also shown schematically in FIG. 2 as a generic representation of such a device. More detailed descriptions may be found in the above-cited references by the inventor in this application. It suffices here to state that the gel 18 and the primary drug 14 and counteractor 16 are contained in the reservoir 12 in a manner to prevent leakage of the substances. Also, there is no short-circuit of electrical current across the skin surface 22 directly to the electrode 36.
When the switches 32, 34 are closed as illustrated, a positive potential appears on the electrode 24 and a negative potential on the electrode 36 causing a current to flow from the source 28 through the current conditioner 30, the electrode 24, reservoir 12 and skin surface 22 in series. A DC current flows within the skin 23 as indicated by the arrow 38, then back through the skin surface 22 to the return electrode 36, and then back through switch 34 to the negative terminal of the DC source 28. The positive potential of the source 28 applied to the electrode 24 and the electrical current drive the primary drug 14 and the counteractor 16 through the interface between the reservoir 12 and the skin surface 22.
In FIG. 1, the human skin 23 is represented in simplified construction as including an outer layer, the epidermis 42, which is broken by hair follicles 44 and sweat ducts 46, and at greater depth blood capillaries 40, glands, etc. In electrical transdermal drug applicators, it is known that small quantities of the drug pass directly through the epidermis 42 as indicated by the arrows 43 but also the drug 14 enters the skin with relative ease through the hair follicles 44 and sweat ducts 46 which act as shunts. Having entered into the skin, the drug 14 is disseminated to the systemic circulatory system by electrokinetic processes, for example, electrophoresis, electroosmosis, iontophoresis, etc. With certain drugs and counteractors it may be desirable to pick skin areas with greater or lesser densities of hair follicles and sweat ducts for application of the transdermal applicator 10 thereto.
Where a reversed polarity from that described in FIG. 2 is required to drive the primary drug 14 and counteractor 16 into the skin tissues, the switches 32, 34 in FIG. 2 are moved to the positions indicated with broken lines, whereby a negative potential is applied to the electrode 24 and a positive potential is applied to the return electrode 36.
Where the primary drug 14 and the counteractor 16 require opposite polarities of voltage to cause the substances to enter into the skin, an alternating DC potential is applied by periodically changing the positions of the switches 32, 34 such that the potentials on the electrodes 24, 36 are periodically reversed. The timing of the switches 32, 34 in each alternating position is based upon the drug 14 and counteractor 16 which are being used. Equal driving times or unequal driving times can be provided as best suited for the substances 14, 16.
Further, in recognition of the work reported by Chien et al as discussed above, it may be desirable, in the process of drug delivery, to incorporate time periods wherein no potential is applied to the electrodes 24, 36 and, it may be desirable during those periods of no driving potential, to apply a short circuit between the electrodes 24, 36 such that charges, if any, built up within the skin during the driving periods may be readily discharged. The switch 48, shown with broken lines in FIG. 2, is connected between the electrodes 24, 36 and when closed provides the desired short circuit.
In electrical transdermal drug applicators in accordance with the invention, wherein a complex operational cycle is desirable, including (for examples) polarity reversals, periods without driving potential, periods of electrode short-circuiting, etcetera, a controller 50, also shown in broken lines in FIG. 2, is used to automatically regulate opening and closing of the switches 32-35, 37, 48 in desired programs.
It should be understood that whereas the power source 28 is indicated in FIG. 2, and in the other Figures for the sake of illustration, as a DC battery, the power source may include circuitry for converting potential from a DC battery to voltages of controlled magnitude with regulated current delivery; the electrodes not being connected directly to the DC battery but to the output of the voltage generating circuitry. Additionally, the switches which are schematically represented in FIG. 2 as electro-mechanical switches can be solid state switches, especially when considering the very low current flows which are frequently involved in electrical transdermal drug applicators as indicated in the patents of the present inventor cited above. Thus complex operational cycles of an applicator in accordance with the invention may be automatically controlled by a microchip.
The counteractors 16, which are added to the reservoir 12, can operate within the skin to accomplish one or more effects which tend to maintain blood circulation in the skin area adjacent the transdermal drug applicator 10, such that the primary drug 14, which enters the skin, is carried away by the bloodstream into systemic circulation for therapeutic purposes. Broadly speaking, the counteractors 16 can include vasodilators which operate by relaxing the muscles surrounding the blood vessel walls, including capillary walls, such that a greater flow area and easier blood flow is possible. A counteractor 16 may fall in the category of antithrombosis agents in that they work to reduce platelet accumulation and blood clotting in the blood vessels, in particular the capillaries, in the area where the drug applicator 10 is applied. A single counteractor which performs both functions may be used in the reservoir 12 or a plurality of counteractors which in combination perform both functions, or a counteractor which performs only one such function may be used in the reservoir 12. Also, the counteractor 16 may be a substance which when introduced into the skin induces the body to produce substances which delay, inhibit, or eliminate blood coagulation or aid in dilating the blood vessels to improve blood circulation. The primary drug and counteractor may be variants of the same substance which do not interact pharmacologically, e.g. nitroglycerine and isosorbide dinitrate. The counteractive substance can be part of the primary drug molecule. Especially sulfonated, phospholated and carboxylated groups attached to the primary drug molecules may be effective in providing a desired increase of the negative charge characteristics of the cellular walls where the applicator is attached.
Substances known to be unsuitable for systemic transdermal delivery as a primary drug with intended therapeutic benefit may be the preferred counteractor as the drug's action will be limited to the target area of applicator attachment and the counteractor will not be available to produce any systemic effects. Thus, such application of substances as counteractors is entirely opposed to prior teachings where it may be indicated that no therapeutic utility for these materials is present in transdermal applicators. The counteractors are formulated to function only as topical agents. For example, if nitrates are used, e.g. nitroglycerin, the flux rate of the counteractor may be adjusted so as not to produce any detectable blood serum level of the counteractor substance, while at the applicator site blood circulation is improved. There is no or negligible systemic effect or pharmacological effect. More specifically, the counteractive substance will be formulated for negligible transdermal delivery when its use is limited only to the counteractive function. The counteractive substance could be of a nature which selectively allows its delivery through the stratus corneum, such as nitroglycerin, whereas the electrokinetic main drug delivery takes place via the skin shunts, perspiration and sebaceous ducts. In such a case the stratum corneum would function as a depot for the counteractive substance even though the counteractive substance previously contained in said applicator reservoir is exhausted from the applicator.
Known vasodilators which may be used as counteractors, and known antithrombosis substances which also may be used as counteractors 16 and substances which may serve as both blood vessel dilators and also act to reduce or eliminate blood coagulation, are set forth herein below.
______________________________________TRADE NAME GENERIC (TRIVIAL) NAME______________________________________CARDIOVASCULAR DRUGS, VASODILATORSCerespan papaverine hydrochlorideCyclospasmol cyclandelateEthatab ethaverine hydrochlorideLipo-Nicin mixture of six agents: nicotinic acid, niacinamide, ascorbic acid, thiamine HCl, riboflavin, pyridoxinePavabid papaverine hydrochlorideTheo-24 theophyllineVasodilan isoxsuprine hydrochlorideCardilate erythrityl tetranitrateIso-bid isosorbide dinitrateIsordil isosorbide dinitrateNitro-Bid nitroglycerineNitroglyn nitroglycerineNitrol (ointment) nitroglycerine (ointment)Nitrospan nitroglycerineNitrostat nitroglycerine/polyethylene glycolPeritrate pentaerythritol tetranitratePersantine dipyridamoleSorbitrate isosorbide dinitrateTridil nitroglycerineArlidin nylidrin hydrochlorideAprosoline HCl hydralazine hydrochlorideArfonad trimethaphan camsylateDibenzyline phenoxybenzamine hydrochlorideEsimil guanethidine sulfate/hydrochlorideHyperstat diazooxideIsmelin guanethidine monosulfateLoniten minoxidilNico-400 nitroglycerinePriscoline HCl tolazoline hydrochlorideSerpasil reserpineANTICOAGULANTSCalciparine calcium heparinCoumadin sodium warfarin (propanol-2 clathrate)Heparin, Na sodium heparinProtamine sulfate protamine sulfateANTIFIBROTICS, systemicPotaba potassium aminobenzoateANTIPLATELETAspirin salicylates, such as salicylic acid, its derivatives and salts thereof OTHER flavoroids (such as riboflavin) and their phenolic breakdown products or compounds. calcitonin gene related peptide (CGRP) nitroprusside prostacylin streptokinaseActivase recombinant alteplase______________________________________
While the above listings are by no means complete, they are nevertheless representative of various categories of drugs or agents which may be suitable in the practice of the invention. Moreover, the present invention contemplates the use of any counteractors which have the specific characteristics and produce the effects desired as have been described in the present application.
FIG. 3 illustrates an alternative embodiment of an electrical transdermal drug applicator 10' in accordance with the invention, wherein the primary drug 14 is contained in a first reservoir 12' and the counteractor 16 is contained in the reservoirs 12". In each reservoir, the substances are suspended in a gel 18. Electrodes 24, 52 are connected in parallel to receive current from the DC power source 28 by way of the electrical current conditioner 30. As illustrated, current flows from the battery 28 through the current conditioner 30 to the electrodes 24, 52, through the associated reservoirs 12', 12" and through the surface 22 of the skin 23. The current flows (arrows 38) within the skin to the return electrode 36 and then back to the DC power source 28.
To suit a particular primary drug 14 and counteractor 16, provision for switching the polarity of the DC source 28 may be provided as indicated in FIG. 2, and a shorting circuit connecting all electrodes 24, 52 directly to the return electrode 36 by way of a switch 48 may also be included. By operation of switches 33, 35, 37, reservoirs may be selectively inactivated while the other reservoirs continue to function. A controller 50 may be used to control the switches 32, 34, 48 (see FIG. 2) when periodic cycling is involved in operation of the transdermal drug applicator 10'.
FIG. 4 illustrates another alternative embodiment of an electrical transdermal drug applicator 10". In this configuration, the reservoir 12' is connected to one terminal of the DC source 28, whereas the reservoir 12" is connected to the other terminal of the DC power source 28. Thereby, opposite polarities are always present on the two reservoirs 12', 12". This is advantageous when the primary drug 14 is delivered through the skin's surface 22 by one electrical potential and the counteractor 16 is delivered through the skin surface 22 by the opposite potential. In this way, both the drug 14 and counteractor 16 can be continuously and concurrently delivered if desired.
A shorting circuit between the electrodes 24, 52 including the switch 48 may be used to remove charge, if any, from the skin during periods when the voltage is not applied. A controller 50 may be used with the configuration of FIG. 4 as described above to control ON/OFF periods, periods when the short circuit through the switch 48 is desired, etc. A return electrode 36 (broken lines) may be used to eliminate the reservoir 12' from the circuit when a switch 39 is closed while switches 47, 54 are open while switch 48 is also open. In this way, delivery of the counteractor substance 16 to the skin may continue while delivery from the reservoir 12' of the primary drug 14 is discontinued. Similarly, the return electrode 36 can be used to eliminate counteractor reservoir 12" when it is desired to deliver the drug 14 while interrupting delivery of the counteractor 16. In this case the switch 47 is closed, switches 38, 48, 49 are open and switch 54 is closed.
The electrical transdermal drug applicator 10 of FIG. 2 was described as containing a drug and a counteractor in suspension, for example, a gel. However, it should be understood that in alternative embodiments of an electrical transdermal drug applicator in accordance with the invention, the reservoir may be in the form of a matrix, liquid, paste, etc. as suits the particular substances in use. Also, FIG. 2 illustrates a generally random and equal distribution of drug 14 and counteractor 16 within the reservoir 12. It should be understood that the reservoir may contain a predominance of one substance over the other. The distribution of materials may not be uniform or randomized. The drug 14 may be in one layer, whereas a counteractor 16 may be in another layer, the layers being at different distances from the skin surface 22. As dictated by the particular application, either the drug 14 or counteractor 16 layer may be closer .to the skin surface. Such layers may themselves combine several substances which can be in varying proportions as suits the particular construction with drug 14 and counteractor 16 in each layer. The layers may be of different thicknesses such that one layer may act as a flow inhibitor of materials from the other layer. There may be several layers each of counteractors and drugs and these layers may be alternated in their stacking within a reservoir.
In an exemplary embodiment of the invention, blockage of the capillaries and stratum corneum of the skin may be avoided or inhibited by sub-therapeutic dosages of an active vasodilator such as nitroglycerin. For example, a therapeutic ointment at 2% concentration is available from the W. H. Rorer Co. (Fort Washington, Pa. 19034) under the tradename NITROL ointment. Since it is known that nitroglycerine relaxes smooth muscles, principally in the smaller blood vessels thus dilating arterioles and capillaries, it may be advantageous to topically apply sub-therapeutic doses of about 0.001 to about 0.2% nitroglycerine ointments to the skin, when employing an otherwise conventional transdermal applicator, such as described in the applicant's own earlier issued U.S. Patents. Thus a counteractor layer is at the skin surface; the primary drug passes through this layer before entering the skin. If desired, the body of the ointment may preferably be a hydrophilic polymer, such as polyvinyl pyrrolidone or neutralized polyacrylic acid and the like in order not to interfere with the hydrophilic adhesive which may be employed in the transdermal applicator.
In another exemplary embodiment, one may utilize a stabilized vasodilator in order to restrict blockage counteraction to the region of the patient's body where the transdermal applicator of the invention is located. This may be achieved by the use of a polymer stabilizer for a vasodilator, such as nitroglycerine. One such polymer stabilizer is polyethylene glycol, but other stabilizers having like properties may also be suitable in the practice of the invention. As is known, a polyethylene glycol of molecular weight 3350 operates to lower the migration of nitroglycerine, (see U.S. Pat. No. 3,789,119). With the present invention, a higher molecular weight would be preferred, for example of from about 5000 to about 20,000 so as to localize the vasodilation of the very region where the electrolytic patch of the invention is applied. Of course, other suitable benign polymers with a molecular weight of from abut 3,000 to about 30,000 may be employed, depending on their diffusion constant.
FIGS. 5-8 illustrate alternative embodiments in accordance with the invention wherein the primary drug indicated in those Figures with a D and the counteractive agent, indicated in those Figures with a C, are located in individual reservoirs. In FIG. 5, counteractor reservoirs 60 alternate with drug reservoirs 62 in the direction of current flow indicated by the arrows 64 when an applicator 66 is attached to the skin surface 22. For the sake of example, the reservoirs are connected in parallel schematically to one terminal of an electrical control unit 68 and current flows from the reservoirs 60, 62 through the skin surface 22 and within the skin to the return electrode 70 indicated in FIG. 5 by the letter R. The skin to which the applicator 66 is attached receives the primary drug from the reservoirs 62, while at the same time a current passing through a counteractor reservoir 60 from the upstream direction (left to right in FIG. 5) delivers the counteractive substance and acts as a preconditioner to the blood vessels in the area of the drug reservoirs 62. The counteractive substance and the primary drug are thereby simultaneously active in the same region of skin.
The FIGS. 5-8 are schematic. Any electrical control, such as polarity reversal, ON/OFF voltage application, electrode short-circuiting, series arrangement of reservoirs, etc., as described above in relation to FIGS. 2-4, can be applied equally to the arrangements of FIGS. 5-8. FIGS. 6, 7 and 8 show applicators with separate drug D reservoirs and counteractor C reservoirs. In each instance, the reservoirs may be electrically connected such that the counteractor substance acts as a preconditioner for the blood vessels in the area where the drug reservoir is applied. With regard to FIGS. 5-8, it should be understood that the relative positions of the primary drug reservoirs D may be interchanged with the counteractive substance reservoirs C as suits the particular substances which are in use. Other configurations as shown in the above cited patents by the inventor here, may also be adapted to utilize counteractors in conjunction with primary drug delivery.
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in carrying out the above method and in the construction set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings, shall be interpreted as illustrative and not in a limiting sense. | An electrical transdermal drug applicator provides enhanced drug flow to the bloodstream of the subject by delivering a primary drug into a subject's circulatory system for therapeutic purposes, and delivering from the same or other reservoir a non-therapeutic counteracting agent to the skin of the patient which induces flow enhancement and allows delivery of the primary drug systemically over a longer period of time and in greater quantity than heretofore appeared possible using electric current. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to alpha-mosaic ("Teletext"/"Viewdata", etc.) decoders, and more particularly to such decoders that are added on ("set-top") to television receivers.
It is known to transmit pulse signals representing alpha-mosaic characters using eight grey scale levels during the vertical blanking interval of a television signal. Recently, interest has expanded to include the use of color characters. Ideally, a decoder for such characters is built into the television receiver during manufacture. In such case, the decoder provides red (R), green (G), and blue (B) pulse signals directly to the video display circuits in the receiver, thus bypassing the limited-bandwidth chroma channel therein. This allows the display of broad bandwidth (high resolution) characters.
However, there are many receivers in use that do not have built-in decoders. For such receivers, if it is desired to receive and display said characters, an external ("set-top") decoder is required. Set-top decoders apply R, G, and B signals representing the characters to a modulator that modulates an R.F. generator, which generator is set to a frequency corresponding to a locally unused television channel. The modulated R.F. signal is applied to the antenna terminals of the receiver, and in the receiver the signal is demodulated, applied to the luminance and chrominance channels, and then applied to the display circuitry. Thus, the pulse character signals are stretched and have their amplitude reduced by the limited-bandwidth receiver chroma channel. However, the bandwidth of the luminance channel is normally sufficient to pass the signals without appreciable pulse stretching or amplitude reduction.
The legibility and contrast of a character depends inter alia upon the ratio of the amplitude of its color signal to the amplitude of the color signal of the surrounding background. For certain combinations, e.g., yellow character against a white background or blue character against a black background, the legibility is reduced. In the first case, the yellow signal is transmitted through the chroma channel, which reduces its relative amplitude (in IRE units), while the white signal is primarily transmitted through the luminance channel, which does not appreciably reduce its relative amplitude (100 IRE units). The relative amplitude of the yellow signal may be so far reduced with respect to the white signal relative amplitude that it cannot be seen against the white background. The same relative amplitude reduction happens to the blue signal with respect to the relative amplitude of the black signal (0 IRE units), and therefore the blue signal is difficult to see against the black background. In general, the most difficult legibility problem occurs when there is a difference of one grey scale level between a character and its background.
It is therefore an object of the present invention to improve the legibility and contrast of alpha-mosaic characters, and more particularly to achieve such with set-top decoders.
SUMMARY OF THE INVENTION
Method and apparatus for increasing the contrast of a quantized pulsatory video signal, comprising determining if the width of pulses within said video signal is less than a predetermined duration, and modifying said video signal to increase the absolute value of the difference of a level of said video signal with respect to the preceeding signal level of the modified signal when said pulse width is less than said predetermined duration and if said absolute value is less than a selected amount.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a system incorporating the invention;
FIG. 2 is a block diagram of an edge detector used in FIG. 1;
FIG. 3 is a block diagram of a pulse width detector used in FIG. 1;
FIG. 4 is a block diagram of a luminance signal correction control circuit used in FIG. 1; and
FIG. 5 is a timing diagram useful in explaining FIGS. 2, 3 and 4.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a block diagram of a system incorporating the invention. Input terminals 10, 12, 14 and 16 respectively receive R (red), G (green), B (blue) color component signals, and composite sync signals from a set-top decoder (not shown). The R, G, and B signals are matrixed by matrix 18 to provide R-Y, B-Y, and Y (luminance) signals. In teletext, the Y signal is quantized using eight grey scale levels (the luminance components of three primary colors, 3 secondary colors and black and white). Alternatively, I (in phase) and Q (quadrature) signals can be produced by matrix 18 instead of the R-Y and B-Y signals respectively. The R-Y and B-Y signals are respectively applied to LPFs (low-pass filters) 20 and 22, which have 1.5 and 0.5 MHz cutoff frequencies respectively, and then to delay lines 24 and 26 (explained below) respectively. Finally, the signals are applied to chroma modulators 28, which provides a 3.58 MHz signal modulated by the R-Y and B-Y signals in phase quadrature. The modulated signal is then applied to adder 30. The composite sync signal at input 16 is applied to delay line 32 (explained below) and then to adder 30. The Y signal from matrix 18 is applied to LPF 34 having a 4.2 MHz cutoff frequency and to input 36 of the LSCS (luminance signal correction system) 38. The output of LPF 34 is applied to delay line 40 (explained below) and then to input 42 of LSCS 38. LSCS 38 comprises an edge detector 44 for detecting pulse edges in the Y signal applied to input 36.
A pulse width detector 46 detects when pulses have widths of less than about 1 μs (microsecond), which is about the duration of pulses that are difficult to reproduce by chroma circuits due to pulse spreading and amplitude reduction. Since it takes about 1 μs to detect if pulses have this duration or less, delay line 48 has about 1 μs delay. Thus, the signals from detectors 44 and 46 will be in synchronization when applied to LSCC (luminance signal correction control circuit) 50. Circuit 50 appropriately modifies (explained below) the luminance signal of a character of less than about 1 μs duration when received at input 42 to increase its contrast with respect to the surrounding background, and applies the thus modified signal to output 52 connected to adder 30. In doing this, a certain delay is inherent in circuit 50 due to switching transients therein, which delay depends upon the speed of the circuitry used in circuit 50. Adder 30 provides a composite video output signal.
It will be appreciated that for proper registration and synchronization to occur when the composite video signal from adder 30 is displayed, the input signals thereof must be properly timed. The delay in LSCS 38 is about 1 μs plus said switching transients. All LPFs introduce some delay, which is inversely proportional to their cutoff frequency. Therefore, the delay of delay lines 24 and 26 is set equal to 1 μs plus said switching transients minus the delay introduced by LPFs 20 and 22 respectively. The delay of delay line 40 is set equal to about 1 μs minus the delay of LPF 34 since its output is applied to LSCC 50, and therefore, switching delays are not yet encountered.
The composite video signal from adder 30 is applied to predistortion or "Fredendall" filter 54 to compensate for the delay introduced by the audio trap of the television set as required and specified by the FCC. The signal from filter 54 is applied to RF modulator 56 that generates an RF signal on a locally unused channel, which RF signal is modulated by the signal from filter 54. The modulated RF signal is applied to VSB (vestigial sideband filter) 58 in accordance with FCC specifications. The output of VSB 58 is applied to the antenna terminals of the television receiver, which is tuned to said locally unused channel.
FIG. 2 shows a block diagram of edge detector 44. An illustrative Y signal that is received from matrix 18 is shown in FIG. 5a. Pulses 501-510 are present in the Y signal. First and last voltage levels 500 and 511 are at black level, while the pulses 501-510 are at various grey levels and represent either characters or backgrounds. Time duration T 0 (in this embodiment 1 μs) is shown for scale and represents the duration of a pulse below which the Y signal is to be modified. The Y signal is applied to R-C differentiator 60 that generates the waveform B having impulses 512-522 (shown in FIG. 5b) that occur at the leading and trailing edges of pulses 501-510. The waveform B is applied to inverter 62 as well as to Schmitt trigger 64. The output signal from inverter 62 is applied to a second Schmitt trigger 66. Triggers 64 and 66 provide output pulses whenever their respective input signals exceed a small positive threshold, and their output signals are summed by adder 68 to form at its output waveform C as shown in FIG. 5c. Thus, pulses 523, 524, 526, 529, 530 and 531 are provided by trigger 64 upon actuation by positive-going impulses 512, 513, 515, 518, 519 and 520, respectively, while pulses 525, 527, 528, 532 and 533 are provided by trigger 66 upon actuation by the negative-going pulses 514, 516, 517, 521 and 522, respectively, due to their inversion by inverter 62. The waveform C from adder 68 is applied to delay line pulse width detector 46 and delay line 48.
FIG. 3 shows a block diagram of a pulse width detector 46. The waveform C from edge detector 44 is applied to the reset input of counter 70 and to delay line 72, which has a delay of T 0 (about 1 μs). Counter 70 receives pulses from oscillator 71 having a frequency of about 20 to 30 MHz. Counter 70 counts pulses from oscillator 71 and provides an output pulse (shown in waveform D in FIG. 5d) after a selected number of pulses have been counted, unless counter 70 is reset by the pulses in waveform C before said selected number has been reached. Said selected number is determined in accordance with the frequency of oscillator 71 so that it will be reached when the interval between pulses in waveform C equals or exceeds T 0 . Thus, in waveform D, pulse 534 occurs since signal C is initially low for a time greater than T 0 . The trailing edge of pulse 534 is determined by pulse 523 which resets counter 70. Further, since the interval between pulses 523 and 524 is greater than T 0 , pulse 535 occurs. Its leading edge occurs at a time T 0 after the trailing edge of reset pulse 523, while its trailing edge is determined by pulse 524. The intervals between pulses 524, 525, 526 and 527 are all less than T 0 , so no pulse occurs in this interval in waveform D. Similarly, pulses 536, 537 and 538 occur in waveform D at a time duration of T 0 , after pulses 527, 529 and 533, respectively, since no reset pulses have occurred within T 0 in the respective intervals. The delay line 72 delays the pulses in waveform C by T 0 to produce waveform E as shown in FIG. 5e with corresponding pulses given corresponding reference numerals with primes added. The waveforms D and E are applied to respective inputs of AND gate 74 to produce the waveform TR of FIG. 5f. Thus, only those pulses of waveform E that occur when D is high, which indicates the start of pulses in the delayed and modified waveform Y in FIG. 5(l) (explained below) having greater duration than T 0 , are passed by gate 74 to inverter 75 to the set (S) input of flip-flop (bi-stable multivibrator) 80. Waveform D is inverted by inverter 76 and then applied together with waveform E to respective inputs of AND gate 78. Therefore, only those pulses of waveform E that occur when waveform D is low are passed by gate 78, e.g., 524', 525', 526', 528', 530', 531', and 532'. This waveform is called "CL" (FIG. 5g) and the first pulses therein occurring after a pulse in waveform TR, e.g., 524', 528', and 530', indicate the end of pulses in the delayed Y signal of FIG. 5(l) that are greater than T 0 and the start of pulses in the delayed Y signal of less than T 0 . Waveform CL is applied to a reset (R) input of flip-flop 80. The output signal of flip-flop 80 is derived from its Q output and is the waveform QM of FIG. 5h. Pulses 523' and 524' cause flip-flop 80 to set and reset respectively, thereby generating pulse 540. Reset pulses 525' and 526' have no effect since flip-flop 80 is already reset. Similarly, pulses 527' and 528' define pulse 541; pulses 529' and 530' define pulse 542; and pulse 533' starts pulse 543, etc. Again note that reset pulses 531' and 532' have no effect on flip-flop 80. Therefore the positive and negative going transitions of waveform QM indicate the start of an interval in the delayed Y signal having only pulses of greater and less than T 0 duration respectively. In other words, when QM is high or low, the interval has only pulses greater or less than T 0 , respectively.
FIG. 4 shows a block diagram of LSCC circuit 50. The Y signal from delay line 40 at input 42 is applied to delay line 82 and to the inverting input of differential amplifier 84. The non-inverting input of amplifier 84 receives a signal that represents the previous level of the modified Y signal of FIG. 5(l) as compared with the present reference level of the Y signal at the inverting input. A signal representing the difference between these signals is present at the output of amplifier 84, and it is applied to amplifier 86 and then to gate 88. Said difference signal is also applied to window comparator 90, which comparator provides an output signal G (FIG. 5i) which is high (pulses 544, 545, and 546) when the absolute value of the difference signal is less than a selected amount. Signal G is applied to one input of AND gate 92. The QM signal from flip-flop 80 is applied to the inverting input of gate 92. Thus, the output signal from gate 92 will be high when signal G is high (small difference signal) and when signal QM is low (pulses less than T 0 ), and it is applied to open (let the signal from amplifier 86 pass through) gate 88 when high.
The output signal from gate 88 is called CS1 (FIG.5k) and has pulses 547, 548, and 549 therein, which pulses coincide with pulses 544, 545, and 546 respectively of signal G. However, note that the polarities can be opposite, e.g., 545 and 548, depending upon the polarity of the difference signal from amplifier 84. Signal CS1 is applied to adder 94, along with the signal from delay line 82, which has a delay to compensate for switching delays in gate 88. If high-speed logic is used for gate 88, then delay line 82 can be eliminated and a direct connection made between input 42 and adder 94.
The output signal from adder 94 thus comprises the Y signal at input 42 plus the amplified difference signal CS1, which signal CS1 has the effect of exaggerating the amplitude difference between pulses of less than T 0 duration and the background when those differences are within the window of comparator 90. The result is the modified luminance signal of FIG. 5(l), where pulses corresponding to those shown in FIG. 5a have corresponding reference numerals with primes added to denote the time delay of T 0 . Note that short pulses 502', 506' and 509' have a greater amplitude difference with respect to their background reference level, pulses 501' and 503', 505' and 507', and 508' and 510', respectively, than do the corresponding pulses in FIG. 5a, thereby improving their legibility when displayed.
In order to obtain the reference level signal for the non-inverting output of amplifier 84, the signal E from delay line 72 of FIG. 3 is applied to the input of T-type flip-flop 102 of FIG. 4. The output signal from the Q output of flip-flop 102 is called "QT" and is shown in FIG. 5j. At every transition of the Y signal, flip-flop 102 changes state, thus pulses 523' and 524' in FIG. 5e define leading and trailing edges of pulse 550, pulses 525' and 526' define pulse 551, pulses 527' and 528' define pulse 552, etc.
When the QT signal is high, such as during pulse 551, sample-and-hold circuit 103 samples the modified luminance signal at output 30 (pulse 503' in FIG. 5(l) and gate 104 allows the signal then stored in sample-and-hold circuit 105 (pulse 502') to be applied to the non-inverting input of amplifier 84 as a reference level signal. During this time, the QT signal from the Q output of flip-flop 102 is low, and thus gate 105 is not sampling the signal at output 30, while gate 106 is closed, not allowing sample-and-hold circuit 103 to provide the signal presently being sampled. At the next transition signal, signal QT becomes low and signal QT is high, and thus circuit 103 provides the previous level 503' to gate 106, which gate 106 allows the stored signal 503' to be applied to the non-inverting input of amplifier 84 as a reference signal. Further, circuit 105 is enabled to sample the signal at output 30 (504') and gate 104 does not allow the output of sample-and-hold circuit 105 to be applied to amplifier 84, at pulse 552 the first of the above-described states reoccurs. The states of the gates and sample-and-hold circuits therefore alternate, and thus the previous level in the modified luminance signal of FIG. 5(l) is supplied as a reference signal to amplifier 84.
With the system described so far, a problem can arise. Consider in FIG. 5(l) if pulses 505' to 507' are closer to black level than actually shown, e.g., a black character against a blue background. The pulse 506' will be driven into the blacker-than-black region by the above-described circuitry. However, such a pulse cannot be accurately reproduced by the television receiver due to possible black level clippers or the fact that the display tube electron beam cannot be cut off to less than zero. Further, consider if pulses 508'-510' are closer to white level than shown, e.g., a white character against a yellow background, then pulse 509' will be driven into the whiter-than-white region. This also cannot be accurately reproduced due to possible white level clippers or due to the fact that the displayed picture will bloom if the electron beam is increased too much, thus destroying the legibility of the character.
To overcome this problem, the output signal from adder 94 is applied to the inputs of adder 96 and to comparators 98 and 100. Comparator 98 detects when the output signal from adder 94 goes blacker-than-black and provides a large positive pulse signal CS2 (not shown) that is applied to adder 96. The amplitude of this pulse is sufficient to overcome both the original negative-going (FIG. 5a) pulse 506 and negative-going pulse 548 of signal CS1 (FIG. 5k) to result in a positive-going pulse 506" in FIG. 5(l). Note the large amplitude difference between pulse 506" and pulses 505' and 507' for good legibility. Similarly, comparator 100 detects when the signal from adder 94 is whiter-than-white and provides a large negative-going pulse CS3 (not shown) sufficient in amplitude to overcome both original positive-going pulse 509 and positive-going pulse 549 in CS1 resulting in pulse 509". There is a large amplitude difference between pulse 509" and pulses 508' and 510' for good legibility. The output of adder 96 comprises the output 52 of LSCC circuit 38. | In add-on alpha-mosaic character (teletext) decoders, the character signals pass through the limited bandwidth chroma channel of the TV receiver. For certain color combinations and signal durations this reduces legibility and contrast due to pulse stretching and amplitude reduction. The present invention determines if a pulse is less than a predetermined pulse width and has an amplitude difference with respect to a preceding pulse of less than a selected amount. If both conditions are met, then a luminance signal pulse is generated to substitute for the original pulse, the generated pulse having a large amplitude difference with respect to the preceding pulse for improved contrast. If the generated pulse would exceed the white level or go below the black level, then a pulse of opposite polarity with respect to the first generated pulse is generated to cancel the first generated pulse but still result in a large amplitude difference with respect to the preceding pulse. | 7 |
FIELD OF THE INVENTION
The present invention concerns a composition for the treatment of burns, sunburns, abrasions, ulcers and cutaneous irritation. More specifically, the invention relates to a preparation for topical administration having analgesic, antiseptic and skin healing promoting activity. The preparation is particularly suitable for the treatment of burns, scalds and sunburns.
BACKGROUND OF THE INVENTION
As it is known, the exposure to an excessive heat of any kind causes on the human epidermis, and often also on the underlying tissues, situations of pathological alteration and lesions the seriousness of which varies according to the duration and the intensity of the exposure, and to the sensitivity of the single individual.
Real burns or scalds may be caused, for instance, by the contact with hot matter or articles, such as flames, hot liquids or burning bodies, or also by an excessive exposure to radiation sources, including the sun.
According to the current clinical classification, a burn may be of first, second or third degree, depending upon the gravity of the lesion.
The first-degree burns are limited to the superficial layers of the epidermis and are characterized by local erythema (redness) and light edema (swelling); the second-degree burns involve a damage extended to the dermis, more marked edema and formation of blisters containing serous exudate, and the third-degree burns are accompanied by a true destruction of the structural elements of the skin, with formation of blisters, sores and the presence, in the most serious cases, of charred zones. In the most critical cases the involvement is extended to general phenomena, such as shock, acute intoxication and anaemia.
In most cases, in agreement with the various levels of severity, recourse is made to the topical administration of remedies that should exert a range of different actions, including an analgesic action, a stimulating action on the reparative processes of the skin tissues, i.e. an action promoting healing of the lesions, an anti-inflammatory action and, moreover, an antiseptic action, in order to prevent the occurrence of secondary infections on the affected zones.
Actually, the injured tissues are particularly prone to the development of infections, which obviously hinder a rapid and complete healing of the skin.
In the use of the above and of other possible remedies against burns, a timely application is extremely important. It may be anticipated that the therapy will be the more effective the shorter is the time elapsed between the event that caused the lesions and the application of the remedy on the said lesions. Suitable products may be in the form of ointments or salves, creams, emulsions, gels, foams, sprays or medicated dressings or bandages, which must be directly applied on the affected zone and must be kept into contact with the lesion, if necessary by soaking the dressing from the exterior with further product, until the reparative process is seen to stably proceed.
In the past, skin burns have been covered with dressings such as salves, vaseline, and fibrous or synthetic polymer bandages, in an effort to prevent dehydration, protect against heat loss, prevent bacterial infection, and to maintain a moist environment about the wound to facilitate debridement. Conventional bandages are made of materials such as natural or synthetic fibers. One problem with such conventional covers is that, as the skin exudes serum and pus, this exudate is absorbed by the bandage. This proteinaceous material provides a culture medium for bacteria. Further, as the exudate hardens, the bandage is likely to become adhered to the skin. As the bandage is removed, the scab is also frequently removed. This can be extremely painful.
Various compounds have been developed as an alternative to, or for use with, bandages. For example, U.S. Pat. No. 85,385 (Hughes) teaches a medicinal compound suitable for treatment of skin ailments including burns, which composition is made by mixing and simmering cider-vinegar, molasses, spirits of turpentine, salt, saltpeter, oil of vitriol, and olive oil.
U.S. Pat. No. 321,839 (Neuer) teaches a medicinal compound for treatment of skin wounds, comprising thymol, boracic acid, potassium chloride, sodium chloride, and oil of wintergreen.
U.S. Pat. No. 390,534 (Tomlinson) teaches a lotion for treatment of sores, wounds and the like, comprising water, gambier extract, salt, and sulphuric acid.
Exemplary of these is U.S. Pat. No. 4,732,755 (Grana), which teaches the application of sodium polyacrylate powder as a dressing over the skin burn area, and wetting the powder such as by spraying with distilled water, until the powder becomes moist. The outer wetted surface of the moistened powder dries to form a parchment like surface, and may remain in place for 2–3 weeks.
U.S. Pat. No. 4,837,019 (Georgalas et al.) teaches a skin treatment composition for treating burned skin, which composition is capable of counteracting moisture loss and promote healing, and which comprises a moisturizing component formed of polyglycerylmethacrylate, glycerine, allantoin, panthenol, amino acid complex, and fibronectin.
U.S. Pat. No. 5,009,890 (DiPippo) discloses a burn treatment product in the form of a water-soluble, biodegradable gel, the active ingredients of which are water and Tea Tree Blend. A gum material is used to maintain the water and Tea Tree Blend in a gel state.
A number of compositions have been developed for the treatment of skin burns, but these compositions contain medications, which are expensive and not readily available.
In each case discussed above, the composition is either expensive or is formulated from ingredients which is not readily available or is not found to be entirely effective. Further, the application of various of the prior art compositions to a burn may require medical training and constant attention. Further, various patients may have reactions to certain of the non-naturally occurring pharmaceutical compositions.
In view of the foregoing, it is an object of the present invention to provide a topical composition for treatment of skin burns which eliminates or minimizes the above-mentioned and other problems, limitations and disadvantages typically associated with conventional topical compositions, and to provide a topical composition which is inexpensive, easily obtainable, simple to manufacture, easy to apply and use, reliable, storage-stable, and which does not necessarily require medical professional to administer.
SUMMARY OF THE INVENTION
In accordance with the invention, there is provided, a topical composition for treatment of burns of the skin consisting essentially of a mixture of olive oil, bees wax, lemon juice, and boric acid, wherein the amounts of olive oil and bees wax are such that the mixture is essentially a cream or thick liquid.
In accordance with the invention there is provided a topical composition for the treatment of burns of the skin, essentially of a mixture of olive oil, bees wax, lemon juice, and boric acid, wherein the amounts of olive oil and bees wax are such that the mixture is essentially a cream or thick liquid wherein the parts by weight ratio of olive oil to bees wax to lemon juice to boric acid are within 50% of 200 to 60 to 40 to 6 respectively, and wherein the ratio of olive oil to bees wax is such that the composition is a cream or liquid
After extensive investigation and experimentation, the present inventor has discovered that the objects of the invention can be simply, eloquently, and inexpensively accomplished by a topical composition for the treatment of burns comprising a mixture of, olive oil, beeswax, lemon juice and boric acid.
Testing was done by treating burns with different combinations of the above-mentioned ingredients and the results were unexpected. Using boric acid (H 3 BO 3 ) alone appeared to advance healing without infection but only in a very limited fashion. Combining boric acid with lemon juice alone did not promote healing in a much more significant way. The use of beeswax mixed with olive oil alone also appeared to advance healing as olive oil is known as known as a demulcent, emollient and soothing to mucous membranes and somewhat effective for burns, bruises, insect bites, sprains and intense itching, however the combination of all four ingredients produced significantly most improved results with the fastest healing with the least amount of scarring.
DETAILED DESCRIPTION OF THE INVENTION
The present invention more specifically concerns a topical composition and method for treatment of traumatized skin, i.e., thermal burns ranging from mild injury to extensive necrosis of the skin and/or underlying tissues. The composition and method not only expedites the healing of first and second degree burns, which are normally capable of healing without scarring, but also promotes the healing of third degree burns without scar tissue.
The ability to heal third degree burns without scarring is important not only for the treatment of accidental burns, but also in the treatment of intentional burns, such as thermal burns for destruction of birthmarks, disfiguring scars resulting from earlier injury, and the like.
The composition of the present invention is capable of application to mammals in general and humans in particular.
This invention is particularly useful when applied to traumatized tissue immediately after injury, but may also be applied one or more days after injury. Healing begins promptly upon application of the composition to the affected area, and the duration of healing will vary, depending upon the extent of the injury, from a few days to a few weeks.
EXAMPLES
In the following example a composition was prepared by mixing approximately by weight 200 grams of olive oil, 60 grams of bees wax, 40 grams of lemon juice and 6 grams of boric acid. There is no particular restriction on the manner of mixing, and common kitchen implements can be used. The composition was applied to a thickness of about ¼ of an inch evenly. For 2 nd and 3 rd degree burns the composition was applied more thickly and was and wrapped with gauze. In all instances optimum results were achieved re-applying three times daily.
Preferably, 40–60% of the composition by weight is olive oil, and 12–25% is beeswax. Notwithstanding, the amount of beeswax should be limited the desired consistency which varies from a thick paste to a more dilute cream or liquid. Lemon juice by weight may range from 5–20% and boric acid by weight comprises less than 10%. In yet a more preferred embodiment, the percentage by weight of olive oil, bees wax, lemon juice, and boric acid is, 60–70%, 16–24%, 10–16% and 1–6% respectively.
In applications where gauze was used, gauze with a fresh amount of cream was used to carefully remove any dead skin after which the a layer of the composition and new gauze was re-applied.
Ensuring that dead skin is removed between applications promoted the best healing with the least scarring.
Example 1
A female in her early 40's was severely burned from boiling liquid over the top of her right hand. Unfortunately this subject had no knowledge of the composition in accordance with this invention, and used ice water and ice packs with sterile gauze padding. Four days later her right hand was very red, painful and unsightly. She started applying the composition of this invention and relief was immediate. It was applied three times a day and the following morning was much less sensitive to touch. To her surprise, four days after applying the cream the burn had healed with no blisters forming, pustules or scarring.
Numerous other patients were treated for first, second and third degree burns with astonishing success. In all instances the surprising results with the instant relief to the pain that was associated with the burn and the lack of or reduced amount of scarring normally associated with such burns.
The composition is made in the following manner.
Approximately 200 grams of olive oil is heated and the 60 grams of hard bees wax is added until it softens, then 6 grams of boric acid is added and the mixture is removed from the heat source. 40 grams of lemon is then added.
It should be understood that the aforementioned amounts by weight are preferable, however, different amounts of these ingredients provide some benefit. What must be taken into account is the required consistency. For example if too much bees wax or too little olive oil is added, the mixture will be too hard to use. Alternatively, more, or less lemon juice can be used with relatively useful results.
The topical composition consists essentially of a mixture of olive oil, bees wax, lemon juice, and boric acid, wherein the amounts of olive oil and bees wax are such that the mixture is essentially a cream or a thick liquid, and wherein the total amounts by weight of olive oil and bees wax to boric acid is at least 10:1. Preferably the parts by weight ratio of olive oil to bees wax to lemon juice to boric acid are within 50% of: 200 to 60 to 40 to 6 respectively.
It is preferred that by weight, more olive oil is present than bees wax; more bees wax is present than lemon juice; and, more lemon juice is present than boric acid.
A preferred range of the constituents by weight is:
olive oil is 40–70%; beeswax is 12–25%; lemon juice is 12–25%; and, boric acid is 0.5–6%.
Yet a more preferred range which has shown to yield optimum results, by weight is: olive oil 60–70% beeswax 16–24% lemon juice 10–16% boric acid 1–6%.
Although olive oil yields excellent results, other oils with similar properties may be substituted.
Numerous other embodiments may be envisaged, without departing from the sprit and scope of the invention. | A topical composition and method of preparation is disclosed wherein olive oil, bees wax, lemon juice and boric acid is combined to yield a cream for application to burns. The composition makes the patient more comfortable and has been shown to promote more rapid healing with less scarring than many other products. | 0 |
BACKGROUND OF THE INVENTION
The Government has rights in this invention pursuant to Contract No. W-7405-ENG-48 awarded by the U.S. Department of Energy.
FIELD OF THE INVENTION
The present invention relates generally a translation apparatus for aligning optical devices. More specifically, the present invention relates to a single stage dual axis translator which can translate optical components or optical signals along two axes in a single geometric plane.
SUMMARY OF THE PRIOR ART
As research has progressed in the field of lasers their use has rapidly expanded into new areas. It is often the case that research and development is finding new uses for lasers faster than machinist can make necessary mounting and aligning apparatus.
For instance in the field of radio-active isotope gases, lasers are used to identify the type of isotope in a gas. Once identified, a laser beam of specific frequency and intensity may be sent into the gas to excite and separate the identified isotope from the gas. Problems arise in this endeavor when an attempt is made to align heavy test equipment and optics. When aligning optics precise movement of the optical beam must be possible, regardless of the weight of the test equipment being aligned. Thus, a demand has arisen for a device which can align heavy optics or test equipment along both a first and second perpendicular axis, for example x and y axes. The device should also be of minimum size to promote efficient use of space.
The prior art has produced an x-y translator which translates a plate along an x and a y axis which are perpendicular to one another. The translator plate is used for mounting optical devices and translating them in a horizontal plane. For instance, an optical device could be mounted on the plate and then moved from side to side for alignment and in and out for focusing. This device can only be used in the horizontal plane. It may be configured with an aperture which passes light. An additional prior art x-y translator provides horizontal and vertical translation. However, it is only a mounting translator, and does not pass light.
These two prior art devices do not have support rods which run across the entire length of the x-y translator. For this reason and because of the general design of the prior art devices, they cannot support translation of heavy test equipment. Also, the prior art devices rely on ball-bearings for low friction movement. The problem is that if the device is tipped at an angle where a plate does not rest squarely on the ball bearings, the plate may catch and stall.
The prior art also contains apparatus which are only capable of translating optical devices along a single axis at a time. For example, Oriel, a major manufacturer of optical positioners from Stratford, Connecticut, makes such a positioner. Oriel produces various configurations of translators (devices which can move optics along an axis). Some have a large opening for the passage of light, but are limited in their range of movement. Others combine movement along a single axis with rotation capabilities. Still, others provide a larger range of movement along an axis but have a small aperture.
Melles Griot, another leading producer, produces optical translator similar to Oriel. There devices are limited, however, to only being able to move in one direction in a given plane.
In an effort to achieve two axis translation in a single plane, the prior art has placed two identical single axis translators on top of one another with one being rotated 90° relative to the other in order to provide optical translation in two perpendicular axes. Since one is on top of the other, however, the perpendicular axes are in different planes.
First, this configuration is unnecessarily bulky. Second and more important, if two translators with fixed apertures are placed on one another, and moved along different axes their common aperture shrinks in size because of overlapping. This curtails the amount of the light which can pass therethrough. The further the movement is off the center point the greater the amount of light that is lost. The more light lost, the less light available for manipulation and alignment. Also, this configuration does not provide the necessary strength to mount heavier optical or analytical equipment.
SUMMARY OF THE INVENTION
It is, therefore, on object of the invention to provide an x-y translator which can translate along both a first and second axis in a given plane and is capable of passing a light beam unobstructed.
It is another object of the invention to provide the same translator as above that is capable of aligning heavy optical and analytical equipment in both a horizontal or vertical plane.
The attainment of these and related objects may be achieved through use of the novel dual axis translation device and system herein disclosed. The dual axis translation device and system in accordance with this invention serves to translate an optical beam along both an x-axis and a y-axis which are perpendicular to one another. This devices includes a beam directing means acting on said optical beam for directing the beam along a particular path transverse to these axes. Furthermore, an arrangement supporting the beam directing means for movement in the x and y direction within a given, single plane is provided. The arrangement includes a first means for translating the beam directing means along the x-axis in the given plane in order to translate the beam along the x-axis. Additionally, the arrangement comprises a second means for translating the beam directing means along the y-axis in the given plane in order to translate the beam along the y-axis.
The attainment of the foregoing and related objects, advantages and features of the invention should be more readily apparent to those skilled in the art, after review of the following more detailed description of the invention, taken together with the drawings.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view schematically illustrating the overall system in which the preferred embodiment is applied.
FIG. 2 is a view of the system shown in FIG. 1, taken generally along line 2--2 in FIG. 1.
FIG. 3 is a side transparent cross-sectional view of the preferred embodiment along a first axis taken along line A--A of FIG. 2.
FIG. 4 is a side transparent cross-sectional view of the preferred embodiment along a second axis, perpendicular to the first axis taken along section line B--B of FIG. 2.
FIG. 5 is a side view of the preferred embodiment along a first axis taken along section line C--C of FIG. 2.
FIG. 6 is a side view of the preferred embodiment along a second, perpendicular to the first axis taken along section line D--D of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the present invention is used in an optical system 10 for the detection of isotopes in a gas. The preferred embodiment 16 is a mechanical device used to align optical components so that an optical beam may pass unobstructed to a desired location. Referring to FIG. 1, a light source 12 outputs a light beam 13 to an optical fiber 14. The light beam is positioned by a dual axis translator 16 to impinge upon a desired portion of a beam splitter 20. Hitting the desired portion of the beam splitter 20 will cause the light beam to propagate through a test chamber 24 and on to a sensor 26.
The principle behind this application of the present invention is to split a beam of light and send one portion 13A to a reference sensor 22. The other portion 13B propagates through a test chamber 24 and is detected by the sensor 26. The properties of the light received by the sensor 26 are then compared against those of the reference sensor 22. From the differences it is possible to determine which isotopes are present in the gas in the test chamber 24. Once that information is known the system can separate the desired isotopes by inputting a more intense laser at a specific frequency.
The beam splitter 20 which passes about 30% of the incident light and deflects about 70% through the test chamber 24 is housed inside an optical chamber 18. To ensure proper alignment of the optical fiber to the beam splitter 20 the dual axis translation device 16 is used. Similarly, a second dual axis translation device 17 is used to align the deflected light out of the optical chamber such that it propagates through the test chamber 24 to the sensor 26. The second translator 17 is identical in principle and operation to the first 16. Therefore, only the first translator 16 is described. The preferred embodiment of this dual axis translation device will now be described in detail with reference to the drawings.
Referring to FIG. 2, the translator which is generally indicated by the reference numeral 30 in that figure, is comprised of a plurality of plates 32, 34, 36 and 38, and a bottom plate 100 (see FIGS. 3-6), which define a frame 31. Within these plates 32-38 is a beam directing member 40. On the top face 42 of the directing member 40 (facing out of the page) the fiber optic cable 14 (FIG. 1) may be attached. The bottom or interior side of the directing member 40 (not shown because it faces into the page) is disposed within and faces into the optical chamber 18 (of FIG. 1). A throughhole 44 is centrally located in the directing member 40 for passing light from fiber optic cable 14.
Through this hole 44 light passes unobstructed to whatever device is connected at the other side of the directing member 40. The hole 44 is occupied by free space (air). The hole 44 may, alternatively, be configured so as to contain a rotatable lens. Surrounding the hole 44 are mounting bores 45-48. These bores may be used to mount optical devices to the bottom or interior side of directing member 40 within chamber 18 or to the top or outer side 42. Examples of optical devices are fiber optic cables, lenses, etc.
Cooperating with the frame 31 is a first arrangement 33A for positioning the directing member 40 at desired locations along an x-axis. Also included is a second arrangement 33B for positioning the directing member 40 along the y-axis. These arrangements move the directing member 40 in the same given plane. Thus, when it is sought to direct light to a specific point on the beam splitter 20 the directing member 40 can be translated in the x and y axes until it reaches a desired location.
Focusing more closely on the x-axis positioning arrangement 33A, a pair of parallel rods 50 and 52 are provided. These rods are parallel to the x-axis and extend through the directing member 40. A very low friction contact is created between the directing member 40 and the parallel rods 50 and 52 so that the directing member may be translated freely along the x-axis. This is accomplished by using ground stock material for the rods 50 and 52 which will track without catching. Also, the interior of the holes drilled through the directing member 40 may be wireburned to make their surface smooth. Wireburn consists of heating a metal wire (with a melting point much greater than the metal of the directing member, which is usually aluminum) and searing the interior of the bore.
These holes drilled in the directing member 40, through which the rods 50 and 52 run, are parallel to the x-axis. Thus, the member 40 may translate freely along the x-axis without the use of teflon shims or ball-bearings.
Each of the rods 50-52 is of equal length. The ends of the rods are collected on one end in a first boot 54. The first boot 54 is housed in plate 38. The ends of the rods are collected on the other end in a second boot 58. The second boot 58 is housed in the plate 34. The boots 54 and 58 are shown by dotted lines in this figure because they are internal to the plates 34 and 38. The first boot 54 rests in a track 55 internal to the plate 38. The second boot 58 rests in a track 59 internal to the plate 34. The internal path of track 55 is shown by the dotted line 57. The internal path of track 59 is shown by the dotted line 61.
To move the directing member 40 a positioning screw 60 is used. A threaded bore 62 is created in the plate 38 through which the screw 60 is threaded. Partially enclosed on the end of the screw 60 is a ball-bearing 64. The ball-bearing 64 is used to minimize friction between the screw 60 and the directing member 40 as the screw 60 is turned and also as the directing member 40 translates along the y-axis. As the screw 60 is turned it advances inward toward the directing member 40 pushing it along the x-axis. The movement of the directing member 40 is guided by the rods 50 and 52. A micrometer could alternatively be used in place of a screw 60.
On the other side of the directing member are a pair of springs 66 and 68. The spring 66 surrounds the rod 50 and is located between the directing member 40 and the plate 34. The spring 68 surrounds the rod 52 and is located between the directing member 40 and the plate 34. The springs 66 and 68 exert a pressure on the directing member 40 in the direction of the position screw 60 so that the member 40 and the screw 60 are always in contact, regardless of the position on the assembly 30 (i.e.. the effects of gravity). Thus, when screw 60 is advanced outward, away from member 40, the latter follows it due to the biasing forces applied to it by springs 66 and 68.
Focusing now on translation along the y-axis, the arrangement 33B for moving the beam directing member 40 in the y-axis operates under the same principle used by the x-axis arrangement 33A. The member 40 and the arrangement 33A including the rods 50 and 52, the boots 54 and 58 and the springs 66 and 68, with the exception of the screw 60, are supported for movement back and forth in tracks 55 and 59 along the y-axis. A pair of springs 76 and 78 bias this configuration (the member 40, rods 50 and 52, boots 54 and 58, and springs 66 and 68) in the direction of a y-axis positioning screw 72 and serve as a resisting apparatus.
More specifically, the plate 36 has a threaded bore 70. The bore 70 is centrally located and parallel to the y-axis. Threaded through the bore 70 is a positioning screw 72. This screw 72 operates in much the same way as screw 60 with respect to the x-axis. As the screw 72 is screwed in it asserts pressure on the directing member 40 pushing it, the parallel rods 50-52 and the attached boots 54 and 58 along the y-axis.
Conversely, as screw 72 is unscrewed, the directing member 40 moves in the opposite direction along the y-axis (pushed along by the springs 76 and 78). The boots 54 and 58 and the tracks 38 and 34 are configured in such a manner as to minimize friction so that the boots 54 and 58 (and the directing member 40 and parallel rods 50 and 52) can move along the tracks 38 and 34 freely. To produce low friction movement the tracks 38 an 34 are wireburned. This leaves a very smooth track surface. Smoother than can be obtained from sanding and buffing. Additionally, the boots 54 and 58 are made of ground stock material. Thus, the boots 54 and 58 can move within the tracks without catching.
FIG. 2 is a top view of the translator 16. Therefore, it shows the screw 60 to be at the same level as the boot 54 and the track 55, intersecting them. In the preferred embodiment the screw 60 is actually above (out of the page from) the track 55 and boot 54. This aspect of the preferred embodiment is further discussed in connection with FIGS. 5 and 6 below.
Located on the end of the screw 72 is a ball-bearing 74. The ball-bearing 74 reduces friction at the screw-directing member interface 75 which may be caused from the turning of the screw 72 and from translation of the directing number 40 along the x-axis. Any alternate friction reducing apparatus could be used.
Focusing now on the springs 76 and 78 serving as a resisting apparatus, pressure is exerted through the tracks 38 and 34 on to the boots 54 and 58, respectively, by means of the springs. Located in track 55 between the boot 54 and the plate 32 is the spring 76. This spring 76 maintains a constant pressure on the boot 54. The spring 78 is similarly located in track 59 between the boot 58 and the plate 32. Spring 78 exerts a constant pressure on boot 58. These two springs 76 and 78 combine to push the directing member 40 toward the y-axis positioning screw 72. Since contact is maintained between the directing member 40 and the positioning screw 72, any movement of the screw 72 is reflected in the directing member 40. Thus, when the screw 72 is moved in or out along the y-axis the directing member 40 is moved by the same amount.
All of the components which make up the translator are made of aluminum. However, any suitable metal could be used. For example, titanium could also be used. The aluminum components are black anodized to harden their surface. That way they do not out gas as much as regular aluminum when in a vacuum chamber. The black anodization makes the surface strong while maintaining the light overall weight of the translator 16 provided by the aluminum.
The strength of the translator 16 of the present invention is significantly greater than that of the prior art. The translator cf the preferred embodiment can move a 15 lb. optical chamber 18. To use a translator of the prior art to accomplish such a task would result in destruction of the prior art translator because its components would bend out of alignment. The added strength of the translator 16 is because of its rods 50 and 52 which traverse across the entire length of the translator 16, and the boots 54 and 58 which securely maintain the rods 50 and 52, and allow very low friction translation throughout any horizontal or vertical position.
Additional components of the translator 16 or 30 described above are mounting bores 80-86 for mounting the translator 30 to various devices. These bores 80-86 permit the translator 30 to be mounted to optical devices (also referred to as optics). Also, bores 80-86 are used to mount the plates 38 and 34 (which contain the tracks 54 and 58, respectively) to the frame 31. These features are perhaps better shown in FIGS. 3-6 which follow.
Referring to FIG. 3, a cross-sectional view of the plates 38 and 34 is shown. The cross-section is cut away at line A--A (of FIG. 2). From this view the dimensions of the track 55 are readily apparent as is the location of the spring 76. To the right, plate 34 is shown. Inside the plate 34 is the track 59. Inside the track is the spring 78. The plates are attached to the base plate 100 which is part of the frame 31. Illustrated by dotted lines are the bores 86 and 84 of plate 32.
Referring to FIG. 4, a cross-sectional view is taken at line B--B (of FIG. 2) of the track 59 and the plate 34. The plate 34 is housed on the frame 31 attaching to the base plate 100 at bores 96 and 94. It is located between plates 32 and 36. The opening of the track 59 is defined by a bottom lip 59b and a top lip 59c. A visible portion of the boot 58 can be seen though the opening defined by the lips 59b and 59c. Cross-sectional portions of the rods 50 and 52 are shown. They are surrounded by springs 66 and 68, respectively. Dotted line 59a represents the bottom of the track 59, not visible from this perspective. Dotted line 59d represents the top of the track 59, likewise not visible from the perspective shown.
Referring to FIG. 5, a view of the translator 30 from line C--C (of FIG. 2) is shown. An x-axis positioning member block 110 is formed on the plate 38. This configuration holds the x-axis positioning screw 60 above the track 54 which is internal to the plate 38, prohibiting, thereby, interference between the x-axis positioning screw 60 and the movement of the boot 54 within the track 55. Plate 38 is joined to the frame 31 which is comprised of the plate 32 and 36 and the bottom plate 100.
Referring to FIG. 6, a plain view is shown from line D--D (of FIG. 2). The x-axis positioning screw 60 is threaded through the bore 62 in the block 110. The screw 60 extends to the directing member 40 at a point above the maximum height of the plate 36 (and all other plates 32-38). It is also above the y-axis positioning screw 72. This configuration eliminates interference between the x and y axis positioning arrangements 33A and 33B as they translate the directing member 40, in the same plane, along their respective axes.
It should further be apparent to those skilled in the art that various changes in form and details of the invention as shown and described may be made. It is intended that such changes be included within the spirit and scope of the claims appended hereto. | A dual axis translation device and system in accordance with this invention, for translating an optical beam along both an x-axis and a y-axis which are perpendicular to one another, has a beam directing means acting on said optical beam for directing the beam along a particular path transverse to said x and y axes. An arrangement supporting said beam directing means for movement in the x and y direction within a given plane is provided. The arrangement includes a first means for translating said beam directing means along the x-axis in said given plane in order to translate the beam along said x-axis. The arrangement comprises a second means for translating said beam directing means along the y-axis in said given plane in order to translate the beam along said y-axis. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an adjustable mounting device for securing an umbrella to a stroller, carriage, pram, walker, wheelchair or other such device to provide protection from environmental conditions to an individual pushing the device, without requiring use of a hand to hold the umbrella.
2. Description of Related Art
Baby strollers often come equipped with canopies and rain covers that protect the child from environmental conditions such as sun and rain. The person pushing the stroller, hereinafter referred to as “a user”, however, is not provided such protection and as such often must hold an umbrella separately, in addition to pushing the stroller. Due to size and other design characteristics, many strollers require two hands to steer properly, so a rainstorm or other such event can provide a frustrating experience to the parent or other individual wheeling the stroller through inclement weather.
Other patents have discussed mechanisms for attaching an umbrella or parasol to a baby carriage or stroller. For example, U.S. Pat. No. 7,493,908 (Carter) relates to an umbrella anchored to a stroller by a guy line or guy lines, belt or buckle. Such method of attachment does not address the critical problem of keeping the umbrella stable and upright while in motion. Such method also does not effectively take into account the direction of the rain or the height of the user.
U.S. Pat. No. 6,244,557 (Maze) relates to a bridging mechanism to attach to two spaced handlebars of a stroller. The application of such mechanism is very limited. For example, the mechanism is not useable on the multitude of strollers that contain a single handlebar, does not permit maneuverability of the umbrella, and does not allow for stow-ability on the stroller.
U.S. Pat. No. 4,919,379 (Goetz) relates to a clamping fixture for attaching umbrellas, parasols, sunscreens and the like to baby carriages or strollers. Such device is intended exclusively to protect the child seated in the stroller and does not address the problem of keeping the user dry in a rainstorm, or the awkwardness of trying to push a stroller on a rainy day, while holding an umbrella. Such device also does not provide adjustability for position or height.
Accordingly, there is room for improvement in mechanisms for providing an umbrella to a user of a stroller.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of umbrella holding methods now present in the prior art, the present invention provides a new umbrella mounting device for a stroller wherein the same can be utilized for protecting the user of a stroller from inclement weather.
In one embodiment of the invention, an umbrella assembly for providing cover to a user pushing a stroller or similar device is provided. The assembly includes a clamp mechanism structured to be coupled to a portion of the stroller and an umbrella portion selectively coupled to the clamp mechanism. The umbrella portion is selectively rotatable relative to the clamp mechanism among a plurality of positions.
The umbrella portion may be moveable among the plurality of positions while coupled to the clamp. The plurality of positions may comprise a first position in which the umbrella is structured to be positioned generally above the user and a second position in which the umbrella portion has been rotated about 180° downward from the first position. The clamp mechanism may comprise a first knob and a second knob, the first knob being structured to tighten or loosen the clamp mechanism from the stroller and the second knob being disposed to adjust the coupling of the umbrella portion and the clamp member. The umbrella portion may comprise a telescoping shaft having a lower portion and an upper portion, the lower portion having a number of apertures disposed therein and the upper portion having a button member protruding radially therefrom. The button member may be structured to selectively engage a selected one of the number of apertures in a manner that allows for the relative positioning of the lower portion and the upper portion to be selectively adjusted.
In another embodiment of the invention, another umbrella assembly for providing cover to a user pushing a stroller or similar device is also provided. The assembly includes an umbrella having a shaft extending therefrom and a clamp mechanism having a first portion structured to be coupled to a portion of the stroller and a second portion coupled to the shaft of the umbrella. The second portion of the clamp mechanism is selectively rotatable about the first portion of the clamp mechanism such that the umbrella may be placed among a plurality of positions.
The second portion of the clamp mechanism may be selectively rotatable with respect to the first portion of the clamp mechanism from a first position to a second position about 180 degrees from the first position. The first portion of the clamp mechanism may comprise a first knob that is structured to tighten or loosen the coupling of the first portion and the portion of the stroller. The second portion of the clamp mechanism may comprise a second knob member that is structured to control rotation of the second portion about the first portion. The second portion of the clamp mechanism may comprise a hollow shaft that slidably engages the shaft of the umbrella. The hollow shaft may comprise a number of apertures disposed therein and the shaft of the umbrella may comprise a button member protruding radially therefrom, the button member being structured to selectively engage a selected one of the number of apertures in a manner that allows for the relative positioning of the shaft of the umbrella within the hollow shaft of the second portion to be selectively adjusted.
It is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
These objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features and advantages of the invention will become apparent upon reading the following detailed description of the invention in conjunction with the attached drawings in which:
FIG. 1 is a side elevational view of a non-limiting embodiment of the present invention installed on an example stroller with the umbrella portion positioned in an active position;
FIG. 2 is a side elevational view of the embodiment of FIG. 2 with the umbrella portion positioned in a different active position;
FIG. 3 is a side elevational view of the embodiment of FIGS. 1 and 2 with the umbrella portion positioned in a stowed position; and
FIG. 4 is an exploded view of the mounting portion of a device according to a non-limiting embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As used herein, the singular form of “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. As used herein, the statement that two or more parts or components are “coupled” shall mean that the parts are joined or operate together either directly or indirectly, i.e., through one or more intermediate parts or components, so long as a link occurs. As used herein, “directly coupled” means that two elements are directly in contact with each other. As used herein, “fixedly coupled” or “fixed” means that two components are coupled so as to move as one while maintaining a constant orientation relative to each other.
As used herein, the word “unitary” means a component is created as a single piece or unit. That is, a component that includes pieces that are created separately and then coupled together as a unit is not a “unitary” component or body. As employed herein, the statement that two or more parts or components “engage” one another shall mean that the parts exert a force against one another either directly or through one or more intermediate parts or components. As employed herein, the term “number” shall mean one or an integer greater than one (i.e., a plurality).
Directional phrases used herein, such as, for example and without limitation, top, bottom, left, right, upper, lower, front, back, and derivatives thereof, relate to the orientation of the elements shown in the drawings and are not limiting upon the claims unless expressly recited therein.
In addressing deficiencies of known designs, embodiments of the present invention provide a mounting device that attaches securely and easily to a stroller, carriage, pram, walker, wheelchair or other pushchair. As employed herein, the term “stroller” shall be used to mean a stroller, carriage, pram, walker, wheelchair or other similar device. It is a further object of the invention to provide an umbrella suitable for attachment to the mounting device that works on strollers, wheelchairs and walkers, and protects users of virtually all heights from all directions of rain. In these respects, the umbrella mounting device for a stroller, according to the present invention, substantially departs from the conventional concepts and designs of the prior art, and in doing so, provides an apparatus primarily developed for purposes of protecting the user of the stroller from inclement weather.
Referring to the drawings, FIG. 1 depicts an adjustable umbrella assembly according to a non-limiting embodiment of the present invention, generally designated with the reference numeral 10 , attached to a conventional folding or collapsible stroller 12 . The stroller 12 seats a young child (not shown) who may be protected from rain, wind and cold by a canopy 14 or other suitable rain shield (not shown), such as those commonly available from stroller manufacturers and retail stores carrying strollers and accessories. The umbrella assembly 10 , which may also attach to a pram, baby carriage, wheelchair, or other suitable device, includes an umbrella portion 15 having a cover 16 and a telescoping shaft 18 . Telescoping shaft 18 includes a lower section 20 and an upper section 22 slidable within lower section 20 . Lower section 20 of shaft 18 is coupled to an upper portion of the frame 23 of the stroller 12 , preferably at or about a handle portion 24 by a clamping mechanism 25 as shown in FIGS. 1-3 . The clamping mechanism is described in further detail below. It is to be readily appreciated that such positioning of the umbrella assembly 10 protects a caregiver (or other person pushing the stroller) from precipitation or other environmental conditions (e.g., without limitation, sunlight).
As commonly utilized in known umbrella designs, cover 16 is generally formed from a lightweight waterproof or water resistant material, such as nylon, vinyl, canvas or other suitable material used in umbrella manufacture, which is sized and cut to provide a selected diameter for the particular umbrella. Such diameter should be selected to provide rain, wind and precipitation protection for an adult standing underneath. Aside from further details of the telescoping shaft provided below, the remainder of umbrella portion 15 may be fabricated using generally any suitable collapsible umbrella mechanism.
Having thus described an overview of an example embodiment of an umbrella portion 15 according to an embodiment of the invention, an example embodiment of a clamping mechanism 25 will now be described in conjunction with the FIGS., particularly in conjunction with the exploded view of FIG. 4 . The example clamping mechanism 25 of FIG. 4 serves two general functions: first it serves to couple umbrella portion 15 to stroller 12 , and second it serves to allow for the adjustment of the relative positing of umbrella portion 15 with respect to stroller 12 .
In providing the first function, clamping mechanism 25 includes a first clamp member 30 having a threaded shaft 32 extending through a portion thereof such that a first end 34 of threaded shaft 32 protrudes from a first side of clamp member 30 , and an opposite second end 36 protrudes from an opposite second side of clamp member 30 . A second clamp member 38 includes a pivot pin 40 that interlocks with a corresponding portion of first clamp member 30 , creating a hinge point that allows the two clamp members 30 , 38 to cooperatively engage, and be tightened, on a selected portion of the stroller 12 , preferably at or near the handle portion 24 . The two clamp members 30 , 38 are tightened by turning a stroller tightening knob 42 threadedly disposed on threaded shaft 32 at or near first end 34 . Stroller tightening knob 42 is preferably formed from an inner half 44 and an outer half 46 that are fused together. A threaded nut 48 is preferably installed in the tightening knob 42 during manufacture. Preferably, such elements are made from a composite material such as reinforced polycarbonate (or other type of composite) or other suitable material. In use, the tightening knob 42 opens and closes the clamp formed by the first and second clamp members 30 , 38 to secure the umbrella assembly 10 to the stroller 12 . Preferably, the tightening knob 42 is manufactured to only loosen a selected amount, and thus cannot be removed from the threaded shaft and potentially lost by a user.
Preferably, one or both of clamp members 30 , 38 are provided with a number of generally small grip protrusions 50 molded into the concave clamp area (not numbered) thereof. The grip protrusions 50 allow the clamp formed by the first and second clamp members 30 , 38 to grip the cushioned (rubber, foam, plastic or metal) handles or other selected portion of a stroller.
In a preferred embodiment, the surface of the outer half 46 of tightening knob 42 contains an embossed star logo to differentiate the tightening knob from the positioning knob (discussed below) for the user.
In providing the second function, clamping mechanism 25 includes a positioning knob 60 formed from inner and outer halves 62 and 64 , respectively. Similar to tightening knob 42 previously discussed, such elements are preferably made from a composite material such as reinforced polycarbonate (or other type of composite) or other suitable material. A threaded nut 66 is preferably installed in the positioning knob 60 during manufacture. When the positioning knob 60 is tightened on threaded shaft 32 at or about second end 36 , the umbrella portion 15 is held in the chosen position. The user is able to adjust the angle of the umbrella portion 15 relative to the stroller 12 depending on the direction of the rain and/or for the placement of the mounting device on the particular stroller. FIG. 1 shows an example of the umbrella portion 15 positioned generally parallel to the ground. FIG. 2 shows an example of the umbrella portion 15 positioned at roughly a 45 degree angle with respect to the ground. It is to be appreciated that such particular positioning as shown in FIGS. 1 and 2 is shown for example purposes only and is not meant to be limiting upon the scope of the present invention and that the umbrella portion 15 may be positioned at other angles other than those shown. As shown in FIG. 3 , the user can also turn the umbrella 180 degrees from the position shown in FIG. 1 so that the umbrella portion 15 can be stored on the stroller 12 in a downward position when not in use. Preferably, the positioning knob 60 is manufactured to only loosen a selected amount and thus cannot be removed from the threaded shaft and potentially lost by a user.
Continuing to refer to FIG. 4 , lower section 20 of shaft 18 is preferably formed from first and second halves 70 and 72 , respectively. During manufacture, first half 70 and second half 72 are fused together with a shaft ring 74 to create a hollow cylindrical tube in which the upper section 22 of telescoping shaft 18 can then be inserted. Shaft ring 74 , which is fused to the upper end of the two halves 70 , 72 reinforces the fusing of the two halves and provides a generally smooth transition for upper section 22 to slide therein.
Lower section 20 of telescoping shaft 18 includes a concentric ring portion 80 at the opposite end of the shaft ring 74 . The concentric ring portion 80 of second half 72 includes a number of depressed detents 82 arranged in a circular manner. The depressed detents 82 correspond to a number of raised buttons 84 disposed on first clamp member 30 . When assembled, each of the number of buttons 84 snap into a corresponding one of the number of detents 82 , thus allowing the angle of umbrella portion 15 to be adjusted by loosening, adjusting, and retightening of positioning knob 60 .
In the example embodiment shown in FIG. 4 , each of the halves 70 , 72 of lower section 20 are provided with a number of recessed apertures 90 spaced at generally equal intervals. In a preferred embodiment, such apertures are spaced generally one inch apart, with finger access to allow umbrella height adjustment for users. Upper section 22 of telescoping shaft 18 is fitted with a spring loaded button 92 that is inserted into the lower section 20 of telescoping shaft 18 . The button 92 locks into one of the multiple recessed apertures 90 as selected by a user according to user height and preference.
It should be appreciated that an umbrella that attaches to a stroller to provide protection for the user in inclement weather has been described, with reference to preferred embodiments illustrated in the accompanying drawings, but that other modifications may be made to this preferred embodiment. It will be appreciated that the present invention is not limited to those precise embodiments, and that various changes and modifications may be made thereto by one of ordinary skill in the art without departing from the scope or spirit of the invention, which is defined in the following claims.
In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word “comprising” or “including” does not exclude the presence of elements or steps other than those listed in a claim. In a device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. In any device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain elements are recited in mutually different dependent claims does not indicate that these elements cannot be used in combination. | An umbrella assembly for providing cover to a user pushing a stroller or similar device includes a clamp mechanism structured to be coupled to a portion of the stroller and an umbrella portion selectively coupled to the clamp mechanism. The umbrella portion is selectively rotatable relative to the clamp mechanism among a plurality of positions. | 0 |
[0001] This application claims priority to U.S. Provisional Application Ser. No. 60/970,075, filed Sep. 5, 2007, entitled “Deposit Container Identification System,” and naming Cochran et al. as inventors, and, U.S. Provisional Application Ser. No. 60/972,126, filed Sep. 13, 2007, entitled “Deposit Container Verification and Identification System,” naming Cochran as the inventor, both of which are incorporated herein by this reference in their entirety.
BACKGROUND
[0002] Returnable beverage and beer containers are not new and have been around for decades. An infrastructure formerly existed in the United States which refunded a deposit on refillable containers when returned to a store that was participating. The infrastructure to facilitate this deposit return was quite extensive but was nearly all manual.
[0003] As all types of disposable, one-way containers gradually replaced returnable and refillable containers, it became clear that it would be desirable to recycle the containers rather than have them end up as just additional product in the waste stream filling the garbage dumps. The three most popular kinds of beverage and beer containers which consist of glass, PET (polyethylene terephthalate), and metal cans (including both steel and aluminum) are all thoroughly recyclable. Some communities have established recycling programs as part of their garbage collection routines—but most have not. Consequently, either out of inconvenience or laziness, only a relatively small percentage of containers are returned through a typical recycling program.
[0004] The manufactures of all three types of containers, both out of solid environmental social responsibility and economics, have been anxious to return back a higher percentage of post-consumer containers for recycling. Some U.S. states have adopted mandatory deposit laws which are intended to dramatically increase the
[0005] State deposit laws have proliferated to some states but they have not been enacted in many other states. Because the manufacturers of the containers have resisted the requests to make and segregate containers specifically for, or mark containers specifically for, the deposit law states, a problem exists. Although illegal, people have begun transporting containers from non-deposit states to deposit states. They will then return the containers in the deposit law state to receive a deposit where one has never been paid. For example, Michigan currently charges a $0.10 deposit while the neighboring states of Indiana and Ohio do not charge deposits. This has turned out to be a problem with either the beer and beverage wholesalers or with the grocery store chains, depending on who is handling the money in the transaction. Some business entity is returning a deposit which was never paid. The size of this problem has grown dramatically in the last several years but the container manufacturers and beer and beverage fillers have not agreed on a palatable course of action to verify that the container came from a deposit state where a deposit had actually been paid. The grocery stores are not inclined to police the situation for fear of alienating customers. As this problem has grown in recent years, it has become a very expensive problem.
[0006] A solution is needed which entails easily and inexpensively applying some indicator to the container when it is known that it will be sold into a deposit state. Traditionally, if marks are put on the container, they are put on at a substantially early time in the manufacturing process. For example, in two-piece aluminum beverage containers, the two letter abbreviations for each of the states that has a deposit law are incised into the converted end during the metal stamping “conversion” process. A so-called converted end, or completed can end, is manufactured in a complex metal stamping press. Shells (sometimes called lids or ends) which do not yet have a tab, are fed into a transfer system and an indexing belt pocket moves the end to each successive transfer die tooling station. The rivet is gradually formed up from the base material in the center of the end until it is ready to have the tab placed over it. It is then staked to hold the tab in place. Simultaneously, strip tab stock material is coil fed through the side window of the press through its own dedicated multi-out progressive die The output from the tab die is typically three or four completed tabs with each stroke of the press. The tabs are held in the progressive strip until the rivet hole is lined up over the “rivet bulge” in the assembly station of the transfer die. As the transfer die closes, it severs the attachment to the progressive feeding strip and then stakes the rivet to its correct size to hold the tab in place.
[0007] If deposit law markings are pressed into the metal by way of embossing or incising or other identifiable geometry, it must be done at or before the afore-described conversion press operation. It has also been proposed in the past to coat the strip stock from which either the end (can lid) is manufactured or from which the tab is manufactured with a UV coating. A UV coating would be defined here as any coating which would fluoresce under a conventional broad-band UV light source. The manufacturing challenge and problem with this approach is that it requires a tremendous amount of tracking and manufacturing discipline. The stamping plant must segregate materials carefully to make sure that the UV coated coils of metal are only used for ends which are destined to a deposit state. Usually, at the time of manufacturing of the converted ends it is not known what its final destination will be. While this sophistication could be added to the manufacturing process, it would be expensive and tedious. There also would be a substantial additional cost factor because it would be expensive to coat the entire surface of the coil stock with the UV coating. It is technologically possible to coat only highly selected portions of the coil but would be an even more cumbersome problem to deal with in the normal converted end manufacturing process. Changing from coated coils to uncoated coils in accordance with the final destination of the product would be a difficult problem for the end-making plant.
[0008] Other problems exist with these proposed approaches at the detection end. Currently, there are tens of thousands of automated machines that are part of the recycling stream in the deposit states. Typically, the consumer who is returning cans or bottles will place them one at a time into a receiving portal in what is known as a “reverse vending” recycling machine. After the mechanism inside the “reverse vending” machine (RV) pulls the container in, it rotates the container looking for the bar coded Universal Product Code (UPC) marking. The UPC code is uniform across all states for a given product regardless of whether they are destined for deposit states or not. Using special UPC codes to indicate deposit or non-deposit or to indicate specific states that correspond to specific deposit amounts would add similar complexities to the manufacturing process as were discussed above. To put the marking on the can decoration, it would be necessary to substitute new decorating blankets corresponding to the special UPC code and then to keep the respective cans segregated within the manufacturing and filling and distribution chains. Again, the tediousness of that type of tracking infrastructure has been resisted by the container manufacturers, the fillers of the products, and the distributors.
[0009] After the UPC code is read, for example, on a metal can in the RV machine, it is crushed and recorded in the tally in the machine. When the consumer is done introducing containers to be recycled, the machine tallies up the number of containers that have been inserted whose UPC codes indicates that they qualify. It then prints out a voucher which is redeemable for merchandise or cash or other value. The voucher is for an amount consistent with a product of the number of qualifying containers inserted times the deposit amount in the state where the reverse vending machine is located. The RV machine has no way of knowing or detecting that the qualifying UPC coded container came from a deposit state or not. It simply assumes that the container came from the same state in which the RV machine is presently located.
[0010] It has been proposed that the reverse vending machines use a broad-band UV light source to trigger fluorescence in a UV coating on the container and then detect it with a sensor. There are several limiting problems with this approach, just as there are problems introduced by it on the manufacturing side. First of all, the conventional broad-band ultra-violet light sources have very limited life, which would be a major maintenance and replacement problem in the tens of thousands of machines that could be deployed in the field. For example, if a fluorescent ultra-violet lamp were used in a machine that had a high duty cycle of usage, it could burn out or be unreliable in less than a year. Specially doped halogen bulbs will typically have an even shorter life span of only a few thousand hours. Xenon bulbs, whether strobed or continuous, would be another choice. They not only have a similarly short life time, but typically require a high-voltage power source which can be another source of unreliability. If not carefully designed, this can also be a safety problem.
[0011] A second problem is the relative lack of selectivity that would be afforded by the broad-band UV light sources. Because their wavelength output spans over a considerable band-width, it is not possible to discriminate by using UV fluorescing compounds which must be stimulated with a higher intensity of a specific wavelength in order to be detected. It has further been proposed that a vision system could be employed which is capable of viewing the top of, for example, a beverage can and detecting a particular mark which is embossed or incised into the end. While this is a technologically feasible system, it requires an unnecessary amount of sophistication which brings along its own problems and cost. This is a major consideration in tens of thousands of unsupervised installations in the field. Set-up and adjustment of a vision system or camera-based system is typically more complicated than with simple sensor based systems. As was described above, putting such marks in the container's surface also requires a substantial change to the manufacturing process and infrastructure which is undesirable to the manufacturers of the containers and the fillers of the containers.
BRIEF DESCRIPTION
[0012] In one aspect of the presently described embodiments, a system comprises at least one emitter operative to emit radiation in a first wavelength band selected for use with the marking and positioned to direct the radiation toward a container, at least one sensor operative to sense a second wavelength band of radiation from the container having the marking and a control system operative to drive the at least one emitter, receive information from the at least one sensor, and process the information to determine eligibility for the container for collection of the monetary deposit.
[0013] In another aspect of the presently described embodiments, the first wavelength band and the second wavelength band comprise wavelengths substantially the same.
[0014] In another aspect of the presently described embodiments, the first wavelength band and the second wavelength band comprise different wavelengths.
[0015] In another aspect of the presently described embodiments, the first wavelength band is a narrow band.
[0016] In another aspect of the presently described embodiments, the second wavelength band is a narrow band.
[0017] In another aspect of the presently described embodiments, the at least one sensor is operative to sense a third wavelength band of radiation from the container having the marking, wherein the marking causes the return of the radiation to the sensor in at least two wavelength bands.
[0018] In another aspect of the presently described embodiments, the system further comprises a lens.
[0019] In another aspect of the presently described embodiments, the lens is disposed between the container and the sensor.
[0020] In another aspect of the presently described embodiments, the emitter is an ultraviolet emitter.
[0021] In another aspect of the presently described embodiments, the emitter is an infrared emitter.
[0022] In another aspect of the presently described embodiments, the sensor is an RGB sensor.
[0023] In another aspect of the presently described embodiments, the control system comprises a microcontroller, an interface to a reverse vending machine controller, and an emitter drive stage.
[0024] In another aspect of the presently described embodiments, the microcontroller is operative to communicate with a reverse vending machine controller through the interface and operative to drive the at least one emitter through the emitter drive stage.
[0025] In another aspect of the presently described embodiments, the at least one emitter and the at least one sensor are housed within a sensor head.
[0026] In another aspect of the presently described embodiments, the sensor head and the control system are housed within a single sensor unit.
[0027] In another aspect of the presently described embodiments, the at least one emitter, the at least one sensor, and the control system are positioned within a reverse vending machine.
[0028] In another aspect of the presently described embodiments, the at least one sensor is a single sensing element.
[0029] In another aspect of the presently described embodiments, a method comprises driving at least one emitter to emit radiation in a first wavelength band selected for use with the marking and positioned to direct the radiation toward a container, sensing through at least one sensor a second wavelength band of radiation from the container having the marking, receiving information from the at least one sensor and processing the information to determine eligibility for the container for collection of the monetary deposit.
[0030] In another aspect of the presently described embodiments, the first wavelength band and the second wavelength band comprise wavelengths substantially the same.
[0031] In another aspect of the presently described embodiments, the first wavelength band and the second wavelength band comprise different wavelengths.
[0032] In another aspect of the presently described embodiments, the first wavelength band is a narrow band.
[0033] In another aspect of the presently described embodiments, the second wavelength band is a narrow band.
[0034] In another aspect of the presently described embodiments, the method further comprises sensing through the at least one sensor a third wavelength band, wherein the marking causes the return of the radiation to the sensor in at least two wavelength bands.
[0035] In another aspect of the presently described embodiments, the emitter is an ultraviolet emitter.
[0036] In another aspect of the presently described embodiments, the emitter is an infrared emitter.
[0037] In another aspect of the presently described embodiments the first wavelength band of irradiation is one of a wavelength and a wavelength mix such that the marking is not visible to the sensor.
[0038] In another aspect of the presently described embodiments, the first wavelength band of irradiation is one of a wavelength and a wavelength mix such that the marking is visible to the sensor.
[0039] In another aspect of the presently described embodiments, the first and second wavelength band are in the visible light range.
[0040] In another aspect of the presently described embodiments, the marking takes the form of at least one of human and machine readable code.
[0041] In another aspect of the presently described embodiments, the marking takes the form of at least one of human and machine readable code.
[0042] In another aspect of the presently described embodiments, the marking takes the form of at least one of human and machine readable code.
BRIEF DESCRIPTION OF DRAWINGS
[0043] FIG. 1 is a block diagram of an example system according to the presently described embodiments;
[0044] FIG. 2 is a block diagram of an example system according to the presently described embodiments; and,
[0045] FIGS. 3( a ) and ( b ) are representative illustrations of an environment into which the presently described embodiments may be implemented.
[0046] FIG. 4 is a flowchart illustrating a method according to the presently described embodiments.
DETAILED DESCRIPTION
[0047] The presently described embodiments are directed to a system which facilitates more economical and more flexible coding of deposited containers and whose detection equipment has a number of important advantages. Implementation of the presently described embodiments will allow for convenient and simple modifications to the current process to achieve substantial advantage.
[0048] Referring now to FIG. 1 , a deposit container verification and/or identification system 100 is illustrated. The system 100 , typically implemented within a reverse vending machine, is used to identify markings on containers such as container 102 and verify that the container is eligible for a return of a previously paid deposit. It should be appreciated that the container 102 may take a variety of forms including aluminum or steel cans, plastic bottles, glass bottles, . . . etc. so long as the container is recyclable or otherwise configured to take advantage of the teachings of the presently described embodiments.
[0049] The system 100 includes a remote sensor head unit 110 and sensor control box or system 140 . The unit 110 may take a variety of forms (including different hardware and/or software configurations) but, in at least one form, includes at least one or a plurality of emitters 112 that may take the form of, for example, ultraviolet (UV) or infrared (IR) emitters operative to emit radiation in selective bandwidths that will suitably irradiate markings (such as that shown at 103 as merely an example) on, for example, the bottom of container 102 . The markings may take any desired form, some of which are described herein, including but not limited to human or machine readable code. The selective bandwidths may be narrow bandwidths in some forms. The emitters may take other forms as well.
[0050] Also shown within the sensor head unit 110 is a sensor 114 . It should be appreciated that sensor 114 may also take a variety of forms but, in one form, is a primary color (RGB) CMOS sensor. These sensors may sense in narrow wavelength bands in some forms. Multiple sensors may also be used; however, to achieve the objectives of robustness and elegance of the presently described embodiments, a single element sensor will be employed—as opposed to a machine vision camera or the like which presently presents an overcomplicated, over-sensitive and over-priced manner to address the needs of the reverse vending industry.
[0051] It will also be understood that the sensor 114 may be selected as a function of the types of emitters implemented, or vice-versa. Further, the emitters may emit in one wavelength band and the sensors detect in another wavelength band, or the emitters may emit in the same wavelength band as the sensors detect, or either of the emitters or sensors may operate in a narrow band, all as a function of, among other things, the marking material that is detected. Indeed, in some forms, the marking material may even result in not only detection in a narrow or different band than emission, but it may also result in emission of multiple bands for detection. It should be understood that the wavelength bands contemplated may be in the visible light range or the non-visible range. Also, it will be appreciated that the wavelengths contemplated (such as those emitted by the emitter) may emit in a band or mix such that the marking is visible to the sensor, or is not visible to the sensor.
[0052] A lens 120 is also provided to the sensor head 110 so that radiation reflected from the container 102 can be suitably focused on the sensor 114 . The lens, likewise, may take a variety of forms, including that of a single lens system, as shown, or a multi-lens system. Also, some systems may not require a lens.
[0053] As noted, the control system 140 is also provided to the system 100 . It should be understood that the control system 140 may be implemented using a variety of hardware configurations and software techniques that will be apparent to those skilled in the art. For example, some components of the system may be hardware-based while other components are implemented as software routines running on these or other hardware components.
[0054] In one form, the control system 140 includes a microcontroller 150 that communicates with a communications interface 152 and is powered by a power supply 154 . It should be appreciated that the communications interface 152 communicates with a reverse vending machine controller (not shown) and provides information to the microcontroller 150 . Through an emitter drive stage 156 , the microcontroller 150 also controls the emitters 112 of the remote sensor unit 110 . It should also be understood that the microcontroller 150 further communicates with the sensor 114 so as to obtain information for processing. In this regard, the sensor information is used by the microcontroller 150 to identify markings on the container 102 and determine if the container is eligible for collection of a previously paid deposit. This may be accomplished in any of a variety of manners to achieve the objectives of the presently described embodiments. For example, the size or signal strength for the detected marking cold be evaluated in view of known or normal markings to make this determination as described in more detail hereafter. Other combinations or variations of these techniques may also be used to achieve the objectives herein.
[0055] With reference now to FIG. 2 , a system 200 is illustrated. The system 200 , like the system 100 , is provided to identify markings on a container 102 so as to verify that the container 102 is eligible for a return of a monetary deposit. The system 200 is provided with a sensor unit 210 . It should be understood that the sensor unit 210 , in this form, includes substantially the same components as the sensor head unit 11 0 and sensor control system 140 of FIG. 1 . As such, the operation and function of these components is also substantially the same.
[0056] With reference now to FIGS. 3( a ) and ( b ), a system 300 is illustrated. The system 300 is a portion of an exemplary reverse vending machine having a variety of components including, for example, rollers 302 . As illustrated, system 300 is an environment into which the presently described embodiments may be incorporated. In this regard, as shown, the sensor head unit 110 and sensor control system 140 and/or the sensor unit 210 may be positioned such that appropriate portions of the container 102 (e.g. those surfaces of the container having suitable markings such as 103 or the like) can be viewed by the system to identify and verify in accordance with the presently described embodiments. The presently described embodiments allow for a convenient retro-fit for the reverse vending machine or a simple add-on in the manufacturing and/or assembly process for the reverse vending machine.
[0057] In operation, with reference to the flowchart of FIG. 4 , the system 100 or 200 will be triggered to initiate, for example, a method 400 to verify whether a container that has been introduced into the machine has the proper deposit marking. In this regard, the microcontroller will prompt the emitter drive stage to drive the emitters to emit radiation in a first wavelength band selected for use with the marking toward the container (at 402 ). The sensors will then sense or detect a second wavelength band of radiation from the container having the marking (at 404 ). Of course, as above, the emitters may emit in one wavelength band and the sensors detect in another wavelength band, or the emitters may emit in the same wavelength band as the sensors detect, or either of the emitters or sensors may operate in a narrow band, all as a function of, among other things, the marking material that is used on the containers and ultimately detected. Also, as above, the radiation may be infrared, ultraviolet, or take on other forms as a function of, among other things, the marking material. The detection or sensing information of the sensors is then passed on to the microcontroller, where it is received (at 406 ) and processed to determine eligibility for the container for collection of the monetary deposit (at 408 ).
[0058] The system will make this determination and then indicate to the reverse vending machine or other designated element (through a variety of manners including wired or wireless communication) whether the inspected container has the required markings or not. In one form, the circuitry in the control system of the reverse vending machine will then determine what will happen after the go/no-go signal is communicated to it from the present system.
[0059] In one form, the system 100 or 200 contemplates utilizing small, sprayed-on “spots” of UV or IR fluorescing compound which can be applied at any desirable point in the container manufacturing, filling, or distribution chain. Various components of this type are available and would meet the objectives of the presently described embodiments. These compounds actually fluoresce with a visible light output component when irradiated with non-visible energy. The non-visible energy could be either in the ultra-violet range or shorter wavelengths than visible light or in the infra-red range of longer wavelengths than visible light, assuming the compound is appropriately formulated for this functionality. These “spots” could be potentially of any shape, whether convenient for the high speed spray applicator or such that the shape was actually indicative of something providing further discrimination.
[0060] The system 100 or 200 contemplates using a narrow-band irradiation source which will be extremely long lived. It further contemplates sometimes using narrow-band fluorescing UV or IR compounds which would correspond to the narrow-band irradiation source such that the system is less prone to false triggering or to counterfeiting. It further contemplates sometimes choosing to use more than one narrow band source each of which will be of different wavelengths which will correspond to the specific wavelength fluorescence of the different compounds. By mixing these compounds, which fluoresce at different wavelengths, and utilizing a detection system which irradiates at different corresponding wavelengths to the compounds, it is possible to design a system which has a high degree of resistance to counterfeiting. The more combinations that are used, the higher the overall counterfeiting security level.
[0061] The system 100 or 200 will utilize as emitters 112 , for example, LEDs, laser diodes, or photon producing transistors as the narrow-band source devices that irradiate in a non-visible portion of the electromagnetic spectrum at a specific center wavelength. The center wavelength of the irradiation source would then be matched to a fluorescing compound which has approximately the same pumping wavelength center. The solid state irradiation devices can be used either singly or in multiple arrays of whatever type is desirable to provide the irradiation intensity, angles, and wavelengths of irradiation desired. If narrow band-width irradiation is desirable (perhaps, 25 nanometers wide) to make the system more secure by providing more selectivity relative to other irradiation and fluorescing compounds, laser diodes may be used. A laser diode will typically have a fraction of the band-width of irradiation as an LED. In this case, it is not being used because of the coherency of the irradiation because this is not important here. The laser diode is being utilized either because it can produce a stronger level of irradiation or because it will typically have a bandwidth that is a fraction of the width of the LED devices. Either type of diode irradiation could provide either strobed or continuous irradiation but would have much longer life if strobed.
[0062] Any of a number of ‘off the shelf’ sensors 114 may be used which are sensitive in the desirable band-width range. A system, for example, could comprise of three UV laser diodes 112 each radiating at a different wavelength but generally co-focused in terms of the location that is irradiated. Three corresponding sensors 114 could be deployed to sense for fluorescence from the sprayed-on spot. Each sensor 114 could employ a sharp cut-off band pass filter which will only allow light to be detected in the narrow bandwidth corresponding to that which is pumped by its corresponding laser irradiation source. This assumes that the UV fluorescing spot contains three distinctly different compounds which will fluoresce at different wavelengths.
[0063] It may be desirable if the compound that has been selected fluoresces a visible light color, to use some baffling to prevent ambient light from iluminating the spot location during the detection cycle. This makes it more difficult for a counterfeiter to substitute ink or paint of the same visible color as the florescence color. It also will prevent various stray colors that may be on the container from causing a false accept of the container. If the compound spot size is to be very small, it is advised to focus both the irradiation and the field of view of the sensor to a size which will allow good signal to noise discrimination in the detection environment.
[0064] Mixing UV fluorescing compounds with IR fluorescing compound could provide another combination which could not be casually counterfeited to ‘beat the system.’ For example, one compound could fluoresce yellow, one blue, and one green. Typically the fluorescing compounds fluoresce in the visible portion of the spectrum but it is also foreseen that compounds could be employed which fluoresce in the non-visible wavelength as long as it is a different wavelength than the irradiation source. This has the additional advantage of requiring special equipment to detect the presence of such compounds which provides for greater security possibilities. Also, since many bars have black lights which put out a substantial amount of broadband UV light, it would make the compounds invisible to the human observer.
[0065] In another form, material other than UV or IR material may be used. In this regard, the system 100 or 200 may utilize LEDs, laser diodes, or photon producing transistors as the narrow-band source devices that irradiate in a visible portion of the electromagnetic spectrum at a specific center wavelength. The center wavelength of the irradiation source would then be matched to an ink or color coating which has approximately the same center “color” wavelength. The system contemplates a differentiating between one color of indication marking and another color for the purpose of determining whether a deposit should have been paid or not on the container.
[0066] One other implementation is to further sophisticate an ink or coating marking that is currently being added to a container. For example, a “manufacturing or expiration” date is currently ink jetted onto the bottom of a container at the approximate time of filling of the container. This may occur just prior to or just after the actual filling and could be either in the filling machine or just outside the filling machine, but is usually closely associated there with. The “manufacturing or expiration” date is typically a dot-matrix code which is human readable and is often a very readable black or dark blue ink. The current invention contemplates sophisticating the current “manufacturing or expiration” date by making it black, for example, for non-deposit states and an alternate color for deposit states. The invention further contemplates an interaction between the chosen colors of the indication marking and a detection system which would be incorporated into the reverse vending machines.
[0067] It is anticipated that the detection system, which is incorporated into the reverse vending machine, would utilize one of several detection methodologies which would increase the robustness of detection while keeping the capital cost reasonable. The detection system would most desirably be an integrated, self-contained system that would include narrow-band illumination, sensor(s), electronic support and logic module, power supply, and an input/output communications module such as that illustrated in FIGS. 1 and 2 .
[0068] It is also anticipated that the detection system would utilize a narrow-band illumination concept. As alluded to above, the narrow-band source could be one of many devices including LEDs, laser diodes, photon-producing transistors (which are still largely experimental), or other electronically pulsable solid state illumination sources. An alternative narrow-band source could utilize a broad-band illumination source with a narrow-band filter interposed between the source and the target container such that only narrow-band illumination of a chosen wavelength range reached the detection area of the container.
[0069] The narrow-band illumination source will be utilized in such a way that it will take advantage of the fact that one color of ink would absorb the narrow-band illumination irradiation while the other color would readily reflect the illumination. The effect is that the ink of the same color as the illumination would disappear or be undetectable on the surface of the container while the ink of the alternate color would absorb the narrow-band illumination and be very detectable. Since there is absorption in one case and reflection in the other, it would create a substantially robust signal differential at the sensor which is deployed to detect the reflection of the illumination. The sensor could be specified as a simple photo cell or could be substantially more sophisticated if desired or required by the application. It could be a CMOS or CCD imaging detector or it could be an RGB type sensor. The narrow-band ilumination can either be continuously “on” during a time when detection is to be preformed or it can be pulsed or strobed only at time of detection. Strobing would stop action and would reduce the effects of vibration, especially when using an imaging chip as the sensor, but would otherwise have similar functionality to continuously on illumination. Strobing also reduces the duty cycle and therefore increases the life of the illumination source which is very desirable in an environment in which an extremely reliable piece of equipment is dictated. The extremely long life is another important reason to use the solid-state illumination source for the contemplated detection system. It is also possible to implement a narrow-band filter in front of the sensor to approximate the similar functionality of rendering the marking of one color undetectable and allowing the marking of another color to be very detectable. The purpose of the narrow-band illumination or narrow-band filters is to dramatically increase the robustness of the detection. It also functions to reduce the ease of counterfeiting for the purpose of trying to beat the system and obtain a deposit return when one is not owed. While the invention can be practiced without the utilization of the narrow-band filter or narrow-band illumination source, it is anticipated that it is the best way of practicing the invention because of the added robustness that can be expected.
[0070] While simply disciplining the plant operation to choose one of two or three colors determined by the deposit amount in the intended state is one way of practicing the invention, it is also possible to add another variable which will further reduce counterfeiting possibilities. Either the standard, non-deposit ink or the special, deposit ink could have a fluorescing component added to it (positive logic or negative logic). It's anticipated that the fluorescing additive would require non-visible light, either ultra-violet or infrared, in order to activate the fluorescence. It is also possible to use compounds that fluoresce at another wavelength in the visible spectrum or are stimulated in the visible but fluorescence in the non-visible. If the additional protection of fluorescence were to be added to the method of practicing the invention, the illumination source in the detection sensors would have to be configured accordingly. Typically, an additional sensor would be added which would be specifically for the purpose of detecting the fluorescence wavelength If a narrow-band illumination source Is employed for the other detection, then an additional narrow-band illumination source would have to be added at the fluorescence pumping wavelength of the added compound. If a broad-band illumination source is used in the system which has a broad enough spectrum of irradiation both the primary detection color and the fluorescent compound pumping, then the sensors could simply be equipped with narrowband filters to facilitate detecting their respective wavelengths. Many different combinations and permutations of this concept could be incorporated and/or anticipated as part of this invention but one skilled in the art should be able to take these teachings and implement them into a reliable deposit detection scheme.
[0071] The solid state irradiation devices can be used either singly or in multiple arrays of whatever configuration is desirable to provide the intensity, angles, and wavelengths of irradiation desired. If narrow band-width irradiation is desirable (perhaps, 25 nanometers wide), laser diodes may be used. A laser diode will typically have approximately one fourth or less of the band-width of irradiation as an LED. In this case, it is not being used because of the coherency of the irradiation because this is not important here. The laser diode is being utilized because it will typically have a bandwidth that is a fraction of the width of the LED devices and may have more output intensity available at the chosen wavelength. The diode irradiation could provide either strobed or continuous irradiation but would have much longer life if strobed.
[0072] Any of a number of ‘off the shelf’ sensors may be used which are sensitive in the desirable band-width range. An RGB, three-color type sensors could be deployed to detect the color of the printing. The sensor could employ a sharp cut-off band pass filter which will only allow light to be detected in the narrow bandwidth corresponding to the ink color.
[0073] It is suggested that the last possible opportunity to apply the indicating marking would be at, during, or after the container filling. Often a “manufacturing or expiration” date is ink-jetted onto the domed bottom of the filled container. This date could be applied with the right specification for practicing this invention. For example, the “manufacturing or expiration” dot-matrix date could be applied in black for non-deposit states and in the correct shade of blue for deposit states. The correct color would be 470 nanometers for one such application which would correspond to the narrowband LED illumination source. As the system checks the container, it would detect a different “signal” level if the black ink exists while it would see a much stronger signal returned if the 470 NM blue ink is present. Because the blue ink reflects more of the 470 NM blue light, that has been chosen for this purpose, than the black ink, there is a differential signal level. If the broad-spectrum light, white light, or another color of narrow-band light were used, the signal differential would be substantially less. If the indicating marking represents a very small overall percentage of the surface area, it is advisable to focus both the irradiation and the field of view of the sensor to a size which will allow good signal to noise discrimination in the detection environment. It may also be required or at least recommended that the indicating marking be applied to the container with a very consistent location tolerance.
[0074] Also, mixing UV fluorescing compounds or IR fluorescing compounds into the deposit or non-deposit ink could provide a combination which should not be casually counterfeited to ‘beat the system.’ For example, the “manufacturing or expiration” dot-matrix printing could fluoresce yellow while being blue in visible light. One type of sensor would be dedicated to each and would require detection (or non-detection, depending on the logic employed) of both signals before indicating that the container is of the deposit variety. As was mentioned, the fluorescing compounds typically fluoresce in the visible portion of the spectrum but it is also foreseen that compounds could be employed which fluoresce at a non-visible wavelength as long as it is a different wavelength than the irradiation source. This has the additional advantage of requiring special equipment to detect the presence of such compounds which provides for greater security possibilities.
[0075] In any of the forms contemplated, the “spot” or marking of fluorescing material or ink can be applied to the container in one of many ways. The assumption is that the compound can be timed or triggered to be deposited onto a surface of the container at a precise time and location. It could be sprayed with an impulse-type spray device. It could be rolled on such that the roller strategically contacted the container for proper application time and location. It could also be ink-jet or electro statically deposited onto the right location on a container. If it is chosen to put the deposit indication marker on earlier in the manufacturing process the converted end transfer die provides a convenient place where an application could be accomplished when the converted end is completely motionless during the metal stamping dwell time. Any convenient place in the manufacturing-filling-distribution chain would be appropriate for practicing this invention. The closest (latest) location to final distribution may prove to be the most optimum from the standpoint of not disturbing the existing container manufacturing infrastructure.
[0076] It will be appreciated that the system of the presently described embodiments will also be implemented to be consistent with the location and method of applying the indicating marking to the container and/or the standardization on the specifications of the color or fluorescing compound(s) that will be incorporated.
[0077] As has been indicated, the indicating marking can take many forms including being multiple purpose to show information such as manufacturing line or filling date. It is anticipated that the invented concept disclosed herein can be practiced with many different combinations of the thoughts and examples cited and is not limited to the specific applications or implementations communicated herein.
[0078] Any simpler or more complex variation on this theme is contemplated by the invention. The system comprised as described above would have many advantages over broadband detection systems.
[0079] The above description merely provides a disclosure of particular embodiments of the invention and is not intended for the purposes of limiting the same thereto. As such, the invention is not limited to only the above-described embodiments. Rather, it is recognized that one skilled in the art could conceive alternative embodiments that fall within the scope of the invention. | A system for identification and confirmation of legitimate deposit refund containers on which a monetary deposit has been collected. The containers include a marking indicating eligibility for collection of the monetary deposit upon return of the containers. The system includes at least one emitter operative to emit radiation positioned to direct the radiation toward a container, at least one sensor operative to sense the radiation reflected back from the container and a control system operative to drive the at least one emitter, receive information from the at least one sensor, and process the information to determine eligibility for the container for the refund of the monetary deposit. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION PARAGRAPH
This application claims the benefit of U.S. Provisional Application No. 61/085,072 filed on Jul. 31, 2008, the content of which is hereby incorporated by reference in its entirety.
BACKGROUND
Advance in cell biology and recombinant protein technologies has led to the development of protein therapeutics.
Yet, major hurdles still exist. Most proteins are susceptible to proteolytic degradation and therefore have a short circulating time. Other disadvantages include low water solubility and inducement of neutralizing antibodies.
Attachment of a polymer, e.g., polyethylene glycol (PEG), to a protein hinders access of proteolytic enzymes to the protein backbone, resulting in enhanced protein stability. In addition, it may also improve water solubility and minimize immuogenicity. There is a need for effective methods of attaching polymer to proteins.
SUMMARY
An aspect of the present invention relates to polymer-polypeptide conjugates of formula I:
wherein each of R 1 , R 2 , R 3 , R 4 , and R 5 , independently, is H, C 1-10 alkyl, C 2-10 alkenyl, C 2-10 alkynyl, aryl, heteraryl, C 3-8 cycloalkyl, or C 3-8 heterocycloalkyl; each of A 1 and A 2 , independently, is a polymer moiety (e.g., a polyalkylene oxide moiety); each of G 1 , G 2 , and G 3 , independently, is a bond or a linking functional group; P is an interferon-β (INF-β) moiety, an erythropoietin (EPO) moiety, or a growth hormone (GH) moiety; m is 0 or an integer of 1-10; and n is an integer of 1-10. In these conjugates, the N-terminus of the INF-β moiety, the EPO moiety, or the GH moiety is bonded to G 3 .
Referring to the above formula, the polymer-polypeptide conjugates have one or more of the following features: A 1 and A 2 are polyalkylene oxide moieties having a molecular weight of 2-100 kD (preferably 10-30 kD, e.g., 20 kD); each of G 1 and G 2 is
(in which the O atom is bonded to A 1 or A 2 , and the N atom is bonded to a carbon atom as shown in formula I; each of G 1 and G 2 is urea, sulfonamide, or amide (in which the N atom is bonded to a carbon atom as shown in formula I); m is 4; n is 2; and each of R 1 , R 2 , R 3 , R 4 , and R 5 is H. In some of these conjugates, P is rINF-β Ser 17 or a modified INF-β moiety containing 1-4 additional amino acid residues at the N-terminus of the INF-β.
Another aspect of the present invention relates to polymer-peptide conjugates of formula II:
A-G 1 -L-G 2 -P, formula II
wherein A is a polymer moiety (e.g., a polyalkylene oxide moiety); each of G 1 and G 2 , independently, is a bond or a linking functional group; L is C 2-10 alkenylene or C 2-10 alkynylene; and P is an INF-β moiety, an EPO moiety, or a GH moiety. In these conjugates, the N-terminus of the INF-β moiety, the EPO moiety, or the GH moiety is attached to G 2 .
Referring to formula II, the polymer-peptide conjugates have one or more of the following features: A 1 and A 2 are polyalkylene oxide moieties having a molecular weight of 2-100 kD (preferably 10-30 kD, e.g., 20 kD), each of G 1 and G 2 is a bond, C 6 is alkenylene, and each of R 1 , R 2 , R 3 , R 4 , and R 5 is H.
Another aspect of the present invention relates to polymer-peptide conjugates of formula III:
wherein each of R 1 , R 2 , R 3 , and R 4 , independently, is H, C 1-10 alkyl, C 2-10 alkenyl, C 2-10 alkynyl, aryl, heteraryl, C 3-8 cycloalkyl, or C 3-8 heterocycloalkyl; n is an integer of 2-10; A is a polymer moiety; G is a linking functional group; and P is a peptide moiety, the nitrogen atom of the N-terminus of the peptide moiety being bonded to the carbon atom in the
moiety shown in the formula above.
Referring to formula II, the polymer-peptide conjugates have one or more of the following features: n is 1; A is polyalkylene oxide moieties having a molecular weight of 10-40 kD or 20-30 kD; G is
in which the O atom is bonded to A, and the N atom is bonded to a carbon atom; and P is an INF moiety, an EPO moiety, a GH moiety.
The term “C 1-10 alkyl” used herein refers to a straight-chained or branched hydrocarbon mono-valent radical containing 1 to 10 carbon atoms. Examples of alkyl groups include methyl, ethyl, n-propyl, isopropyl, tert-butyl, and n-pentyl. Similarly, the term “C 2-10 alkenyl” refers to a straight-chained or branched hydrocarbon mono-valent radical containing 2 to 10 carbon atoms and one or more double bonds. The term “C 2-10 alkynyl” refers to a straight-chained or branched hydrocarbon mono-valent radical containing 2 to 10 carbon atoms and one or more triple bonds. The term “C 2-10 alkenylene” refers to a straight-chained or branched hydrocarbon bi-valent radical containing 2 to 10 carbon atoms and one or more double bonds. The term “C 2-10 alkynylene” refers to a straight-chained or branched hydrocarbon bi-valent radical containing 2 to 10 carbon atoms and one or more triple bonds.
The term “aryl” used herein refers to a hydrocarbon ring system (mono-cyclic or bi-cyclic) having at least one aromatic ring. Examples of aryl moieties include, but are not limited to, phenyl, naphthyl, and pyrenyl.
The term “heteroaryl” used herein refers to a hydrocarbon ring system (mono-cyclic or bi-cyclic) having at least one aromatic ring which contains at least one heteroatom such as O, N, or S as part of the ring system and the reminder being carbon. Examples of heteroaryl moieties include, but are not limited to, furyl, pyrrolyl, thienyl, oxazolyl, imidazolyl, thiazolyl, pyridinyl, pyrimidinyl, quinazolinyl, and indolyl.
The term “cycloalkyl” used herein refers to a partially or fully saturated mono-cyclic or bi-cyclic ring system having only carbon ring atoms. Examples include, but are not limited to, cyclopropanyl, cyclopentanyl, and cyclohexanyl.
The term “heterocycloalkyl” used herein refers to a partially or fully saturated mono-cyclic or bi-cyclic ring system having, in addition to carbon, one or more heteroatoms (e.g., O, N, or S), as ring atoms. Examples include, but are not limited to, piperidine, piperazine, morpholine, thiomorpholine, and 1,4-oxazepane.
Alkyl, alkenyl, alkynyl, alkenylene, alkynylene, aryl, heteroaryl, cycloalkyl, and heterocycloalkyl mentioned herein include both substituted and unsubstituted moieties. Examples of substituents include C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 8 cycloalkyl, C 5 -C 8 cycloalkenyl, C 1 -C 10 alkoxy, aryl, aryloxy, heteroaryl, heteroaryloxy, amino, C 1 -C 10 alkylamino, C 1 -C 20 dialkylamino, arylamino, diarylamino, hydroxyamino, alkoxyamino, C 1 -C 10 alkylsulfonamide, arylsulfonamide, hydroxy, halogen, thio, C 1 -C 10 alkylthio, arylthio, cyano, nitro, acyl, acyloxy, carboxyl, and carboxylic ester.
The term “polymer moiety” refers to a mono-valent radical derived from linear, branched, or star-shaped polymer. The molecular weight of the polymer moiety may be 2-100 kD. Examples of the polymer moiety include, but are not limited to, polyethylene oxide, polyethylene glycol, polyisopropylene oxide, polybutenylene oxide, polyethylene glycol, and copolymers thereof Other polymers such as dextran, polyvinyl alcohols, polyacrylamides, or carbohydrate-based polymers can also be used as long as they are not antigenic, toxic, or eliciting immune response.
The term “polypeptide moiety” refers to a mono-valent radical derived from either a naturally occurring polypeptide or a modified polypeptide. The naturally occurring peptide can be INF-α 2b , INF-β, GH, EPO, and granulocyte colon-stimulating factor, or antibody. The modified peptide can be, e.g., a peptide containing INF and 1-4 additional amino acid residues at the N-terminus of the INF-α 2b . An example of such a modified INF is
IFN representing an INF-α 2b moiety, the amino group at the N-terminus of which is bonded to the carbonyl group.
The term “interferon-β” refers to a family of highly homologous proteins that inhibit viral replication and cellular proliferation and modulate immune response. See Derynck et al., (1980). Nature 285 (5766): 542-7; and Taniguchi et al., (1980). Gene 10 (1): 11-5. It includes both naturally occurring INF-βs and their functional equivalents, i.e., a polypeptide having at least 80% (e.g., 85%, 90%, 95%, or 99%) identical to its wild-type counterpart. Examples of INF-β include the active ingredients in the commercially available drugs, such as Avonex, Betaseron, and Rebif. See, e.g., Etemadifar M. et al., Acta Neurol. Scand., 2006, 113(5): 283-7.
Listed below are amino acid sequences of exemplary human INF-β proteins, either in precursor form or in mature form:
mtnkcllqia lllcfsttal s msynllgfl qrssnfqcqk
llwqlngrle yclkdrmnfd ipeeikqlqq fqkedaalti
yemlqnifai frqdssstgw netivenlla nvyhqinhlk
tvleekleke dftrgklmss lhlkryygri lhylkakeys
hcawtivrve ilrnfyfinr ltgylrn
(See GenBank Accession No.: M28622, the Apr. 27, 1993 version; italicized portion refers to the signal peptide)
mnsfstsafg pvafslglll vlpaafpapv ppgedskdva
aphrqpltss eridkqiryi ldgisalrke tcnksnmces
skealaennl nlpkmaekdg cfqsgfneet clvkiitgll
efevyleylq nrfesseeqa ravqmstkvl iqflqkkakn
ldaittpdpt tnaslltklq aqnqwlqdmt thlilrsfke
flqsslralr qm
(See GenBank Accession No.: CAA00839, the Dec. 3, 1993 version)
In one example, the INF-β is mutant rINF-β Ser 17 (recombinant INF-β, in which serine is in place of cysteine at position 17 in the native mature INF-β sequence). The amino acid of this mutant is shown below:
synllgflqr ssnfqsqkll wqlngrleyc lkdrmnfdip
eeikqlqqfq kedaaltiye mlqnifaifr qdssstgwne
tivenllanv yhqinhlktv leeklekedf trgklmsslh
lkryygrilh ylkakeyshc awtivrveil rnfyfinrlt gylrn
In another example, the INF-β is a modified native INF-β, in which 1-4 additional amino acid residues are attached to the N-terminus of the native INF-β.
EPO, produced by either liver or kidney, is a glycoprotein hormone that controls erythropoiesis or red blood cell production. It includes both naturally occurring EPO and its functional equivalents. See U.S. Pat. No. 5,621,080 and US Patent Application Publication 20050176627. The amino acid sequences of human EPO (in precursor and mature form) are shown below:
mgvhecpawl wlllsllslp lglpvlgapp rlicdsrvle
rylleakeae nittgcaehc slnenitvpd tkvnfyawkr
mevgqqavev wqglallsea vlrgqallvn ssqpweplql
hvdkavsglr slttllralg aqkeaisppd aasaaplrti
tadtfrklfr vysnflrgkl klytgeacrt gdr (precursor)
apprlicdsr vlerylleak eaenittgca ehcslnenit
vpdtkvnfya wkrmevgqqa vevwqglall seavlrgqal
lvnssqpwep lqlhvdkavs glrslttllr algaqkeais
ppdaasaapl rtitadtfrk lfrvysnflr gklklytgea
crtgdr (mature form)
An EPO protein used to make the conjugate of this invention can be an EPO protein, either in precursor or mature form, produced by a suitable species, e.g., human, murine, swine, or bovine. In one example, the EPO protein has an amino acid sequence at least 80% (e.g., 85%, 90%, 95% or 99%) identical to one of the amino acid sequences shown above. In another example, the EPO is a modified native EPO in which 1-4 additional amino acid residues are attached to the N-terminus of the native EPO.
The term “growth hormone” refers to the naturally occurring human growth hormone, either in precursor or mature form, and its functional variants, i.e., having an amino acid sequence at least 80% (e.g., 85%, 90%, 95%, or 99%) identical to the naturally occurring human growth hormone and possessing the same physiological activity of that human growth hormone. In one example, the growth hormone is a modified native growth hormone in which 1-4 additional amino acid residues are attached to the N-terminus of the native growth hormone. The amino acid sequences of the naturally occurring human growth hormone (in precursor and mature form) are shown below:
matgsrtsll lafgllclpw lqegsafpti plsrlfdnam
lrahrlhqla fdtyqefeea yipkeqkysf lqnpqtslcf
sesiptpsnr eetqqksnle llrislllig swlepvqflr
svfanslvyg asdsnvydll kdleegiqtl mgrledgspr
tgqifkqtys kfdtnshndd allknyglly cfrkdmdkve
tflrivqcrs vegscgf (precursor)
fptiplsrlf dnamlrahrl hqlafdtyqe feeayipkeq
kysflqnpqt slcfsesipt psnreetqqk snlellrisl
lliqswlepv qflrsvfans lvygasdsnv ydllkdleeg
iqtlmgrled gsprtgqifk qtyskfdtns hnddallkny
gllycfrkdm dkvetflriv qcrsvegscg f (mature form)
mfptiplsrl fdnamlrahr lhqlafdtyq efeeayipke
qkysflqnpq tslcfsesip tpsnreetqq ksnlellris
llliqswlep vqflrsvfan slvygasdsn vydllkdlee
giqtlmgrle dgsprtgqif kqtyskfdtn shnddallkn
ygllycfrkd mdkvetflri vqcrsvegsc gf (modified
form)
The “percent identity” of two amino acid sequences is determined using the algorithm of Karlin and Altschul Proc. Natl. Acad. Sci. USA 87:2264-68, 1990, modified as in Karlin and Altschul Proc. Natl. Acad. Sci. USA 90:5873-77, 1993. Such an algorithm is incorporated into the NBLAST and XBLAST programs (version 2.0) of Altschul, et al. J. Mol. Biol. 215:403-10, 1990. BLAST protein searches can be performed with the XBLAST program, score=50, wordlength=3 to obtain amino acid sequences homologous to the protein molecules for use in the invention. Where gaps exist between two sequences, Gapped BLAST can be utilized as described in Altschul et al, Nucleic Acids Res. 25(17):3389-3402, 1997. When utilizing BLAST and Gapped BLAST programs, the default parameters of the respective programs (e.g., XBLAST and NBLAST) can be used.
The term “linking functional group” refers to a bi-valent functional group, one end being connected to the polymer moiety and the other end being connected to the peptide moiety. Examples include, but are not limited to, —O—, —S—, carboxylic ester, carbonyl, carbonate, amide, carbamate, urea, sulfonyl, sulfinyl, amino, imino, hydroxyamino, phosphonate, or phosphate group.
The peptide-polymer conjugate described above can be in the free form or in the form of salt, if applicable. A salt, for example, can be formed between an anion and a positively charged group (e.g., amino) on a peptide-polymer conjugate of this invention. Suitable anions include chloride, bromide, iodide, sulfate, nitrate, phosphate, citrate, methanesulfonate, trifluoroacetate, and acetate. Likewise, a salt can also be formed between a cation and a negatively charged group (e.g., carboxylate) on a polypeptide-polymer conjugate of this invention. Suitable cations include sodium ion, potassium ion, magnesium ion, calcium ion, and an ammonium cation such as tetramethylammonium ion.
In addition, the peptide-polymer conjugate may have one or more double bonds, or one or more asymmetric centers. Such a conjugate can occur as racemates, racemic mixtures, single enantiomers, individual diastereomers, diastereomeric mixtures, and cis- or trans- or E- or Z-double bond isomeric forms.
Examples the polymer-peptide conjugate of this invention is shown below:
in which mPEG represents methoxy-capped polyethylene glycol having a molecular weight of 20 kD, and the N-termini of rINF-β Ser 17 , EPO, and GH are attached to the rightmost carbon shown in the above structures.
Certain proteins have therapeutic utilities. The conjugates of this invention, containing a peptide moiety, can therefore be used to treat disease. For example, INF-β is an immunomodulating medication for treating HCV or HBV infection. See, e.g., Journal of Vascular and Interventional Radiology 13 (2002): 191-196. Thus, within the scope of this invention is a method of treating hepatitis C virus (HCV) infection or hepatitis B virus (HBV) infection with an INF-β-polymer conjugate described above. As another example, EPO is a hormone produced by the kidney to promote the formation of red blood cells in the bone marrow. It has been used as an immunomodulating medication for treating anaemia resulting from chronic kidney disease, anemia secondary to zidovudine treatment of AIDS, and anemia associated with cancer. Recent studies have also found that EPO enhances neurogenesis and plays a critical role in post-stroke recovery. See, e.g., P. T. Tsai, Journal of Neuroscience, 2006, 26: 1269. Thus, another aspect of this invention relates to a method of treating aneamia or enhancing neurogenesis by an EPO-polymer conjugate described above.
Also within the scope of this invention is a composition containing the INF-β-polymer conjugate described above for use in treating HCV infection or HBV infection, and a composition containing the EPO-polymer conjugate described above for use in treating aneamia or enhancing neurogenesis, as well as the therapeutic use and use of the conjugate for the manufacture of a medicament for treating HCV infection, HBV infection, or aneamia, or for enhancing neurogenesis.
The details of one or more embodiments of the invention are set forth in the description below. Other features, objects, and advantages of the invention will be apparent from the description and from the claims.
DETAILED DESCRIPTION
The peptide-polymer conjugates of the present invention can be prepared by synthetic methods well known in the chemical art. For example, one can combine a linker molecule having one or more active functional groups with two polymer molecules having a functional group reactive to those on the linker molecule. Subsequently, a peptide molecule containing a functional group is reacted with a functional group of the linker molecule to form a peptide-polymer conjugate of this invention. Two illustrative synthetic schemes are provided herein.
Scheme 1 below shows an example of preparing the peptide-polymer conjugates of formula I. Diamine compound 1, which contains an acetal group, is reacted with N-hydroxysuccinimidyl carbonate mPEG (i.e., compound 2) to form di-PEGylated compound 3, which is subsequently converted to aldehyde 4. This aldehyde compound is reacted with peptide H—P having a free amino group via reductive alkylation to afford a peptide-polymer conjugate of this invention.
Scheme 2 below shows an example of preparing the peptide-polymer conjugates of formula II. Chemical 6 has a polymer moiety and an aldehyde functional group. It can be reacted with peptide 7, which has a free amino functional group. The resulting product 8 is subsequently reduced, e.g., by hydrogenation or by NaBH 3 CN, to afford peptide-polymer conjugate 9.
Scheme 3 below is an example of preparing a peptide-polymer conjugate of formula III. Compound 10 having an acetal group, which can be prepared from β-amino acid, is reacted with N-hydroxysuccinimidyl carbonate mPEG 2 to form PEGylated compound 11, which is subsequently converted to aldehyde 12. This aldehyde compound is reacted with peptide H—P having a free amino group via reductive alkylation to afford desired compound 13.
The chemical reactions described above include using solvents, reagents, catalysts, protecting group and deprotecting group reagents, and certain reaction conditions. They may additionally include steps, either before or after the steps described specifically herein, to add or remove suitable protecting groups in order to ultimately allow for synthesis of a peptide-polymer conjugate. In addition, various synthetic steps may be performed in an alternate sequence or order to give the desired polypeptide-polymer conjugates. Synthetic chemistry transformations and protecting group methodologies (protection and deprotection) useful in synthesizing applicable peptide-polymer conjugates are known in the art and include, for example, those described in R. Larock, Comprehensive Organic Transformations , VCH Publishers (1989); T. W. Greene and P. G. M. Wuts, Protective Groups in Organic Synthesis, 2d. Ed., John Wiley and Sons (1991); L. Fieser and M. Fieser, Fieser and Fieser's Reagentsfor Organic Synthesis, John Wiley and Sons (1994); and L. Paquette, ed., Encyclopedia of Reagents for Organic Synthesis , John Wiley and Sons (1995) and subsequent editions thereof.
A peptide-polymer conjugate thus synthesized can be further purified by a method such as ion exchange chromatography, gel filtration chromatography, electrophoresis, dialysis, ultrafiltration, or ultracentrifugation.
The peptide-polymer conjugate of the invention may be pharmaceutically active in the conjugate form. Alternatively, it can release a pharmaceutically active peptide in vivo (e.g., through hydrolysis) by enzymatically cleaving the linkage between the peptide moiety and the polymer moiety. Examples of enzymes involved in in vivo cleaving linkages include oxidative enzymes (e.g., peroxidases, amine oxidases, or dehydrogenases), reductive enzymes (e.g., keto reductases), and hydrolytic enzymes (e.g., proteases, esterases, sulfatases, or phosphatases).
Thus, one aspect of this invention relates to a method of administering an effective amount of one or more of the above-described peptide-polymer conjugates for treating a disorder (e.g., HCV or HBV infection, or aneamia). Specifically, a disease can be treated by administering to a subject one or more of the peptide-polymer conjugates in an effective amount. Such a subject can be identified by a health care professional based on results from any suitable diagnostic method.
As used herein, the term “treating” or “treatment” is defined as the application or administration of a composition including a peptide-polymer conjugate to a subject (human or animal), who has a disorder, a symptom of the disorder, a disease or disorder secondary to the disorder, or a predisposition toward the disorder, with the purpose to cure, alleviate, relieve, remedy, or ameliorate the disorder, the symptom of the disorder, the disease or disorder secondary to the disorder, or the predisposition toward the disorder. “An effective amount” refers to an amount of a peptide-polymer conjugate which confers a therapeutic effect on the treated subject. The therapeutic effect may be objective (i.e., measurably by some tests or markers) or subjective (i.e., a subject gives an indication of or feels an effect).
To practice the method of the present invention, a composition having one or more of the above-mentioned conjugates can be administered parenterally, orally, nasally, rectally, topically, or buccally. The term “parenteral” as used herein refers to subcutaneous, intracutaneous, intravenous, intramuscular, intraarticular, intraarterial, intrasynovial, intrasternal, intrathecal, intralesional, intraperitoneal, intratracheal or intracranial injection, as well as any suitable infusion technique.
A sterile injectable composition can be a solution or suspension in a non-toxic parenterally acceptable diluent or solvent, such as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that can be employed are mannitol, water, Ringer's solution, and isotonic sodium chloride solution. In addition, fixed oils are conventionally employed as a solvent or suspending medium (e.g., synthetic mono- or di-glycerides). Fatty acid, such as oleic acid and its glyceride derivatives are useful in the preparation of injectables, as are natural pharmaceutically acceptable oils, such as olive oil or castor oil, especially in their polyoxyethylated versions. These oil solutions or suspensions can also contain a long chain alcohol diluent or dispersant, or carboxymethyl cellulose or similar dispersing agents. Other commonly used surfactants such as Tweens or Spans or other similar emulsifying agents or bioavailability enhancers which are commonly used in the manufacture of pharmaceutically acceptable solid, liquid, or other dosage forms can also be used for the purpose of formulation.
A composition for oral administration can be any orally acceptable dosage form including capsules, tablets, emulsions, and aqueous suspensions, dispersions, and solutions. In the case of tablets, commonly used carriers include lactose and corn starch. Lubricating agents, such as magnesium stearate, are also typically added. For oral administration in a capsule form, useful diluents include lactose and dried corn starch. When aqueous suspensions or emulsions are administered orally, the active ingredient can be suspended or dissolved in an oily phase combined with emulsifying or suspending agents. If desired, certain sweetening, flavoring, or coloring agents can be added.
A nasal aerosol or inhalation composition can be prepared according to techniques well known in the art of pharmaceutical formulation. For example, such a composition can be prepared as a solution in saline, employing benzyl alcohol or other suitable preservatives, absorption promoters to enhance bioavailability, fluorocarbons, and/or other solubilizing or dispersing agents known in the art. A composition having one or more of the above-described compounds can also be administered in the form of suppositories for rectal administration.
A pharmaceutically acceptable carrier is routinely used with one or more active above-mentioned conjugates. The carrier in the pharmaceutical composition must be “acceptable” in the sense that it is compatible with the active ingredient of the composition (and preferably, capable of stabilizing the active ingredient) and not deleterious to the subject to be treated. One or more solubilizing agents can be utilized as pharmaceutical excipients for delivery of an above-mentioned compound. Examples of other carriers include colloidal silicon oxide, magnesium stearate, cellulose, sodium lauryl sulfate, and D&C Yellow # 10.
The examples below are to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever. Without further elaboration, it is believed that one skilled in the art can, based on the description herein, utilize the present invention to its fullest extent. All publications cited herein are hereby incorporated by reference in their entirety.
EXAMPLE 1
IFN-β-di-PEG polymer conjugate
Preparation of di-PEG aldehyde
20 kD PEGO(C═O)OSu was prepared from 20 kD mPEGOH purchased from (SunBio Inc., CA, USA) according to the method described in Bioconjugate Chem. 1993, 4, 568-569.
A solution of 6-(1,3-dioxolan-2-yl)hexane-1,5-diamine in dichloromethane (11.97 g of the solution containing 9.03 mg of diamine, 47.8 μmol) was added to a flask containing 20 kD PEGO(C═O)OSu (1.72 g, 86.0 μmol). After PEGO(C═O)OSu was completely dissolved, N,N-diisopropylethylamine (79 μL, 478 μmol) was added. The reaction mixture was stirred at room temperature for 24 h, and then methyl t-butyl ether (200 mL) was added dropwise with stirring. The resulting precipitate was collected and dried under vacuum to give di-PEG acetal (1.69 g, 98%) as a white solid.
1 H NMR (400 MHz, d 6 -DMSO) δ 7.16 (t, J=5.2 Hz, 1H), 7.06 (d, J=8.8 Hz, 1H), 4.76 (t, J=4.8 Hz, 1H), 4.10-3.95 (m, 4H), 1.80-1.65 (m, 1H), 1.65-1.50 (m, 1H), 1.48-1.10 (m, 6H).
Di-PEG acetal (4.0 g, 0.2 mmol) was suspended in pH 2.0 buffer (critic acid, 40 mL). The reaction mixture was stirred at 35° C. for 24 h and then extracted with dichloromethane (3×50 mL). The combined organic layers were dried over magnesium sulfate, concentrated, and then re-dissolved in dichloromethane (20 mL). The solution was added dropwisely to methyl t-butyl ether (400 mL) with stirring. The resulting precipitate was collected and dried at reduced pressure to give di-PEG aldehyde (3.8 g, 95%) as a white solid.
1 H NMR (400 MHz, d 6 -DMSO) δ 9.60 (s, 1H), 7.24 (d, J =8.4 Hz, 1H), 7.16 (t, J=5.2 Hz, 1H), 4.10-3.95 (m, 4H), 3.95-3.80 (m, 1H), 3.00-2.85 (m, 2 H), 2.58-2.36 (m, 2H), 1.46-1.15 (m, 6H).
Alternatively, di-PEG aldehyde was prepared in the following manner:
The two amino groups of commercial available homo-lysine (Astatech Pharmaceutical Co., Ltd, China) were protected by benzyloxycarbonyl. The N-protected homo-lysine was esterified and reduced to form an aldehyde compound. The aldehyde group was subsequently protected with ethylene glycol. The benzyloxycarbonyl protecting group then was removed by hydrogenation in the presence of a palladium catalyst. The N-deprotected compound was reacted with activated mPEGOH (Sunbio Chemicals Co., Ltd., South Korea) in a mild basic condition. The resulting product was stirred in pH 2.0 citric acid buffer (Sigma-Aldrich, Germany) at 25° C. for 72 hours to remove the aldehyde protecting group. 109 g of di-PEG polymer aldehyde was obtained (yield: 95%). Purity was more than 97.7% (determined by HPLC) and more than 95% (determined by 1 H NMR analysis).
Prep aration of Human rhIFN-β Ser 17
A DNA fragment encoding human INF-β Ser 17 was cloned into expression vector pET24a to produce an expression plasmid rhIFN-β Ser 17 -pET24a. This expression plasmid was transformed into E. coli and positive transformants, i.e., clones carrying the expression plasmid, were selected, cultivated, and the resultant E. coli cultures were stored at −80° C.
10 μl of a stored E . coli culture mentioned above were inoculated into 200 ml of a seeding medium consisting of Terrific Broth and glycerol, for about 15 hours at 37° C. and 200 rpm. 150 ml of the E. coli culture thus obtained were transferred to 2.5 L culture medium containing glucose (10 g/L), MgSO 4 .7H 2 O (0.7 g/L), (NH 4 ) 2 HPO 4 (4 g/L), KH 2 PO 4 (3 g/L), K 2 HPO 4 (6 g/L), citrate (1.7 g/L), Yeast Extract (10 g/L), kanamycin (50 mg/ml), chloramphenicol (50 mg/ml), an antifoaming agent, and trace elements including FeSO 4 .7H 2 O (10 mg/L), ZnSO 4 .7H 2 O (2.25 mg/L) CuSO 4 .5H 2 O (1 mg/L), MnSO 4 .H 2 O (0.5 mg/L), H 3 BO 3 (0.3 mg/L), CaCl 2 .2H 2 O (2 mg/L), (NH 4 ) 6 Mo 7 O 24 (0.1 mg/L), EDTA (0.84 mg/L), and Cl (50 mg/L), and cultivated at 37° C. When the OD 600 of the E. coli culture reached 120 to 140, IPTG (1 M) was added to the culture to induce expression of rhIFN-β Ser 17 . The induced culture was incubated at 37° C. and 300 rpm for 3 hours. When necessary, a feeding medium containing 800 g/l glucose and 20 g/L MgSO 4 was added to the E. coli culture during incubation.
The E. coli culture obtained as described above was subjected to centrifugation to harvest E. coli cells. The cells were resuspended in a PBS buffer (0.1 M Na 2 HPO 4 , 0.15 M NaCl) and disrupted in an APV Homogenizer. The homogenized solution thus obtained was centrifuged at 10,000 rpm, 4° C. for 15 min. The precipitates (including inclusion body) were collected, resuspended in PBS, and stirred at room temperature for 20-30 min to form a suspension. NaOH (6 N) was added to the suspension to adjust its pH to 12 to allow dissolution of proteins included in the inclusion body. About 2 minutes later, the pH value of the suspension was adjusted to 7.5 with 6 N HCl. The suspension was then subjected to centrifugation and the supernatant thus formed was collected, its protein concentration being determined using a spectrophotometer. The supernatant was mixed with a refolding buffer (TEA, pH 8.3) and incubated at room temperature without being stirred for 24˜48 hours. It was then concentrated and dialyzed, using the TFF system and PLCCC cassette provided by Millipore, Inc. The resultant solution was subjected to ultrafiltration, dialysis, and fractionation with a SPFF Sepharose column. Fractions A9 and A10 thus obtained, containing the recombinant protein rhIFN-β Ser 17 , were further fractionated with another SPFF Sepharose column to enrich the recombination protein (in Fractions A8-A10). These rhIFN-β Ser 17 -containing fractions were further purified by gel filtration (Superdex 75 HR 10/300) to obtain the rhIFN-β Ser 17 protein (1 mg/ml) having a purity of greater than 90%. The bioactivity of the recombinant protein was >2×10 7 IU/mg protein.
Preparation of IFN-β-di-PEG polymer conjugate
18.9 mg rhINF-β Ser 17 and 1.51 g diPEG aldehyde were suspended in 26 mL of 0.1 M sodium phosphate buffer (pH 5.0). To this solution was added 400 eq. of NaCNBH 3 (Acros Organics, Belgium). The reaction mixture was stirred at room temperature for 16 hours and then subjected to dialysis with 25 mM tris-HCl (pH 7.8). The crude product was purified by an ion-exchange column to afford 2 mg of IFN-β-di-PEG polymer.
Preparation of human IFN-β
Transformed E. coli BLR (DE3)-RIL cells, carrying the encoding sequence of IFN-β operatively linked to an E. coli promoter, were inoculated in 250 mL SYN medium (10 g/L of select soytone, 5 g/L Yeast extract, and 10 g/L NaCl) supplemented with 50 μl/mL kanamycin and 50 μl/mL chloramphenicol. The cells were then cultured at 37° C. in a shaker incubator at 220 rpm overnight (i.e., 16 hours).
250 mL of the overnight culture mentioned above were inoculated into 3.0 L basic medium (10 g/L of Glucose, 0.7 g/L of MgSO 4 .7H 2 O, 4 g/L of (NH 4 ) 2 HPO 4 , 3 g/L of KH 2 PO 4 , 6 g/L of K 2 HPO 4 , 2 g/L of Citrate, 10 g/L of Yeast extract and 2 g/L of Isoleucine) supplemented with 10 g/L basic glucose, 0.7 g/L feeding MgSO 4 , 30 mL feeding trace element (10 g/L of FeSO 4 .7H 2 O, 2.25 g/L of ZnSO 4 .7H 2 O, 1 g/L of CuSO 4 . 5H 2 O, 0.5 g/L of MnSO4.H 2 O, 0.3 g/L of H 3 BO 3 , 2 g/L of CaCl 2 .2H 2 O, 0.1 g/L of (NH4) 6 Mo 7 O 24 , 0.84 g/L of EDTA, 50 ml/L of HCl), 25 μl/mL kanamycin and 25 μl/mL chloramphenicol and cultured in a five liter fermentor (Bioflo 3000; Brunswick Scientation Co., Edison N.J.). During fermentation, the pH of the medium was controlled at pH 7.1 by automated addition of a 37% NH 4 OH solution. The dissolved oxygen (DO) level was maintained at 30%. The feeding solution (800 g/L of glucose, 20 g/L of MgSO 4 , 50 μl/mL kanamycin and 50 μl/mL chloramphenicol) was added using a program-controlled pump, which was set to feed when DO level exceeds 40˜60. When the cell density (OD 600 ) in the fermentation culture reached 180 to 200, 4 mL of 1 M Isopropyl-β-D-1-thiogalactopyranoside (IPTG) was added to the fermentation culture to induce IFN β expression, together with 30 mL of feeding trace elements and 25 g of yeast extract. Cells were harvested 5 hours after IPTG induction by centrifugation.
The cell pellets were suspended in PBS buffer (0.1M sodium phosphate, 0.15M sodium chloride, pH 7.4) at an approximate ratio of 1:3 (wet weight g/mL), disrupted by a microfluidizer, and then centrifuged at 10,000 rpm for 20 min at 4° C. The pellet containing inclusion body (IB) was washed twice with PBS buffer, centrifuged as described above, and suspended in 1 L PBS solution (0.1M sodium phosphate, 0.15M sodium chloride, pH 7.4, 3% zwittergent 3-14, 5 mM DTT). After being stirred for 30 minutes, the suspension was subjected to pH adjustment to 12 with 6.0 M NaOH, while stirring to solubilize the pellet. The pH of the suspension was then adjusted to pH 7.5 with 6 N HCl. Upon centrifugation at 10,000 rpm for 20 min, the supernatant, containing soluble IFN β, was collected.
The soluble INF-β was then subjected to refolding as follows. The supemant mentioned above was diluted in 10 L of a freshly prepared refolding buffer (100 mM Tris-HCl (pH 7.6), 0.5 M L-Arginine, 2 mM EDTA) for form a refolding mixture. The mixture was incubated for 48 hr without stirring. After incubation, the mixture, containing refolded recombinant IFN-β, was dialyzed against 20 mM Tris (with 100 mM NaCl, 0.05% zwittergent 3-14, pH 7.0) buffer.
The dialyzed mixture was loaded onto a SP-Sepharose column (GE Amersham Pharmacia), which was pre-equilibrated and washed with a 20 mM Tris-HCl, 100 mM NaCl buffer (pH 7.0). IFN β was eluted with a solution containing 20 mM Tris-HCl buffer (pH 7.0) and 200 mM NaCl. Fractions containing IFN β was collected based on their absorbance at 280 nm. The IFN β contained therein was further purified by a hydrophobic interaction column (GE healthcare, Butyl Sepharose Fast Flow), which was pre-equilibrated and washed with a solution containing 1.0 M ammonium sulphate, 20 mM sodium acetate and 0.05% zwittergent (pH 4.5). IFN β was eluted using a solution containing 0.5 M ammonium sulphate and 20 mM sodium acetate. Fractions containing the protein were collected based on their absorbance at 280 nm. These fractions were pooled and the concentration of IFN β was determined by BCA protein assay (BCA™ Protein assay, Pierce).
Preparation of PEG-IFN-β conjugate
To a solution of di-PEG aldehyde (296 mg, 7.4 μmol) in water (1.46 mL) was added 2 M sodium phosphate buffer (pH 4.0, 0.37 mL), zwittgen 3-14 (1.48 mL, 10% in water) and INF-β (14.8 mg in 3.7 mL of pH 4.5 buffer containing 20 mM sodium acetate, 0.7% ammonium sulfate and 0.05% detergent). The reaction mixture was stirred at room temperature for 10 minutes, followed by addition of the cyanoborohydride aqueous solution (400 mM, 92.5 μL, 37 μmol). The reaction mixture was stirred in the dark for 40 hours and purified by SP HP Sepharose chromatography. Fractions containing the desired PEG-IFN β conjugate were collected based on their retention time and absorbance at 280 nm. The concentration of the conjugate was determined by BCA protein assay (BCA™ Protein assay, Pierce).
Pharmacokinetic Study in Rats
A pharmacokinetic study was performed in a rat model to compare serum half-life of IFN-β and PEG-IFN-β. Male rats (250˜350 gm) were administered intravenously at a dose of 600 μg/kg IFN β (n=3) and PEG-IFN β (n=3). Blood (250 μL) was collected from each rat before administration and at 0.1, 1, 2, 4, 6, 10, 24, 48, 72, and 96 hours after administration. Serum samples were prepared from the blood and the amounts of IFN-β contained in the samples were analyzed by an Enzyme-linked immunoassay (ELISA). The serum half-life of IFN-β and PEG-IFN-β was 2 hours and 20 hours respectively, calculated from the serum concentration of the last three time points.
EXAMPLE 2:
EPO-PEG polymer conjugate
Preparation of PEG-EPO
To a solution of di-PEG aldehyde (267 mg, 6.1 μmol) in water (2.67 mL) was added 2 M sodium phosphate buffer (pH 4.0, 1 mL) and EPO (10 mg in 3.03 mL of pH 7.3 buffer containing 20 mM sodium phosphate and 150 mM NaCl). The reaction mixture was stirred at room temperature for 10 minutes, followed by the addition of the Sodium cyanoborohydride aqueous solution (400 mM, 100 μL, 40 μmol). The reaction mixture was stirred in the dark for 17 hours and purified by a SP Toyopearl column (Tosoh). The column was equilibrated with 20 mM Sodium acetate buffer, pH 4.5. The reaction mixture was diluted to a concentration of 0.3-0.4 mg/ml and loaded onto the SP Toyopearl column. Fractions containing the desired PEG-EPO conjugate were collected based on their retention time and absorbance at 280 nm. The concentration of the conjugate was determined by 280 nm UV absorbance.
Pharmacokinetic Study in Rats
A pharmacokinetic study was performed in a rat model to compare serum half-life of EPO and PEG-EPO. Male rats (250˜350 gm) were administered intravenously with EPO (n=5) and PEG-EPO (n=5) at a dose of 25 μg/kg. Blood (250 μL) was drawn from each rat before administration and 0.088, 0.75, 1.5, 3, 6, 10, 24, and 48 hours post administration. For PEG-EPO treated rats, blood samples were further collected at 72 and 96 hours after administration. Serum samples were prepared from the blood and analyzed with an Enzyme-linked immunoassay (ELISA) to determine the amounts of EPO contained therein. The results show that the serum half-life of EPO was 9 hours while that of PEG-EPO was significantly increased, i.e., 38 hours.
Preparation of EPO-PEG polymer conjugate
0.2 mg of EPO (Cashmere Scientific Company, Taiwan) and 4 mg of di-PEG aldehyde (20 equal.) were suspended in 0.1 M phosphate buffer (pH 5.0). To this solution was added 400 eq. of NaCNBH 3 . The reaction mixture was stirred at room temperature for 16 hours. HPLC confirmed formation of EPO-di-PEG polymer.
EXAMPLE 3
GH—PEG polymer conjugate
Preparation of Met-hGH
Transformed E. coli BLR (DE3)-RIL cells, capable of expression Met-hGH, were cultured following the fermentation procedure described above for expression of Met-hGH.
Cells were harvested via centrifugation and cell pellet was suspended in TE buffer (50 mM Tris-HCl, 1 mM EDTA, pH 8.0) at an approximate ratio of 1:3 (wet weight g/mL). The cells were then disrupted by a microfluidizer and then centrifuged at 10,000 rpm for 20 min. The pellet containing inclusion body (IB) was washed twice with TED buffer (50 mM T ris-HCl, 1 mM EDTA, 2% Deoxycholate, pH 8.0), centrifuged as described above, and suspended in MilliQ water and centrifuged at 20,000 rpm for 15 min. The IBs were suspended in 400 mL of 50 mM TUD solution (50 mM Tris-HCl, 4 M Urea, 2.5 mM DTT, pH 10.0) and the suspension was centrifuged at 20,000 rpm for 20 min; supernatant collected.
The supernatant was diluted in 2.0 L of a freshly prepared refolding buffer (50 mM Tris-HCl, 0.5 mM EDTA, 5% glycerol 10 mM GSH/1 mM GSSG, pH 8.0). The mixture thus formed was incubated for 36hr without stirring and then dialyzed against 20 mM Tris buffer (pH 7.0).
The dialyzed mixture, containing Met-hGH, was loaded onto a Q-Sepharose column (GE Amersham Pharmacia, Pittsburgh, Pa.), which was pre-equilibrated and washed with a 20 mM Tris-HCl buffer, pH 7.0. Met-hGH was eluted a solution containing 20 mM Tris-HCl buffer, pH 7.0 and 100 mM NaCl. Fractions containing Met-hGH, determined by their absorbance at 280 nm, were collected, pooled, and loaded onto a hydrophobic interaction column (GE Amersham Pharmacia, Pittsburgh, Pa.), pre-equilibrated and washed with a 20 mM sodium acetate buffer (pH 7.0), at a flow rate of 5 ml/min. Met-hGH was eluted with a solution containing 20 mM sodium acetate buffer and 150 mM ammonium sulfate. A fraction containing Met-hGH was collected and subjected to BCA protein assay (BCA™ Protein assay, Pierce) to determine the Met-hGH concentration.
Preparation of PEG-Met-hGH conjugate
To a solution of di-PEG aldehyde (74 mg, 1.7 μmol) in water (387 μL) was added 2 M sodium phosphate buffer (pH 4.0, 374 μL) and human GH (22.4 mg in 6.5 mL of pH 4.5 buffer containing 20 mM sodium acetate and 150 mM NaCl). The reaction mixture was stirred at room temperature for 10 minutes, followed by the addition of the sodium cyanoborohydride aqueous solution (400 mM, 140 μL, 56 μmol). The reaction mixture was stirred in the dark for 17 hours and purified by SP XL Sepharose chromatography. Fractions containing the desired polymer-protein conjugate were collected based on their retention time and absorbance at 280 nm. The concentration of conjugate was determined by a protein assay kit using the Bradford method (Pierce, Rockford, Ill.).
Pharmacokinetic Study in Rats
A pharmacokinetic study was performed in a rat model to compare serum half-life of Met-hGH and PEG-Met-hGH. Male rats (250˜350 gm) were administered intravenously with Met-hGH (n=5) or PEG-Met-hGH (n=5) at a dose of 100 μg/kg. Blood samples were collected from Met-hGH-treated rats before administration and 0.083, 1, 2, 4, 8, 12, and 24 hours after administration; and were collected from PEG-Met-hGH-treated rats before administration and 0.33, 1, 4, 8, 12, 24, 48, 72, and 96 hours after administration. Serum samples were prepared from the blood and analyzed with an Enzyme-linked immunoassay (ELISA) to determine hGH concentrations. The serum half-life of Met-hGH and PEG-Met-hGH was 3 hours and 35 hours respectively.
Other Embodiments
All of the features disclosed in this specification may be combined in any combination. Each feature disclosed in this specification may be replaced by an alternative feature serving the same, equivalent, or similar purpose. Thus, unless expressly stated otherwise, each feature disclosed is only an example of a generic series of equivalent or similar features.
From the above description, one skilled in the art can easily ascertain the essential characteristics of the present invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. Thus, other embodiments are also within the scope of the following claims. | This invention relates to a conjugate of a polymer moiety and an interferon-β moiety, an erythropoietin moiety, or a growth hormone moiety. | 0 |
[0001] This application claims priority from U.S. Provisional Application No. 60/858,973 filed Nov. 14, 2006 and U.S. Provisional Application No. 60/906,796 filed Mar. 13, 2007.
FIELD OF THE INVENTION
[0002] The present invention relates to a ceramic cowling for connecting a hot gas source to a Stirling engine or a turbine, the use of the cowling while housed in an insulated shroud, and systems that use the ceramic cowling/shroud combination to provide hot gas to a Stirling engine or a turbine to produce electrical power, but also to the provision of alternative sources of energy, such as steam or hot air.
BACKGROUND OF THE INVENTION
[0003] This invention deals with a ceramic cowling that is used as the connection between a hot gas source and a Stirling engine or a turbine. The ceramic cowling is designed and fabricated with non-dusting, high temperature, dense, low thermal expansion ceramic. It must also be highly resistant to thermal shock. This invention also deals with a combination of a ceramic cowling just described Supra, and a shroud for covering and holding the ceramic cowling on a Stirling engine or a turbine such that the hot gases can flow through the ceramic cowling and into the heat exchanger coil of the Stirling engine or the turbine and exhaust in a controllable manner. This invention further deals with a method of enhancing the power efficiency of a Stirling engine or a turbine and with systems including the use of an enhanced power, Stirling engine or turbine.
[0004] Stirling engines have been known and used for at least a decade. These engines work by supplying to them a fixed quantity of gaseous working medium that is contained and enclosed within each cylinder of the engine. A portion of the engine is maintained at a constant high temperature by burning any of a wide variety of fuels in the combustor and transferring heat to the gas via heater tubes. The other portion of the engine is maintained at a constant low temperature by circulating the gas through coolers. The working gas is transferred back and forth between the hot and cold portions of the engine and alternately expanded and compressed by the movement of the engine's pistons. The reciprocating motion of the pistons is converted to rotary motion via a swash plate drive which powers the generator. In each cylinder, gas passing through the heater tubes absorbs heat from the combustion and expands, pushing the piston down and thereby doing work in the swash plate. As the piston comes back up, it forces the gas out of the cylinder and through a regenerator, which absorbs heat from the gas passing through it, and stores it temporarily. The gas then passes through the tubes of a cooler and rejects heat to the coolant passing through it. The cooled gas then enters the compression space below the adjacent piston, and as this piston comes down, it is compressed and pushed back up through the regenerator, where it picks up the heat previously stored there, passes through the heater tubes, and the cycle begins again. An example of one such Stirling engine can be fund in U.S. Pat. No. 5,074,114 that issued on Dec. 24, 1991 to Meijer, et al Likewise, the use of turbines to produce energy from syngas has been known for a long time. These engines are mounted to a combustor of some sort that is capable of burning a wide variety of conventional fuels such as natural gas, hydrogen, and propane gas, and to less conventionally used fuels, if they are cleaned, such as scrap wood, forest products and waste, corn and other biomasses to supply the heated gas.
[0005] These engines also work well with resource recovery fuels such as flare gas and coal bed methane gas and renewable biogas fuels from landfills or anaerobic digesters such as from sewage or agricultural waste. This results in the conversion of a wide variety of fuels into valuable electrical power and hot water for commercial, industrial and residential applications.
[0006] The combustion gas is brought into a cowling or combustion chamber and there is some cooling effect that protects the metal enclosure. A certain amount of heat has to be transferred with a floor of about 1500 dF exit gas temperature. For example, a 55 kw Stirling engine has to transfer 550,000 Btu. At 1650 dF inlet temperature, one would need 6,600 pounds of mass. When one raises the inlet temperature to 2000 dF, one needs only about 4,200 pounds of mass. The pressure drop across the internal heat exchanger coil is 13.2 inches w.c. at 1650 dF, and only 4 inches w.c. at 2000 dF. The higher this mass and pressure drop, the more expensive the capital equipment, that is larger ducts, bigger fans, and increased operating costs, primarily for the fan horsepower to move the mass in and out of the engine.
[0007] The limiting factor for temperatures being achieved above 1650 dF, that is, combustion inside the cowling, has been the metal cowling. If one cools the metal with water or air to preserve the cowling, one can drain away essential heat needed to produce power. Much experimentation has been done in bringing clean process flue gas, ranging in temperatures from 1600 dF to 2000 dF, directly into the engine. It was discovered that without exception, even exotic metals failed when the inlet temperature was above about 1600 dF. It should also be noted that one still needs the 1500 dF exit temperature, so that the thermal head is small when the inlet temperature is 1600 dF, and the amount of mass needed to carry 550,000 Btu becomes inordinately high, so one starts reducing power production as inlet air temperature decreases.
[0008] A review of Table I will quickly make clear to those skilled in the art why it is a major advantage to be able to increase the temperature to a Stirling engine. At about 1652° F., it is noted, that there is a sharp drop off in engine pressure dropping about three inches w.c. The drop in engine pressure is even more significant as the temperature increases.
[0000]
TABLE I
ENGINE
INLET AIR
AIR MASS
OUTLET AIR
PRESSURE
TEMPERATURE
FLOW
TEMPERATURE
DROP
° C.
° F.
G/Sec.
Lb/Hr
° C.
° F.
kPa
in. wc
800 1
1472
1000
7937
677
1251
3.11
12.5
825 2
1517
1000
7937
699
1290
3.18
12.79
850 3
1562
1000
7937
722
1332
3.25
13.07
875 4
1607
1000
7937
744
1371
3.32
13.35
900 5
1652
1000
7937
767
1413
3.39
13.63
925 5
1697
855
6786
770
1418
2.55
10.25
950 5
1742
770
6111
778
1432
2.12
8.52
975 5
1787
705
5595
787
1449
1.82
7.32
1000 5
1832
633
5024
791
1456
1.50
6.03
1025 5
1877
575
4566
794
1462
1.26
5.07*
1050 5
1922
533
4229
803
1478
1.10
4.42*
1075 5
1967
488
3872
806
1483
0.94
3.78*
1100 5
2012
451
3576
810
1490
0.80
3.22*
*Calculated
1 = 46 kw
2 = 48 kw
3 = 51 kw
4 = 53 kw
5 = 55 kw
[0009] The only materials available that can drive an engine with high temperatures are ceramics. Thus, any type of industrial process that generates a high temperature waste flue gas, that is relatively clean and containing few or no particulates and low acid content, can be sent directly to the engine. If the process generates a medium temperature flue gas, say about 1200 dF, the flue gas can be supplemented with natural gas to raise the flue gas to 2000 dF.
[0010] It should be noted that it is at this point that the instant invention differs markedly from the prior art systems. One of the biggest disadvantages of direct-firing a Stirling engine or a turbine with a waste gas flow is that every combustion process, no matter how clean, such as natural gas, has some particulate and some acid. Many, in fact most industrial processes, will have some contaminates. When one adds air for combustion and tempering purposes to a waste combustion gas, one has a flue gas that is high in energy but has no other purpose than to transfer energy. It has to be exhausted after the energy is removed as a contaminated combustion product. This is why Stirling engines and turbines are most popular when one can use both power and, downstream of the engine, a heat recovery device, such as a boiler or hot water heater, for co-generation. The products exiting from the direct-fired Stirling or a turbine in current systems are dirty.
[0011] Secondly, the chance for fouling and deterioration are magnified when one uses a process gas, and they are susceptible to upset. For example, if one uses a clean syngas from a wood-fired gasifier and there was a blip that set sent unburned carbon or ash particles directly to the engine, this could completely destroy the heat recovery coil in the engine.
[0012] The ceramic cowling and the connecting ductwork to that cowling have to be designed and fabricated with non-dusting, high temperature, dense, low thermal expansion ceramic. It must be highly resistant to thermal shock. Tests have been done using ceramics that can take the temperatures, but they cracked within a matter of hours because they could not handle thermal shock and, in some cases, the ceramic dusted and literally sand blasted the internal of the engine.
[0013] The ceramics used in the cowling of this invention are non-dusting, high temperature, dense, low thermal expansion ceramics. Ceramics that are capable of these properties are, for example, Metal Rock 70M from Allied Mineral Products, Inc. Columbus, Ohio, USA and Thermo-Sil® fused silica ceramics from Ceradyne, Inc. Scottdale, Ga., USA. Such materials have bulk densities from about 1.8 to about 2.12 g/cc, compressive strengths of about 27 to 240 MPa (ASTM C-133), linear shrinkage at 1100° C. of zero to about 0.4%, flexural strengths of about 6.9 to 58 MPa, thermal conductivity of abut 0.6 to about 0.8 W/m° C., coefficient of thermal expansion from about 0.5 to about 1.7 10 −6 /° C. and a volume percent apparent porosity of from about 7 to about 15 (ASTM C-20).
[0014] In summary, one can now fire a Stirling engine or a turbine at higher than normal temperatures with clean, hot air into a ceramic cowling that will take those temperatures, at a reduced mass flow, and lower pressure drop, than can be obtained with even the best combustion process inside a metal cowling to provide enhanced efficiency of the Stirling engine or the turbine.
[0015] Another long-term benefit is that an air-fired engine will definitely live longer than a flue gas-fired engine. The ability of the ceramic exchanger to handle corrosive, particulate-laden process gas opens up a plethora of markets, heretofore unavailable. For example, one can now fire coal tailings, poultry litter, and forest products. One can even use hazardous wastes.
[0016] In the instant invention, in every case, the indirect-fired Stirling engine or the turbine exits clean, hot air at 1500 dF. This hot air can be returned to the combustion process into either the primary or secondary chamber and used as preheated combustion air. This substantially reduces the amount of fuel need to operate the system. For example, a direct-fired Stirling engine that generates 110 kw would need 1,100 pounds of waste wood per hour. An indirect-fired engine would require only 800 pounds of wood per hour.
[0017] A co-generation plant can give one a productive side effect assuming the customer needs steam in the process. Assume the customer wants to fire a conventional boiler with waste wood. The higher the temperature, the more efficient the process, however, slagging at temperatures between 1800 dF and 2200 dF is a real problem. The optimum waste wood-fired boiler would have a flue inlet temperature of about 1600 dF. If one fires a ceramic heat exchanger, as in this invention, at 2200 dF, and drops the flue gas temperature to 1600 dF, and then takes the balance of the heat out with a boiler, one ends up with the best of both worlds. Slagging is no longer a problem, the boiler will have long life, and one can remove heat with the Stirling engine or a turbine at its optimum temperature levels. One can reduce the amount of fuel by providing 100% of the combustion air as preheated air, and the down stream boiler economizer can be sized to drop the stack temperature to between 300 dF and 350 dF.
THE INVENTION
[0018] What is thus described and claimed in this invention is, in one embodiment, is a cowling for connecting a hot gas source to a Stirling engine or a turbine. The cowling has a first portion, a second portion and a third portion that form an integral configuration wherein the first portion is a front, hollow hub of a pre-determined size. The first portion has a front edge and a back end. The second portion is a partial hollow hub having a size larger than the first portion. The second portion has a front end and an open back end and an outside surface. The second portion is integrally attached at the front end with the back end of the first portion such that gas can flow through the first portion into a Stirling engine heat exchanger coil or a turbine, and exit through the second portion.
[0019] The third portion is rectangular in shape and has a bottom end and a top edge. The third portion is integrally attached at the bottom end to a portion of the outside surface of the second portion such that gas can exit through the third portion.
[0020] There is integrally attached to the back end of the second portion, a fourth portion that is a circular hub wherein the circular hub has a set-off distal edge wherein the set-off distal edge has a flat surface. The set off distal edge has a means for attachment to the support of a Stirling engine or a turbine.
[0021] The ceramic cowling has the capability of withstanding high temperatures for prolonged periods of time. By this, it is meant that the ceramic cowling can withstand up to 2400° F. for at least one year. Preferably the duration at the higher temperatures is between 2000° F. and 2200° F. at least two years, and more preferably, the duration at the higher temperatures is at least several months, that is, at least several years.
[0022] In another embodiment of this invention, there is in combination, the cowling as set forth just Supra and an insulated shroud that essentially covers the cowling. The shroud has a front, four side walls, and a back. The shroud is fabricated from a metal, and has a first opening through the front for the first portion front edge of the cowling. There is a second opening through one side wall for the top edge of the second portion of the cowling and a third opening in the back to allow the pass through of gas from the second portion of the cowling into a Stirling engine or turbine heat exchanger coil. The shroud has insulation between the cowling and the shroud and the shroud has a means for attaching to a Stirling engine or turbine support structure and a means for attaching the cowling to the shroud.
[0023] In yet another embodiment of this invention, there is a method of enhancing the power performance of a Stirling engine or a turbine, the method comprising equipping a Stirling engine or turbine with a cowling and shroud combination as set forth just Supra, and operating the Stirling engine or the turbine with a hot gas temperature in excess of 1652° F.
[0024] In still another embodiment of this invention there is a method of powering a Stirling engine or a turbine and providing alternative non-electric power, said Stirling engine or turbine having a heat exchanger coil that has a longitudinal axis.
[0025] A further embodiment of this invention is a system for powering a Stirling engine or a turbine, said system comprising in combination a gasifier having a feed mechanism for combustible materials and an ash removal system, a low NOx oxidizer, a metal heat exchanger, a ceramic heat exchanger, at least one Stirling engine, or at lease one turbine and controls for the combination, wherein any Stirling engine or turbine in the combination is fitted with a ceramic cowling in combination with a shroud for the cowling.
[0026] Additionally, there is an embodiment of this invention that is a system for providing power and alternative energy, said system comprising in combination a gasifier having a feed mechanism for combustible materials and an ash removal system, a low NOx oxidizer, a metal heat exchanger, a ceramic heat exchanger, at least one Stirling engine or turbine, at least one firetube boiler, and controls for the combination, wherein any Stirling engine or turbine in the combination is fitted with a ceramic cowling in combination with a shroud for the cowling.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a view in perspective of a ceramic cowling of this invention.
[0028] FIG. 2 is a view of a cross section of the ceramic cowling of FIG. 1 through line A-A in a set off from a full side view of a Stirling engine.
[0029] FIG. 3 is a full side view of a ceramic cowling and shroud of this invention.
[0030] FIG. 4 is a cross sectional view of FIG. 3 through line B-B.
[0031] FIG. 5 is a view of FIG. 4 with full side view of a Stirling engines mounted therein.
[0032] FIG. 6 is a schematic drawing of a wood fired power plant of this invention utilizing two Stirling engines or two turbines.
[0033] FIG. 7 is a schematic drawing of a wood fired power and steam plant utilizing two Stirling engines or two turbines.
[0034] FIG. 8 is a schematic drawing of a system for providing hot air from a Stirling engine or turbine, to a conventional biomass dryer.
[0035] FIG. 9 is a schematic drawing of a system for providing hot air to a wood drying kiln.
DETAILED DESCRIPTION OF THE INVENTION
[0036] Now, with more specificity, and turning to FIG. 1 , there is shown a ceramic cowling 100 of this invention. The ceramic cowling 100 is an integral unit comprised of four portions, that is, a first portion 1 comprising a hollow hub 5 of a pre-determined size. The hollow hub 5 can be any size desired by the user, but it is generally sized according to the size of the heat exchanger coil of the Stirling engine that it is to be used on (Stirling engines are described infra), it being sized such that the front opening 6 of the hub 5 is the same size as the diameter of the heat exchanger coil of the Stirling engine.
[0037] The engines of the prior art have the inlet and outlet ducts on the same vertical face, or nearly so, and with heat driven engines with metal cowlings, there was considerable difficulty in insulating the inlet duct and the outlet duct because they were just a few inches apart from each other. The reduced diameter of each duct to fit it in this arrangement, also increased the pressure drop in the engine. The outlet duct had to make a ninety degree turn related to the flow through the engine heat exchanger coil and this meant that the pressure drop across that coil was not uniform and there was a reduction in the coil's heat exchange efficiency. Therefore, the preferred arrangement of the ceramic cowling 100 of this invention is to have the inlet duct (the first portion 1 ) directly in line with the heat exchanger coil and to have the first portion 1 of the ceramic cowling 100 to be at least as large as the coil of the heat exchanger on the Stirling engine.
[0038] The first portion 1 has a front edge 7 and a back end 8 with a back edge 15 (see FIG. 2 ), the significance of which is set forth Infra.
[0039] The second portion 2 is a partial hollow hub 9 having a circumference size larger than the first portion 1 . The reason for a larger circumference than the hub 5 is that this portion of the ceramic cowling 100 is the exhaust part of the ceramic cowling 100 . This is also the portion of the ceramic cowling 100 that surrounds the heat exchanger coil of the Stirling engine, and there must be room for the hot gases to exhaust past the heat exchanger of the Stirling engine without severely impeding the flow thereof. The second portion 2 has a front end 10 and an open back end 11 (see FIG. 2 ) and an outside surface 12 . The second portion 2 is integrally attached at the front end 10 to the back end 7 of the first portion 1 such that any hot gas provided to the ceramic cowling 100 can flow through the first portion 1 (indicated by the arrow Q) and into the Stirling engine heat exchanger coil, and exit through the second portion 2 and exit (indicated by arrow X) out of the third portion 3 .
[0040] Now, the third portion 3 is rectangular in shape and has a bottom end 13 and a top edge 14 . The third portion 3 is integrally attached at the bottom end 13 to a portion of the outside surface 12 of the second portion 2 . As can be observed from FIGS. 1 and 2 , the reason that the bottom end 13 is attached to a portion of the outside surface 12 of the second portion 2 is so that there is a curved inside surface 16 and an open air channel 17 for the expedient exhausting of the hot gases (see FIG. 2 ).
[0041] There is a fourth portion 4 that is integrally attached to the back surface 18 of the second portion 2 . This fourth portion 4 is a circular hub 19 that has a set-off distal edge 20 . The set-off distal edge 20 has a flat surface 21 that is used for interfacing with a seal (not shown) for the ceramic cowling 100 , to the Stirling engine support 22 . The ceramic cowling 100 has a means of attachment (in this example, a bolt 23 ) to the support 22 for the Stirling engine.
[0042] FIG. 3 is a full cross sectional side view of the combination of the ceramic cowling 100 , the shroud 15 .
[0043] Turning now to FIG. 3 , wherein there is shown a full side view of a ceramic cowling 100 and shroud 15 combination of this invention and to FIG. 4 , which is a cross sectional view of FIG. 3 , there is shown in addition, support saddles 16 for the shroud 15 , alloy steel bolt rings 17 for bolts 18 , which bolts 18 are used to attach the ceramic cowling 100 to the shroud 15 . The bolts 18 are also furnished with gasketing 24 . The shroud casing 19 is fabricated from steel and the preferred material is ten gage carbon steel. The metal shell or casing 19 is full seam weld and supports the ceramic cowling 100 . The inlet (portion 1 ) and the outlet (portion 4 ) connections are gas tight and have gasketed seals. The inlet seal 20 and the outlet seal 21 are between the engine and the inlet and outlet ducts, 1 and 2 respectively. The outlet duct 1 has a very positive pressure and in some cases it could be slightly negative. The inlet duct 1 , however, has to have metal outer flange sleeve 22 that bolts up against the mating flange 23 on the steel casing 19 . This duct can contain an expansion joint, not shown. There is insulation 25 sandwiched between the steel casing 19 and the ceramic cowling 15 .
[0044] FIG. 5 is a view of a full Stirling engine 90 inserted into the combination of the ceramic cowling 100 and the shroud 15 . The heat exchanger coil 91 is also shown to clarify how the engine occupies the combination.
[0045] Turning now to FIG. 6 , there is shown a schematic of a system of this invention that is a wood fired power plant utilizing two Stirling engines to generate electrical power, in which there is shown a gasifier 40 , in this case, a ram feed gasifier, a feed hopper 41 for the biomass, an ash removal system 42 , a syngas exit port 43 , and an auxiliary air fan 44 . The details of the gasifier 40 , the low NOx oxidizer 45 , the metal heat exchanger 60 , the ceramic heat exchanger 50 , boilers, and Stirling engines 70 , do not need to be defined as such components are conventional and well-known in the art.
[0046] The gasifier 40 is fed biomass that is incinerated to produce hot syngas. Ambient air 49 is fed into the gasifier 40 to temper and help burn the biomass. The hot syngas produced by this burning is ducted at about 1150° F. (66) to a low NOx oxidizer 45 . The low NOx oxidizer 45 is equipped with a syngas inlet port 46 , a syngas outlet port 47 , and two additional inlet ports 48 for heated air at 1500° F., 68 from the Stirling engines. The heated gas from the Stirling engines can also be fed to the metal heat exchanger 60 at about 1500° F. at 72 . The NOx oxidizer 45 is ducted to the outlet port 43 of the gasifier 40 , and is ducted at its outlet end 47 to a ceramic heat exchanger 50 . The ceramic heat exchanger 50 has an inlet port 51 for the heated, NOx-free syngas and an outlet port 52 . The cleaned syngas is fed ( 67 ) to the ceramic heat exchanger 50 at about 2200° F. and moved into the interior of the ceramic heat exchanger 50 and flows around the lower ceramic tubes 53 and the upper ceramic tubes 62 within the heat exchanger 50 , and exits 69 at 1600° F. through the outlet port 52 and moves into an alloy metal heat exchanger 60 through an inlet port 54 . The alloy metal heat exchanger 60 also has an outlet port 55 that exhausts to an induction draft fan 56 that is interconnected to the stack 57 where exhaust exits 65 the stack 57 at approximately 575° F. to the atmosphere. The alloy metal heat exchanger 60 has an overfire air fan 58 vented into it through an inlet port 59 that brings in ambient air 71 .
[0047] Turning back to the ceramic heat exchanger 50 , it should be noted that heated outside air from the alloy metal heat exchanger 60 is passed through the metal heat exchanger 60 and ducted into the ceramic heat exchanger 50 through inlet port 61 , and that this air is moved through the ceramic tubes 53 and is thereby heated by the heated syngas. The heated air travels through the lower set of ceramic tubes 53 , into the upper set of ceramic tubes 62 , and out of the ceramic heat exchanger 50 and about 1800° F. (72) and into the double set of Stirling engines 70 through an air inlet 63 in each such engine. The heated air moves through the Stirling engines 70 , powering them.
[0048] In another embodiment of this invention, the preheated combustion air from the Stirling engines 70 is moved 74 at about 1500° F. to a firetube boiler 64 to provide saturated steam 76 ( FIG. 6 ). It should also be noted in FIG. 6 , which is a schematic of a system in which the Stirling engines feed directly into a firetube boiler 64 , that the hot gas 66 from the Stirling engines do not feed into the oxidizer 45 and instead, the oxidizer is fed ambient air 74 from a fan 75 .
[0049] There are typically five arrangements that can be configured from using hot air from a ceramic heat exchanger 50 to drive Stirling engines 70 and wherein the heated air from the Stirling engines can be used in energy production as an alternative to electrical energy provided by the Stirling engines.
[0050] Such heated air from Stirling engines has to be processed indirectly, such as sending it to a waste heat boiler as described just Supra.
[0051] A first arrangement would be where the air is returned to the combusters, such as the gasifier 40 or the oxidizer 45 , as preheated combustion air, such as is shown in FIG. 6 . This substantially reduces the amount of fuel required.
[0052] In a second arrangement, the heated air is mixed with the flue gas between the ceramic heat exchanger 50 and the metal heat exchanger 60 as shown in FIG. 6 . This reduces the size of the metal heat exchanger 60 because one has a higher flue gas mass to transfer heat.
[0053] A third arrangement is where there is a need for steam or hot water, the heated air can be sent to the boiler or water heater as combustion air for the auxiliary natural gas and/or oil fired burner as shown in FIG. 6 . The end user of the system normally requires turndown or peaking of these heat recovery units. Solid waster-fired systems do not have a large turndown ratio or the ability to respond readily to steam or water demands. The auxiliary burner can supply peak energy rapidly and use the engine hot air exhaust as preheated combustions air. The auxiliary burner also assists in start-up and shutdown, and is a heat source if the solid waste train is down for maintenance.
[0054] In a fourth arrangement, one of the best waste fuels is wet forest products. Most waste products' moisture can range as high as 60%, since it is bark, small limbs, and leaves. When one gets to about 52% moisture, one doesn't have sufficient energy available to reach a high enough entrance temperature to the ceramic heat exchanger to transfer heat to the engine air. When the forest products are in the 20% range, that is kiln dried, to 45%, that is, air dried surface moisture range, the gasifiers and oxidizers work very well. Pre-drying of the fuel makes firing of high moisture material practical.
[0055] Most of the forest products in the logging industry are in the 59% range and they need power so the engine air 74 can be sent to a conventional rotary or conveyor dryer 77 located between the storage and the feed hopper 41 , and then conveyed by a rotary conveyor 79 to the feed hopper 41 . The high temperature air would be mixed with ambient air 81 from a fan 80 , and in turn would mix directly with the biomass to reduce the moisture content down to the 35% to 40% range. Partially drying wood with hot air gives one a non-polluting affluent. This is shown in FIG. 9 .
[0056] With regard to arrangement five, there are industries that need clean hot air for particular processes. For example, lumber mills require humidity controlled hot air to dry wood. The engine air 74 can be sent directly to a wood drying kiln 78 where it is mixed with humid air being recirculated, with a portion exhausted to the atmosphere. This is shown in FIG. 9 .
[0057] Also contemplated within the scope of this invention is the use of a turbine in place of a Stirling engine, or the use in combination with a Stirling engine, either singly, or in multiple units of either a Stirling engine or a turbine.
[0058] Turbines, as used herein, means any conventional turbine. These have been defined as a machine for generating rotary mechanical power from the energy in a stream of fluid supplied to the turbine. “Fluid” as used herein means those fluids most commonly used in turbines such as steam, hot air, or combustion products and water. Steam raised in fossil fuel fired boilers or nuclear reactor systems is widely used in turbines for electrical power generation, ship propulsion, and mechanical drives. The combustion gas turbine has these applications in addition to important uses in aircraft propulsion. Water turbines are used for electrical power generation.
[0059] Energy, originally in the form of head or pressure energy, is converted to velocity energy by passing through a system of stationary and moving blades in the turbine. Changes in the magnitude and direction of the fluid velocity are made to cause tangential forces on the rotating blades, producing mechanical power via turning rotors. Turbines effect the conversion of fluid to mechanical energy through the principles of impulse, reaction, or a mixture of the two. | Ceramic cowlings that are used as the connection between a hot gas source and a Stirling engine or a turbine. The ceramic cowling is designed and fabricated with non-dusting, high temperature, dense, low thermal expansion ceramic. It must also be highly resistant to thermal shock. Also, a combination of a ceramic cowling and a shroud for covering and holding the ceramic cowling on a Stirling engine or turbine such that hot gases can flow through the ceramic cowling and into the heat exchanger coil of the Stirling engine and exhaust in a controllable manner. A method of enhancing the power efficiency of a Stirling engine and with systems including the use of at least one enhanced power Stirling engine. | 5 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of provisional application No. 61/324,654, filed on Apr. 15, 2010, the full disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This disclosure relates to the field of medical devices, specifically to the use and structure of balloon angioplasty or dilatation catheters.
[0004] Despite being in widespread use for over 20 years and substantial development efforts, the delivery of angioplasty balloons to a target lesion in a patient's vasculature is often a challenge. During delivery, the operator often has to overcome tortuous anatomy, long and calcified lesions (especially in peripheral arteries) and tight turns. Further difficulties can arise from the need to cross previously treated lesions where restenosis has occurred.
[0005] Balloon catheters are usually delivered over a guide wire that is inserted into the vasculature and through the target lesion prior to advancement of the balloon catheter. With most balloon catheters, the operator controls advancement by pushing/pulling the catheter shaft from over the guide wire. During delivery, the operator will push the catheter shaft over the guide wire until the balloon reaches the target lesion. When encountering an obstacle, the operator can pull back and push again forcefully in the hope that the balloon catheter will overcome this obstacle. Some catheters have improved torque transmitting capabilities but these are limited and work best in short balloons.
[0006] In conventional balloon catheter constructions, at least at a distal segment of the shaft near the balloon is made from a relatively soft polymer material which is very ineffective for transmitting pushing force and torque to the catheter tip, typically relying on the stiffness of the guide wire which is often insufficient. The balloon region of a balloon catheter is made of a very thin folded balloon; it is the weakest in terms of push force and torque. The distal section of the balloon is attached to the catheter's guide wire lumen at the very distal end of the catheter, and to the catheter distal shaft (but only to the inflation lumen and not to its internal concentric guide wire lumen) on its proximal balloon taper. Therefore this segment of the catheter has inefficient structural integrity in delivering the push force to the catheter tip in attempt to overcome an obstacle.
[0007] The difficulties described above are exacerbated in catheters having long balloons, such as those used in peripheral arteries. Such balloons can reach or exceed 30 cm in length. Further difficulty arises in peripheral arteries when attempting to cross the iliac arch where wire bending may occur as the push force is not effectively transferred to the distal part of the catheter. Attempts to reinforce the catheters using metallic inner members or stiff members have failed since the catheter must be flexible in order to travel through the arteries without damaging the vessels. Other limitations to reinforcing the balloon include the need to keep a low profile (minimize the addition of new materials or layers of tubing) and the need to have short inflation/deflation times (maximizing the area of the inflation lumen to allow rapid liquid flow into the balloon during inflation and out of the balloon during deflation).
[0008] Thus, the ability of balloon catheters and especially balloon catheters with long balloons used to treat peripheral arteries (with balloon lengths up to 30 cm) to reach and cross target lesions is often limited and can prolong procedures requiring the use of excessive contrast media and radiation, both of which can be harmful to the patient.
[0009] For all of the above reasons, it would be desirable to provide improved angioplasty balloon catheters and methods for their use. In particular, it would be desirable if the balloon catheters could have improved pushability or column strength, particularly over their distal regions comprising the balloon, as well as improved torqueability, and thus be capable of being advanced through tortuous regions of the vasculature and through restricted, difficult-to-pass vascular lesions. In addition to possessing such improved column strength and torsional stiffness, it is desirable that the flexibility of the distal region of the catheter, particularly that comprising a balloon, remain sufficiently high to that the balloon remains sufficiently conformable to be delivered around tight bends and through tortuous regions of the vasculature. At least some of these objectives will be met by the inventions described below.
[0010] 2. Description of the Background Art
[0011] Patents describing balloon angioplasty catheter constructions include U.S. Pat. Nos. 7,491,213; 7,635,347; 7,273,470; 7,022,106; 6,030,405; and 5,827,231.
BRIEF SUMMARY OF THE INVENTION
[0012] This invention discloses a balloon catheter with improved ability to deliver torque and push throughout the device, including the relatively weak balloon segment of a catheter, to the distal end of the catheter. The balloon catheter typically includes a rotatable asymmetric tip and a reinforced shaft with an improved ability to transmit torque to rotate and realign a leading edge of the tip to facilitate passage through an obstruction. The tip is preferably asymmetric around its axis, usually being beveled, and the reinforced catheter shaft is capable of transmitting rotation and push force to the catheter tip while maintaining flexibility and deployment performance. When an obstacle is encountered rotation of the catheter allows the tip to pass through the obstacle.
[0013] A particularly advantageous feature of the present invention is referred to as a “slide lock mechanism” which provides intra-balloon support while maintaining flexibility and uniform inflation. This can be achieved through extending a support lumen thru the inflatable part of the balloon to fit inside or close to the distal balloon leg. Attempts to provide full intra-balloon support tubes which are anchored at both ends to the catheter can cause the balloon to deform and assume a non-cylindrical configuration when fully inflated (as shown in FIG. 2 ). By decoupling the two ends of the balloon from the shaft while providing support tube throughout the full length of the balloon, as achieved with the present invention, such balloon deformation can be avoided. The particular slide lock mechanism of the present invention is also able to provide for both increased column strength (catheter pushability) and torsional rigidity (the ability to rotate the proximal end of the catheter shaft about its axis and cause a comparable rotation of the distal end of the shaft even when the shat is passing through tortuous regions of the vasculature), which are advantageous in catheter placement. Increased column strength and torsional rigidity allow improved transmission of both turning and translation of the shaft from the proximal end so that such motions are accurately reflected in the distal end of the catheter and can allow crossing of tight, long and diffuse lesions that currently are very difficult to treat and may eventually lead to amputation.
[0014] In a first aspect of the present invention, the balloon catheter comprises a shaft having an inner member a proximal end, a distal end, and a guide wire lumen extending therethrough. When the guide wire lumen extends fully through the inner member, the catheter will have an “over-the-wire” configuration where the guide wire passes through the entire length of the catheter. When the guide wire lumen passes through only a portion of the inner member or other structure of the shaft, the catheter can have a “rapid exchange” configuration where only a short length of the guide wire, typically from 10 cm to 35 cm, is received through the catheter and passes through the catheter balloon.
[0015] The catheter will further include a distal tip disposed at the distal end of the catheter shaft. The tip could be symmetric or the distal tip will have an asymmetric configuration, typically being beveled at an angle in the range from 30 degrees to 60 degrees, usually being about 45 degrees, so that a leading edge of the tip can be oriented relative to a luminal obstruction to facilitate passing that obstruction. Usually, the distal tip will be a separate component attached to a distal end of the inner member of the catheter shaft. In other instances, particularly when a distal end is not beveled, a distal tip may be formed integrally in the inner member or other portion of the shaft itself.
[0016] The balloon catheter of the present invention further comprises a reinforcement sleeve which is disposed coaxially over the inner member. The reinforcement sleeve has a proximal end and a distal end and, when in place over the inner member, provides an annular inflation lumen between an outer surface of a shaft and inner wall of the sleeve.
[0017] The balloon catheter further includes an inflatable balloon, typically a non-distensible balloon formed of a conventional balloon material such as nylon or pebax or other materials known in the arts. The balloon has a distal end and a proximal end where the distal end is secured directly or indirectly to the distal tip and/or to the distal end of the inner member. The proximal end of the balloon is secured to the reinforcement sleeve, typically near the distal end of the reinforcement sleeve. As at least the distal end of the reinforcement sleeve will be free to move relative to the inner member, as described in more detail below, the distal end of the balloon will be able to move relative to the proximal end of the balloon as the balloon is inflated, reducing the risk that the balloon will deform from the desired cylindrical configuration as it is inflated.
[0018] In the preferred constructions, a distal end of the extended outer shaft will directly couple or engage the distal tip of the catheter when the balloon is deflated and the catheter is being advanced through the vasculature. By engaging or otherwise being coupled to the distal tip, the reinforcement sleeve is able to transmit both axial force (i.e., increase the overall column strength of the catheter) as well as torsional force from the proximal end of the catheter to the distal end. The enhanced column strength and torsional rigidity are achieved during the catheter advancement, which is when they are most needed. Moreover, the torsional rigidity and column strength of the reinforcement sleeve are provided in addition to the strength and rigidity of the catheter shaft itself so that the overall column strength and torsional rigidity are the sum of the contributions of each component.
[0019] While the distal end of the reinforcement sleeve will engage or otherwise be coupled to the distal tip (or the distal end of the balloon) while the balloon is deflated during catheter advancement, the reinforcement sleeve will not be attached to the catheter tip so that the reinforcement sleeve will be able to move or retract in a proximal direction in response to balloon elongation when the balloon is inflated. Thus, two ends of the balloon will be able to move apart from each other and the stress on the balloon which would result from the balloon ends being anchored is eliminated. Thus, the balloon will be able inflate with less risk of the deformation than if the balloons were both attached to the balloon shaft.
[0020] The distal end or region of the reinforcement sleeve will have one or more ports or passages formed therethrough in order to permit balloon inflation. An inflation medium can be introduced into the annular lumen between the sleeve and the shaft, typically through an inflation port on a proximal hub of the catheter. The inflation medium can travel the length of the catheter through the annular lumen. The distal region of the sleeve may be generally cylindrical so that the annular lumen continues the entire length of the catheter to reach the distal tip. With such a fully extending sleeve, the inflation ports can be formed along the length of the sleeve at multiple locations within the balloon. Alternatively, in order to produce the crossing profile of the balloon, the sleeve can be tapered so that it lies immediately over the outer surface of the distal end of the inner member, thus eliminating the inflation medium over a distal region of the balloon. In such cases, the holes will need to be located in the proximal area of the balloon before the out shaft if fully tapered.
[0021] The inner member may have any conventional angioplasty balloon shaft structure, typically comprising a hypotube or other metal body portion over at least a portion of its length. Alternatively, the inner member could be a polymeric body over at least a portion of its length, typically being reinforced with a braid, mesh, embedded wires, or the like, in order to increase column strength and torsional rigidity.
[0022] The reinforcement sleeve will typically comprise a polymer tube over at least a portion of its length, where the polymer may be reinforced with meshes, braids, wires, or the like, in order to increase both its column strength and torsional rigidity.
[0023] In a specific embodiment of the catheter, the balloon will include at a distal constriction (distal leg) which does not inflate with introduction of the inflation medium. This distal restriction is spaced apart from the inner member so that a channel is created which receives the distal end of the reinforcement sleeve. Usually, the channel will be sufficiently long so that the reinforcement sleeve remains in the channel even when it is fully retracted in its proximal direction when the balloon is fully inflated.
[0024] In a second aspect, the present invention provides a method for dilatating a body lumen, typically dilatating a lesion in a blood vessel. The method comprises providing a catheter having an inner member, a distal tip (area distally to the inflatable balloon), a reinforcement sleeve (outer shaft), and an inflatable balloon connected at a distal end to the inner member and at a proximal end to the reinforcement sleeve. The catheter is advanced through a patient's vasculature by pushing a proximal end of the catheter shaft to transmit a push force to the distal tip of the catheter through both the inner member and the reinforcement sleeve. While the catheter is being advanced by pushing, the distal ends of the both the inner member and the outer shaft remain engaged against the distal tip of the catheter in order to facilitate positioning of the balloon at the lesion or other target site. Once at the lesion or other target site, the balloon is inflated so that the balloon radially expands and elongates. As the balloon elongates, the reinforcement sleeve separates from the distal tip to accommodate such balloon elongation, whereby stresses and constricting forces which could deform the balloon are greatly reduced. Usually, while a balloon is being advanced, it is also being rotated, where the rotational torque is transmitted to the distal tip through both the inner member and the reinforcement sleeve, both of which remain engaged against the tip during catheter advancement. Usually, the distal will have a beveled or other asymmetric end which may be reoriented relative to an obstruction in the vasculature in order to help pass the obstruction as the catheter is advanced and rotated.
[0025] In another aspect of the present invention, the catheter inner member may utilize reinforced tubes allowing rotation and push force transmission. This reinforcement is achieved by use of braided shafts where a braid of thin metallic or polymer ribbons that increase the inner member torque and push force transmission without compromising the shafts flexibility. The braided shafts can be the external shaft or the internal shaft (inner member) or both. The internal shaft is connected to the balloon distal end and the external shaft is connected to the balloon proximal end, often these two are not connected. Reinforcing those shafts, especially the inner shaft, greatly improves the operators control over the balloon throughout the catheters length all the way to the tip, mainly torque and pushability.
[0026] In yet another aspect of the present invention, the catheter shaft may utilize reinforced tubes or support material in the internal shaft, and/or external shafts and the two are connected at an anchoring area near the proximal end of the balloon, allowing enhanced control of the balloon by the operator.
[0027] In still another aspect of the present invention, an inner construction of the balloon comprises a continuation of the distal shaft/inflation lumen that extends through the balloon all the way to the balloon distal leg or tip. This elongated distal shaft could be bonded at the balloon distal end or can be stabilized by pressure applied from the balloon leg. To provide effective inflation/deflation the inflation lumen that extends throughout the balloon contains holes, openings or cavities underlining the balloon section to allow for inflation medium such as saline or saline's mix to reach and inflate the balloon.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 illustrates a balloon catheter of the type which may incorporate the slide lock of the present invention;
[0029] FIG. 2 illustrates a prior art balloon with internal reinforcement which has been inflated without the slide lock mechanism of the present invention where the balloon profile becomes deformed.
[0030] FIGS. 3A-3C illustrate a first embodiment of a balloon catheter employing the slide lock mechanism of the present invention where the reinforcement sleeve has a generally constant diameter along its entire length.
[0031] FIGS. 4A-4C illustrate a second embodiment of a catheter construction employing the slide lock mechanism of the present invention where a reinforcement sleeve has a tapered distal end.
[0032] FIGS. 5A-5C illustrate use of the balloon catheter of the present invention for dilating a lesion in a blood vessel.
DETAILED DESCRIPTION OF THE INVENTION
[0033] The following description will describe various aspects of the invention. Embodiments of this invention relate to a balloon catheter with improved rotational torque and column strength that reach through the balloon and to the tip of the catheter, providing improved obstacle crossing capabilities. This design allows for better control of the catheter by the operator. The embodiments relate to treatment of occlusions in blood vessels (both coronary and peripheral) but can also find use in treating other body lumens such as the urinary and reproductive systems.
[0034] Referring now to FIG. 1 , a balloon catheter 10 of the type which may employ the slide lock mechanism of the present invention comprises a shaft assembly 12 having a distal end 14 and a proximal end 16 . An inflatable balloon 18 is mounted on a distal region of the shaft assembly 12 , and will have dimensions selected based on its intended use. For example, in treating long lesions of the peripheral vasculature, the balloon will typically have a length exceeding 10 cm, often exceeding 20 cm, and in some instances approximately 30 cm. In balloon catheters without the slide lock mechanism in the present invention, where both ends of the balloon are attached to the shaft assembly which holds the end at a fixed distance, the balloon 18 when inflated may become deformed, as shown in full line in FIG. 2 . By employing the slide lock mechanism of the present invention, however, the balloon will typically inflate to a more perfect cylindrical configuration, as shown in broken line in FIG. 2 .
[0035] Reference is made to FIGS. 3A-3C which provide a schematic representation of an extended distal shaft extending throughout the balloon. The extended distal shaft or reinforcement member (also described as torque transmission member, a push transmission member, or a buckling resistant member) extends to the distal part of the balloon. This reinforcement member can be made of braided or conventional polymer and will be able to transfer the push and torque forces to the tip of the balloon. Since this reinforcement member also provides the inflation lumen, a distal portion of the member inside the balloon will be customized with holes, slits, and voids or alike to accommodate balloon inflation and deflation. The elongated distal shaft can be bonded to the balloon distal leg or tip. Preferably, the elongated member can be inserted and held in place by pressure and/or friction applied from the balloon distal leg by using dimensional fit but it can also extend all the way to the distal balloon area without pressure fit or special dimensional fit. The pressure and friction forces improve transfer of push and torque forces to the distal section of the balloon.
[0036] The catheter 10 illustrated in FIGS. 3A-3C comprises a shaft assembly 12 including an inner member 30 and a coaxially disposed reinforcement sleeve 32 . The reinforcement sleeve 32 is cylindrical along its entire length having generally constant diameter such an annular inflation lumen 34 is defined between an outer surface of the inner member 30 and an inner wall of the reinforcement sleeve 32 . The annular inflation lumen 34 extends the entire length from inflation port 22 on proximal hub 20 of the balloon catheter 10 ( FIG. 1 ) to the distal tip 24 . The inflation medium can be released into the region beneath balloon 18 through a plurality inflation port 36 located along the length of the reinforcement sleeve 32 beneath the balloon.
[0037] Referring now in particular to FIGS. 3B and 3C , at all times, at distal end 38 of the inner member 30 is fixedly attached to a proximal side of the distal tip 24 . An opening or port 40 formed through the distal tip 24 opens into a hollow lumen 42 of the inner shaft 30 in order to receive a guidewire which can be passed into the lumen through a guidewire port 44 on the proximal hub 20 ( FIG. 1 ).
[0038] The balloon 18 has a constricted region or collar 48 at it's distal end (and typically also at its proximal end) which is fixedly attached to the proximal end or surface of the distal tip 24 such that the balloon is sealed to the tip to provide containment of the inflation medium within the lumen. Collar 48 defines an annular channel 50 between the collar and outer surface of the inner member 30 , and it is within this channel that the distal end 52 of the reinforcement sleeve 32 passes and engages the proximal end of distal tip 24 . The distal end 52 of the reinforcement sleeve 32 is not, however, attached to the distal tip 24 , but it will remain engaged against the tip so long as the balloon remains uninflated. Upon balloon inflation, however, the distal end 52 of the reinforcement sleeve 32 will be drawn approximately to cause a gap 60 between the distal end and the proximal end of the distal tip 24 , as shown in FIG. 3C . This gap is caused by movement of the sleeve 32 relative to the inner member 30 which in turn is caused by elongation of the balloon 18 as it is inflated. The length of the gap 60 will thus generally correspond to the magnitude of the balloon elongation, typically being at least several millimeters, often being in the range from 0.5 cm to 5 cm, usually being in the range from 1 cm to 3 cm.
[0039] By comparing the configurations of FIGS. 3B and 3C , it can be seen that while the balloon is uninflated and the catheter is being advanced, the enforcement sleeve 32 engages the distal tip 24 and can thus enhance both the column strength and the torsional rigidity of the catheter so that movement of the proximal end of the catheter can be faithfully transmitted to the distal tip. In contrast, when the balloon 18 is inflated at the target site or lesion, as illustrated in FIG. 3C , the annular gap which is created enhances the flexibility and the conformability of the catheter and in particular reduces the risk of balloon deformation which is a principal objective of the present invention.
[0040] FIG. 4A-4C illustrate a preferred embodiment of the elongated distal shaft described in the previous paragraph. In this embodiment the distal shaft is tapered to the inner member allowing a smaller diameter and reducing balloon profile. Thus the balloon will have better crossing capabilities without compromising push and torque force transfer. In this case since the distal shaft is tapered the holes are located in the tapered area to allow liquid or gas to flow and enable balloon inflation. Another type of reinforcing member can be metallic wire or ribbon that help support the inner member of the balloon during delivery while providing flexibility. In such case inflation holes may not be required.
[0041] As illustrated in FIGS. 4A-4C , the catheter 10 ′ is identical in all respects to the catheter 10 except that reinforcement sleeve 32 ′ is tapered and has a smaller diameter over a region 62 which lies beneath lumen 18 and over inner-shaft 30 . Note that all identical components will be given identical reference numbers in both FIGS. 3A-3C and FIGS. 4A-4C . By reducing the diameter of the distal region 62 of the sleeve 32 ′, typically so that it has an inner diameter which is greater than the outer diameter of inner member 30 by distance sufficient only to allow sliding of the sleeve 32 ′ over the inner member 30 , the crossing profile of the catheter can be significantly reduced.
[0042] The tapering of the distal region 62 also changes the distal engagement configuration of the distal end 52 ′ of the reinforcement sleeve 32 ′ and the tip 24 , as best seen in FIGS. 4B and 4C . In particular, the distal end 52 ′ of the reinforcement sleeve 32 ′ will be sandwiched between the distal color region 48 of the balloon 18 prior to balloon inflation, as best seen in FIG. 4B . The diameter of the distal tip 24 and the collar region 48 of the balloon 18 can be correspondingly decreased. As the distal end of the 52 ′ of the reinforcement sleeve 32 ′ is proximally retracted upon balloon inflation, as shown in FIG. 4C , the gap 60 ′ will also have a reduced width relative to the gap 60 of catheter 10 as shown in FIG. 3C . Other operational characteristics of the catheter 10 ′ will generally be identical to those of the catheter 10 .
[0043] Referring now to FIGS. 5A-5C , catheter 10 may be introduced to a blood vessel BV by any conventional technique, including surgical cut down. Usually, however, the catheter 10 will be introduced by the Seldinger technique through an access sheath AS so that the balloon 18 enters the blood vessel BV over a guidewire GW. The intent is to advance the balloon 18 until it reaches an occlusive site OS at a region in the vasculature which is typically remote from the access site. The occlusion site OS may be in the peripheral vasculature, the coronary vasculature, or elsewhere. Long balloons having lengths over 10 cm, often over 20 cm, will often find greatest use in the peripheral blood vessels.
[0044] After initial introduction, the catheter 10 will be advanced through the vasculature until the balloon 18 reaches occlusive site OS, as illustrated in FIG. 5B . During the advancement, however, of the present invention allows the catheter to be both pushed and rotated, as shown by the arrows in FIG. 5B , to facilitate advancement of the distal tip of the catheter past intermediate occlusions and through tortuousities. Usually, the distal tip 24 will have a beveled or otherwise asymmetric tip which has a leading edge which may be reoriented to facilitate passing through or past occlusions. The enhanced torsional strength and rigidity of the present invention make axially advancing and rotating the distal tip of the catheter much easier than would otherwise be the case in the absence of the reinforcement structure.
[0045] As shown in FIG. 5C , after reaching the occlusion site OS, the balloon 18 is inflated by introducing inflation medium through the port 22 on hub 20 . The slide lock mechanism in the present invention, as described in detail above, allows the balloon 18 to inflate with a reduced tendency to deform so that the fully inflated profile is in a preferred cylindrical configuration.
[0046] The significance of having the reinforcement sleeve not bonded distally (or proximally, or discontinued at any point along its length in a manner that will deliver push, torque or resist buckling) can be explained as follows. During inflation the balloon inflates both in radial and longitudinal directions, i.e. the one of the “side effects” of the balloon inflation is the fact that the balloon also lengthen during inflation. Typically, the balloon length can lengthen 5%-15% relatively to its diameter depending on its material, wall thickness, length, pressure and other factors. For example, 20 cm length balloon can grow approximately 10 mm in length during inflation and in extreme cases can grow 30 mm in length. Since the reinforcement sleeve is stiffer than the balloon thin wall and typically does not grow as much during inflation, the member constrains the balloon from growing axially and as a result the balloon shape changes. The balloon may obtain a “banana” shape,” an “S” shape, or other non-cylindrical shapes. This phenomenon is undesired and may affect the balloon performance and its affect of the vessel wall by adding undesired forces that contribute to vessel trauma. Keeping the reinforcement member unbound and unattached in a manner that will allow the balloon to lengthen without constraint (e.g. weak bond that can detached or similar mechanisms) allows for the balloon to inflate without significant constraint from the shaft. However, the reinforcing member will not deliver as much force if it is not extended all the way to the distal balloon end and have physical interaction enabling force and/or torque transmission. Therefore, “clutch” mechanism that can transmit forces during delivery and crossing lesions but can allow unconstrained inflation of the balloon is desirable.
[0047] While the above is a complete description of the preferred embodiments of the invention, various alternatives, modifications, and equivalents may be used. Therefore, the above description should not be taken as limiting the scope of the invention which is defined by the appended claims. | A balloon catheter capable of delivering torque and pushing through obstructions includes a relatively weak balloon segment of a catheter and rotatable asymmetric tip. A reinforcement sleeve increases column strength and torque transmission to push the balloon and rotate the tip to facilitate passage through said obstructions. The tip is preferably asymmetric around its axis, usually being beveled, and the reinforcement slide includes a slide lock mechanism which increases shaft flexibility after balloon deployment. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to solid supports and is particularly concerned with solid supports which can be used in the storage, recovery and further processing of biological materials such as biopharmaceutical drugs.
BACKGROUND TO THE INVENTION
[0002] The use of solid supports such as filter paper for the collection and analysis of human blood dates back to the early 1960s, when Dr. Robert Guthrie used dried blood spot (DBS) specimens to measure phenylalanine in newborns for the detection of phenylketonuria (Mei, J., et al., 2001; Journal of Nutrition, 131:1631S-1636S). This novel application for collecting blood led to the population screening of newborns for the detection of treatable, inherited metabolic diseases. DBS have now been used for over 40 years to screen for a large range of neonatal metabolic disorders.
[0003] DBS specimens are collected by spotting whole blood onto a solid support, such as a membrane, glass fiber or paper, either from venous blood or directly from a finger or heel prick, making this method particularly suitable for the shipment of specimens from peripheral clinics to central laboratories. Furthermore, DBS packed in zip-lock plastic bags with desiccant can be stored and shipped at ambient temperature, thus avoiding the need for i) cold chain storage and ii) fast specialized transportation. DBS collected by applying a drop of blood onto an absorbent material such as Whatman 903 Neonatal STD paper are not subject to the IATA Dangerous Goods Regulations (Addendum II, Mar 2005).
[0004] Additional solid paper supports that are used for collecting, transportation and storing DBS and other bodily fluids for newborn and neonatal screening purposes include—
1. Ahlstrom 226 2. Munktell TFN (CE marked) 3. Toyo Roshi grade 545 Advantec Toyo, Tokyo (see Elvers L et al 2007; J. Inherit Medtab Dis 30, 4, 609).
[0008] All of these papers like the Whatman 903 Neonatal STD paper consist of cotton linters. The Whatman 903 Neonatal STD and Ahlstrom 226 papers are classified as Class II Medical devices. Solid paper supports that have the potential to be developed into devices for newborn and neonatal screening purposes include those manufactured by Macherey Nagel (e.g. MN818), Reeve Angel (e.g. Double ring) and Hahnemuhle Grade 2292.
[0009] The consumable costs for DBS are less than US$1 per test, and transport costs are markedly reduced compared with plasma, which requires a liquid format and specialized transportation conditions (Johannessen, A., et al., 2009; J Antimicrobial Chemotherapy, 64, 1126-1129). Although the actual assay costs remain unchanged, and the extraction of analytes from DBS involves some extra hands-on time at a centralised laboratory, the use of DBS and specifically solid paper supports is increasingly used in the storage and/or analysis of biological materials such as nucleic acids, proteins etc. In addition, DBS have also been utilised during the drug discovery process in which candidate low molecular weight drug compounds have been introduced into test animals and concentration levels in the blood monitored.
[0010] In recent years, biotechnologically-derived recombinant proteins, peptides and antibody-based drugs, as well as antisense oligonucleotides and DNA for gene therapy, have developed into mainstream therapeutic agents and now constitute a substantial portion of the compounds under clinical development. These agents are commonly termed “biotech-drugs” or “biopharmaceutical drugs” to differentiate them from low molecular weight drug compounds.
[0011] Drug Metabolism and Pharmacokinetic (DMPK) analysis of Biotech-drugs and low molecular weight drug compounds is important as DMPK analysis is vital to drug discovery as it provides insight into how drug candidates may be absorbed, metabolised and excreted by the body. Analyses are routinely performed at the drug discovery stage and involve dosing animals with the compound of interest, and measuring the drug (or metabolite) concentration in biological fluids as a function of time. This generates valuable information such as drug clearance, bioavailability etc, but demands a significant amount of time and resource (Beaudette, P., et al., 2004; J. of Chromatography B 809, 153-158).
[0012] Major problems associated with the DMPK analysis, typically conducted in drug screening programmes, are the apparent lack of a suitable storage media for maintaining stability and integrity in blood samples prior to analysis. Current methodologies use plasma or whole blood collected from the dosed animals at designated times. However, this method has a number of drawbacks including the involvement of time-consuming procedures which create a bottleneck in the analysis process. In addition, the multiple bleeding of individual animals for time-course experiments is restrictive. This puts a limitation on throughput and increases the use of animals, which has the result that fewer lead compounds can be advanced.
[0013] The small blood volume needed for DBS enables serial blood sampling from one animal rather than composite bleeds from several animals which significantly improves the quality of DMPK and toxicokinetic data and assessments. The ethical benefits of the reduced blood volume (typically 15-20 μl per spot) needed for DBS with regard to the “3Rs” (reduction, refinement, and replacement) are obvious in preclinical drug development. The numbers of test animals can be significantly reduced. In addition, non-terminal blood sampling is possible in juvenile toxicity studies which are increasingly required by authorities as part of the safety evaluation of drugs for paediatric use. Another advantage for regulatory animal toxicology studies is the increase in data quality.
[0014] Therefore due to the growing need for rapid analysis of large quantities of blood samples in pharmacokinetic research, DBS have become an attractive option. For paper to perform as a solid support for DBS it is desirable that the paper combines satisfactory mechanical properties with an ability to hold the biological material of interest in a stable condition in such a way that it can be subjected to further processing and/or analysis post-storage. Examples of such papers used for DMPK analyses are those known as 903 Neonatal specimen collection papers and also papers known as FTA and FTA Elute described, for example, in U.S. Pat. Nos. 5,75,126 and 5,939,259.
[0015] Additional solid paper supports used for DMPK analyses include the following—
1. Ahlstrom grade 226 paper: Use of Dried Plasma Spots in the Determination of Pharmacokinetics in Clinical Studies: Validation of a Quantitative Bioanalytical Method. Barfield, M., et al., (2011), Anal., Chem., 83, 118-124. 2. Standardized Filter paper: Drug monitoring of lamotrigine and oxcarbazepine combination during pregnancy Wegner, I., et al., (2010), Epilepsia, 51, 2500-2502. 3. Whatman 903, FTA (DMPK-A) and FTA Elute (DMPK-B) substrates: Effect of storage conditions on the weight and appearance of dried blood spot samples on various cellulose-based substrates. Denniff, P., et al., (2010), Bioanalysis, 2, 11, 1817-22. 4. Whatman DMPK-A, -B, -C: Application of DBS for quantitative assessment of the peptide Exendin-4; comparison of plasma and DBS method by UHPLC-MS/MS. Kehler, R., et al., (2010), Bioanalysis, 2, 8, 1461-1468. 5. Ahlstrom grade 237 paper: Application of a Liquid Extraction Based Sealing Surface Sampling Probe for Mass Spectrometric Analysis of DBS & Mouse Whole-Body Thin Tissue Sections Van Berkel, G., et al., (2009), Anal., Chem., 2009, 81, 21, 9146-9152. 6. Whatman FTA blood spot cards: Dried blood spots as a sample collection technique for the determination of pharmacokinetics in clinical studies: considerations for the validation of a quantitative bioanalytical method. Spooner, N., et al., (2009), Anal Chem. 81, 1557-63. 7. Whatman FTA Elute Micro card: Study of dried blood spots technique for the determination of dextromethorphan and its metabolite dextrorphan in human whole blood by LC-MS/MS. Liang, X., et al., (2009), J. Chrom B, Anal. Tech Biomed & Life Sci, 877, 799-806. 8. Whatman filter paper cards: A liquid chromatography/Tandem mass spectrometry method for determination of 25-hydroxy vitamin D2 and 25-hydroxy vitamin D3 in dried blood spots: a potential adjunct to diabetes and cardiometabolic risk screening. Newman, M., et al., (2009), J Diabetes Sci and Tech. 3, 156-162. 9. Toyo Roshi No. 545 filter paper (Advantec Toyo, Tokyo): Simultaneous determination of 17α-hydroxypregnenolone and 17α-hydroxyprogesterone in DBS from low birth weight infants using LC-MS/MS. Higashi, T., et al., (2008), J. Pharm and Biomedical Analysis, 48, 1, 177-182. 10. Whatman specimen collection paper BFC 180: Determination of morphine & 6-acetylmorphine in blood with use of dried blood spots. Garcia-Boy, R., et al., (2008), Therapeutic Drug Monitoring, 30, 6, 733-739. 11. Whatman filter paper (catalog no. 10535097): Quantification of cationic anti-malaria agent methylene blue in different human biological matrices using cation exchange chromatography coupled to tandem mass spectrometry. Burhenne, J., et al., (2008), J. Chrom B, Anal. Tech Biomed & Life Sci, 863, 273-282. 12. Whatman 3MM: Use of filter paper for sample collection and transport in steroid pharmacology. Howe, C., et al., (1997), Clin Chem. 43, 1408-15. 13. Whatman FTA, FTA Elute, DMPK-A, B, C, Ahlstrom 226— Determination of Tamiflu® and active metabolite in dried blood spots using the SCAPTM DBS system and column-switching LC-MS/MS. Heinig, K., et al., F. Hoffmann-La Roche, Basel, Switzerland. (see: http://www.presearch.co.uk/pages/products applications/1725/Determination%20of%20T amiflu%C2%AE%20and%20active%20metabolite%20in%20dried%20blood%20spots% 20using%20the%20SCAPTM%20DBS%20system.pdf)
[0056] Solid paper supports that have the potential to be developed into devices for DMPK purposes include Munktell TFN grade, Toyo Roshi grade 545, Macherey Nagel (e.g. MN818), Reeve Angel (e.g. Double ring) and Hahnemuhle Grade 2292).
[0057] For effective downstream processing and analysis, the analyte of interest (such as endogenous proteins or Biotech drugs) must be easy to extract from the solid paper support using relatively simple techniques that are amenable to high throughput.
[0058] The combination of DBS and the detection of endogenous protein has been described in the scientific literature. For example, the biomarker for cystic fibrosis (CF) immunoreactive trypsin (IT), the first reported use of endogenous IT from DBS for CF screening was published by Ryley et al., in 1981 (J. Clin. Pathol. 34, 906-910). Since then, IT has been routinely used as an indicator of CF using DBS from neonates. A number of commercial organisations supply FDA approved immunoassay kits for this application. Many simply use a “paper-in” approach, in which a paper punch containing the DBS is applied directly in to the immunoassay and the analyte of interest is extracted in situ. Recently (Lindau-Shepard & Pass, 2010, Clinical Chem. 56, 445-450) demonstrated that IT exists in two different isoforms. These authors reported the development of a suspension (or paper-in) array-based immunoassay for the diagnosis of CF using the two different isoforms of IT. All these protein-based studies were carried out on uncoated Guthrie cards (Whatman 903 paper).
[0059] Since the inception of anonymous human immuno-deficiency (HIV) screening, over 1.2 million DBS tests have been carried out for the serological detection of endogenous anti-HIV antibodies in the blood from expectant mothers.
[0060] These studies have proved that i) concerns about long-term storage of blood and any associated proteins of interest have proved unfounded and ii) the presence of haem in the DBS does not interfere with assay performance.
[0061] It is therefore desirable to produce solid supports which provide a simple, stable storage medium for biological materials, including i) endogenous moieties and ii) biopharmaceutical or biotech drugs, which give a high yield or recovery of the biological material on further processing. The present invention addresses these needs and provides methods that enhance the recovery levels of biological materials such as biopharmaceutical drugs from biological samples stored as DBS on solid supports, particularly solid paper supports.
DEFINITIONS
[0062] The term “biological material” as used herein shall mean any “biomolecule”, “synthetically-derived biomolecule”, “biopharmaceutical drug” or “cellular component” as defined below:
i) A biomolecule is any organic molecule that is produced by a living organism, including large polymeric molecules such as proteins, polysaccharides, and nucleic acids as well as small low molecular weight molecules such as primary metabolites, secondary metabolites, and natural products. ii) A synthetically-derived biomolecule, is a “biomolecule” as defined in i) above that is generated using recombinant DNA technologies or chemically synthesised by other non-living in-vitro methods. iii) A biopharmaceutical drug (or “biotech drug”) is a biotechnologically-derived recombinant protein, peptide or antibody-based drug, or an antisense oligonucleotide, protein nucleic acid (PNA) or deoxy ribonucleic acid (DNA) for gene therapy. iv) A cellular component is a unique, highly organized substance or substances of which cells, and thus living organisms, are composed. Examples include membranes, organelles, proteins, and nucleic acids. Whilst the majority of cellular components are located within the cell itself, some may exist in extracellular areas of an organism.
SUMMARY OF THE INVENTION
[0067] According to a first aspect of the present invention, there is provided a solid support having at least one surface coated with a chemical that enhances the recovery of a biological material from said surface, wherein the chemical is selected from the group consisting of vinyl polymer, non-ionic synthetic polymer and protein.
[0068] In one aspect, the solid support is selected from the group consisting of paper, glass microfiber and membrane.
[0069] In another aspect, the paper is a cellulose paper. Preferably the paper is a 903 Neonatal STD or a DMPK-C card.
[0070] In a further aspect, the membrane is selected from the group consisting of polyester, polyether sulfone (PES), polyamide (Nylon), polypropylene, polytetrafluoroethylene (PTFE), polycarbonate, cellulose nitrate, cellulose acetate and aluminium oxide.
[0071] In another aspect, the vinyl polymer is polyvinyl pyrrolidone (PVP).
[0072] In a further aspect, the non-ionic synthetic polymer is poly-2-ethyl-2-oxazoline (PEOX).
[0073] In one aspect, the protein is selected from the group consisting of albumin and casein.
[0074] According to a second aspect of the present invention, there is provided a method of recovering a biological material from a solid support comprising the steps of
i) contacting a surface of a solid support as hereinbefore described with a sample containing a biological material; ii) drying the sample on the surface of the support; iii) storing the support; and iv) extracting the biological material from the surface.
[0079] In one aspect, step iii) comprises storing the paper support at a temperature in the range of 15 to 40° C. Preferably, the temperature is in the range of 20 to 30° C. In another aspect, the paper support is stored at a lower temperature depending on the thermal stability of the biological material.
[0080] The nature of the sample will depend upon the source of the biological material. For example, the source may be from a range of biological organisms including, but not limited to, virus, bacterium, plant and animal. Preferably, the source will be a mammalian or a human subject. For mammalian and human sources, the sample may be selected from the group consisting of tissue, cell, blood, plasma, saliva and urine.
[0081] In another aspect, the biological material is selected from the group consisting of biomolecule, synthetically- derived biomolecule, cellular component and biopharmaceutical drug.
[0082] In a further aspect, the biological material is a biopharmaceutical drug.
[0083] In one aspect, the support is a paper. Preferably the paper is a cellulose paper. More preferably, the paper is a 903 Neonatal STD or a DMPK-C card.
[0084] According to a third aspect of the present invention, there is provided a method of making a solid support as hereinbefore described, comprising coating at least one surface of a solid support with a solution of a chemical that enhances the recovery of a biological material from said surface, wherein the chemical is selected from the group consisting of vinyl polymer, non-ionic synthetic polymer and protein.
[0085] In one aspect, the chemical is selected from group consisting of polyvinyl pyrrolidone (PVP), poly-2-ethyl-2-oxazoline (PEOX), albumin and casein.
[0086] In another aspect, the solid support is a paper. Preferably the paper is a cellulose paper. More preferably, the cellulose paper is a 903 Neonatal STD or a DMPK-C card.
[0087] According to a fourth aspect of the present invention, there is provided a use of a solid support as hereinbefore described for enhancing the recovery of a biological material from a surface thereof.
[0088] In one aspect, the biological material is a biopharmaceutical drug.
BRIEF DESCRIPTION OF THE FIGURES
[0089] FIG. 1 presents the recovery of exogenously-added IL-2 from dried blood spots applied to various paper matrices.
[0090] FIG. 2 presents the recovery of exogenously-added IL-2 from dried blood spots applied to 903 Neonatal STD papers coated with various chemicals.
[0091] FIG. 3 presents the recovery of exogenously-added IL-2 from dried blood spots applied to DMPK-C papers coated with various chemicals.
DETAILED DESCRIPTION OF THE INVENTION
[0092] Recombinant IL-2±carrier (R & D Systems; Cat. 202-IL-CF-10 μg; lot AE4309112 and Cat. 202-IL-10μg; lot AE4309081 respectively) was dissolved in either Dulbecco's PBS without calcium and magnesium (PAA; Cat. H15-002, lot H00208-0673), EDTA-anti-coagulated human, rabbit or horse blood (TCS Biosciences) at 50 pg or 100 pg/μl.
[0093] Aliquots (1 μl containing 0, 50 or 100 pg of IL-2) were applied to the following GE Healthcare filter papers; 903 Neonatal STD card, Cat. 10538069, lot 6833909 W082; DMPK-A card, Cat. WB129241, lot FT6847509; DMPK-B card, Cat. WB129242, Lot FE6847609 and DMPK-C card, Cat. WB129243, Lot FE6847009. Samples were allowed to dry overnight at ambient temperature and humidity.
[0094] Punches (3 mm diameter) were extracted from each paper type using the appropriately sized Harris Uni-core punch (Sigma, Cat.Z708860-25ea, lot 3110). Single punches were placed into individual wells of the IL-2 microplate derived from the Human IL-2 Quantikine ELISA (R & D Systems, Cat. D0250, lot 273275). These plates are coated with a mouse monoclonal antibody against IL-2. The IL-2 protein was eluted from the paper punch using the assay buffer (100 μl) supplied with the Quantikine kit. All subsequent steps were performed according to the instructions supplied with the Quantikine kit using a “paper in” method (paper punches are placed directly into the assay buffer and the analyte eluted directly in situ). On completion of the assay the optical density of the microplate was monitored at 450 nm using a Thermo Electron Corporation, Multiskan Ascent. The recovery of IL-2 was determined by comparing values to a standard curve of known IL-2 concentrations. A fresh IL-2 standard curve was prepared for each individual experiment.
[0095] Additional experiments involved the addition of IL-2-spiked blood to the 903 Neonatal STD and DMPK-C cards after the cards had been saturation dipped in several chemical solutions (as described below).
Chemicals Used
[0096] A list of the chemicals and their sources is given below.
Poly-ethyl-enemine, 50% in water (Fluka; Cat. P3143, lot 29k1492). Poly-vinyl-pyrolodine, 1% in water (Sigma; Cat.PVP40-100 mg, lot 11 pk0097). Inulin, 1% in water (Sigma; Cat. 12255-100 g, lot 079F7110). Poly-2-ethyl-2-oxazoline, 1% in water (Aldrich Cat. 372846, lot 30498PJ). Albumin, 1% in water (Sigma, Cat A2153-10 g, lot 049k1586). Caesin from bovine milk, 1% in water (Sigma, Cat. C5890-500 g, lot 089k0179). Poly-ethylene glycol 1000, 1% in water (Biochemika, Cat. 81189, lot 1198969). Poly-ethylene glycol 200, 1% in water (Fluka, Cat. 81150, lot 1384550).
Experimental Results
[0105] When IL-2 was dissolved in EDTA-anti-coagulated blood, the 903 and DMPK-C cards facilitated the recovery of 45-55% of the cytokine, while only 2-3% was recovered from the DMPK-A and B cards (see Table 1 and FIG. 1 ). The 903 and DMPK-C cards are the basic base papers and have not been dipped or coated with any chemical, whilst the DMPK-A and B cards are coated with a proprietary mixture of chemicals that facilitate the denaturation and inactivation of proteins, micro-organisms and cells respectively. These cards have been designed to facilitate the transportation and prolonged storage of nucleic acids. Therefore the low IL-2 recovery levels observed when using the DMPK-A and B cards may actually be a reflection of the presence of these denaturing reagents and the ELISA-based antibody detection system used. The ELISA detection system requires the eluted IL-2 to exhibit an intact native structure.
[0000]
TABLE 1
The Recovery of exogenously-added IL-2 from dried blood spots
applied to various paper types. The p-value compares ± carrier for each
paper type. The presence of the carrier had no significant effect on the
recovery of IL-2 (p-value > 0.05).
Paper type
IL-2 recovery (%)
p-value
903; minus carrier
46.9 ± 13.3
>0.05
903; plus carrier
50.7 ± 5.8
DMPK A; minus carrier
2.0 ± 0.0
>0.05
DMPK A; plus carrier
2.0 ± 0.0
DMPK B; minus carrier
2.0 ± 0.0
>0.05
DMPK B; plus carrier
2.0 ± 0.0
DMPK C; minus carrier
53.9 ± 4.8
>0.05
DMPK C; plus carrier
45.2 ± 5.4
[0106] No IL-2 recovery was observed when the cytokine was dissolved in PBS irrespective of the paper type used (data not shown). The IL-2 recovery levels observed in the absence of added IL-2 were essentially equivalent to background levels indicating that the EDTA-anti-coagulated blood contain negligible amounts of endogenous IL-2 (data not shown).
[0107] Several chemicals were used to saturation dip the 903 Neonatal STD and DMPK-C cards, some of which appeared to facilitate the recovery of elevated IL-2 levels compared to non-dipped papers (p-value<0.05). For both the 903 Neonatal STD and DMPK-C cards (Tables 2 and 3; FIGS. 2 and 3 ), chemicals such as poly-vinyl-pyrolodine, poly-2-ethyl-2-oxazoline, albumin and casein facilitated a significant increase in IL-2 recovery levels (mean>55% compared to ˜45% observed for the corresponding un-dipped paper).
[0000]
TABLE 2
The Recovery of exogenously-added IL-2 from dried blood spots
applied to 903 Neonatal STD papers coated with various chemicals.
The table is derived from 2 independent experiments (n = 6).
The p-value compares the values derived from the dipped papers to
those derived from the Un-dipped 903 paper.
Chemical
IL-2 recovery (%)
p-value
Un-dipped
44.9 ± 6.5
n/a
Poly-ethyl-enemine (PEI)
41.8 ± 6.0
>0.05
Poly-vinyl-pyrolodine (PVP)
62.0 ± 10.7
<0.05
Inulin
50.4 ± 7.6
>0.05
Poly-2-ethyl-2-oxazoline (PeOX)
66.1 ± 12.6
<0.05
Albumin
73.8 ± 13.6
<0.05
Caesin
55.0 ± 7.8
<0.05
Poly-ethylene glycol 1000 (PEG 1000)
42.5 ± 9.1
>0.05
Poly-ethylene glycol 200 (PEG 200)
43.3 ± 11.0
>0.05
[0000]
TABLE 3
The Recovery of exogenously-added IL-2 from dried blood spots
applied to DMPK-C coated with various chemicals (n = 3). The p-value
compares the values derived from the dipped papers to those derived from
the Un-dipped DMPK-C paper. Albumin* n = 1.
Chemical
IL-2 recovery (%)
p-value
Un-dipped
49.0 ± 2.1
n/a
Poly-ethyl-enemine (PEI)
55.8 ± 12.2
>0.05
Poly-vinyl-pyrolodine (PVP)
74.7 ± 7.8
<0.05
Inulin
33.6 ± 15.4
>0.05
Poly-2-ethyl-2-oxazoline (PeOX)
62.2 ± 2.0
<0.05
Albumin*
63.7
increase
Caesin
57.7 ± 1.5
<0.05
Poly-ethylene glycol 1000 (PEG 1000)
31.0 ± 2.8
>0.05
Poly-ethylene glycol 200 (PEG 200)
33.5 ± 15.7
>0.05
[0108] While preferred illustrative embodiments of the present invention are described, one skilled in the art will appreciate that the present invention can be practised by other than the described embodiments, which are presented for the purposes of illustration only and not by way of limitation. The present invention is limited only by the claims that follow. | The present invention relates to solid supports that are used for the storage and further processing of biological materials. The invention is particularly concerned with solid supports which have at least one surface coated with a chemical that enhances the recovery of the biological material from the support. Methods of preparing and using the solid supports are also described. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of Ser. No. 812,167 filed Dec. 23, 1985, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to synthetic lubricants which are a suitably inhibited blend of (1) an ester of a monohydric alcohol having 4 to 18 carbon atoms with one or more aromatic or alkane dicarboxylic acids and (2) one or more polyether polyols.
Reciprocating air compressors having air cushioned valves are well known in the art.
It is well known to use hydrocarbon lubricating oils to lubricate the pistons and piston rings of the foregoing air compressors and lubricate the bearings. Due to the high temperature and pressure of the air, it has been found that these hydrocarbon oils break down, leave deposits, and prevent the valves from operating correctly in a relatively short time. This requires manual repairs to clean the valves.
It is known that synthetic esters made from dicarboxylic acids have been used to produce long lasting compressor fluids, such as Anderol 495 sold by Nuodex for rotary screw air compressors. The major component of Anderol 495 is believed to be a dialkyl adipate. However, Anderol 495 does not have sufficient high temperature viscosity for suitable lubrication of the pistons and cylinders of reciprocating air compressors.
It is also known from U.S. Pat. No. 4,302,343 that rotary screw air compressors can be lubricated with a blend of polyhydric alcohol esters and polyether polyols. However, these lubricants are relatively expensive and leave deposits on the valves of a reciprocating air compressor.
Anderol 500 (a dialkyl phthalate composition) is known to be useful in reciprocating air compressors. However, this synthetic ester has the disadvantage of having a high viscosity during start up at low temperatures.
The U.S. Pat. No. 4,072,619 polyesteralkylene glycol compositions are disclosed wherein phenothiazine is incorporated into the alkylene glycols. However, these compositions have been found to degrade in a relatively short time i.e. 1000 hours.
Synthetic lubricants comprising a major amount of a polyester and a minor amount of a monocapped polyglycol are known from British Pat. Nos. ,933,721; 986,066; and 1,162,818, however all these compositions are disclosed to be only useful in aircraft gas turbines where a different viscosity range is needed.
SUMMARY OF THE INVENTION
It now has been found that a suitably inhibited blend of esters of aliphatic monohydric alcohols with one or more aromatic or alkane dicarboxylic acids have the required high temperature viscosity and stability to heat, air, and water.
More specifically, the synthetic base lubricants of this invention comprise a lubricant composition comprising,
(A) about 15 to 45 weight percent of an ester of a monohydric alcohol having 4 to 18 carbon atoms with one or more aromatic or alkane dicarboxylic acids having 4 to 18 carbon atoms, and
(B) about 85 to 55 weight percent of one or more polyether polyols have a flash point greater than 375° F. (191° C.) and which have the formula
Z--[(--R.sup.1 O).sub.n R.sup.2 ].sub.m
where Z is the residue of a compound having 1-8 hydroxyl groups,
R 1 is an alkylene radical having 2 to 4 carbon atoms,
n is a number having an average value which will give a number average molecular weight range from about 400 to about 5000 for the final compound,
m is an integer having a value of from 1 to about 8,
R 2 is hydrogen or an alkyl group of 1 to 6 carbon atoms.
An additional aspect of the present invention comprises the above base lubricant with the addition of effective amounts of oxidation inhibitors, corrosion inhibitors, and metal or copper deactivators and a method of lubricating air compressors using the inhibited lubricant.
DETAILED DESCRIPTION OF THE INVENTION
The neutral esters used in this invention are commercially available. Examples of suitable esters are the esters of monohydric alcohols having 4 to 18 carbons such as butanol, octanol, decanol, etc with aromatic dicarboxylic acids such as phthalic, terephthalic and isophthalic acids.
Also useful are the esters of the above monohydric alcohols with alkanedioic acids having 4 to 18 carbons such as succinic, adipic, suberic, tetradecane 1,14-dioic acid, and hexadecane-1,16-dioic acid,
Examples of the polyether polyols or polyoxyalkylene polyols used in this invention are those derived from ethylene oxide, propylene oxide, 1-2, or 2-3 butylene oxide. The above oxides may be polymerized alone, i.e., homopolymerized or in combination. The combined oxides may also be combined in a random or block addition. While some of the above compounds may be of a hydrophilic nature, those of a hydrophobic nature are preferred, such as those derived from propylene oxide, butylene oxides or combinations thereof.
Examples of suitable capped polyoxyalkylene glycols are those derived from ethylene, propylene, and butylene oxides wherein the alkylene oxides are initiated from a compound having 1 to 8 active hydrogens in a known manner. The terminal hydroxyl groups may be further reacted with organic acids to form esters or with alkyl or aryl halides to form alkyl or aryl capped polyoxyalkylene are well known from the book "Polyurethanes" by Saunders and Frisch, Interscience Publishers (1962), pages 33-39. This book is incorporated by reference herein.
Examples of suitable initiator compounds which are employed to prepare the above polyether polyols are compounds having 1-8 active hydrogens such as for example water, methanol, ethanol, propanol, butanol, ethylene glycol, propylene, glycol, butylene glycol, 1,6-hexane diol, glycerine, trimethylolpropane, pentaerythritol, sorbitol, sucrose, mixtures thereof and the like.
Other initator compounds which are useful include monohydric phenols and dihydric phenols and their alkylated derivatives such as phenol, o, m, and p cresol, guaiacol, saligenin, carvacrol, thymol, o and p -hydroxy diphenyl, catechol, resorcinol, hydroquinone, pyrogallol, and phloroglucinol.
The foregoing polyether polyols should have a flash point greater that 375° F. (191° C.) and preferably greater than 450° F. (232° C.). They also should have a number average molecular weight range from about 400 to 5000 and preferably in the range 700 to 2500.
The foregoing polyether polyols are blended to give a base lubricant composition containing 15 to 45 weight percent of the esters and 85 to 55 weight percent of the polyols with the ranges 15 to 25 and 85 to 75 being the preferred ranges, respectively.
The compositions of this invention are used in a reciprocating air compressor and are selected so as to have a viscosity in the range of 5 to 25 centistokes at 210° F. (99° C.) and preferably 6 to 16 centistokes at 210° F. (99° C.) and a pour point in the range of 0° to -65° F. (18° to -54° C.).
The final lubricant compositions of this invention may contain effective amounts of ashless additives, such as antioxidants, corrosion inhibitors, metal deactivators, lubricity additives, extreme pressure additives, dispersants, detergents, demulsifiers or such additives as may be required.
Examples of useful ashless antioxidants which can be used herein are phenyl naphthylamines, i.e., both alpha and beta-naphthyl amines; diphenyl amine; iminodibenzyl; p,p-dibutyl-diphenylamine; p,p'-dioctyldiphenylamine; and mixtures thereof. Other suitable antioxidants are hindered phenolics such as 6-t-butylphenol, 2,6-di-t-butylphenol and 4-methyl-2,6-di-t-butylphenol and the like.
Examples of suitable ashless metal corrosion inhibitors are commercially available, such as Irgalube 349 from Ciba-Geigy. This inhibitor compound is an aliphatic amine salt of phosphoric acid monohexyl ester. Other useful metal corrosion inhibitors are NA-SUL DTA and Na-SUL EDS from the White Chemical Company (diethylenetriamine dinonylnapthalene sulfonate and ethylene diamine dimonylnaphthalene sulfonate), respectively.
Examples of suitable ashless cuprous metal deactivators are imidazole, benzimidazole, pyrazole, benzotriazole, tolutriazole, 2-methyl benzimidazole, 3,5-dimethyl pyrazole, and methylene bis-benzotriazole.
An effective amount of the foregoing additives for use in a reciprocating air compressor is generally in the range from 0.1 to 5% by weight for the antioxidants, 0.1 to 5.0% by weight for the corrosion inhibitors, and 0.001 to 0.5 percent by weight for the metal deactivators. The foregoing weight percentages are based on the total weight of the polyether polyols and the esters. It is to be understood that more or less of the additives may be used depending upon the circumstances for which the final composition is to be used.
The following preparation and examples are presented to illustrate but not limit the invention.
PREPARATION
A formulation consisting of the following blend was prepared
(A) 11,489 pounds 5211.4 kg (77.48%) of polypropylene glycol (number average molecular weight 1200)
(B) 2,872 pounds 1302.7 kg (19.37%) of Mobil Ester DB-32( 1 )
(C) 296 pounds 134.3 kg (2.0%) of p,p'-dioctyl diphenylamine
(D) 148 pounds 67.1 kg (1.0%) of Ciba-Geigy IRGALUBE 349( 2 )
(E) 0.37 pounds 0.167 kg (25 parts per million) of Dow Corning DC-200( 3 )
(F) 15 pounds 6.8 kg (0.1%) of Mobil MOBILAD C-402( 4 )
(G) 7.4 pounds 3.35 kg (0.05%) of Sherwin-Williams CORBRATEC TT-100( 5 )
In a suitable vessel, the ester and additives were blended together. After sufficient agitation time, the ester/additive mixture was transferred to the vessel which holds the polyglycol. The mixture was heated to 80° C. and agitated until the solution was clear. If the additives are ignored, the formulation contains 20% by weight of the ester and 80% by weight of the polypropylene glycol.
The above fluid was tested for corrosion resistance in accordance with ASTM D-665--procedure A and ASTM D-665--procedure B. The fluid passed both tests.
The fluid was found to have the following characteristics:
______________________________________ ViscosityTemperature, (centistokes)______________________________________210° F. (99° C.) 9.4100° F. (38° C.) 59.3 0° F. (-18° C.) 3670______________________________________
EXAMPLES 1-14
The above fluid was placed in fourteen reciprocating air compressors made by different manufacturers. The valves in each compressor were checked intermittently over a long period of time as shown in the table. The valves were found to be in excellent condition having no deposits or residues. The same compressors using petroleum oils have service deposits after 1000 to 4000 hours of operation which create reduced performance with the possibility of line fires.
TABLE______________________________________ Valve Discharge Hours of Temperature,Example Compressor Operation °F. (°C.)______________________________________1 Ingersoll-Rand(XRE) 12,000 176(80)2 Ingersoll-Rand(PRE) 12,000 208(98)3 Ingersoll-Rand(XLE) 4,380 250(121)4 Quincy intermittent 150(66)5 Ingersoll-Rand(ES-1) 10,950 N/A6 Chicago Pnuematic 14,500 280(138)7 Chicago Pneumatic 9,850 280(138)8 Ingersoll-Rand(ER-1) 5,330 N/A9 Ingersoll-Rand(Type 30) 6,302 N/A10 Ingersoll-Rand(Type 30) 1,144 N/A11 Ingersoll-Rand(Type 30) intermittent 155(68)12 Ingersoll-Rand(PRE) 11,260 270(132)13 Ingersoll-Rand(PRE) 11,210 270(132)14 Ingersoll-Rand(XLE) intermittent 360(182)______________________________________ N/A = not available | Synthetic lubricants comprising 15 to 45 weight percent of an ester of a monohydric alcohol of 4 to 18 carbon atoms with one or more aromatic or alkane dicarboxylic acids having 4 to 18 carbon atoms blended with 85 to 55 weight percent of one or more polyether polyols having a number average molecular weight from about 400 to 5000. The blends are compounded with antioxidants, corrosion inhibitors, and metal deactivators to produce a superior lubricant for reciprocating air compressors which gives a long life to the compressors. | 2 |
FIELD OF THE INVENTION
This invention relates to the field of techniques and systems for controlling traffic and more particularly to a system for switching an automatic traffic control system to a manual mode and automatically switching back to an automatic mode after a period of inactivity.
BACKGROUND OF THE INVENTION
We see traffic control systems at many road intersections. In the United States, the acceptable traffic control system is a traffic light system for each intersection direction having a red, yellow and green indicator (light) The green indicates the traffic in that direction can proceed through the intersection. The yellow indicates that the traffic light is transitioning between green and red and traffic should prepare to stop. The red indicates the traffic in that direction should stop. In some systems, multiple sets of lights are configured in a given direction with some dedicated to traffic in turn lanes.
The traffic control system has timers that are programmed to control the duration of each signal depending upon the average traffic levels and the amount of time required to move across an intersection, etc. Some traffic control systems are coupled to one or more nearby traffic control systems to provide synchronization between multiple traffic control systems to aid in the efficient flow of traffic. Additionally, some traffic control systems are capable of being centrally controlled by an operator, whereby an operator is provided with tools to change timing, etc., to improve traffic flow.
During unusual traffic patterns such as when an event begins or is finished, often the traffic control system is manually operated by a police officer. In such, the police officer access the control box (unlocks and opens a door) of the traffic control system and switches the traffic control system from automatic to manual. From there, the police officer changes the state of the traffic control system by operating a manual control. When finished, the police officer switches the traffic control system back into automatic mode and closes/locks the traffic control system door. Unfortunately, there are circumstances where the police officer must leave in an emergency. In such, if the police officer forgets to switch the traffic control system back to automatic mode, the traffic control system will remain green in one direction and red in the other direction, causing a major traffic problem.
What is needed is a traffic control system that will revert to an automatic mode when left unattended in a manual mode.
SUMMARY OF THE INVENTION
In one embodiment, a traffic control system is disclosed including an enclosure for containing the traffic control system that has an access door with a lock for controlling access to the enclosure through the access door. The traffic control system has an automatic mode of operation and a manual mode of operation, whereas the traffic control system automatically transitions a state of a plurality of traffic lights when in the automatic mode of operation and cycles the state of the plurality of traffic lights in response to a change signal when in the manual mode of operation. An automatic mode activation switch is housed within the enclosure. Activation of the automatic mode activation switch changes the state of the traffic control system from the automatic mode of operation into the manual mode of operation. A watchdog timer is coupled to the traffic control system, The watchdog timer is reset when the automatic mode activation switch is operated and in response to the change signal. If the watchdog timer expires, the traffic control system switches to the automatic mode of operation.
In another embodiment, a method of controlling traffic is disclosed including unlocking an enclosure of a traffic control system and changing an operating mode of the traffic control system from an automatic mode of operation to a manual mode of operation. The changing of the operating mode of the traffic control system also starts a watchdog timer. A traffic control device connected to the traffic control system is operated to cycle a plurality of traffic lights, said operation of the traffic control device also resets the watchdog timer. If the watchdog timer expires, the mode of operation of the traffic control system is changed from the manual mode of operation back into the automatic mode of operation.
In another embodiment, a traffic control system is disclosed including an enclosure for containing the traffic control system with an access door and a lock controlling access to the enclosure through the access door. The traffic control system has an automatic mode of operation and a manual mode of operation, whereas the traffic control system automatically cycles the state of traffic lights when in the automatic mode of operation and cycles the state of the traffic lights in response to a change signal when in the manual mode of operation. An activation device within the enclosure changes the traffic control system into the manual mode. A watchdog timer is reset both when the automatic mode activation switch is operated and in response to the change signal. A wireless transmitter transmits a wireless change signal in response to pressing of a control on the wireless transmitter. A wireless receiver coupled to the traffic control system receives the wireless change signal and, in response, sends the change signal to the traffic control system and resets the watchdog timer. If the watchdog timer expires, the traffic control system switches back to the automatic mode of operation.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which:
FIG. 1 illustrates a perspective view of a system of a first embodiment of the present invention.
FIG. 2 illustrates a schematic view of a system of the present invention.
FIG. 2A illustrates a schematic view of a timing diagram of the system of the present invention.
FIG. 3 illustrates a block diagram of the present invention.
FIG. 4 illustrates a block diagram of a computer system of an alternate embodiment of the present invention.
FIG. 5 illustrates a flow chart of the prior art.
FIG. 6 illustrates a first flow chart of the alternate embodiment of the present invention.
FIG. 7 illustrates a second flow chart of the prior art.
FIG. 8 illustrates a second flow chart of the alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures.
Referring to FIG. 1 , a perspective view of a system of a first embodiment of the present invention is shown. In this example, a police officer holds a wireless remote control 70 for a traffic control system 10 . Although the present invention works equally as well with a traffic control system that has a tethered (wired) hand control, the present invention is intended for traffic control systems that have a wireless hand control 70 (as shown). The main reason for such is that since the police officer may be operating the traffic control system 10 from a distance, perhaps across the street, if the officer should receive an emergency call, the officer may forget or explicitly decide to abandon the traffic control system 10 , leaving it in its manual mode until returning later. By doing such, major traffic problems will arise.
FIG. 1 shows an exemplary traffic control system with multi-colored traffic control lights 82 , the traffic control box 10 with an access door 94 that has a lock 92 shown with keys 96 present. In this example, an antenna 73 provides for receipt of wireless manual control signals from the antenna 71 of the hand held traffic control transmitter 70 . The locking access door 94 provides a level of security so an unauthorized person would have difficulty accessing the traffic control system 10 .
Referring to FIG. 2 , a schematic view of a system of the present invention is shown. In this embodiment, an industry standard 555 timer 50 is employed to generate a watchdog timer period (T 1 ). The circuit of FIG. 2 is an astable multivibrator whose watch dog timer period is determined by R 1 52 , R 2 54 and C 1 58 . The cycle begins when the manual mode push button switch 64 is depressed. This action triggers the 555 timer 50 (pin 2 ) causing the output (pin 3 ) to go high as shown in the timing diagram FIG. 2A . The output of the 555 timer 50 is an input to an AND gate 74 . When the output of the 555 timer is high, the AND gate 74 permits traffic control signals from the wireless receiver 72 to pass to the traffic control system. Additionally, it enables manual mode operation of the traffic control system.
Now, R 1 52 charges C 1 58 through diode D 1 56 until the voltage across C 1 58 reaches a threshold at pin 6 of the 555 timer 50 . At that point, the output of the 555 timer 50 goes low, thereby disabling the manual mode and preventing further wireless control signals from passing to the signal control. The watchdog time period (T 1 ) is determined by the values of R 2 54 and C 1 58 . The time period (T 1 ) is approximately 0.69(R 1 +R 2 )*C 1 . The trigger input and output signal of the 555 timer 50 is shown on oscilloscope screen 80 of FIG. 2A . For example, using a 1.8M resistor for R 1 52 , a 15K resistor for R 2 54 and a 1000 uf capacitor for C 1 56 yields a time period (T 1 ) of approximately 20 minutes.
If a wireless signal is received from the antenna 71 of the wireless transmitter 70 at the antenna 73 of the wireless receiver 72 before the watchdog timer expires, the wireless signal resets the timing capacitor C 1 58 , thereby restarting the watchdog timer period. In this way, as long as a signal is received periodically (e.g., the police officer is actively controlling the traffic control system 10 ), the watchdog timer is repeatedly reset and doesn't expire.
Alternately, the alternate tethered signal change control includes a wired pushbutton switch 65 used to control the cycling of the traffic lights and to reset the watchdog timer.
A pull-up resistor R 3 62 biases the trigger to a positive voltage until the wireless signal (or tethered signal) is received or until the push-button switch 64 is pressed.
Referring to FIG. 3 , a block diagram of the present invention is shown. In this embodiment, the traffic control system 10 has an access door 94 that is locked by a lock 92 that has a lock arm 90 that helps prevent the access door 94 from being opened without a key. Any type of lock known in the industry is anticipated. Once the access door 94 is open, the user (police officer) has access to the “Initiate Manual Control” push button switch 64 . Once pressed, the push button switch 64 signals the watch dog timer to start timing and to output a signal to enable manual control of the traffic controller 80 .
While in manual mode, the user periodically sends signals to control the traffic patterns. In this example, a wireless system is used, although a wired (tethered) system works equally as well. The wireless signal is sent from a hand-held wireless transmitter 70 with antenna 71 to a wireless receiver 72 that also has an antenna 73 . The change signal from the wireless receiver 72 does two things; it resets the watchdog timer 76 and, passing through the AND gate 74 , it manually controls the traffic controller 80 , changing the outputs of the traffic controller 80 and, hence, the lighted patterns on the traffic light 82 .
This embodiment operates slightly differently from that of FIG. 2 . That is, once the watchdog timer expires and the output of the watchdog timer goes low, all signals from the wireless receiver 72 are stopped by the AND gate 74 and, therefore, do not reset the watchdog timer after it expires. In this embodiment, once the watchdog timer expires, the user needs to press the “Initiate Manual Control” push button 64 to re-enter manual mode.
Referring to FIG. 4 , a block diagram of a computer system of an alternate embodiment of the present invention is shown. In this embodiment, the traffic signals 82 are controlled by a computer system. The computer system has a processor (CPU, controller, etc.) 110 with internal or external memory 120 and a system bus 130 for connecting stored program memory 140 and other peripherals. The processor 110 can be any processor or a group of processors, for example an Intel Pentium-4® CPU or the like. The memory 120 is connected to the processor and can be any memory suitable for connection with the selected processor 210 , such as SRAM, DRAM, SDRAM, RDRAM, DDR, DDR-2, etc. Firmware is stored in firmware storage 140 that is connected to the processor 110 and may include initialization software. The firmware storage 140 is any known persistent storage such as ROM, PROM, EPROM, EEPROM, FLASH, FERAM, etc.
Connected to the bus 130 are relay drivers 150 / 160 / 170 for controlling relays 155 / 165 / 175 that are used to illuminate the red, yellow and green lights of the traffic signal 82 . This is an example of one way for a computer system to control lights and other ways known in the industry are equally suited for the present invention including direct drive with open collector (open drain) transistors, etc.
In this embodiment, the wireless receiver 72 is connected to an input bit 180 for signaling the firmware running on the processor 110 when a wireless signal is received. Likewise, the push button switch 195 is connected to another input 190 for signaling the firmware running on the processor 110 when the push button is pressed. Many ways are known in the industry to communicate external signals to a processor, all of which are anticipated and included here within. Likewise, other inputs and outputs are anticipated such as diagnostic control signals, etc.
Referring to FIG. 5 , a flow chart of the prior art is shown. A typical traffic control system of the prior art using a computer system similar to FIG. 4 (without the wireless control) would have an initial state having traffic flowing in one direction (Direction-A) and stopped in the other direction (Direction-B). The system begins with turning on green in Direction-A and red in Direction-B 200 . The system then waits for the amount of time allowed for Direction-A 202 then the system turns off the green and turns on the yellow signal for Direction-A 204 . After a short period of time determined by the timer 206 , the system turns off the yellow in Direction-A, turns on the red in Direction-A, turns off the red in Direction-B and turns on the green in Direction-B 208 . Next, after the amount of time allotted to Direction-B expires 210 , the system turns off the green in Direction-B and turns on the yellow in Direction-B 212 . After another timer 214 , the sequence repeats.
In some known traffic control systems, the sequencing of lights differs from the examples presented. The present invention is for the automatic and manual operation of a traffic control system and operates with any sequencing of traffic lights known or unknown, including any red clearances as well as yellow clearances and systems that employ different configurations of light such as systems with only red and green lights. Additionally, some systems use sequences that permit the operation of more than one light at a time such as illuminating red and yellow concurrently. All such systems are incorporated in the present invention.
Referring to FIG. 6 , a flow chart of the alternate embodiment of the present invention is shown. A typical traffic control system using a computer system similar to FIG. 4 (without the wireless control) would have an initial state having traffic flowing in one direction (Direction-A) and stopped in the other direction (Direction-B). The system begins with turning off all signal lights except turning on green in Direction-A and red in Direction-B 220 . The system then waits for a manual change signal 222 then the system turns off the green and turns on the yellow signal for Direction-A 224 . The system then waits for a manual change signal 226 , then the system turns off the yellow in Direction-A, turns on the red in Direction-A, turns off the red in Direction-B and turns on the green in Direction-B 228 . Next, after the system then waits for a manual change signal 230 , the system turns of the green in Direction-B and turns on the yellow in Direction-B 232 . After waiting for a manual change signal 234 , the sequence repeats. This is a typical flow and many traffic systems are known with different flows accommodating left-turn arrows, right-turn arrows, multiple directions of traffic flow, etc. Furthermore, other traffic control systems automatically time the caution period (yellow) even during manual control. All such timings and features are included in the present invention.
Referring to FIG. 7 , a second flow chart of the prior art is shown. In the prior art, the wait for button press operation was exactly that, the software waited for a button press signal 250 .
Referring to FIG. 8 , a second flow chart of the alternate embodiment of the present invention is shown. This flow is performed in place of the “waiting for button press 222 / 226 / 230 / 234 of FIG. 6 . In this example, waiting for the button press includes checking to see if the watchdog timer has expired 260 . If it has, the automatic mode is entered 262 . If it has not expired yet, a check is made to see if a wireless signal was received 264 signaling the traffic control system to change. If no wireless signal was received 264 , the process is repeated until either the watchdog timer expires or a wireless signal is detected 264 . If the wireless signal is received 264 , the watchdog timer is reset 266 and waiting is done. In a non-wireless system (tethered control), the system checks for a button press of the tethered control device (not shown) instead of checking for a wireless signal 264 .
Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result.
It is believed that the system and method of the present invention and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes. | An application for a traffic control system includes an enclosure for containing the traffic control system that has an access door with a lock for controlling access to the enclosure through the access door. The traffic control system has an automatic mode of operation and a manual mode of operation, whereas the traffic control system automatically transitions a state of a plurality of traffic lights when in the automatic mode of operation and cycles the state of the plurality of traffic lights in response to a change signal when in the manual mode of operation. An automatic mode activation switch is housed within the enclosure. Activation of the automatic mode activation switch changes the state of the traffic control system from the automatic mode of operation into the manual mode of operation. A watchdog timer is coupled to the traffic control system, The watchdog timer is reset when the automatic mode activation switch is operated and in response to the change signal. If the watchdog timer expires, the traffic control system switches to the automatic mode of operation. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of pending U.S. patent application Ser. No. 10/809,839, filed Mar. 24, 2004.
TECHNICAL FIELD
This present invention is related generally to a memory system for a processor-based computing system, and more particularly, to a hub-based memory system having an arbitration system and method for managing memory responses therein.
BACKGROUND OF THE INVENTION
Computer systems use memory devices, such as dynamic random access memory (“DRAM”) devices, to store data that are accessed by a processor. These memory devices are normally used as system memory in a computer system. In a typical computer system, the processor communicates with the system memory through a processor bus and a memory controller. The memory devices of the system memory, typically arranged in memory modules having multiple memory devices, are coupled through a memory bus to the memory controller. The processor issues a memory request, which includes a memory command, such as a read command, and an address designating the location from which data or instructions are to be read. The memory controller uses the command and address to generate appropriate command signals as well as row and column addresses, which are applied to the system memory through the memory bus. In response to the commands and addresses, data are transferred between the system memory and the processor. The memory controller is often part of a system controller, which also includes bus bridge circuitry for coupling the processor bus to an expansion bus, such as a PCI bus.
In memory systems, high data bandwidth is desirable. Generally, bandwidth limitations are not related to the memory controllers since the memory controllers sequence data to and from the system memory as fast as the memory devices allow. One approach that has been taken to increase bandwidth is to increase the speed of the memory data bus coupling the memory controller to the memory devices. Thus, the same amount of information can be moved over the memory data bus in less time. However, despite increasing memory data bus speeds, a corresponding increase in bandwidth does not result. One reason for the non-linear relationship between data bus speed and bandwidth is the hardware limitations within the memory devices themselves. That is, the memory controller has to schedule all memory commands to the memory devices such that the hardware limitations are honored. Although these hardware limitations can be reduced to some degree through the design of the memory device, a compromise must be made because reducing the hardware limitations typically adds cost, power, and/or size to the memory devices, all of which are undesirable alternatives. Thus, given these constraints, although it is easy for memory devices to move “well-behaved” traffic at ever increasing rates, for example, sequel traffic to the same page of a memory device, it is much more difficult for the memory devices to resolve “badly-behaved traffic,” such as bouncing between different pages or banks of the memory device. As a result, the increase in memory data bus bandwidth does not yield a corresponding increase in information bandwidth.
In addition to the limited bandwidth between processors and memory devices, the performance of computer systems is also limited by latency problems that increase the time required to read data from system memory devices. More specifically, when a memory device read command is coupled to a system memory device, such as a synchronous DRAM (“SDRAM”) device, the read data are output from the SDRAM device only after a delay of several clock periods. Therefore, although SDRAM devices can synchronously output burst data at a high data rate, the delay in initially providing the data can significantly slow the operating speed of a computer system using such SDRAM devices. Increasing the memory data bus speed can be used to help alleviate the latency issue. However, as with bandwidth, the increase in memory data bus speeds do not yield a linear reduction of latency, for essentially the same reasons previously discussed.
Although increasing memory data bus speed has, to some degree, been successful in increasing bandwidth and reducing latency, other issues are raised by this approach. For example, as the speed of the memory data bus increases, loading on the memory bus needs to be decreased in order to maintain signal integrity since traditionally, there has only been wire between the memory controller and the memory slots into which the memory modules are plugged. Several approaches have been taken to accommodate the increase in memory data bus speed. For example, reducing the number of memory slots, adding buffer circuits on a memory module in order to provide sufficient fanout of control signals to the memory devices on the memory module, and providing multiple memory device interfaces on the memory module since there are too few memory module connectors on a single memory device interface. The effectiveness of these conventional approaches are, however, limited. A reason why these techniques were used in the past is that it was cost-effective to do so. However, when only one memory module can be plugged in per interface, it becomes too costly to add a separate memory interface for each required memory slot. In other words, it pushes the system controllers package out of the commodity range and into the boutique range, thereby, greatly adding cost.
One recent approach that allows for increased memory data bus speed in a cost effective manner is the use of multiple memory devices coupled to the processor through a memory hub. In a memory hub architecture, or a hub-based memory sub-system, a system controller or memory controller is coupled over a high speed bi-directional or unidirectional memory controller/hub interface to several memory modules. Typically, the memory modules are coupled in a point-to-point or daisy chain architecture such that the memory modules are connected one to another in series. Thus, the memory controller is coupled to a first memory module, with the first memory module connected to a second memory module, and the second memory module coupled to a third memory module, and so on in a daisy chain fashion.
Each memory module includes a memory hub that is coupled to the memory controller/hub interface and a number of memory devices on the module, with the memory hubs efficiently routing memory requests and responses between the controller and the memory devices over the memory controller/hub interface. Computer systems employing this architecture can use a high-speed memory data bus since signal integrity can be maintained on the memory data bus. Moreover, this architecture also provides for easy expansion of the system memory without concern for degradation in signal quality as more memory modules are added, such as occurs in conventional memory bus architectures.
Although computer systems using memory hubs can provide superior performance, various factors may affect the performance of the memory system. For example, the manner in which the flow of read data upstream (i.e., back to the memory hub controller in the computer system) from one memory hub to another is managed will affect read latency. The management of the flow of read data by a memory hub may be generally referred to as arbitration, with each memory hub arbitrating between local memory read responses and upstream memory read responses. That is, each memory hub determines whether to send local memory read responses first or to forward memory read responses from downstream (i.e., further away from the memory hub controller) memory hubs first. Although the determination of which memory read response has lower priority will only affect the latency of that specific memory read response, the additive effect of the memory read responses having increased latency will affect the overall latency of the memory system. Consequently, the arbitration technique employed by a memory hub directly affects the performance of the overall memory system. Additionally, the implementation of the arbitration scheme will affect the overall read latency as well, since inefficient implementation will negatively impact system memory performance despite utilizing a desirable arbitration scheme. Therefore, there is a need for a system and method for implementing an arbitration scheme for managing memory responses in a system memory having a memory hub architecture.
SUMMARY OF THE INVENTION
A method according to one aspect of the invention includes transmitting a read response on a data path of a memory hub interposed between a transmitting memory hub and a receiving memory hub. The method includes receiving at the memory hub an arbitration packet including data indicative of a data path configuration for an associated read response. The arbitration packet is decoded, and the data path is configured in accordance with the data of the arbitration packet. The associated read response is received at the memory hub and the associated read response is coupled to the configured data path for transmitting the same to the receiving memory hub.
In another aspect of the invention, a memory hub coupled to at least one memory device is provided. The memory hub includes remote and local input nodes, an output node, and a configurable data path coupled to the remote and local input nodes and further coupled to the output node. The memory hub further includes an arbitration control circuit coupled to the configurable data path, the output node, and the remote input node. The arbitration control circuit generates an arbitration packet for an associated read response coupled through the local input node that includes data indicative of a data path configuration for the associated read response. The arbitration control circuit can further configure the configurable data path in accordance with the data included with an arbitration packet coupled thorough the remote input node in preparation of coupling an associated read response coupled through the remote input node to the output node.
In another aspect of the invention, a memory hub is provided having a bypass data path coupled between an input node and an output node on which read responses are coupled in response to being enabled, and further includes an arbitration control circuit. The arbitration control circuit is coupled to the bypass data path and generates an arbitration packet in response to retrieving read data from a memory device coupled to the memory hub. The arbitration packet has a data path field including activation data to enable a bypass data path of an upstream memory hub. The arbitration control circuit also receives an arbitration packet from a downstream memory hub and enables the bypass data path to couple a read response also received from the downstream memory hub from the input node to the output node.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial block diagram of a computer system having a memory hub based system memory in which embodiments of the present invention can be implemented.
FIG. 2 is a functional block diagram of a arbitration control component according to an embodiment of the present invention that can be utilized in the memory hubs of FIG. 1 .
FIG. 3 is a data structure diagram of a arbitration packet and memory response according to an embodiment of the present invention.
FIG. 4 is a flow diagram of the operation of the arbitration control component of FIG. 3 according to an embodiment of the present invention
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates a computer system 100 having a memory hub architecture in which embodiments of the present invention can be utilized. The computer system 100 includes a processor 104 for performing various computing functions, such as executing specific software to perform specific calculations or tasks. The processor 104 includes a processor bus 106 that normally includes an address bus, a control bus, and a data bus. The processor bus 106 is typically coupled to cache memory 108 , which, is typically static random access memory (“SRAM”). The processor bus 106 is further coupled to a system controller 110 , which is also referred to as a bus bridge.
The system controller 110 also serves as a communications path to the processor 104 for a variety of other components. More specifically, the system controller 110 includes a graphics port that is typically coupled to a graphics controller 112 , which is, in turn, coupled to a video terminal 114 . The system controller 110 is also coupled to one or more input devices 118 , such as a keyboard or a mouse, to allow an operator to interface with the computer system 100 . Typically, the computer system 100 also includes one or more output devices 120 , such as a printer, coupled to the processor 104 through the system controller 110 . One or more data storage devices 124 are also typically coupled to the processor 104 through the system controller 110 to allow the processor 104 to store data or retrieve data from internal or external storage media (not shown). Examples of typical storage devices 124 include hard and floppy disks, tape cassettes, and compact disk read-only memories (CD-ROMs).
The system controller 110 contains a memory hub controller 128 coupled to several memory modules 130 a - n through a bus system 154 , 156 . Each of the memory modules 130 a - n includes a memory hub 140 coupled to several memory devices 148 through command, address and data buses, collectively shown as bus 150 . The memory hub 140 efficiently routes memory requests and responses between the controller 128 and the memory devices 148 . Each of the memory hubs 140 includes write buffers and read data buffers. Computer systems employing this architecture allow for the processor 104 to access one memory module 130 a - n while another memory module 130 a - n is responding to a prior memory request. For example, the processor 104 can output write data to one of the memory modules 130 a - n in the system while another memory module 130 a - n in the system is preparing to provide read data to the processor 104 . Additionally, a memory hub architecture can also provide greatly increased memory capacity in computer systems.
FIG. 2 is a functional block diagram illustrating an arbitration control component 200 according to one embodiment of the present invention. The arbitration control component 200 can be included in the memory hubs 140 of FIG. 1 . As shown in FIG. 2 , the arbitration control component 200 includes two queues for storing associated memory responses. A local response queue 202 receives and stores local memory responses LMR from the memory devices 148 on the associated memory module 130 . A remote response queue 206 receives and stores downstream memory responses which cannot be immediately forwarded upstream through a bypass path 204 . An arbitration control circuit 210 is coupled to the queues 202 , 206 through a control/status bus 136 , which allows the arbitration control circuit 210 to monitor the contents of each of the queues 202 , 206 , and utilizes this information in controlling a multiplexer 208 to thereby control the overall arbitration process executed by the memory hub 140 . The control/status bus 136 also allows “handshaking” signals to be coupled from the queues 202 , 206 to the arbitration control circuit 210 to coordinate the transfer of control signals from the arbitration control circuit 210 to the queues 202 , 206 .
The arbitration control circuit 210 is further coupled to the high-speed link 134 to receive arbitration packets from downstream memory hubs. As will be explained in more detail below, arbitration packets are provided in advance of an associated memory response, and provide the arbitration control circuit 210 of an upstream memory hub with information to enable the appropriate path through the receiving memory hub in anticipation of receiving the associated memory response. Additionally, the arbitration control circuit 210 generates an arbitration packet to be provided prior to an associated LMR to serve as an early indication of the associated memory response when data is read from the memory devices 148 ( FIG. 1 ) in response to a read request. As previously discussed, the arbitration packet will provide upstream memory hubs with appropriate information and give the respective arbitration control circuits 210 time to make decisions regarding enablement of the appropriate data paths before the memory response arrives. The arbitration control circuit 210 prepares the arbitration packet while read data for the memory response is being retrieved from memory devices 148 . The arbitration packet is provided through a switch 212 to either the multiplexer 208 or the local response queue 202 , depending on whether if the upstream memory hub is idle or busy. The multiplexer 208 , under the control of the arbitration control circuit, couples the high-speed link 134 to receive memory responses from the remote response queue 206 or the bypass path 204 , arbitration packets from the arbitration control circuit 210 , or arbitration packets and memory responses from the local response queue 202 . In an alternative embodiment of the present invention, the arbitration packets are generated in an arbitration packet circuit, rather than in the arbitration control circuit 210 , as shown in FIG. 2 . Additionally, although shown in FIG. 2 as providing the arbitration packet to the multiplexer 208 to be injected into the stream of data, the arbitration packet can alternatively be provided to the local response queue 202 and placed before the associated read response packet to be injected into the data stream. It will be appreciated by those ordinarily skilled in the art that modifications to the embodiments of the present invention, such as the location at which the arbitration packet is generated or the manner in which the arbitration packet is placed into the data stream prior to the associated read packet, can be made without departing from the scope of the present invention.
FIG. 3 illustrates a data structure 300 for arbitration packets and memory responses according to an embodiment of the present invention. The data structure 300 is divided into 8-bit bytes of information, with each byte of information corresponding to a sequential bit-time. Each bit-time represents an increment of time in which new data can be provided. A response header field 302 includes two bytes of data that indicate the response is either an arbitration packet or a memory response. An address field 304 includes data that is used to identify the particular hub to which the arbitration packet or memory response is directed. A command code field 306 will have a value to identify the data structure 300 as an arbitration packet, and not as a memory response. Arbitration packets and memory responses are similar, except that the data payload of data fields 308 are “don't cares” for arbitration packets. In the data structure 300 , all 16 bits of size fields 310 carry the same value to indicate the size of the data payload carried by the memory response. For example, a “0” indicates that 32 bytes of data are included, and a “1” indicates that 64 bytes of data are included. It will be appreciated by one ordinarily skilled in the art that the embodiment of the data structure 300 shown in FIG. 3 has been provided by way of example, and that modifications to the data structure 300 can be made without deviating from the scope of the present invention. For example. the number and type of data fields of the data structure 300 can be changed or the number of bits for each bit time can be changed and still remain within the scope of the present invention.
Operation of the arbitration control component 200 ( FIG. 2 ) will be described with reference to the flow diagram of FIG. 4 . Following the receipt of a read data command, at a step 402 the memory hub initiates a read operation to retrieve the requested read data from the memory devices 148 ( FIG. 1 ) for the memory response that will be provided to the requesting target. At a step 404 , the arbitration control circuit 210 of the memory hub determines whether the local data path is idle by checking the status of the local response queue 202 . If the local data path is idle, an arbitration packet is generated by the arbitrations control circuit 210 during the retrieval of the read data from the memory devices 148 at a step 406 . When the arbitration packet and the memory response have been prepared, and are ready for transmission, at a step 408 an upstream memory hub is queried to determine if it is busy. Where the upstream memory hub is idle, the arbitration packet is sent to the upstream memory hub, followed by the memory response at steps 410 , 412 . However, if the upstream memory hub is busy, the arbitration packet is discarded at a step 414 and the memory response is stored in a local response queue 202 at a step 416 . Similarly, in the event that at the step 404 it was determined that the local data path is busy, the memory response is also stored in the local response queue at the step 416 . At a step 418 the memory response is stored in the local response queue 202 until it is selected for transmission to the upstream memory hub in accordance with an arbitration scheme implemented by the memory hub. At a step 420 , the memory response is transmitted through each upstream memory hub in accordance with the arbitration scheme until the memory response reaches the target destination. Suitable arbitration schemes are well known in the art, and will not be described in detail herein. An example of an arbitration scheme that is also suitable for use is described in more detail in commonly assigned, co-pending U.S. patent application Ser. No. 10/690,810, entitled ARBITRATION SYSTEM AND METHOD FOR MEMORY RESPONSES IN A HUB-BASED MEMORY SYSTEM to James W. Meyer and Cory Kanski, filed on Oct. 20, 2003, which is incorporated herein by reference.
As described therein, the local and remote response queues 202 , 206 and the bypass path 204 are utilized to implement various response arbitration schemes. For example, in one embodiment, the arbitration control circuit executes an arbitration scheme that gives downstream responses, or remote responses, priority over local responses. Alternatively, in another embodiment described, the arbitration control circuit executes an arbitration scheme that gives priority to local responses over downstream responses. In another embodiment, the arbitration control circuit alternates between a predetermined number of responses from local and downstream memory, for example, local and remote responses can be alternately forwarded, or two local responses are forwarded followed by two remote responses, and so on. Another embodiment described therein utilizes an oldest first algorithm in arbitrating between local and downstream memory responses. That is, in operation, the arbitration control circuit 210 monitors response identifier portions of the memory responses stored in the local response queue and the remote response queue and selects the oldest response contained in either of these queues as the next response to be forwarded upstream. Thus, independent of the response queue in which a memory response is stored, the arbitration control circuit forwards the oldest responses first.
It will be appreciated by those ordinarily skilled in the art that other arbitration methods and schemes can be utilized without departing from the scope of the present invention.
Returning to the steps 410 , 412 where the arbitration packet is first transmitted to an upstream memory hub and then followed by the memory response, the arbitration control circuit 210 of the upstream memory hub receives the arbitration packet at a step 422 . The arbitration packet is decoded, and the appropriate data path is enabled by the arbitration control circuit 210 based on the information decoded at steps 424 , 426 . By the time the memory response is received at a step 430 , the appropriate data path is enabled by the arbitration control circuit 210 . At a step 428 , the next upstream memory hub is queried to determine if it is busy. If not, the arbitration packet and then the memory response are transmitted to the next upstream memory hub in a bypass fashion at a step 432 . The transmission of the arbitration packet and the memory response in the bypass fashion is facilitated by enabling the appropriate data path through the memory hub based on the decoded information of the arbitration packet that is sent at the step 410 before the associated memory response is sent at the step 412 .
Returning to the step 428 , if it is determined that the next upstream memory hub is busy, the arbitration packet is discarded at the step 440 , and the memory response is stored in the remote response queue 206 until the memory response is selected for transmission to the next upstream memory hub according to the arbitration scheme employed at a step 442 . At the step 420 , the memory response will make its way upstream through the memory hubs in accordance with the arbitration scheme until reaching its target destination.
From the foregoing it will be appreciated 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. For example, embodiments of the present invention have been described herein with respect to a memory hub-based system memory used in a computer system. However, it will be appreciated that embodiments of the present invention can be used in memory systems other than hub-based memory systems, where appropriate. Moreover, embodiments of the present invention can also be used in memory hub-based systems that are utilized in processor based systems, as known in the art, other than computer systems. Accordingly, the invention is not limited except as by the appended claims. | A memory hub and method for transmitting a read response on a data path of a memory hub interposed between a transmitting memory hub and a receiving memory hub. An arbitration packet including data indicative of a data path configuration for an associated read response is received at the memory hub. The arbitration packet is decoded, and the data path is configured in accordance with the data of the arbitration packet. The associated read response is received at the memory hub and the associated read response is coupled to the configured data path for transmitting the same to the receiving memory hub. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to an integral, multi-step commercial process for the production of intravenously administrable immune globulin containing IgG (γ-globulin) as the main ingredient.
Various processes are known for obtaining intravenously administrable γ-globulin solutions from starting materials resulting from Cohn fractionation of human plasma. Certain of the Cohn fractions contain higher titres of γ-globulin than others. Usual starting materials for a γ-globulin solution are Cohn Fraction II or Cohn Fraction II+III.
Although prior art processors employ various separation and sterilization techniques, process modifications are constantly sought for improving final product purity and safety, and overall yield.
Many commercial processes employ either a solvent/detergent step for viral inactivation, or a heat treatment step for viral inactivation. To date, the art has not provided a multi-step process beginning with Cohn Fraction II paste or II+III paste including two different viral inactivation procedures as part of an efficient, high yield γ-globulin manufacturing process.
U.S. Pat. No. 5,151,499 by Kameyama et al. is directed to a process for producing viral inactivated protein compositions in which a protein composition is subjected to a viral inactivation for envelope viruses in a solvent/detergent treatment of the protein composition and a viral inactivation for non-envelope viruses in a heat treatment of the protein composition. The '499 patent teaches that preferably the solvent/detergent step occurs first and in the presence of a protease inhibitor, followed by a heat treatment, which in most examples thereof is a dry heat treatment. Where the heat treatment is carried out in the liquid state, the protein is first recovered from the solvent/detergent by adsorption onto an ionic exchange column, prior to any heat treatment. The liquid heat treatment can be carried out in the presence of a sugar, sugar alcohol or amino acid stabilizer. Although the '499 patent lists many starting protein compositions including immunoglobulin, its production examples employ Factor VIII, Factor IX, thrombin, fibrinogen and fibronectin.
U.S. Pat. No. 5,371,196 by Uuki et al. is directed to purifying secretory immunoglobulin A. A liquid heat treatment or various combinations of liquid heat treatment and solvent treatment viral inactivation are described. A polyethylene glycol fractionation is employed following each step and always as a final step. This patent does not relate to immune serum globulin of high γ-globulin titre.
Certain prior art processes for production of intravenously injectable γ-globulin solutions describe the incorporation of a liquid heat treatment carried out in the presence of sorbitol heat stabilizer in a multi-step purification procedure beginning with Cohn Fraction II +III paste. In U.S. Pat. No. 4,845,199 by Hirao et al., Cohn Fraction II+III is subjected to polyethylene glycol (hereinafter “PEG”) fractionation (8% w/v PEG for precipitating impurities and aggregate followed by 12% w/v PEG for precipitating the γ-globulin), then ion exchange chromatography (DEAE-SEPHADEX®, Pharmacia, anion exchanger) and removal of human blood group antibody prior to a liquid heat treatment in the presence of sorbitol as a protein stabilizer. On the other hand, Example 1 of U.S. Pat. No. 4,876,088 by Hirao et al. describes the preparation of intravenously injectable γ-globulin solution from Cohn Fraction II+III paste in which the paste is suspended in water, its pH adjusted to 5.5 and centrifuged, with the supernatant then being heat treated for viral inactivation in the presence of 33% w/v of sorbitol, followed by PEG fractionation (6%/12%), and then by other purification steps including DEAE-Sephadex ion exchange chromatography.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an integral, commercially useable process for producing a highly purified γ-globulin solution from the Cohn fractionation process.
Another object of the present invention is to provide very pure intravenously administrable γ-globulin solution free of both envelope and non-envelope viruses, including all heat sensitive viruses.
A further object of the present invention is to provide a commercial γ-globulin process including two sequential viral inactivation steps without the need for recovery of γ-globulin protein following the first viral inactivation step nor prior to the second viral inactivation step.
The above and other objects which will be apparent to the skilled artisan are provided by the present invention in which an alcoholic Cohn fraction, which may be partially purified, but is rich in γ-globulin, is first subjected to PEG fractionation, and then to two viral inactivation treatments, one being a viral inactivation in the presence of a solvent, preferably a solvent-detergent mixture, for disruption of envelope viruses, and the other being a heat treatment viral inactivation, without recovery of γ-globulin between the two viral inactivations. Then, any aggregate formed by the heat treatment is removed from the heat treated and solvent treated solution.
In a preferred embodiment of the present invention, sorbitol is the heat stabilizer and trialkyl phosphate is the solvent.
In another embodiment of the present invention, any particulates present are removed prior to the solvent-detergent treatment.
In another embodiment of the present invention, the γ-globulin solution is subjected to PEG fractionation following the completion of viral inactivation.
In yet another embodiment of the present invention, the γ-globulin solution is treated with a cationic exchange resin following the completion of viral inactivation.
In certain preferred embodiments of the present invention a single stage polyethylene glycol fractionation step is carried out without precipitation of the γ-globulin.
In another preferred embodiment of the invention, solvent-detergent viral inactivation is carried out before the heat treatment viral inactivation.
In still another embodiment of the invention, there is provided a heat-sterilized and solvent-detergent sterilized γ-globulin suitable for intravenous administration.
DETAILED DESCRIPTION OF THE INVENTION
A fraction containing immunoglobulin is used as the starting material. This fraction is not particularly limited in so far as it originates from human plasma and contains an immunoglobulin fraction. Specific examples of such an immunoglobulin-containing fraction include Fraction II+III and Fraction II obtainable by ethanol fractionation of Cohn, and paste of immunoglobulin-containing fractions equivalent thereto. Other starting materials are Fractions I+II+III, and Fraction II+IIIw. The starting material may contain impurities, such as human blood-group antibodies, plasminogen, plasmin, kallikrein, prekallikrein activator, IgM, IgA, IgG polymers (hereinafter and hereinbefore “aggregates”), etc.
The preferred starting materials are Cohn Fraction II or Cohn Fraction II+III. When Cohn Fraction II+III paste is used, it is recommended that it first be subjected to a preliminary washing procedure to form Fraction II+IIIw, which is thereafter used in the process of this invention. “Fraction II+IIIw” is a disodium phosphate solution-washed Cohn Fraction II+III precipitate.
Fraction II+IIIw can be obtained by suspending Fraction II+III precipitate in cold water for injection in a ratio of about 1 kilogram of II+III paste per about 20 volumes of water. A sodium phosphate solution is added to the final concentration of approximately 0.003M sodium phosphate for solubilizing lipids, lipoproteins and albumin. Cold ethanol is added to bring the final alcohol concentration to about 20%. During the alcohol addition, temperature is gradually lowered to −5±1° C. and pH is maintained or adjusted to 7.2±0.1, for example by using acetate buffer or dilute sodium hydroxide. The Fraction II+IIIw precipitate which forms is recovered by centrifugation and/or filtration while maintaining the temperature at −5±1° C.
Prior to PEG fractionation as carried out in accordance with the processing sequence of the present invention, various preliminary purification and/or aggregate-reducing steps can be carried out. For example, when Fraction II+IIIw paste is used, typically containing about 20% alcohol, and more than 70% of the protein present is IgG, the Fraction II+IIIw paste can be suspended in 3 to 10 volumes, preferably 3 to 5 volumes, of cold water at a temperature of about 0 to 5° C. and with pH being adjusted to be between 4.5 to 6.0, preferably 5.0 to 5.5 using pH 4.0 acetate buffer or hydrochloric acid. The mixture is agitated for about 2 to 15 hours to allow all of the γ-globulin to go into solution. Thereafter, undissolved protein such as albumin and α-globulins can be removed by centrifugation and/or filtration.
Where a different starting Cohn fraction is employed, the initial step or steps of the process can be appropriately selected where desired for carrying out a preliminary purification for obtaining a fraction of high IgG content to be further processed. For example, where Cohn Fraction II (contains over 95% pure IgG) has been separated from Cohn Fraction III, with Fraction II to be further processed, the initial processing can be at an acid pH of 3.2 to 5.0, preferably 3.8 to 4.2, as described by Uemura et al. U.S. Pat. No. 4,371,520, in order to break down immune globulin aggregates present into immune globulin monomers and dimers, since aggregates are known to possess anti-complementary activity (ACA). As another alternative, with Cohn Fraction II+III starting material, the Uemura, et al. patent low pH treatment can be carried out as an additional step following an initial purification step as above described and prior to the PEG fractionation step.
PEG fractionation is carried out prior to the viral inactivation. PEG fractionation is a well known procedure in the art of purification of immune globulin in order to separate the desired IgG monomer and dimer from IgG aggregate and from other impurities naturally occurring in the starting plasma protein fraction. The removal of aggregate and some of the impurities present prior to the viral inactivation reduces the degree of aggregation and turbidity otherwise occurring during the heat treatment step, for example, when carried out at 60° C. for 10 hours.
A second PEG fractionation step following heat treatment viral inactivation is beneficial in removing denatured impurities and/or aggregates generated during the heat treatment process.
Any of the PEG fractionation procedures documented in the prior art can be used. In general, one stage or two stages of PEG fractionation are carried out. In the first stage of PEG fractionation, PEG concentration and pH are selected so that the desired IgG monomer and dimer remain in solution while undesired proteins such as aggregate are precipitated out of solution. Following centrifugation and/or filtration, PEG concentration is optionally increased with adjusting the pH to cause the desired IgG monomer and dimer to precipitate.
For example, a first stage of PEG fractionation can be carried out at a pH of about 5.0 to 7.5, preferably within about 6.5 to 7.5 pH when Fraction II+IIIw paste is used as starting material, and preferably within about 5.5 to 6.0 pH when Fraction II+III paste is used as starting material, with a PEG concentration ranging from about 4 to 8%, preferably either 4 to 6% when Fraction II+IIIw paste is used as starting material, or 6 to 8% when Fraction II+III paste is used as starting material. While maintaining cold temperatures of about 0 to 2° C., the first stage of PEG fractionation can be carried out for about 1 to 8 hours, after which the precipitate containing undesired protein including aggregate is removed as above-described. Where it is desired to collect the purified immunoglobulin, the filtrate will then have its pH adjusted to about 8.0 to 9.0, preferably about 8.5 to 8.9, and additional PEG added for final concentration of about 10 to 15%, preferably about 12%. The precipitate formed, which is purified immunoglobulin, is removed by filtration and/or centrifugation.
Further details of PEG fractionation procedures usable in the practice of the present invention can be found in the above-described U.S. Pat. No. 4,876,088 by Hirao et al. and U.S. Pat. No. 4,845,199 by Hirao et al.
The next essential step of the present invention is to carry out a first viral inactivation procedure selected from a heat treatment and a solvent or solvent-detergent mixture treatment. Therefore, a second viral inactivation procedure, which is the other of the heat treatment and solvent or solvent-detergent treatment not used as the first viral inactivation, is carried out. As described below, further purification procedures, specifically those involving the use of ionic exchange resins, can be carried out prior to and/or following the solvent-detergent treatment and/or following the heat treatment.
A particularly advantageous procedure is to carry out an anionic exchange treatment prior to the solvent detergent viral inactivation as a first viral inactivation and then a cationic exchange treatment after the heat treatment viral inactivation as a second viral inactivation. By this procedure, certain undesirable protein materials (such as prekallikrein activator, IgA, IgM and albumin) found within human plasma can be removed from the IgG by use of the anionic exchanger and then further such materials (prekallikrein activator, IgA, IgM and albumin) along with the PEG, residual reagents from the solvent-detergent treatment and denatured proteins (impurities and/or aggregates) resulting from the heat treatment can be removed through the cationic exchange procedure. Thus, the cationic exchange procedure can be employed in place of the second PEG fractionation after completion of viral inactivation for removing the denatured impurities and aggregate generated by the heat treatment viral inactivation.
If not otherwise accomplished during the overall process, the solution to be subjected to the solvent-detergent should be treated for removal of all particulate matter, which can include denatured protein. Therefore, it is preferred to filter the solution with a 1 micron or finer filter prior to solvent-detergent addition. This will also reduce the likelihood of virus being present within a large particle and thereby possibly avoiding exposure to the solvent-detergent.
Today, the preferred solvent for inactivation of envelope viruses is trialkyl phosphate. The trialkyl phosphate used in the present invention is not subject to particular limitation, but it is preferable to use tri(n-butyl)phosphate (hereinafter “TNBP”). Other usable trialkyl phosphates are the tri(ter-butyl)phosphate, the tri(n-hexyl)phosphate, the tri(2-ethylhexyl)phosphate, and so on. It is possible to use a mixture of 2 or more different trialkyl phosphates.
The trialkyl phosphate is used in an amount of between 0.01 to 10 (w/v)%, preferably about 0.1 to 3 (w/v)%.
The trialkyl phosphate may be used in the presence or absence of a detergent or surfactant. It is preferable to use trialkyl phosphate in combination with the detergent. The detergent functions to enhance the contact of the viruses in the immune globulin composition with the trialkyl phosphate.
Examples of the detergent include polyoxyethylene derivatives of a fatty acid, partial esters of anhydrous sorbitol such as Polysorbate 80 (Tradename: Tween 80, etc.) and Polysorbate 20 (Tradename: Tween 20, etc.); and nonionic oil bath rinsing agent such as oxyethylated alkylphenol (Tradename: Triton X100, etc.) Examples include other surfactants and detergents such as Zwitter ionic detergents and so on.
When using the detergent, it is not added in a critical amount; for example, it may be used at ratios between about 0.001% and about 10%, preferably between about 0.01% and 3%.
In the present invention, the trialkyl phosphate treatment of the immune globulin containing composition is carried out at about 20 to 35° C., preferably 25 to 30° C., for more than 1 hour, preferably about 5 to 8 hours, more preferably about 6 to 7 hours.
During the trialkyl phosphate treatment, immune globulin is present at about a 3 to 8% protein solution in aqueous medium.
The trialkyl phosphate and optional detergent can be added directly to the filtrate resulting from a single stage of PEG fractionation where the γ-globulin is not to be precipitated by adding additional PEG. Dilution of the protein may be necessary. Otherwise, the precipitated γ-globulin is suspended in cold water for injection, pH can be adjusted to about 5.0 to 6.0, and the organic solvent and optional detergent are added thereto.
For the heat sterilization step, the solution of the immune globulin protein as obtained from the PEG fractionaction or from the solvent (detergent) step without purification is used as is, and a sugar, sugar alcohol and/or amino acid heat stabilizer is added thereto. pH is adjusted to about 4.5 to 6.0; preferably about pH 5.0 to 5.5. The heat stabilizer is preferably sucrose, maltose, sorbitol or mannitol, most preferably sorbitol. The sugar or sugar alcohol is added to the immune globulin solution as a powder or first mixed with a small volume of water and then added, to provide a final concentration of about 10 to 50 w/w%, up to saturation.
Following addition of the heat stabilizer, the mixture is heated at about 50-70° C. for about 10-100 hours, preferably at about 60° C., for about 10 to 20 hours, for viral inactivation of heat sensitive viruses. The heat treatment step not only inactivates viruses, but also through the protein denaturization effect thereof, can preferentially reduce the amount of certain undesirable proteins normally associated with Cohn Fractions II+III, such as prekallikrein activator, plasmin and plasminogen.
After the heat treatment, the solution is cooled to about 0 to 30° C., preferably about 10° C. and pH is adjusted to about 5.0 to 6.0, preferably about pH 5.0 to 5.5.
If not carried out prior to the solvent-detergent treatment, an anionic exchange treatment can be carried out on the heat treated immune globulin. Preferably, at least a cationic exchange treatment is carried out on the heat treated product after completion of viral inactivation and the anionic exchange treatment is carried out prior to use of the solvent-detergent treatment as a first viral inactivation. The ionic exchange treatments are carried out with immune globulin dissolved in an aqueous solvent, generally having a pH of about 5.0 to 5.5, with where desired low ionic strength for maximum adsorption of IgG. The protein concentration generally is within the range of about 1-15 w/v %, more preferably from about 3 to 10 w/v%. The ionic exchanger is equilibrated with the same aqueous solvent as used, and either a batch or continuous system can be carried out. For instance, anionic exchange batch-wise treatment can be carried out by mixing the immune globulin solution with the anionic exchanger in an amount from about 10 to 100 ml per ml of the pretreated anionic exchanger (for example, 1 gram of DEAE Sephadex A-50 resin swells to about 20 grams wet weight in 0.4% sodium chloride solution), stirring the mixture at about 0-5° C. for about 0.5 to 5 hours, and then filtering or centrifuging at 6,000 to 8,000 rpm for 10 to 30 minutes to recover the supernatant liquor. Continuous treatment can be affected by passing immune globulin solution through a column of the anionic exchanger at a flow rate sufficient to adsorb impurities to the ionic exchanger and recovering the non-adsorbed fraction.
The anionic exchanger to be used, for example, comprises anion exchanging groups bonded to an insoluble carrier. The anion exchanging groups include diethylaminoethyl (DEAE), a quaternary aminoethyl (QAE) group, etc., and the insoluble carrier includes agarose, cellulose, dextran, polyacrylamide, etc.
Examples of usable cationic exchangers are carboxy methyl SEPHADEX® (CM-SEPHADEX®, Pharmacia) CM-cellulose, SP-SEPHADEX®(Pharmacia), CM-SEPHAROSE® and SP-SEPHAROSE®(Pharmacia). 1 ml of pretreated cationic exchanger (for example, 1 gram of CM-SEPHADEX®(Pharmacia) C-50 resin swells to about 30-35 grams wet weight in 0.4% sodium chloride solution) is mixed with 0.5 ml to 5 ml of immune globulin solution and stirred at 0-5° C. for 1-6 hours. The suspension is centrifuged or filtered to recover the IgG adsorbed resin. Also, a continuous process can be employed.
When the above-described conditions are used with the cationic exchanger, the IgG will be adsorbed, and thereafter following washing of the protein-adsorbed cationic exchange resin, IgG can be eluted, for example by about a 1.4 N sodium chloride solution.
Following the steps of the above process, the IgG is clarified, diafiltered and concentrated to the extent needed. If desired, a stabilizer such as D-sorbitol can be added and final adjustments made to yield a solution of a composition containing about 50 mg/ml or 100 mg/ml IgG, and 50 mg/ml D-sorbitol, with pH being at 5.4. This solution is then sterile filtered through sterilized bacterial retentive filters and filled into vials.
The following example is set forth to illustrate the invention but is non-limiting.
Where desired, other immune globulin purification procedures can be appropriately combined with the processes described herein. For example, a bentonite clarification step, useful for reducing the levels of kallikrein and pre-kallikrein activator can be employed. An illustration of this is set forth in Example 1, hereinbelow.
EXAMPLE 1
Solvent-detergent and Heat Treated γ-Globulin
Six hundred and eighty five grams of Fr II+IIIw paste is suspended in about 11.9 kg of cold water. Sodium acetate trihydrate solution is added to the suspension to a final concentration of approximately 0.04M to selectively solubilize IgG. After mixing for about 15 minutes, pH of the suspension is adjusted to 5.2 with pH 4.0 acetate buffer. Cold alcohol (95%) is added to the suspension to a final concentration of 17%. During the alcohol addition the temperature of the suspension is lowered gradually to about −6° C. Three hundred and three grams of acid washed diatomaceous earth filter aid CELITE® available from Celite Corporation is added as a filter aid to the suspension to a final concentration of about 2.0%. After mixing for one hour, the Celite and the Fraction III paste containing unwanted protein such as plasmin, plasminogen, IgA and IgM are then removed by filtration utilizing a filter press. The filtrate is further clarified by 0.45 μm and 0.2 μm filters. Thereafter the Fraction III supernatant is adjusted to pH 7.0 with 1.0M sodium bicarbonate, temperature is lowered to −7° C. while cold alcohol (95%) is added to a final concentration of 25%. The pH of the suspension if required, is adjusted to 7.2 and the precipitate, Fraction II is removed by filtration at −7° C.
Each kilogram of Fraction II paste is suspended in approximately 1.5 kg of cold aqueous solution maintained at 0 to 2° C. containing 0.2% albumin (human) and approximately 2.0% polyethylene glycol. pH is adjusted to 3.7±0.2 with dilute hydrochloric acid, after which the suspension is held at that pH while being mixed for 15 hours.
The pH of the solution is adjusted to 5.3 with dilute sodium hydroxide while maintaining the temperature at 0 to 2° C. and 50% polyethylene glycol (PEG) 3350 is added to the solution to give a final PEG concentration of 4%. The precipitate so formed is removed at 1° C. by filtration or centrifugation. The pH of the filtrate is adjusted to 4.9 with 1.0 N hydrochloric acid and bentonite is added to a final concentration of about 0.25%. The pH of the bentonite suspension is readjusted to about 5.2 and then the suspension is filtered or centrifuged at 1° C. to remove bentonite. The filtrate pH is adjusted to 8.0 with 0.25 N sodium hydroxide and 50% PEG 3350 solution is added to a final PEG concentration of 12%. The precipitate so formed (purified immune globulin) is removed at 0 to 2° C. by filtration or centrifugation.
The above sets forth a typical process usable for carrying out PEG fractionation. Other PEG fractionation processes are known in the art.
One hundred grams of PEG-purified immune globulin paste is suspended in 450 ml of cold water for injection. The pH of the suspension is adjusted to 5.5 by the addition of 5% acetic acid. After mixing the suspension for two hours at +5° C., 33.3 g of DEAE SEPHADEX® A-50 (pharmacia) preequilibrated with 0.3% sodium chloride at pH 5.5 is added. After absorption for two hours, the DEAE resin is removed by filtration.
Tri-n-butyl phosphate (TNBP) and Polysorbate 80 mixture is added to the filtrate to yield a final concentration of 0.3% TNBP and 1.0% Polysorbate 80. The solution is incubated overnight at +5° C. D-Sorbitol is then added to the treated solution to a final concentration of 33% and the stabilized IgG solution is mixed for one (1) hour, pH adjusted to 5.5 and heated overnight at 60° C.
The mixture is cooled to +5° C. and pH is adjusted to 5.8. To remove the solvent detergent, PEG and sorbitol, the mixture is treated with CM-Sephadex C-50 as follows: The solvent/detergent treated and heat treated solution is diluted fourfold with cold water. The diluted solution is split into three aliquotes. Sodium chloride is added to the aliquotes to yield a final concentration of 0.2%, 0.4% and 0.6% for suspensions a, b and c, respectively. Each aliquot is then treated with 0.65 g dry weight per gram of protein of CM-SEPHADEX® C-50 (Pharmacia) resin, pre-equilibrated at pH 5.8 and corresponding NaCl concentrations.
After the adsorption of the protein by the resin for 3±2 hours, the liquid is removed by filtration. The protein adsorbed resins are then washed with 0.2%, 0.4% and 0.6% sodium chloride solution, respectively, to remove residual polysorbate 80, TNBP, PEG and sorbitol. The washed protein adsorbed CM-SEPHADEX® C-50 (Pharmacia) resins are then resuspended in 1.5±0.5 N sodium chloride solution for 2±1 hours to desorb the adsorbed protein. The resins are separated from the desorbed protein solution by filtration.
As discussed herein, the 12% PEG stage and the anionic exchange resin treatment are optional steps. Further, a second PEG fractionation step can be employed instead of or in addition to cationic exchange resin treatment. Also, the heat treatment and solvent (solvent-detergent) viral inactivation steps can be carried out in any order.
Variations of the invention will be apparent to the skilled artisan. | A process for producing an intravenously-administrable gamma globulin solution substantially free of contaminating viruses by fractionating an impure gamma globulin solution and then treating the purified gamma globulin, with a solvent-detergent for viral inactivation and a heat treating for viral inactivation. Thereafter, denatured impurities, residual solvent and aggregate generated by the heat treatment are removed from the gamma globulin. | 2 |
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to a gasket and more particularly to an intake manifold gasket having a rubber compression limiter and a rubber sealing member disposed thereon.
Gaskets are typically placed between a pair of mated mechanical components having a quantity of fluid contained between them. The gasket, so placed, acts to seal the contained fluid so as to prevent the fluid from escaping into the surrounding area.
These gaskets usually contain a plastic core upon which rubber or fiber type material is placed. The core and deposited material define the body of the gasket. A number of openings are placed through the gasket body, each opening allowing a single shank of a conventional fastener, such as a stud bolt, to pass therethrough thereby securing the gasket between the mated components. A raised rubber sealing member is also deposited upon the gasket body and cooperates with the body to provide the aforementioned sealing action. Such sealing members may be placed upon both sides of the gasket body.
These prior gaskets have also included compression limiters, placed upon the gasket body, which have limited the amount by which the raised rubber sealing members may be compressed. Such compression is known to result from many sources including the compressing action of the attachment bolt head. These limiters have proven to be an important part of the gasket design since overcompression may result in structural damage to the sealing member and may result in a concominant loss of sealing ability.
These previous limiters were typically made of metal and were ordinarily placed upon and attached to the body of the gasket. In some previous designs, the metal limiters were replaced with a groove placed upon the plastic core and the sealing member was normally placed within the groove. The depth of the groove compared to the height of the rubber sealing member determined the maximum compression of the member.
Two separate molding steps are required to manufacture these prior gaskets. One molding step was needed to mold the plastic core and the other to mold the sealing member thereon. Additionally, the manufacture of these gaskets usually required the additional step of securing the metal limiters to the core or the creation of the limiter grooves thereon. If sealing members were required on both sides of the gasket, holes were usually placed through the core to facilitate this two-sided molding of the sealing members upon the body.
While these prior gaskets have proven to provide effective sealing action they have many drawbacks. That is, the manufacturing costs associated with these gaskets is relatively high due to the two required molding steps, the separate attachment of the metal limiters, and the placement of the holes through the core. Additionally, these prior gaskets have great variations in the height of the compression limiter relative to the height of the sealing member. This variation not only causes great differences in compression tolerances across a wide range of manufactured gaskets but also causes differences in compression tolerances within a single gasket wherein these differences depend upon the point that the sealing member is being compressed.
It is therefore an object of this invention to provide a gasket having a compression limiter of the same material as the sealing member and having a relatively low height and large compression area compared to the sealing member so as to prevent the overcompression of the sealing member.
It is another object of this invention to provide a gasket having a compression limiter and sealing member disposed thereon wherein, the height of the sealing member is greater than the height of the compression limiter so that the seal member is compressed to achieve the desired gasket action before the limiter is engaged to prevent undue compression of the seal.
It is yet another object of this invention to provide a gasket having a perforated steel body and having a relatively low manufacturing cost.
These and other aspects, features, advantages, and objects of this invention will be more readily understood upon reviewing carefully the following detailed description taken in conjunction with the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The various advantages of the present invention will become apparent to those skilled in the art by reading the following specification and by reference to the drawings in which:
FIG. 1 is a top view of an intake manifold gasket made in accordance with the teaching of the preferred embodiment of this invention; and
FIG. 2 is an enlarged sectional view of the gasket shown in FIG. 1 taken substantially along line 2--2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 there is shown an intake manifold gasket 10 consisting of a substantially planar flat core 12 formed of perforated steel and having flat top and bottom surfaces 13 and 15, respectfully. A body 14 of rubber or other similar material is deposited on the core 12 so as to substantially encapsulate the core 12.
The gasket 10 has a plurality of openings 16 through which air flows, each of which allows corresponding openings in two conventional mated machined parts (not shown), between which the gasket 10 is placed, to be in communication. The gasket 10 also has raised seal members 18 or beads, formed of a compressible material such as rubber or similar material, which cooperate with body 14 to seal the mated machined parts so that air flowing through the openings 16 will not leak between the machined parts.
Body 14 further defines a plurality of attachment bolt openings 20 each of which allows a bolt to pass through and enable the gasket 10 to seal the joint between the mated machined parts. In close proximity to substantially every opening 20 is a rubber compression limiter 22.
The limiters 22 are of the same height h 1 which is substantially lower than the height h 2 of the seal members 18. In contrast, the width of each limiter 22 is many times greater than the width of seal members 18 which are very narrow.
The seal members or beads 18, as they are often called, are sufficiently narrow to allow lateral displacement of the rubber, or like material from which they are formed, to thereby enable compression of the beads 18 when loaded. Such loading occurs when the gasket 10 is clamped between the mating parts.
The limiters 22, however, are of sufficient area, in horizontal section, to preclude any compression of the limiters when similarly loaded.
The limiters 22 are positioned at the bolt holes 20 so that they prevent the mating parts from being distorted during tightening of the bolts. This positioning of the limiters 22 also locates the limiters 22 at high unit loading areas of the beads 18 so as to protect the beads 18 against damage from overcompression.
It is also to be noted that in all cases the limiters 22 are spaced from the adjacent bead 18 sufficiently to allow for the heretofore described lateral expansion of the adjacent bead 18.
In operation, the gasket 10 is placed upon a first machined part (not shown), such as a manifold casting, and attached thereto by securing another part (not shown) to the manifold casting so that the gasket is clamped between the parts so as to prevent fluid leaks from occurring in the planar area between the parts. Attachment bolts in the parts (not shown) are extended through the gasket openings 20 and tightened so that the gasket 10 seals the joint between the parts.
During clamping of the gasket 10 between the mating parts, the seals 18, which are higher than the limiters 22, are subjected to compressing forces which tend to compress the seals 18 and improve their ability to seal around the openings 16. As the compressive forces on the seals 18 are increased they expand laterally and the height h 2 of the seals 18 is decreased. When the height of the seals is reduced to the height h 1 of the limiters 22, the limiters 22 are also subjected to the compressive forces. However, by virtue of the large horizontal area of the limiters 22, they are substantially incompressible so that further movement of the mating parts toward each other is prevented. The gasket beads 18 are thus fully functional at this time.
The result is a gasket 10 which retains its structural integrity and performs its sealing function effectively.
Gasket 10 is also relatively economical to manufacture since the use of the perforated metal core 12 eliminates the need to structure the core, during the manufacture of gasket 10, to accommodate the sealing members 18.
Additionally, only a single molding step is required in the manufacture of gasket 10 since the rubber seal members 18 and limiters 22 are molded in a substantially simultaneous manner. This single molding also eliminates the need to separately place the limiters 22 on body 14 and results in a more consistent relationship of the height of the limiters 24 to the height of the seals 18.
It is to be understood that the above-identified embodiment is merely illustrative of some of the many specific embodiments which represent applications of the principles of the present invention. Clearly, other arrangements can be readily devised by those skilled in the art without departing from the scope of the invention. | A gasket comprising a perforated steel body and a rubber sealing member disposed thereon. The gasket body has a plurality of bolt holes therethrough and at least one rubber compression limiter, disposed upon the body, so as to limit compression of the sealing member. The limiter has a relatively large area and small height in comparison to the sealing member and serves to protect the sealing member from overcompression. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/EP2006/061217, filed Mar. 31, 2006 and claims the benefit thereof. The International Application claims the benefits of European application No. 05007416.0 filed Apr. 5, 2005, both of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The present invention relates to a method for starting up a gas and steam turbine system, and in particular a method for a fast startup of a system of said kind.
BACKGROUND OF THE INVENTION
[0003] In a gas turbine system a gaseous or liquid fuel, for example natural gas or crude oil, is mixed with compressed air and combusted. The pressurized combustion exhaust gases are supplied to the turbine of the gas turbine system as the working medium. The working medium sets the turbines under expansion into rotation, with thermal energy being converted into mechanical work, i.e. the rotation of the turbine shaft. When the expanded working medium is discharged from the gas turbine system said medium typically still has a temperature of 500-600° Celsius.
[0004] In a gas and steam turbine system the expanded working medium, also called flue gas, from the gas turbine system is used to generate steam for driving a steam turbine. Toward that end the working medium is supplied to a heat recovery steam generator connected downstream of the gas turbine system on the exhaust gas side, in which steam generator heating surfaces are arranged in the form of pipes or pipe bundles. Said heating surfaces are in turn connected into a water-steam cycle of the steam turbine system which has at least one, but mostly a plurality of pressure stages. The pressure stages differ from one another in that the water supplied to the heating surface for the purpose of generating steam has different pressure levels. A gas and steam turbine system comprising a water-steam cycle having only one pressure stage is described in DE 197 36 888 A1, and such a system comprising three pressure stages, namely a high-pressure stage, a medium-pressure stage and a low-pressure stage, is described in DE 100 04 187 C1.
[0005] Currently, in order to start a gas and steam turbine system, the gas turbine system is usually started up and the expanded working medium is supplied to the heat recovery steam generator of the steam turbine system. Initially, however, the steam generated in the heat recovery steam generator is not fed to the turbine part of the steam turbine system, but is directed past the turbine via diverter stations and supplied directly to a condenser which condenses the steam to water. The condensate is then supplied to the steam generator again as feedwater. In many embodiment variants of gas and steam turbine systems the diverted steam is also conveyed to the atmosphere.
[0006] The steam turbine is only switched into the cycle when certain steam parameters in the steam lines of the water-steam cycle or in the steam lines leading to the turbine part of the gas turbine system, for example certain steam pressures and temperatures, are complied with. Complying with said steam parameters is designed to keep potential stresses in thick-walled components at a low level.
[0007] After the startup of the gas turbine system there is a power increase which leads to an increase in pressure in the steam system. The load gradient at which the gas turbine system is started up, i.e. the power increase of the gas turbine system per time unit, is critically dependent on the implementation and mode of construction of the heat recovery steam generator as well as on the structural limitations within the steam turbine. As the gas turbine load and consequently the temperature or, as the case may be, the volume flow rate of the exhaust gas emitted from the gas turbine system increase, the steam temperature and the pressure in the steam system are also increased.
[0008] Before the steam turbine starts up, the gas turbine is typically kept at a specific partial load until stationary states have come about in the gas turbine system and in the steam system. As soon as stable steam production has been reached, the steam contained in the steam system is channeled to the steam turbine, thereby accelerating the steam turbine. The turbine speed is then increased to nominal speed. Following synchronization of the generator coupled to the steam turbine with the power supply system, or in the case of single-shaft systems, following the engagement of the overrunning clutch, the steam turbine is subjected to further load as a result of an increase in the steam supply. At the same time the diverter stations close more and more in order to keep the steam pressure roughly constant and minimize level fluctuations in the heat recovery steam generator.
[0009] As soon as the diverter stations are closed and the steam produced in the heat recovery steam generator is channeled in its entirety to the steam turbine, a further increase in the gas turbine power output takes place when there is a higher power requirement on the part of the system which is now operating in the gas and steam turbine mode.
[0010] By definition, the startup operation of a gas and steam turbine system is terminated only when the gas turbine has reached the base load and all diverter stations are closed.
SUMMARY OF INVENTION
[0011] The object of the present invention is to provide a method for starting up a gas and steam turbine system which enables a faster startup operation than the method described in the introduction.
[0012] This object is achieved by means of a method for starting up a gas and steam turbine system as claimed in the claims. The dependent claims contain advantageous embodiments of the method.
[0013] According to the invention, a method is provided for starting up a gas and steam turbine system, in particular for fast starting up of a gas and steam turbine system which has a gas turbine system comprising at least one gas turbine as well as a steam turbine system having at least one steam turbine and at least one steam system and in which the waste heat of a working medium expanding in the gas turbine is supplied to the steam system for the purpose of generating the steam driving the steam turbine.
[0014] In the method according to the invention, at startup time the gas turbine is started first, before the steam turbine is started. The steam turbine is then already started up when the first steam is present in the steam system and is impinged upon by steam.
[0015] In the method according to the invention, the steam turbine is started up at the earliest possible time and accelerated by means of the first steam from the heat recovery steam generator, without waiting for stationary states in the steam system. This measure enables the startup operation of the gas and steam turbine system to be shortened considerably.
[0016] In contrast to the usual startup method, the steam temperature in the steam system at the time of starting the steam turbine can be less than the material temperature of the steam turbine or of its housing. The early channeling of the steam to the steam turbine can therefore lead to a cooling down of the components and to thermal stresses. However, a certain compensation can be achieved if the gradients are kept correspondingly low during the following increase in the steam temperatures.
[0017] Advantageously, the tuning of the steam system during the startup operation is chosen in such a way that the steam pressure increases continuously. This can be achieved, for example, by opening a steam diverter station of the steam system only so wide that a minimum steam quantity required for accelerating and/or synchronizing the steam turbine is generated using a part of the waste heat of the working medium and a pressure increase in the steam system is produced by means of the remaining part of the waste heat of the working medium.
[0018] In addition to a pressure increase in the steam system, the comparatively small opening of the steam diverter station leads to a reduction in the steam production in the heat recovery steam generator. As a result the thermal load to the condenser is reduced and the diverter station can close more quickly.
[0019] In a special embodiment of the method according to the invention the diverter station is not opened at all.
[0020] The method according to the invention can be embodied in particular in such a way that the gas turbine system experiences a load increase during the entire startup operation, in particular until the base load is reached. In other words, the method dispenses with keeping the gas turbine system at a certain partial load and waiting until the gas turbine system and the steam system of the steam turbine system have settled into stationary states. This measure also leads to a reduction in the startup time of the gas turbine system and thus enables a fast startup.
[0021] In a special embodiment the gas turbine system's load is increased at maximum load ramp, which is to say that there is a maximum increase in the gas turbine power output per time unit.
[0022] The gas and steam turbine system during the starting up of the gas turbine system to base load is preferably switched over into the gas and steam turbine operating mode, with the result that the startup operation is, by definition, terminated when the gas turbine base load is reached. The switchover into the gas and steam turbine operating mode can include in particular the synchronization of a generator coupled to the steam turbine with the power supply system or, in the case of single-shaft systems, the engagement of the automatic overrunning clutch.
[0023] The described method according to the invention for starting up a gas and steam turbine system shortens the startup time of the system considerably. Compared with the method described in the introduction, a reduction in the starting time by approximately 50% is achievable. A gas and steam turbine operator can therefore respond very flexibly to short-term requirements, as a result of which the revenues from the purchase of power can be increased. As a result of the early steam takeover of the steam turbine and the reduced thermal load in the condenser, which leads to smaller power losses, there is also an increase in the averaged efficiency of the gas and steam turbine system, which is a significant factor in particular in the case of frequent starts and increases the cost-effectiveness of the system.
[0024] Moreover, the lower steam production in the method according to the invention for starting up a gas and steam turbine system also enables smaller diverter stations to be installed, thereby reducing investment costs.
[0025] The described startup method enabling a fast startup of a gas and steam turbine system can essentially be realized by means of software modifications. It is therefore also possible to convert existing gas and steam turbine systems to the startup method according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Further features, characteristics and advantages of the present invention will emerge from the following description of an exemplary embodiment with reference to the accompanying figure.
[0027] FIG. 1 shows a schematic diagram for a gas and steam turbine system.
DETAILED DESCRIPTION OF INVENTION
[0028] The gas and steam turbine system 1 represented schematically in FIG. 1 comprises a gas turbine system 1 a as well as a steam turbine system 1 b . The gas turbine system 1 a is equipped with a gas turbine 2 , a compressor 4 , and at least one combustion chamber 6 connected between the compressor 4 and the gas turbine 2 . By means of the compressor 4 , fresh air L is drawn in, compressed and supplied via the fresh air line 8 to one or more burners of the combustion chamber 6 . The supplied air is mixed with liquid or gaseous fuel B fed via a fuel line 10 and the mixture ignited. The resulting combustion exhaust gases form the working medium AM of the gas turbine system 1 a , which working medium AM is supplied to the gas turbine 2 , where it produces work under expansion and drives a shaft 14 coupled to the gas turbine 2 . The shaft 14 is coupled not only to the gas turbine 2 but also to the air compressor 4 as well as to a generator 12 in order to drive the latter. The expanded working medium AM is conducted via an exhaust gas line 34 to a heat recovery steam generator 30 of the steam turbine system 1 b.
[0029] In the heat recovery steam generator 30 the working medium output by the gas turbine 1 a at a temperature of approx. 500-600° Celsius is used for generating and superheating steam.
[0030] In addition to the heat recovery steam generator 30 , which can be embodied in particular as a once-through, forced-flow system, the steam turbine system 1 b comprises a steam turbine 20 having turbine stages 20 a, 20 b, 20 c and a condenser 26 . The heat recovery steam generator 30 and the condenser 26 , in combination with condensate lines and feedwater lines 35 , 40 as well as steam lines 48 , 53 , 64 , 70 , 80 , 100 , form a steam system which, together with the steam turbine 20 , forms a water-steam cycle.
[0031] Water from a feedwater reservoir 38 is supplied by means of a feedwater pump 42 to a high-pressure preheater 44 , also known as an economizer, and from there is forwarded to an evaporator 46 which is designed for once-through operation and is connected to the economizer 44 on the output side. For its part, the evaporator 46 is in turn connected on the output side to a superheater 52 via a steam line 48 into which a water separator 50 is inserted. The superheater 52 is connected on the output side via a steam line 53 to the steam input 54 of the high-pressure stage 20 a of the steam turbine 20 .
[0032] In the high-pressure stage 20 a of the steam turbine 20 , the superheated steam from the superheater 52 drives the turbine before it is passed on via the steam output 56 of the high-pressure stage 20 a to an intermediate superheater 58 .
[0033] After being superheated in the intermediate superheater 58 , the steam is forwarded via a further steam line 81 to the steam input 60 of the medium-pressure stage 20 b of the steam turbine 20 , where it drives the turbine.
[0034] The steam output 62 of the medium-pressure stage 20 b is connected via an overflow line 64 to the steam inlet 66 of the low-pressure stage 20 c of the steam turbine. After flowing through the low-pressure stage 20 c and the driving of the turbine associated therewith, the cooled and expanded steam is output via the steam output 68 of the low-pressure stage 20 c to the steam line 70 , which leads it to the condenser 26 .
[0035] The condenser 26 converts the incoming steam into condensate and forwards the condensate by means of a condensate pump 36 to the feedwater reservoir 38 via the condensate line 35 .
[0036] In addition to the already mentioned elements of the water-steam cycle, the latter also comprises a bypass line 100 , what is referred to as the high-pressure diverter line, which branches off from the steam line 53 before the latter reaches the steam inlet 54 of the high-pressure stage 20 a. The high-pressure bypass line 100 bypasses the high-pressure stage 20 a and flows into the feed line 80 to the intermediate superheater 58 . A further bypass line, referred to as the medium-pressure bypass line 200 , branches from the steam line 81 before the latter flows into the steam inlet 60 of the medium-pressure stage 20 b. The medium-pressure bypass line 200 bypasses both the medium-pressure stage 20 b and the low-pressure stage 20 c and flows into the steam line 70 leading to the condenser 26 .
[0037] Incorporated into the high-pressure bypass line 100 and the medium-pressure bypass line 200 are the shutoff valves 102 , 202 , by means of which said lines can be shut off. Shutoff valves 104 , 204 are also included in the steam line 53 and in the steam line 81 , in each case between the branching-off point of the bypass line 100 and 200 , respectively, and the steam inlet 54 of the high-pressure stage 20 a and the steam inlet 60 of the medium-pressure stage 20 a, respectively.
[0038] Incorporated into the medium-pressure bypass line 200 is a shutoff valve 202 by means of which said line can be shut off. A shutoff valve 104 is also included in the steam line 53 , namely between the branching-off point of the bypass line 100 and the steam inlet 54 of the high-pressure stage 20 a of the steam turbine 20 .
[0039] The bypass line 100 and the shutoff valves 102 , 104 are used during the starting up of the gas and steam turbine system 1 to divert a part of the steam for the purpose of bypassing the steam turbine 2 .
[0040] An exemplary embodiment of the method according to the invention for starting up a gas and steam turbine system is described below based on the system 1 described with reference to FIG. 1 .
[0041] At the start of the method the gas turbine system 1 a is started and the working medium AM being discharged from the system is supplied to the heat recovery steam generator 30 via an input 30 a. The expanded working medium AM flows through the heat recovery steam generator 30 and exits the latter via an output 30 b in the direction of a vent stack (not shown in FIG. 1 ). As the working medium AM flows through the heat recovery steam generator 30 , heat is transferred from the working medium AM to the water or steam in the water-steam cycle.
[0042] After the gas turbine system has been started up, the waste heat of the working medium in the heat recovery steam generator 30 leads to the start of steam production in the steam system.
[0043] In this early phase of the startup operation the shutoff valves 102 and 104 or 202 and 204 are set in such a way that only a small part of the generated steam flows through the bypass lines 100 , 200 and already in this phase of the startup operation the majority of the steam is supplied to the steam turbine 20 . The part of the steam supplied to the steam turbine 20 accelerates the steam turbine and preheats the latter insofar as the steam is hotter than the material of the turbine and the steam lines.
[0044] Since only a small amount of steam flows directly to the condenser 26 via the medium-pressure bypass line 200 , the waste heat not used during the acceleration and preheating of the steam turbine 20 leads to a pressure increase in the steam system. In the further course of the startup operation the steam pressure therefore increases continuously in the steam system, as a result of which steam production in the heat recovery steam generator is reduced. This leads to a reduction in the heat input into the condenser 26 and as a result the shutoff valves 102 and 202 , which are not fully open anyway, can be closed quickly compared to prior art starting methods.
[0045] Once the gas turbine system 1 a has been started, the load of the gas turbine system is increased preferably at maximum load ramp until the base load is reached.
[0046] If the steam temperature is less than the material temperature of the turbine 20 at the start of the introduction of steam into the steam turbine 20 , the steam temperature will steadily increase during the startup of the load of the gas turbine system and relatively soon exceed the material temperature of the steam turbine and the lines leading thereto. If the rapid rise from a relatively cool temperature of the turbine components to a high temperature would exceed a certain predefined limit of the thermal stresses in the material due to the starting up of the gas turbine system at maximum load ramp, the power output of the gas turbine system can also be increased at a lower ramp than the maximum load ramp, with the result that the steam temperatures rise more slowly.
[0047] Since the bypass lines 100 , 200 are closed at an early stage in the startup method according to the invention and the gas and steam turbine system 1 is switched over into the gas and steam turbine operating mode already during the starting up of the gas turbine system 1 a to base load, the startup operation is terminated when the gas turbine base load is reached.
[0048] Even if the steam turbine load were to reach only a magnitude of approximately 80-90% when the gas turbine base load is reached, the startup operation is deemed to be completed according to the definition whereby the startup operation is terminated when the base load of the gas turbine system is reached and the bypass lines are closed. Depending on the dynamic characteristics of the heat recovery steam generator, a further pressure increase will take place over several minutes and will be completed after approximately 10-20 further minutes. The amount of steam will increase accordingly, and steam turbine power output ratings in excess of 95% will be achieved as a function of steam temperature.
[0049] The startup method according to the invention has been described with reference to a gas and steam turbine system comprising a water-steam cycle which has only one pressure stage. It should, however, be pointed out at this juncture that the method according to the invention can also be applied in the case of gas and steam turbine systems which have more than one pressure stage in the water-steam cycle. A gas and steam turbine system comprising three pressure stages, namely a high-pressure stage, a medium-pressure stage and a low-pressure stage in the water-steam cycle, for which the startup method according to the invention can also be used, is described for example in DE 100 04 187 C1, to which reference is made in relation to the embodiment of a gas and steam turbine system comprising a plurality of pressure stages. | The invention relates to a method for starting a gas and steam turbine system which comprises a gas turbine system which comprises at least one gas turbine, in addition to at least one steam turbine system which comprises at least one steam turbine and at least one steam system. Heat produced by the working fluid and which is released in the gas turbine is guided to the steam system in order to produce steam which drives the steam turbine. According to the invention, during starting, the gas turbine is started prior to the steam turbine and the steam turbine is started in the presence of the first steam in the system and is impinged upon by said steam. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a fiber control apparatus in an open end spinning frame. More particularly, the present invention relates to an improved spinning rotor for use in an open end spinning frame.
2. Description of the Prior Art
As a conventional open end spinning frame, there is known an open end spinning frame of the self-exhaust type in which a plurality of exhaust vents are formed at the bottom of a rotor defining a spinning chamber in radial directions of the rotor. Air is exhausted from the spinning chamber through the exhaust vents by the centrifugal force produced by rotation of the rotor to produce a negative pressure within the spinning chamber. Fibers opened by combing roller disposed within a spinning body are carried from a fiber passage into the spinning chamber by this negative pressure. The fibers are caused to move and are deposited onto the inner circumferential surface of the rotor. Those deposited fibers are displaced to the sliding wall of the rotor by the rotary centrifugal force of the rotor. The fibers are further gathered in the form of a ribbon in a gathering groove. The ribbon of fibers is withdrawn continuously from a yarn guide hole formed in the central portion of a separator to create spun yarns.
In this spinning frame, the factors displacing the fibers to the sliding wall of the rotor are the rotary centrifugal force of the rotor and the rotary stream of accompanying air generated by the viscosity between the sliding wall and air. It has been interpreted that, if we consider the speed variation of this rotary stream in relation to the radial position of the spinning chamber, the speed of the rotary stream with respect to the radial position of the spinning chamber increases toward the sliding wall from the rotary center of the rotor. Such speed variation of the rotary stream is hereinafter refered to as the speed distribution of the rotary stream. It has also been considered that the above-mentioned speed distribution and the pressure thereof are important factors dominating the behavior of fibers in the spinning chamber and, hence, influencing the quality of the resultant yarn.
SUMMARY OF THE INVENTION
The present inventors researched the above-mentioned rotary stream by using a Pitot tube in a conventional self-exhaust type spinning rotor. As the result, the present inventors succeeded in developing a spinning rotor producing a rotary stream capable of controlling the behavior of fibers to a level higher than that attainable by conventional spinning rotors. Specifically, it is a primary object of the present invention to provide a spinning rotor having a structure capable of producing a rotary stream by which breaking or bending of fibers or formation of flying fibers in a spinning chamber of the spinning rotor can be effectively controlled. This object can be attained by a spinning rotor according to the present invention, which is provided with the following structural features.
For the sake of easily understanding the present invention, the following definitions are first made. "Imaginary plane" here means the plane passing through the center of the inside opening of the exhaust vent and perpendicular to the rotation axis of the spinning rotor. "Predetermined radius" means the radius of the spinning rotor along the imaginary plane passing through the center of the inside opening of the exhaust vent. "Predetermined central axis of the exhaust vent" means the line passing through the above-mentioned center of the inside opening of the exhaust vent. The following two conditions are essential to create the structural features of the present invention:
(1) The center of the inside opening of the exhaust vent of the spinning rotor is displaced outward in position from the center of the rotor.
(2) A first imaginary line which is a projection of the predetermined central axis of the exhaust vent on the imaginary plane is inclined to a second imaginary line which is a projection of the predetermined radius toward or opposite to the rotational direction. Such a condition must be satisfied in each exhaust vent. The angle between the above-mentioned two imaginary lines with respect to each exhaust vent is preferably identical.
The results of the present inventors' research showed that one rotary stream is created in the vicinity of the sliding wall of the rotor, another rotary stream is created along with the opening of the exhaust vent, and a low-pressure trough stream portion is created at the position between the above-mentioned two rotary streams. The former rotary stream is hereinafter referred to as the first rotary stream, while the latter rotary stream is hereinafter referred to as the second rotary stream.
It was confirmed that if the above-mentioned first condition is satisfied, the width of the above-mentioned low-pressure trough portion along the radial direction of the spinning rotor can be decreased remarkably, the noticeable reduction speed of the trough stream portion can be prevented, and the static pressure in the area near the central portion of the spinning rotor can be maintained low. Consequently, the creation of floating fibers, bent fibers, and fiber wrapping about the separator of the spinning rotor can be remarkably reduced. Accordingly, it is possible to produce a yarn of better quality than with conventional spinning rotors.
Since the position of the inside opening of the exhaust vent is restricted so as to satisfy the above-mentioned condition (1), if the above-mentioned condition (2) is not satisfied, the axial length of the exhaust vent is shortened. However, in the present invention, the above-mentioned condition (2) is satisfied, consequently, the above-mentioned shortening of the axial length of the exhaust vent can be avoided. Due to this structural feature of the present invention, the resistance on air flowing into the inside opening of the exhaust vent is reduced, whereby the volume of exhaust air can be increased. As the result, the possible creation of floating fibers and bent fibers can be remarkably reduced and the yarn quality can further be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view illustrating a spinning chamber and a surrounding portion thereof in a conventional open end spinning frame;
FIG. 2 is a plan view illustrating just the rotor in the spinning frame shown in FIG. 1;
FIG. 3 is a diagram showing the speed distribution of a rotary stream in the spinning chamber shown in FIG. 1;
FIG. 4 is a sectional view illustrating a spinning chamber and a surrounding portion thereof for one embodiment of the open end spinning frame according to the present invention;
FIG. 5 is a plan view showing just the rotor in the spinning frame shown in FIG. 4;
FIG. 6 is a diagram showing the speed distribution of a rotary stream in a spinning chamber shown in FIG. 4;
FIGS. 7 and 8 are photographic prints indicating the results of visual experiments which were carried out to confirm the existence of the rotary streams in the spinning chamber for a conventional spinning rotor and a spinning rotor according to the present invention, respectively;
FIG. 9 is a plan view illustrating another embodiment of the rotor of the present invention; and
FIG. 10 is a view showing the section taken along the line X--X in FIG. 9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For facilitating understanding of the structure and functional effect of the present invention, the results of analysis made on rotary streams created in a spinning chamber of a conventional self-exhaust type spinning rotor shown in FIG. 1 will first be described.
In the self-exhaust type spinning rotor shown in FIG. 1, a spinning chamber 1 comprises a bottom 2a of the rotor 2, a sliding wall 2b of the rotor 2, and a gathering groove 2c for gathering fibers thereon. A plurality of exhaust vents 3 are arranged at the bottom 2a in radial directions of the rotor 2. Air is discharged from the spinning chamber 1 through the exhaust vents 3 by the centrifugal force generated by rotation of the rotor 2 so that a negative pressure is created within the spinning chamber 1. Fibers opened by combing roller 5 disposed in a spinning body 4 are carried from a fiber passage 6 into the spinning chamber 1 by this negative pressure. The fibers are caused to move and are deposited onto the inner circumferential surface of the rotor 2. Those deposited fibers are displaced to the sliding wall 2b of the rotor 2 by the rotary centrifugal force of the rotor 2. The fibers are further gathered in the form of a ribbon in the gathering groove 2c. The ribbon of fibers is withdrawn continuously from a yarn guide hole 8 formed in the central portion of a separator 7 to create spun yarns.
In this spinning frame, the factors displacing the fibers to the sliding wall 2b of the rotor 2, are the rotary centrifugal force of the rotor 2 and the rotary stream of accompanying air current generated by the friction between the sliding wall 2b and air. It has been considered that the speed of this rotary stream in the spinning chamber increases toward the sliding wall 2b from the rotational center O1 of the rotor 2, as indicated by V1 or V2 in FIG. 3.
On the other hand, the results of tests using a Pitot tube, have confirmed that in the spinning chamber 1, as is seen from the speed distribution indicated by the solid line in FIG. 3, wherein the ordinate represents the speed of the rotary stream while the abscissa represents the distance from the rotational center O1 of the spinning rotor, a rotary stream V3 having a considerably high speed, which depends upon an accompanying air current, is formed in the boundary layer in close proximity to the sliding wall 2b. In other regions, however, there is only a rotary stream V4 which is formed by the flow of air into the inner opening 3a of the exhaust vent 3.
It is known that if the length of the exhaust vent 3 in the direction of the radius is l, as the length l becomes shorter by displacement of the opening of the spinning chamber outward from the center of the rotor, the speed of air discharged from the exhaust vent 3, that is, the exhaust air quantity, is reduced (this phenomenon is explained in detail on page 408 of "Collection of Textile Technique Data" published by the Japanese Spinners' Association, Oct. 1, 1971). Accordingly, in the conventional spinning rotor, a predetermined amount of exhaust air is maintained by forming the center 02 of the opening 3a closer to the center O1 of the rotor than to the center of the radius of the spinning chamber. Consequently, the rotary stream V4 formed by the exhaust vent 3 is biassed toward the center O1 of the rotor. The width in the radial direction of the rotor and the depth, representing the pressure drop, of the trough V5 between the rotary streams V3 and V4 are increased, and the speed of the rotary stream of this trough, represented by V5, is decreased.
Therefore, in the conventional spinning rotor, fibers carried into the spinning chamber 1 from the fiber passage 6 of the spinning body 4 are shifted to the low speed trough V5, and the speed of the fibers is reduced and lost. Accordingly, the creation of floating fibers and bent fibers is enhanced. The floating fibers are caught in the turning yarn being run to the yarn guide hole 8, and bending of fibers is frequently created. As the result, the yarn quality is reduced.
From the results of the experimental tests of the conventional spinning frame, it has been found that the static (negative) pressure in the central portion of the rotor is high. Floating fibers are readily stored in this high static pressure portion and fibers are readily wound on the separator 7. Furthermore, these fibers are caught in the yarn being taken to the yarn guide hole 8, thereby reducing the yarn quality.
Based on the view point that the speed distribution of the rotary stream in the spinning chamber 1 is as indicated by V1 or V2, a method has been tried to smoothly guide fibers to the sliding wall 2b by carrying the fibers on a high-speed rotary stream. In this method, the top end of the fiber passage 6 is brought as close as possible to the sliding wall 2b, which has an accompanying air current, by way of a tube (not shown). However, assembly limitation make it impossible to form the top end of the tube very close to the sliding wall 2b. Accordingly, in actual spinning operations, fibers are guided to the position of the above-mentioned trough V5, whereby yarn quality is reduced.
Another modified method has been considered to guide the fibers from the fiber passage 6 toward the position of the rotary stream V4. Also in this case, however, the radial width of the low speed trough V5 is large. While the fibers pass through the position of this trough V5, floating fibers and bent fibers are formed and the above-mentioned problem is not substantially solved.
The structure and functional effect of the self-exhaust type spinning rotor according to the present invention will now be described in detail with reference to FIGS. 4 through 6.
The present invention is different from the above-mentioned conventional spinning frame only in the position and shape of the exhaust vent 3 formed on the rotor 2. Accordingly, members corresponding to the members of the conventional spinning frame shown in FIG. 1 are represented by the same reference numerals.
In this embodiment, as shown in FIG. 5, the center 02 of an opening 3a of an exhaust vent 3 on the side of a spinning chamber 1 is located outward of the center 03 of the distance between the center 01 of the rotor 2 and a gathering groove 2c. The above-mentioned distance corresponds to the maximum inner diameter portion. The radius of the spinning chamber 1 is now represented by R. The angle between the radius passing through the center 02 of an opening 3a and a projection of the central axis l--l of the exhaust vent 3 (on a plane perpendicular to the rotational axis of the spinning chamber 1 and containing the center 02) is defined as the inclination angle α of the exhaust vent 3. When the above-mentioned projection of the central axis l--is inclined in the rotation direction of the rotor 2 (indicated by arrow P in FIG. 5) with respect to the radius R, the inclination angle α is defined as positive, while when the above-mentioned projection of the central axis l--l is inclined backward from the rotation direction P with respect to the radius R, the inclination angle α is defined as negative. The above-mentioned inclination angle α is optionally set within a range of from +20° to + 60° or from -20° to -60°, preferably from +40° to +50° or from -40° to -50°.
The operation of the spinning frame having the above-mentioned structure will now be described.
To effectively place on the rotary stream V6 the fibers carried from the fiber passage 6 to the spinning chamber 1, it is preferable to form an outlet opening of the fiber passage at a position facing the inside opening of the exhaust vent 3.
The speeds of the rotary streams in the spinning chamber 1 were measured by using a Pitot tube. The results are given in the speed distribution diagram of FIG. 6, wherein the ordinate represents the speed of the rotary stream while the abscissa represents the radial distance from the rotational center of the spinning chamber. A comparison of this speed distribution diagram with the speed distribution diagram of the conventional spinning frame of FIG. 3 shows that the rotary stream V6 formed by the exhaust vent 3 in the present embodiment is located outward of the rotary stream V4 in the conventional spinning frame and that the radial width and the speed reduction represented by the depth of the trough V7 between the rotary stream V6 and the rotary stream V3 are smaller than those of the trough V5 in the conventional spinning frame (the speed of rotary stream at the trough V7 is higher than that of the trough V5). Accordingly, the radial width of the rotary stream V6 is increased and the radial width of the rotary stream represented by the trough V7 is reduced in the present embodiment. Therefore, the degree of reduction of the speed of the fibers delivered into the spinning chamber 1 from the fiber passage 6, carried with the rotary streams, and moved to the sliding wall by the centrifugal force is much lower than in the conventional spinning frame. As a result, formation of floating fibers and bent fibers is reduced, the number of fibers caught in the formed yarn is decreased, and the yarn quality is improved.
When the static pressure of the central portion 01 of the rotor in the present embodiment was measured, it was found to be lower than in the conventional spinning frame. Accordingly, formation of floating fibers or winding of fibers on the separator can be reduced and the number of fibers caught in the yarn taken into the yarn guide hole 8 can be decreased, whereby the yarn quality can be remarkably improved.
The conventional spinning frame and the spinning frame of the present embodiment were driven at a rotor speed of 50,000 or 60,000 rpm. The exhaust air quantity and the static pressure of the central portion of the rotor were measured. The resultant data are shown in Tables 1 and 2.
TABLE 1______________________________________Rotor Speed = 50,000 rpmInclination angle (å) Exhaust air Static pressure (mmag) ofof exhaust vent quantity (l/sec) central portion of rotor______________________________________-45 3.1 -355-22.5 2.9 -4060 2.7 -45622.5 2.9 -42445 3.1 -370______________________________________
TABLE 2______________________________________Rotor Speed = 60,000 rpm In- Ex- creased Increased static haust exhaust Static Pressure pressureInclination air air (MMAg) (MMAg)angle (å) of quantity quantity of Central of centralexhaust vent (l/sec) (l/sec) portion of rotor portion of rotor______________________________________-45 3.7 0.6 -498 143-22.5 3.5 0.6 -551 1450 3.1 0.4 -616 16022.5 3.4 0.5 -571 14745 3.7 0.6 -508 138______________________________________
In the above tables the symbol l indicates liters, the symbol Ag indicates water, and the symbol mm indicates millimeters.
From the results shown in Table 1 and 2, the following facts can be seen. The exhaust air quantity is larger in the embodiment of the present invention, where the inclination angle α of the exhaust vent is ±22.5° or ±45°, than in the conventional spinning frame, where the inclination angle α is 0°. Furthermore, the static pressure of the central portion of the rotor is reduced in the present invention. The increase of the exhaust air quantity by the increase of the rotor speed of the spinning rotor is larger in the present embodiment, and the increase of the static pressure by the increase of the rotor speed of the spinning rotor is smaller in the present embodiment. Accordingly, it will readily be understood that according to the present invention, a spinning operation can be carried out under better conditions than in the conventional spinning frame, consequently, yarn quality can be improved.
Examination of the qualities of two yarns obtained by a conventional spinning frame and the spinning frame of the above-mentioned embodiment of the present invention at a spinning rotor speed of 60,000 rpm and a winding speed of 125 m/min (forming cotton spun yarn having a count number of 6 s and a twist number of 480 T/m) showed that the yarn obtained according to the present invention was superior in the lea strength, U%, nep number, and substantial twist number, as shown in Table 3.
TABLE 3______________________________________Rotor Speed of 60,000 rpm Conventional Present technique invention______________________________________Lea strength, kg 148 156U % 10.7 10.2Nep number per 1000 m 21 12Cubstantial twist number, T/m 415 465______________________________________
The rotary streams V4 and V6 formed in the conventional spinning frame and the spinning frame of the present invention can be confirmed by the flow visualization method in which titanium oxide is dissolved in an oil, the solution is coated on the top face of the spinning body, and the moving state of the solution is observed while rotating the rotor 2. According to this method, with the conventional technique, as shown in FIG. 7, a white annular portion is formed where the solution gathers at a position corresponding to the opening 3a of the exhaust vent 3. This white annular portion corresponds to the rotary stream V4. The radius r from the center 01 of the rotor is small. With the present invention, as shown in FIG. 8, the radius r1 of the rotary stream V6, indicated by the white annular portion, from the center 01 of the rotor is larger than the radius r in the conventional spinning frame.
As another conventional rotor, there is known a rotor in which an exhaust vent 3 is formed on a gathering groove 2c to perform air-exhaust effectively and to smoothly suck fibers into the gathering groove 2c. In this rotor, however, good quality fibers are readily caused to fly out from the exhaust vent and the two ends of fibers can be introduced into two different exhaust vents, i.e., "bridging", with the result that it becomes difficult to obtain spun yarns having a good quality. Therefore, the opening 3a should be formed on the bottom 2a of the rotor 2.
In addition to the foregoing embodiment, the present invention includes the following embodiments.
(1) As shown in FIGS. 9 and 10, the gathering groove 2c of the rotor 2 is formed at a position raised from the surface of the bottom 2a, and the center 02 of the opening 3a of the exhaust vent 3 is located more outward than in the above-mentioned first embodiment.
Results of experiments have confirmed that, as shown in Table 4, also in this embodiment, the exhaust air quantity is larger than in the conventional technique, the static pressure is lower than in the conventional technique, and the yarn quality is improved as in Table 3 over the quality of the yarn obtained according to the conventional technique.
TABLE 4______________________________________ ExhaustInclination angle (å) air quantity Static pressure (mmAg) ofof exhaust vent (l/sec) central portion of rotor______________________________________-60 3.3 -409-45 3.2 -458-22.5 3.0 -5130 2.9 -56522.5 3.0 -52545 3.1 -47460 3.4 -418______________________________________
(2) The position of the fiber passage 6 is set so that fibers coming from the fiber passage 6 are carried on the rotary stream V6. In this embodiment, also the shape of the separator 7 should be changed. The fibers carried on the rotary stream V6 receive a large centrifugal force while they are violently turned. The fibers smoothly pass through the portion corresponding to the trough V7 in FIG. 6 and are guided to the sliding wall 2b. Accordingly, in this embodiment, formation of floating fibers or bent fibers can be much more reduced than in the case where fibers are directly introduced to the portion corresponding to the trough V7 in FIG. 6. The yarn quality can therefore further be improved over the quality of the yarn obtained in the above-mentioned first embodiment.
As will be apparent from the foregoing description, according to the present invention, by intentionally fixing the center of the opening of the exhaust vent on the bottom of the rotor outward of the central portion of the distance between the rotational center of the rotor and the fiber gathering groove, that is, the central portion of the maximum radius of the spinning chamber, the radial width and the slow down of the air stream represented by the depth of the trough between the rotary stream produced in the vicinity of the sliding wall of the rotor and the rotary stream produced by air flowing into the opening of the exhaust vent can be reduced, and, simultaneously, the static pressure of the central portion of the rotor can be reduced, whereby formation of floating fibers and bent fibers in the spinning chamber or winding of fibers on the separator can effectively be controlled and reduced and the yarn quality can be remarkably improved.
These effects can be enhanced if the angle α, between the radius passing through the center of the opening and the projection of the central axis of the exhaust vent on a plane perpendicular to the rotational axis of the spinning chamber and containing the above-mentioned center of the opening, is inclined at 20° to 60° C. in the direction of rotation of the rotor or the direction opposite thereto. | A fiber control apparatus in an open end spinning frame, which is a spinning rotor provided with a structure capable of producing a rotary stream by which breaking or bending of fibers or formation of floating fibers in a spinning chamber of the rotor can be effectively controlled. This structure is mainly characterized by the arrangement of the exhaust vents formed in the spinning rotor. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application is related to and claims priority from prior provisional application Ser. No. 61/875,605, filed Sep. 9, 2013 which application is incorporated herein by reference.
COPYRIGHT NOTICE
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 37 CFR 1.71(d).
BACKGROUND OF THE INVENTION
The following includes information that may be useful in understanding the present invention(s). It is not an admission that any of the information provided herein is prior art, or material, to the presently described or claimed inventions, or that any publication or document that is specifically or implicitly referenced is prior art.
1. Field of the Invention
The present invention relates generally to the field of fencing and more specifically relates to an adjustable sectional privacy fence system for modular use.
2. Description of the Related Art
Modernly many people live in houses on property. “Good fences make good neighbors,” observed the poet Robert Frost; and although he was speaking of the New Hampshire stone walls that separated his land from that of his neighbor, the fact is that since his time, America has become a nation of fences with good neighbors. In cities and suburbs across the country, fences often define our household boundaries, and fences separate us, our pets and our properties, one from another.
Fences establish a perimeter to our properties, enclosing what we own and value within a solid barrier, blocking entry to those who might covet our possessions or threaten us with harm. Fences provide a ‘visual curtain’ as well, ensuring that even in a densely populated urban or suburban setting, we can enjoy a measure of personal or familial seclusion on our own parcel of earth. There is no doubt that a privacy fence is a great means of keeping your neighbor from minding your business and protecting your property. The trouble with a privacy fence is that view may be compromised for the occupants who from time to time might prefer to adjust, and enjoy a longer view that may be realized from a lower fence. A fence system that allows for adjustability is desirable.
Various attempts have been made to solve the above-mentioned problems such as those found in U.S. Pat. No. 5,661,946 to Kenneth Davis; U.S. Pat. No. 5,577,710 to George T. Kirby; and U.S. Pat. No. 6,772,998 to Ronald William Bebendorf. This art is representative of fences. None of the above inventions and patents, taken either singly or in combination, is seen to describe the invention as claimed.
Ideally, an adjustable sectional privacy fence system should provide privacy when desired and efficiency in use and, yet would operate reliably and be manufactured at a modest expense. Thus, a need exists for a reliable adjustable sectional privacy fence system to avoid the above-mentioned problems.
BRIEF SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known fencing products art, the present invention provides a novel adjustable sectional privacy fence system. The general purpose of the present invention, which will be described subsequently in greater detail is to provide a novel sectional privacy fence that may be easily raised or lowered in height according to circumstances and the desire of the owner. At full height, the adjustable fence ensures a homeowner's privacy; and when a lower position a lower level of privacy and a wider view is achieved; the adjustable fence may be quickly and easily lowered to achieve this effect.
An adjustable sectional privacy fence system is disclosed herein, in a preferred embodiment, comprising: a plurality of adjustable sectional privacy fence assemblies; each of the adjustable sectional privacy fence assemblies comprising: at least one post; at least one post-cap; and at least one panel-section; a powerer; a remote controller; and a mechanical adjusting assembly; wherein the adjustable sectional privacy fence system comprises the plurality of adjustable sectional privacy fence assemblies, the powerer, the remote controller, and the mechanical adjusting assembly in functional combination.
Each of the adjustable sectional privacy fence assemblies comprises the at least one post, the at least one post-cap, and the at least one panel-section. The post-cap is able to be installed in a top of the post to upwardly enclose an interior volume of the post (some may be integral.) The at least one panel-section is able to move in relation to the at least one post (up and down) via the mechanical adjusting assembly as powered by the powerer; the powerer controllable by the remote controller. Some embodiments may be telescopic and move in relation to the next telescopic section. Certain alternate embodiments may allow horizontal travel. The adjustable sectional privacy fence system comprises a modular fencing system which is handy for use on a variety of surface contours and terrains.
The mechanical adjusting assembly is in communication with the powerer (electrical source or the like.) The at least one post preferably comprises at least one track located on an external surface of the at least one post to enable smooth operation of the mechanical adjusting assembly. Alternate embodiments may have one post on either side of the panel-section. Some versions may be connected post to post adjacently to form the modular connection(s). Other embodiments comprise connections modularly able to be made wherein a post-panel-section to an adjacent post-panel-section connection is enabled. The various versions may be used together to form the desired perimeter (corners, straight-sections, etc.).
Each of the adjustable sectional privacy fence assemblies may comprise a pin-and-hole detent means for adjusting and locking the at least one post in relation to the at least one panel-section, the pin-and-hole detent means able to be repeatedly locked and unlocked to limit and unlimit travel respectively as determined by a user to attain the user-preferred privacy level. Other suitably equivalent moving means, manipulating means and locking/unlocking means may be used. The at least one panel-section preferably comprises vinyl to provide a colored esthetic (fit and) finish and protection from environmental degradation (corrosion or the like.)
Each of the adjustable sectional privacy fence assemblies are able to be independently manipulated through ten feet of travel (four to ten feet in preferred embodiments). As such, the “travel” comprises a range from an upper position to a lower position; wherein the lower position provides maximum visual exposure and minimum privacy and the upper position provides minimum visual exposure and maximum privacy. In vertically moveable versions the travel is vertically orientated along the at least one post (adjacent the vertically at least one panel-section.) Travel in telescopic version is relative between adjacent sections.
Preferred embodiments of the mechanical adjusting assembly may comprise a chain and sprocket system, pulley/cable or chain systems or the like. Hydraulic, pneumatic, mechanical, electrical means for manipulation via mechanical adjusting assembly may be used to create substantially equivalent results. The post preferably comprises a square cross-section; however other cross-sections may be used. The adjustable sectional privacy fence system is structured and arranged such that adjustment is available to a user-preferred privacy level as controlled by the user.
A kit is also disclosed including: the plurality of adjustable sectional privacy fence assemblies; the powerer; the mechanical adjusting assembly; the remote controller; and a set of user installation instructions.
A method of using an adjustable sectional privacy fence system is described herein comprising the steps of: installing a set of adjustable sectional privacy fence assemblies in relation to a ground surface according to a ground-surface-contour; manipulating at least one panel-section in relation to at least one post to create a user-preferred privacy level as controlled by a user; and independently adjusting the adjustable sectional privacy fence assemblies in relation to an adjoining section as desired. Telescoping may provide adjustment.
The present invention holds significant improvements and serves as an adjustable sectional privacy fence system. For purposes of summarizing the invention, certain aspects, advantages, and novel features of the invention have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any one particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein. The features of the invention which are believed to be novel are particularly pointed out and distinctly claimed in the concluding portion of the specification. These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The figures which accompany the written portion of this specification illustrate embodiments and method(s) of use for the present invention, adjustable sectional privacy fence system, constructed and operative according to the teachings of the present invention.
FIG. 1 shows a perspective view illustrating an adjustable sectional privacy fence system as to be assembled according to an embodiment of the present invention.
FIG. 2 is a perspective view illustrating an adjustable sectional privacy fence assembly of the adjustable sectional privacy fence system according to an embodiment of the present invention of FIG. 1 .
FIG. 3 is a perspective view illustrating the adjustable sectional privacy fence assembly of the adjustable sectional privacy fence system according to an embodiment of the present invention of FIG. 1 .
FIG. 4 is a perspective view illustrating versions of tops of the adjustable sectional privacy fence assembly of the adjustable sectional privacy fence system according to an embodiment of the present invention of FIG. 1 .
FIG. 5 is a close up perspective view illustrating the various tops of the adjustable sectional privacy fence assembly of the adjustable sectional privacy fence system according to an embodiment of the present invention of FIG. 1 .
The various embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like designations denote like elements.
DETAILED DESCRIPTION
As discussed above, embodiments of the present invention relate to a fencing product and more particularly to an adjustable sectional privacy fence system as used to improve the efficiency and effectiveness of fences.
Generally speaking, the adjustable sectional privacy fence system as disclosed herein is used to improve the adjustability of fencing via modular means. The adjustable fence may be a vinyl or vinyl-clad sectional privacy fence, preferably fabricated and sold in 6-foot, ready-to-install sections, featuring a unique, retractably elevating design which permits the fence height to be altered easily and repeatedly. The adjustable fence, in superficial appearance, may closely resemble other high-quality vinyl or vinyl-clad galvanized privacy fencing, with squared posts, pyramidal post-caps, and intermediate sections of continuous, vertically oriented slat-style panels. Like other privacy fencing, the adjustable fence may be produced in several alternative designs with round posts and scalloped panels, or a woven-rail appearance, for example. As noted, the adjustable fence may be produced in modular, 6-foot sections comprising either of a mid-post and two panels, or a single panel and two end-posts. The sections may molded and pre-fitted to join and lock together, and virtually any property line or slope profile may be accommodated.
Unlike other vinyl or vinyl-clad privacy fencing, the adjustable fence design permits the height of the fence to be varied. This is accomplished by an extendable, retractable design in which the standard 6-foot fence-posts and panels conceal within their interior another, slightly thinner set of posts and panels that may be raised on a sliding track-and-channel mechanism to extend upward, adding height to the fixed fence and appearing continuous with it. The system might for example employ a pin-and-hole, variable-height locking system that may be operated manually, section-by-section, by the homeowner; or a motorized, chain-and-sprocket system, electrically powered and operated by a wired or wireless switch or remote-control, that may raise and lower multiple sections of the fence simultaneously. In either case, the extending sections of the Adjustable Fence may be continuous with the fixed sections, and the slot through which the interior posts and panels rise may be sealed with a flexible, two-sided rubber gasket. Various adjusting means may be used.
The adjustable fence may be raised and extended from a fixed height of 6 feet to a maximum height of 8 to 10 feet, thus offering the homeowner a significant choice in the level of privacy, or the expansiveness of view, afforded by the fence. This adaptability may be ideal for those who, for example, wish to enjoy a more expansive view of their surroundings during the day, yet desire a high level of visual privacy at night. The adjustable fence may be ideal for households with swimming pools or spas; and the height-adjustable design might also appeal strongly to a variety of commercial and institutional enterprises and establishments.
Referring now to the drawings more specifically by numerals of reference there is shown in FIGS. 1-5 , various views of adjustable sectional privacy fence system 100 comprising: a plurality of adjustable sectional privacy fence assemblies 110 ; each of adjustable sectional privacy fence assemblies 110 comprising at least one post 120 , at least one post-cap 130 , and at least one panel-section 140 (may be telescopically related as shown), powerer 150 , and (version of) mechanical adjusting assembly 160 ; wherein adjustable sectional privacy fence system 100 comprises the plurality of adjustable sectional privacy fence assemblies 110 (in adjacent communication and connection as a modular coupled apparatus/system), powerer 150 , and mechanical adjusting assembly 160 in functional combination.
Each of the adjustable sectional privacy fence assemblies 110 comprises the at least one post 120 , the at least one post-cap 130 , the at least one panel-section 140 in connection with each other for user-friendly use. Post-cap 130 is able to be installed in a top 122 of post 120 to upwardly enclose interior volume 124 of post 120 to prevent rain and precipitation from entering therein. Relationally speaking, top 122 of post 120 is not adjacent ground surface 190 .
The at least one panel-section 140 is able to move in relation to the at least one post 120 via mechanical adjusting assembly 160 as powered by powerer 150 . Movement may be telescopic or linear. Mechanical adjusting assembly 160 is in communication with powerer 150 . Adjustable sectional privacy fence system 100 is structured and arranged such that adjustment is available to a user-preferred privacy level as controlled by a user. Adjustable sectional privacy fence system 100 comprises modular fencing system 104 of the plurality of adjustable sectional privacy fence assemblies 110 adjacently placed for use.
Each of the adjustable sectional privacy fence assemblies 110 may comprise two post(s) 120 in certain embodiments, as previously mentioned. Regardless the version having one post 120 ; this version may comprise at least one track 126 located on external surface 128 of the at least one post 120 to enable relative movement of the at least one panel-section 140 via mechanical adjusting assembly 160 .
At least one panel-section 140 preferably comprises vinyl to provide a colored esthetic finish and thus protection from environmental degradation (snow, rain, sunlight and the like.) Alternately, the at least one panel-section 140 comprises vinyl-cladding to envelope galvanized material; the vinyl-cladding providing colored esthetic finish and protection from environmental degradation and minimize corrosion as is the vinyl version. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as user preferences, design preference, structural requirements, marketing preferences, cost, available materials, technological advances, etc., other fencing component materials such as, for example, plastic, non-plastic, ferrous, non-ferrous, composites, etc., may be sufficient.
Each of the adjustable sectional privacy fence assemblies 110 are able to be independently manipulated through about ten feet of travel; wherein the travel is vertically orientated (and/or horizontally orientated.) In telescopic versions a range of about 3 feet per section may be traveled. Post 120 comprises a square cross-section, in certain embodiments as shown; other posts 120 may comprise a circular cross-section. Other cross-sections may be used.
The at least one panel-section 140 may comprise scallops (other profiles may be used, as those disclosed previously.) Each of the adjustable sectional privacy fence assemblies 110 may comprise pin-and-hole detent means 170 for adjusting and locking the at least one post 120 in relation to the at least one panel-section 140 ; pin-and-hole detent means 170 are able to be repeatedly locked and unlocked to limit and unlimit the travel respectively as determined by the user to attain the user-preferred privacy level. The travel has a range from an upper position to a lower position; wherein the lower position provides maximum visual exposure and minimum privacy and the upper position provides minimum visual exposure and maximum privacy. Various intermediate adjustments as to height may be use. Horizontally adjustable versions may comprise various intermediate adjustments. Views and privacy may be manipulated as per user-preference for example for maximum view in daylight conditions and maximum privacy in non-daylight conditions.
Mechanical adjusting assembly 160 may comprise a chain and sprocket system. Cable, pneumatic, hydraulic, electric and other equivalent means may be used to provide relative movement within the present system. Adjustable sectional privacy fence system 100 may further comprise remote controller 180 . Those with ordinary skill in the art will now appreciate that upon reading this specification and by their understanding the art of movement providing means as described herein, methods of activation and use will be understood by those knowledgeable in such art.
Adjustable sectional privacy fence system 100 may be sold as a kit comprising the following parts: a plurality of adjustable sectional privacy fence assemblies 110 ; at least one powerer 150 ; at least one mechanical adjusting assembly 160 ; at least one remote controller 180 ; and a set of user installation instructions. The kit has instructions such that functional relationships are detailed in relation to the structure of the invention (such that the invention can be used, maintained, or the like in a preferred manner). Adjustable sectional privacy fence system 100 may be manufactured and provided for sale in a wide variety of sizes and shapes for a wide assortment of applications. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other kit contents or arrangements such as, for example, including more or less components, customized parts, different panel combinations, parts may be sold separately, etc., may be sufficient.
Method of using an adjustable sectional privacy fence system 100 comprises the steps of: installing a set of adjustable sectional privacy fence assemblies 110 in relation to ground surface 190 according to a ground-surface-contour; manipulating at least one panel-section 140 in relation to at least one post 120 (or telescoping the section) to create a user-preferred privacy level as controlled by a user; and independently adjusting the adjustable sectional privacy fence assemblies 110 in relation to an adjoining section as desired.
It should be noted that the steps described in the method of use can be carried out in many different orders according to user preference. The use of “step of” should not be interpreted as “step for”, in the claims herein and is not intended to invoke the provisions of 35 U.S.C. §112, ¶6. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other methods of use arrangements such as, for example, different orders within above-mentioned list, elimination or addition of certain steps, including or excluding certain maintenance steps, etc., may be sufficient.
The embodiments of the invention described herein are exemplary and numerous modifications, variations and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention. Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientist, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. | A privacy fence includes a lower base portion and a telescopically extendable upper portion that is vertically movable relative to the lower base portion to provide a privacy fence that has a selectively adjustable height. The lower base portion is formed of a panel section extending between two spaced apart posts. The upper telescopic portion also includes a panel member extending between two post members wherein the panel member is received within the interior of the base panel portion and the two post members are received within the posts and connected to an actuation mechanism. As desired, the actuation mechanism can be operated to move the post members vertically, which in turn raises the panel member telescopically out of the base panel portion. Optional flower pots can be mounted on top of the post members to be movable therewith, or to provide flower pots on conventional fence posts. | 4 |
The present invention relates to a method of preparing compounds as defined below, either as a single enantiomer or in an enantiomerically enriched form, by biooxidation of their sulphide equivalents.
BACKGROUND TO THE INVENTION
The racemic form of the compounds prepared by the method of the present invention are known compounds. Some of the compounds are also known in single enantiomeric form. The compounds are active H + K + ATPase inhibitors and they, including their pharmaceutically acceptable salts, are effective acid secretion inhibitors, and known for use as antiulcer agents. The compounds, which include the known compounds omeprazole (compound of formula (IIa) below), lansoprazole (compound of formula (IIc) below) and pantoprazole (compound of formula (IIb) below), are known for example from European Patent Specifications EP 5129 and 124495, EP 174726 and EP 166287.
These compounds, being sulfoxides, have an asymmetric centre in the sulfur atom, i.e. exist as two optical isomers (enantiomers). It is desirable to obtain compounds with improved pharmacokinetic and metabolic properties which will give an improved therapeutic profile such as a lower degree of interindividual variation.
The separation of enantiomers of omeprazole in analytical scale is described in e.g. J. Chromatography, 532 (1990), 305-19. Also the separation of enantiomers of compounds, including omeprazole and pantoprazole, is described in German Patent Specification DE 4035455.
Recently there has been a great deal of literature published relating to the synthesis of optically active compounds using biocatalysts. The majority of this work has been aimed at finding routes to single enantiomer forms of pharmaceuticals. The reactions receiving most attention have been those involved in the preparation of esters, acids and alcohols due to the general utility of these functionalities in synthesis and also because the biocatalysts are readily available.
Studies on the synthesis of optically active sulfoxides are relatively rare partly due to the small number of pharmaceuticals containing sulfoxide groups and partly due to the fact that enzymes that react with the sulphur centre are not available commercially. The synthesis of optically active sulfoxides has been described in Holland, H. L. (1988) Chem. Rev. 88, 473-483 and Phillips, R. S. and Sheldon W. M., Enzyme Microb. Technol., 1981, Vol. 3, January, 9-18.
DESCRIPTION OF THE INVENTION
According to the present invention there is provided a method of preparing a compound of formula (II) either as a single enantiomer or in an enantiomerically enriched form: ##STR1## wherein Het 1 is ##STR2## and Het 2 is ##STR3## and X is ##STR4## wherein: N in the benzimidazole moiety means that one of the carbon atoms substituted by R 6 -R 9 optionally may be exchanged for an unsubstituted nitrogen atom;
R 1 , R 2 and R 3 are the same or different and selected from hydrogen, alkyl, alkoxy optionally substituted by fluorine, alkylthio, alkoxyalkoxy, dialkylamino, piperidino, morpholino, halogen, phenylalkyl, phenylalkoxy;
R 4 and R 4' are the same or different and selected from hydrogen, alkyl, aralkyl;
R 5 is hydrogen, halogen, trifluoromethyl, alkyl, alkoxy;
R 6 -R 9 are the same or different and selected from hydrogen, alkyl, alkoxy, halogen, haloalkoxy, alkylcarbonyl, alkoxycarbonyl, oxazolyl, trifluoroalkyl or adjacent groups R 6 -R 9 may complete together with the carbon atoms to which they are attached optionally substituted ring structures;
R 10 is hydrogen or alkoxycarbonyloxymethyl;
R 11 is hydrogen or forms an alkylene chain together with R 3 ;
R 12 and R 13 are the same or different and selected from hydrogen, halogen or alkyl, which method comprises stereoselective biooxidation of the pro-chiral sulfide counterpart compound.
The compounds of formula (II) are active H + K + ATPase inhibitors. By the method of the invention these compounds, which are sulfoxides, are obtained in single enantiomer form or such that one enantiomeric form is present in excess leading to an optically active product, by stereoselective biooxidation of the pro-chiral starting sulfide counterpart compound.
In the above definitions alkyl groups or moieties may be branched or straight chained or comprise cyclic alkyl groups, for example cycloalkylalkyl.
Preferably:
Het 1 is ##STR5## and Het 2 is ##STR6## and ##STR7## (wherein R 1 , R 2 , R 3 , R 6 to R 9 , R 10 and R 11 are as defined above).
Most preferably the compounds of formula (II) are compounds of the formula (IIa) to (IIe): ##STR8##
An example of a compound of formula (II) wherein R 10 is alkoxycarbonyloxymethyl is ##STR9##
The starting prochiral sulfides used in the method of the present invention are of the formula:
Het.sub.1 --X--S--Het.sub.2 (I)
wherein Het 1 , X and Het 2 are as defined above.
In order to obtain each of the above compounds (IIa)-(IIf), the following starting compounds of formula (Ia) to (If), respectively will be required: ##STR10##
The compounds prepared by the method of the invention possess a stereogenic (asymmetric) centre which is the sulfur atom which forms the sulfoxide group between the Het 1 --X-moiety and the Het 2 -moiety.
The stereoselective biooxidation according to the present invention may be carried out using a microorganism or an enzyme system derivable therefrom. Suitable microorganisms may be selected from alkane oxidisers including Arthrobacter petroleophagus, Brevibacterium paraffinolyticum, and Acinetobacter species, alkene oxidisers such as Mycobacterium species, and a variety of fungal species particularly Penicillium species (Penicillium frequentans).
According to one embodiment of the invention the method comprises contacting the pro-chiral sulfide counterpart compound with a microorganism which is
Penicillium frequentans
Rhizopus stolonifer
Cunninghamella elegans
Ustilago maydis
Arthrobacter petroleophagus
Brevibacterium paraffinolyticum
Acinetobacter sp.
Mycobacterium sp.
or Aspergillus niger
Preferably the microorganism is:
Penicillium frequentans BPFC 386, 585, 623, 733
Rhizopus stolonifer BPFC 1581
Ustilago maydis BPFC 1198, 6333
Arthrobacter petroleophagus ATCC 21494
Brevibacterium paraffinolyticum ATCC 21195
Actinetobacter Sp. NCIMB 9871
Mycobacterium sp. BPCC 1174, 1178, 1179, 1186, 1187
or Aspergillus niger BPFC 32
The microorganisms may be grown on suitable medium containing an appropriate carbon source such as octane, ethene, cyclohexanone or glucose for example.
The compounds of formula (II) are generally acid labile and thus the use of acid conditions is to be avoided. Generally the method according to the invention may be carried out at a pH of 7.6 to 8, suitably about 7.6, and at temperature of 25°-35° C., suitably about 28° C.
The present invention will now be illustrated with reference to the Examples.
EXAMPLE 1
The following microorganisms were screened for sulfoxidation activity against compounds of formula (Ia):
Penicillium frequentans BPFC 386
Penicillium frequentans BPFC 585
Penicillium frequentans BPFC 623
Penicillium frequentans BPFC 733
Rhizopus stolonifer BPFC 1581
Ustilago maydis BPFC 1198
Ustilago maydis BPFC 6333
Arthrobacter petroleophagus ATCC 21494
Brevibacterium paraffinolyticum ATCC 21195
Acinetobacter sp NCIMB 9871
Mycobacterium sp BPCC 1174
Mycobacterium sp BPCC 1178
Mycobacterium sp BPCC 1179
Mycobacterium sp BPCC 1186
Mycobacterium sp BPCC 1187
Growth Conditions
The growth conditions for the above microorganisms were as follows. The following fungi:
Penicillium frequentans BPFC 386
Penicillium frequentans BPFC 585
Penicillium frequentans BPFC 623
Penicillium frequentans BPFC 733
Rhizopus stolonifer BPFC 1581
Ustilago maydis BPFC 1198
Ustilago maydis BPFC 6333
were grown in 200 ml of sterile liquid medium (I) with the composition of (per liter) K 2 HPO 4 (1.9 g), NaH 2 PO 4 2H 2 O (2.02 g), ammonium sulfate (1.8 g), magnesium sulfate (0.2 g), ferric chloride (0.97 mg), and trace elements solution (1 ml) pH 7.2. The composition of the trace elements solution used was as follows (in g/l):
______________________________________ CuSO.sub.4.5H.sub.2 O 0.02 MnSO.sub.4.4H.sub.2 O 0.1 ZnSO.sub.4.7H.sub.2 O 0.1 CaCO.sub.3 1.8______________________________________
The above medium was supplemented with 0.2% w/v yeast extract and 2.2% w/v glucose. The medium contained in 1L baffled flasks was inoculated either by adding a suspension of spores in sterile distilled water or by the addition of a plug of agar containing the fungi from a Sabouraud Dextrose plate. Fungi were grown at 28° C. on a rotary shaker at 150 rpm for 48 hours. With the exception of Ustilago maydis, the fungal biomass obtained from liquid culture was harvested by filtration on a Whatman Grade 113 filter paper and washed on the filter with 50 mM sodium phosphate buffer, pH7.6. Ustilago maydis was harvested by centrifuging for 20 minutes at 8,000 rpm and 4° C. The biomass was washed by resuspending in 50 mM sodium phosphate buffer, pH 7.6 and centrifuging as above.
The bacteria were grown with the sources of carbon shown in Table 1:
TABLE 1______________________________________Microorganism Carbon Source______________________________________Arthrobacter petroleophagus ATCC 21494 OctaneBrevibacterium paraffinolyticum ATCC 21195 OctaneAcinetobacter sp NCIMB 9871 CyclohexanoneMycobacterium sp BPCC 1174, 1178, 1179, 1186, 1187 Ethene______________________________________
The growth of Acinetobacter sp. NCIMB 9871 on cyclohexanone was performed in 100 ml of liquid medium (I) in a 500 ml baffled flask containing a centre well. Cydohexanone was placed in the centre well. The microorganism was grown at 28° C. on a rotary shaker at 150 rpm for 24-48 hours.
Growth of Arthrobacter petroleophagus ATCC 21494 and Brevibacterium paraffinolyticum ATCC 21195 on octane was performed in 200 ml of liquid medium (I) containing 0.2% w/v yeast extract in a 1L baffled flask. Octane (1 ml) was added directly to the medium without sterilization. The above microorganisms were grown at 28° C. on a rotary shaker at 150 rpm for 24-48 hours.
Mycobacterium sp BPCC 1174, 1178, 1179, 1186 and 1187 were grown in 500 ml liquid medium (I) in a 2L non-baffled flask fitted with a rubber bung. The flask was partially evacuated and then charged with ethene. Growth was conducted at 28° C. on a rotary shaker at 150 rpm for 7 days.
Growth of Arthrobacter petroleophagus ATCC 21494 and Brevibacterium paraffinolyticum ATCC 21195 was also performed on glucose. Each microorganism was inoculated into 200 ml medium (I) containing 0.2% w/v yeast extract and 2.2% w/v glucose. Growth was performed at 28° C. on a rotary shaker at 150 rpm for 24-48 hours.
All bacteria were harvested from liquid medium by centrifuging at 8,000 rpm and 4° C. for 20 minutes. Cells were washed by resuspending in 50 mM sodium phosphate buffer, pH 7.6 followed by centrifuging as above.
Biooxidation Reactions
Biotransformations were performed for each microorganism in 50 mM sodium phosphate buffer, pH 7.6 with 5-10 g/l dry cell weight and a substrate concentration of 1 g/l. The cells were incubated with the compound of formula (Ia) on a rotary shaker at 28° C. for 18-20 hours.
Samples were removed from the biotransformation and either centrifuged or filtered to remove biomass and analysed directly.
Detection of Products
The biooxidation of the compound of formula (Ia) was followed by reverse phase HPLC on a Spherisorb S5-ODS2 reverse phase column eluted with a 50:50 mixture of acetonitrile and 25 mM sodium phosphate buffer, pH 7.6 at a flow rate of 0.8 ml/min. Under such conditions the compounds of formulae (IIa) and (Ia) were well resolved with retention times of 5.2 and 9.8 minutes respectively. Both compounds were detected at a wavelength of 300 nm.
The enantiomeric composition of the compound of formula (IIa) formed was investigated by the following method. After removal of biomass the aqueous media was extracted with two volumes of ammonia saturated dichloromethane. The pooled organic extracts were dried over anhydrous sodium sulfate and the solvent was evaporated under reduced pressure to afford a pale brown solid. Then the enantiomeric composition of sulfoxide was determined by chiral HPLC on a Chiralpak AD Column under the following conditions:
Column Chiralpack AD 250 mm×4.6 mm interior
diameter with 50 mm guard column
Eluent Hexane:Ethanol:Methanol (40:55:5% V/V)
Flow 1.0 ml/min
Injection Volume 20 μl
Wavelength 300 nm
Retention times
Compound of formula (Ia) 5.1 min
Compound of formula (IIa):
(+) Enantiomer 8.5 min
(-) Enantiomer 13.4 min
The following results were obtained:
TABLE 2______________________________________ Compound Enantio- of Formula meric EnantiomerMicroorganism (IIa) (ppm) excess (%) ((+) or (-))______________________________________Penicillium frequentans 23 >99 (-)BPFC 386Penicillium frequentans 2.1 >99 (-)BPFC 585Penicillium frequentans 3.0 95 (-)BPFC 623Penicillium frequentans 2.6 87 (-)BPFC 733Rhizopus stolonifer BPFC 1581 3.0 56 (-)Ustilago maydis BPFC 1198 8.0 88 (-)Ustilago maydis BPFC 8333 34.0 99 (-)Arthrobacter petroleophagus 24.0 96 (-)ATCC 21494Brevibacterium paraffinolyticum 13.0 >99 (-)ATCC 21195Acinetobacter sp NCIMB 9871 0.4 17 (-)Mycobacterium sp BPCC 1174 10.0 97 (-)Mycobacterium sp BPCC 1178 3.3 93 (-)Mycobacterium sp BPCC 1179 9.0 96 (-)Mycobacterium sp BPCC 1186 11.0 97 (-)Mycobacterium sp BPCC 1187 6.0 96 (-)______________________________________
The enantiomeric excess value gives an indication of the relative amounts of each enantiomer obtained. The value is the difference between the relative percentages for the two enantiomers. Thus, for example, when the percentage of the (-) enantiomer of the formed sulfoxide is 97.5% and the percentage for the (+) enantiomer is 2.5%, the enantiomeric excess for the (-) enantiomer is 95%.
With Arthrobacter petroleophagus ATCC 21494 and Brevibacterium paraffinolyticum ATCC 21195 the stereoselectivity of the biooxidation was unaffected by the choice of carbon source used for growth (octane and glucose).
EXAMPLE 2
Compounds of formula (Id) and (Ie) were screened against a range of microorganisms for the production of the corresponding sulfoxides. The growth of microorganisms and subsequent biotransformations were performed as in Example 1 except that the reaction times were as listed in Tables 5 and 6. Aspergillus niger BPFC 32 was grown in the same way as the fungi were grown in Example 1.
Detection of Products
The biooxidation of the compounds of formula (Id) and (Ie) was followed by reverse phase HPLC as in Example 1 except that the retention times were as follows:
TABLE 3______________________________________Compound of formula Retention time (min)______________________________________Id 13.7IId 5.0Ie 9.4IIe 4.3______________________________________
The enantiomeric composition of the compounds of formula (IId) and (IIe) was investigated by the method of Example 1 except in the chiral HPLC the solvent compositions, flow rates and retention times were as follows:
TABLE 4______________________________________Com-pound Flow rateof formula Solvent Compositon (ml/min) Retention Time______________________________________IId Hexane/Ethanol 1.0 12.9 (Enantiomer A) (70:30% v/v) 21.7 (Enantiomer B) Hexane/Ethanol/Methanol 1.0 7.4 (Enantiomer A) (40.55:5% v/v) 10.6 (Enantiomer B)IIe Hexane/Ethanol 1.0 26.0 (Enantiomer A) (70:30% v/v) 30.5 (Enantiomer B)______________________________________
In Table 4 the first enantiomer eluted is referred to as enantiomer A and second as enantiomer B. The results are summarised in Tables 5 and 6.
TABLE 5__________________________________________________________________________ Aqueous concentration (PPM) Compound Compound Reaction of formula of formula E.e.Microorganism time (h) (Id) (IId) % Enantiomer__________________________________________________________________________Mycobacterium sp. BPCC 1174 42 5 16.7 >99 AMycobacterium sp. BPCC 1178 42 5.9 14.4 >99 AMycobacterium sp. BPCC 1179 42 6.6 17.4 >99 AMycobacterium sp. BPCC 1186 42 4.8 42 >99 AMycobacterium sp. BPCC 1187 42 7.4 18.3 >99 AArthrobacter petroleophagus ATCC 21494 42 3.5 6.6 >99 ABrevibacterium paraffinolyticum ATCC 21195 42 2.6 21.7 >99 AUstilago maydis BPFC 1198 18 6.7 45 >99 AUstilago maydis BPFC 6333 18 4.6 43 >99 AAspergillus niger BPFC 32 42 5.6 2.7 -- --Penicillium frequentans BPFC 386 18 5 0 -- --Penicillium frequentans BPFC 585 48 5.2 0 -- --Penicillium frequentans BPFC 623 48 4.5 0 -- --Penicillium frequentans BPFC 733 18 3.5 0 -- --__________________________________________________________________________ (E.e. means Enantiomeric excess)
TABLE 6__________________________________________________________________________ Aqueous concentration (PPM) Compound Compound Reaction of formula of formula E.e.Microorganism time (h) (Ie) (IIe) (%) Enantiomer__________________________________________________________________________Mycobacterium sp. BPCC 1179 42 1.6 3.3 >99 AArthrobacter petroleophagus ATCC 21494 42 3.2 0 -- --Brevibacterium paraffinolyticum ATCC 21195 72 4.0 1.6 -- --Ustilago maydis BPFC 1198 18 2.3 0 -- --Ustilago maydis BPFC 6333 72 3.2 0 -- --Asergillus niger BPFC 32 72 3.7 9.2 -- --Penicillium frequentans BPFC 386 72 3.1 0.5 -- --Penicillium frequentans BPFC 585 48 3.2 3.2 -- --Penicillium frequentans BPFC 623 48 2.9 1.5 83.4- BPenicillium frequentans BPFC 733 18 3.2 0 --__________________________________________________________________________
The oxidation of the compound of formula (Id) produced in all cases the "A" enantiomer of the compound of formula (IId) in excellent enantiomeric excess but in low yield. The four strains of Penicillium frequentans previously shown to oxidise the compound of formula (Ia), failed to oxidise the compound of formula (Id).
The oxidation of the compound of formula (Ie) produced fewer results. This compound proved to be particularly insoluble making the detection of product difficult. Whilst in a number of cases sulfoxide was produced, its concentration was too low to determine the enantiomeric excess. However two results were obtained with Mycobacterium sp. and Penicillium frequentans both affording sulfoxide of high enantiomeric excess but interestingly of opposite stereoselectivity.
EXAMPLE 3
The microorganisms listed in Table 9 below were screened for sulfoxidation activity against compounds of formula (Ib). They were grown under the same condition as in Examples 1 and 2.
Biotransformations were performed following the protocol of Example 1 except that the dry cell weight was increased to approximately 20 gL -1 and the reaction time was extended.
Detection of Products
The biooxidation of the compound of formula (Ib) was followed by reverse phase HPLC as in Example 1 except that the retention times were as follows:
TABLE 7______________________________________Compound of formula Retention time (min)______________________________________Ib 8.1IIb 4.2______________________________________
The enantiomeric composition of the compound of formula (IIb) was investigated by the method of Example 1 except in the chiral HPLC the solvent composition, flow rate and retention time were as follows:
TABLE 8______________________________________Solvent composition Flow Rate (ml/min) Retention times (min)______________________________________Hexane/ethanol (70:30%) 1.0 32.3 (Enantiomer A) 36.6 (Enantiomer B)______________________________________
In Table 8 the first enantiomer eluted is referred to as enantiomer A and the second as enantiomer B.
The results are summarised in the following table:
TABLE 9__________________________________________________________________________ Aqueous concentration (PPM) Compound Compound Reaction of formula of formula E.e.Microorganism time (h) (Ib) (IIb) % Enantiomer__________________________________________________________________________Mycobacterium sp. BPCC 1178 72 8.6 3.4 8.2 BBrevibacterium paraffinolyticum ATCC 21195 72 8.4 4.0 26.6 BUstilago maydis BPFC 6333 72 8.2 4.3 >99 AAspergillus niger BPFC 32 72 5.6 28.0 >99 APenicillium frequentans BPFC 386 72 8.4 4.5 -- --Penicillium frequentans BPFC 585 48 6.5 11.4 -- --Penicillium frequentans BPFC 623 48 7.7 6.5 -- --__________________________________________________________________________ (E.e. means enantiomeric excess)
The microorganisms listed in Table 9 were also screened under identical conditions for sulfoxidation of the compound of formula (Ic) but no product of formula (IIc) could be detected.
Deposits Of Microorganisms
The following microorganisms were deposited at the National Collections of Industrial and Marine Bacteria Ltd (NCIMB), 23 St. Machar Drive, Aberdeen, Scotland AB2 1RY on 25 Nov. 1994:
1. Mycobacterium sp BPCC 1174 Accession No. NCIMB 40695
2. Mycobacterium sp BPCC 1178 Accession No. NCIMB 40696
3. Mycobacterium sp BPCC 1179 Accession No. NCIMB 40697
4. Mycobacterium sp BPCC 1186 Accession No. NCIMB 40698
5. Mycobacterium sp BPCC 1187 Accession No. NCIMB 40699
The following microorganisms were deposited at the International Mycological Institute (IMI), Bakeham Lane, Englefield Green, Egham, Surrey TW20 9TY, England on 28 Nov. 1994:
6. Penicillium frequentans BPFC 386 Accession No. IMICC 364802
7. Penicillium frequentans BPFC 585 Accession No. IMICC 364801
8. Penicillium frequentans BPFC 623 Accession No. IMICC 364800
9. Penicillium frequentans BPFC 733 Accession No. IMICC 364799
10. Rhizopus stolonifer BPFC 1581 Accession No. IMICC 364798
11. Ustilago maydis BPFC 1198 Accession No. IMICC 364797
12. Ustilago maydis BPFC 6333 Accession No. IMICC 364796
13. Asperigillus niger BPFC 32 Accession No. IMICC 364795 | Enantiomeric or enantiomerically enriched H + K + ATPase inhibiting pyridinylsulfinyl--benzimidazoles are prepared using microorganisms or microbial enzyme systems to enantioselectively biooxidize corresponding prochiral sulfide compounds and isolating the pharmaceutically active enantiomer or enantiomerically enriched sulfoxide form. | 2 |
BACKGROUND OF THE INVENTION
I. Field of the Invention
This invention relates to cutting tools and particularly to rotatable cutting tools of the type having at least one cutting element the position of which relative to the tool is adjustable by remotely controllable adjusting devices. More particularly, this invention relates to improved actuators for remotely controlled adjusting of relative position of cutting elements of rotatable cutting tools.
II. Description of Related Art
Known rotatable tools comprising position adjustable cutting elements use various means for effecting changes of position of the cutting elements. Examples of such rotatable tools using mechanical actuating devices are illustrated in EP Patent Application No. 1123766. An example of a rotatable tool using hydraulic actuating devices requiring supply of hydraulic fluid is illustrated in Japanese Utility Model Application No. 62-201231. Tools of this type have the inherent disadvantage of requiring couplings for supply of hydraulic fluid through the tool driving device. U.S. Pat. No. 4,941,782 illustrates tools of the type wherein pneumatic pressure is supplied to a rotatable tool from an external source to control operation of a hydraulically operated device within the tool body. Such known tools have the disadvantage of requiring sliding seals between internal pistons and cavities containing hydraulic fluids. Such seals, if not routinely replaced and reconditioned are a common source of leakage of hydraulic fluid, impairing operation of the adjusting devices. In light of known rotatable tools providing remotely controllable hydraulically operated adjusting devices for adjusting the position of cutting elements, there is a need for improved actuators for such tools to overcome the disadvantages associated with the known hydraulic devices.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a rotatable cutting tool having mounted within an internal cavity a totally enclosed hydraulic force multiplier responsive to a control force for effecting adjustment of position of a cutting element mounted to the tool.
It is a further object of the present invention to provide a rotatable cutting tool having a cutting element mounted to a support member, a totally enclosed hydraulic force multiplier mounted within an internal cavity of the tool and responsive to a control force, a push rod responsive to force applied by the force multiplier to move along a first vector, and a drive member interposed between the push rod and the support member for converting motion along the first vector to motion along a second vector intersecting the first vector.
Further objects and advantages of the invention shall be made apparent from the accompanying drawings and the following description thereof.
In accordance with the aforesaid objects the present invention provides a rotatable cutting tool having a shank portion for mounting to a tool driving device and a cutting portion to which is attached at least one support member for retention of a replaceable cutting element. The support member is so arranged to permit displacement of at least the portion thereof retaining the cutting element whereby the position of the cutting element relative to the body of the cutting tool may be changed by such displacement. A totally enclosed hydraulic force multiplier is mounted within an internal cavity of the cutting tool. The force multiplier is responsive to a control force to effect the displacement of the support member, the control force advantageously supplied by application of pneumatic pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a three dimensional view of a cutting tool having a repositionable cutting element cartridge.
FIG. 2 is a partial sectional view of the cutting portion of the cutting tool of FIG. 1
FIG. 3 is an enlarged view of a portion of a cutting tool showing an alternative cutting element cartridge.
FIG. 4 a is an enlarged view of a portion of a cutting tool of FIG. 2 showing the push rod advanced.
FIG. 4 b is an enlarged view of a portion of the cutting tool of FIG. 2 showing the push rod retracted.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention shall be described with reference to a preferred embodiment illustrated in the accompanying figures. While the preferred embodiment illustrates features of the invention, it is not the intention of applicants that the invention be limited to particular details of the preferred embodiment.
A rotatable cutting tool 10 depicted in FIG. 1 includes a shank portion 12 and a cutting portion 14 . Shank portion 12 is suitable for mounting to an adapter 16 for connection to a tool driving apparatus such as the rotatable spindle of a machine. Adapter 16 may be suitable for tool driving spindles of machines lacking automatic tool changing mechanisms. Further, adapter 16 advantageously conforms to standards to assure compatibility with standardized automatic tool changing equipment, such as well known standards for such adapters: HSK; DIN ISO/DIS 12164-1 & -2; ANSI 7/24 tapers; and, Japan's BT 7/24 tapers. Cutting portion 14 is generally cylindrical and comprises a cutter body 22 to which cutting elements are mounted. As illustrated in FIG. 1 , a cutting element 18 is mounted to a support member 20 which is attached to cutter body 22 .
Continuing with reference to FIG. 1 , cutting element 18 is advantageously a replaceable body seated upon a recess of a support member, such as cartridge 20 ( FIG. 2 ) and retained thereupon by screws, clamps, shims and the like to achieve a desired orientation of the cutting element with sufficient rigidity to resist dislocation of the cutting element by cutting forces. Cutting element 18 may comprise one or more cutting edges and is retained on cartridge 20 to expose at least one cutting edge for contact with a workpiece while tool 10 is rotated. The cutting edge so arranged is referred to as the “active cutting edge”. Adjustment of the position of cutting element 18 relative to tool 10 is achieved by adjustment of the position of, at least, the portion of cartridge 20 to which cutting element 18 is affixed by a drive member within tool 10 .
Cutting element 18 advantageously comprises a replaceable insert made of hard materials, such as high-speed steel, cemented tungsten carbide, ceramic materials, and the like, as are well known. The replaceable insert is advantageously made to include particular geometric features to enhance cutting performance in particular applications, including relief surfaces, chipbreaking features, chip controlling grooves and the like, all as are well known. Further, the replaceable insert may be formed to effect particular orientations of the cutting edges relative to the cutting tool axis of rotation as the inserts are mounted to the tool body, as is well known. Replaceable inserts usable in the present invention may be of a wide variety of shapes and sizes chosen for the particular type of machining to be performed all as are well known.
Referring to FIG. 2 , cartridge 20 is pivotally mounted to cutter body 22 by pivot pin 24 . Cartridge 20 is pivoted on pin 24 by radial displacement of a drive member such as follower 26 (see FIG. 3 ). Advantageously, to effect radial displacement of the drive member, and hence changes of radial position of cutting element 18 , without transverse mounting of an actuator, a push rod 40 is interposed between follower 26 and an actuator. Head 28 of follower 26 engages driving region 42 of push rod 40 , reciprocation of push rod 40 parallel to the longitudinal axis of tool 10 being converted to radial motion of follower 26 . Hence, push rod 40 and follower 26 are effective to convert motion of an actuator along a first vector to motion of the driving member along a second vector intersecting the first vector. A restoring force opposing displacement of follower 26 is provided by biasing member 30 (shown dashed in FIG. 2 ). Advantageously, biasing member 30 acts on follower 32 engaging restoring region 44 of push rod 40 , whereby the restoring force can be varied within the span of displacement of follower 26 . Hence, where biasing member 30 comprises a spring or other resilient member wherein the restoring force is a function of the effective length of the resilient member, the restoring force may be kept substantially constant throughout the travel of follower 26 .
Referring to FIG. 3 , an alternative arrangement for cutting element cartridge 21 is illustrated in an enlarged partial section. Cutting element cartridge 21 is attached to cutter body 22 by a fixed mounting using mounting screws 50 and 52 so as to leave a portion of cutting element cartridge 21 free from cutter body 22 . Follower 32 engages the free portion of cutting element cartridge 21 . Displacement of follower 32 away from push rod 40 elastically deforms cutting element cartridge 21 to radially adjust the position of cutting element 18 relative to cutter body 22 . The elastic deformation of cutting element cartridge 21 provides a restoring force without use of an additional member such as biasing member 30 illustrated in FIG. 2 .
Irrespective of whether the cutting element cartridge is pivotally mounted to cutter body 22 as shown in FIG. 2 or attached by a fixed mounting as shown in FIG. 3 , reciprocation of push rod 40 within cutter body 22 displaces driving region 42 relative to follower 26 . As shown in the enlarged partial sectional view of FIG. 4 a , with push rod 40 advanced, oblique surface 46 ( FIG. 4 b ) of driving region 42 engages oblique surface 48 of head 28 to displace follower 26 away from push rod 40 . As shown in the enlarged partial sectional view of FIG. 4 b , with push rod 40 retracted, oblique surface 46 of driving region 42 is disengaged from oblique surface 48 ( FIG. 4 a ) of head 28 allowing the restoring force of biasing member 30 to displace follower 28 toward push rod 40 . The radial displacement of follower 26 effects rotation of cartridge 20 about pivot pin 24 altering the position of cutting element 18 relative to cutter body 22 .
Continuing with reference to FIG. 2 , reciprocation of push rod 40 is effected by hydraulic force multiplier 70 within cutter body 22 and restoring spring 56 fitted between end face 58 of push rod 40 and seat 60 of cavity 62 in cutter body 22 . Force multiplier 70 responds to application of a control force, advantageously provided by a variable pneumatic pressure, to produce sufficient force to overcome the restoring force of spring 56 to advance push rod 40 to compress spring 56 . Push rod 40 and force multiplier 70 may be advantageously mechanically connected by attachment of push rod 40 to piston 74 of force multiplier 70 . In FIG. 2 an interfitting connection is shown in dashed lines at the interface of push rod 40 and piston 74 , the dashed lines representative of, for example, a threaded connection whereby stand off of push rod 40 from piston 74 is adjustable. Not shown in FIG. 2 , there will be provided conventional facilities for locking the connection of push rod 40 and piston 74 once the desired stand off has been established. With a mechanical connection of push rod 40 and piston 74 , as an alternative arrangement to single spring 56 acting on push rod 40 , one or more springs may be arranged to act directly on piston 74 .
Force multiplier 70 comprises small piston 72 and large piston 74 . Large piston 74 is slidably supported within cavity 80 in the interior of cutter body 22 . Force multiplier 70 further comprises small bellows 76 surrounding small piston 72 and large bellows 78 surrounding the volume within which small piston 72 is displaceable. Small bellows 76 and large bellows 78 are advantageously formed of material permitting repeated compaction and expansion along their respective longitudinal axes without perforation from deformation of the bellows folds. Applicants have chosen metallic bellows for both small bellows 76 and large bellows 78 . A rearward extension of mounting flange 82 closely surrounds a portion of small bellows 76 , large bellows 78 surrounds the rearward extension of mounting flange 82 surrounding small bellows 76 , and mounting flange 82 is rigidly fixed to the interior of cutter body 22 . It will be seen that adjustment of stand off of push rod 40 from large piston 74 permits compensation for manufacturing tolerances of the distance from the fixing surface of mounting flange 82 to large piston 74 with large bellows 78 relaxed, i.e. neither expanded nor compacted. The portion of mounting flange 82 surrounding small bellows 76 serves to maintain alignment of small bellows 76 along the longitudinal axis of cavity 80 as small bellows 76 is compacted and expanded. A forward extension of large piston 74 is slidably received within a bore (shown dashed in FIG. 2 ) of small piston 72 , this sliding engagement maintaining alignment of small piston 72 and large piston 74 . A front end of small bellows 76 is fixed to the rear of small piston 72 to form a seal therewith and a rear end of small bellows 76 is fixed to the front face of the rear end of flange 82 to form a seal therewith. A front end of large bellows 78 is fixed to the rear of the front end of flange 82 to form a seal therewith and a rear end of large bellows 78 is fixed to the front face of large piston 74 to form a seal therewith.
By virtue of the sealed attachments of the front and rear ends of large bellows 78 and small bellows 76 as described, a volume is contained within the space surrounded by large bellows 78 and small bellows 76 whereby hydraulic force multiplier 70 constitutes a totally enclosed force multiplier. The totally enclosed volume is filled with an essentially incompressible fluid. As small piston 72 is moved in the direction of large piston 74 , collapsing small bellows 76 , the fluid displaced applies a force on the front face of large piston 74 . With sufficient force thereby applied to large piston 74 to overcome the restoring force of spring 56 , large piston 74 moves away from small piston 72 , expanding large bellows 78 . By virtue of the ratio of effective areas of large piston 74 and small piston 72 , a relatively small force acting on small piston 72 is multiplied to a relatively large force acting on push rod 40 . Further, by virtue of the ratio of the relatively small diameter of small bellows 76 and the relatively large diameter of large bellows 78 , a relatively large translation of small piston 72 is converted to a relatively small translation of large piston 74 . Hence, precise changes of location of cutting element 18 relative to tool 10 , precisely changing the effective machining dimension of tool 10 , may be made within the range of adjustment permitted by the range of travel of large piston 74 . The use of surrounding bellows in force multiplier 70 overcomes the chronic leaking of known hydraulic force multipliers operating with pistons sealed within fixed volume cavities by sliding seals.
Continuing with reference to FIG. 2 , front face 84 of small piston 72 abuts cuphead 86 . Cuphead 86 abuts rolling diaphragm 88 fixed at its periphery to cutter body 22 so as to form a seal therewith creating a sealed volume of cavity 90 . A controlling force is applied to rolling diaphragm 88 by pneumatic pressure via channel 92 through cutter body 22 . Rolling diaphragm 88 deforms in response to pressure differences between pressure in the sealed volume of cavity 90 and the pressure applied through channel 92 . Rolling diaphragm 88 deforms so as to change the offset of the relatively large projecting central portion from the relatively narrower annular recessed portion while simultaneously changing the distance of the annular recessed portion from the surface to which the periphery of diaphragm 88 is affixed. Small piston 72 is moved in response to the force applied by deformation of rolling diaphragm 88 and the restoring force of spring 56 transferred through force multiplier 70 . A restoring spring 94 is interposed between the interior of cuphead 86 and the front face of the front end of mounting flange 82 and surrounding the portion of small bellows 76 projecting forwardly beyond mounting flange 82 . Restoring spring 94 provides a restoring force to return rolling diaphragm 88 to its equilibrium shape. Hence, by controlling the pneumatic pressure applied through channel 92 , deformation of rolling diaphragm 88 can be controlled, and location of small piston 72 within its range of motion can be controlled. Since relatively large changes of location of small piston 72 effect relatively small changes of location of large piston 74 , precise adjustment of the location of cutting element 18 relative to tool 10 can be achieved with regulation of the applied pneumatic pressure. Hence, precise adjustment of effective machining dimensions of tool 10 can be achieved throughout the range of displacement of cutting element 18 by controlling the applied pneumatic pressure.
While the invention has been described with reference to a preferred embodiment, and the preferred embodiment has been described in considerable detail, it is not the intention of the applicants that the invention be defined by the preferred embodiment. Rather, it is the intention of the applicants that the invention be defined by the appended claims and all equivalents thereto. | A rotatable cutting tool has a shank portion for coupling to a tool driving device and a cutting portion to which is attached at least one support member for retention of a replaceable cutting element. The support member is so arranged to permit displacement of at least the portion thereof retaining the cutting element whereby the position of the cutting element relative to the body of the cutting tool may be changed by such displacement. A totally enclosed hydraulic force multiplier is mounted within an internal cavity of the cutting tool. The force multiplier is responsive to a control force to effect the displacement of the support member, the control force advantageously supplied by application of pneumatic pressure. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority of German Patent Application No. DE 10 2014 109 616.9, filed Jul. 9, 2014, which is hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a 9-speed transmission for a motor vehicle, which theoretically is composed of an input-side drive group made up of two simple planetary gear sets and an output group connected to the drive group via two connecting shafts, each including multiple shift elements.
Such a transmission is known both from US 2012/01721 72 A1 and from DE 10 2009 025 609 A1.
The output groups of these transmissions and the drive groups are composed of two simple planetary gear sets having associated shift elements. In total, six shift elements are provided, namely three brakes and three clutches. The known transmissions implement a multi-stepped, progressive transmission range of the 9 forward gears where, in each gear, three of the present shift elements are closed and the remaining are open. The disadvantage with the known transmissions is, in part, the very high circumferential speeds which may occur in particular on one of the ring gears of the output group. According to a realistic estimation based on typical stationary gear ratios and transmission dimensions, the ring gear of the output group rotating the fastest may encounter circumferential speeds of 60 m/s to 70 m/s. Such circumferential speeds must be considered borderline even with a very strong (and consequently expensive) design of the elements.
SUMMARY OF THE INVENTION
It is the object of the present invention to refine the known transmissions in such a way that lower the maximum circumferential speeds which occur at a functionally approximately identical behavior.
This object is achieved by a transmission system of the present invention, namely by a transmission system for a motor vehicle including a drive stage coupleable via an input shaft to a drive assembly of the motor vehicle, an output stage connected to the drive stage via a first connecting shaft and a second connecting shaft and couplable to an output of the motor vehicle via an output shaft, and a transmission housing surrounding the drive stage and the output stage, the drive stage including
a first planetary gear set having a first sun gear, a first ring gear and a first planet carrier, on which a set of first planet gears is rotatably mounted, which mesh with the first sun gear on the one hand and with the first ring gear on the other hand, a second planetary gear set having a second sun gear, a second ring gear and a second planet carrier, on which a set of second planet gears is rotatably mounted, which mesh with the second sun gear on the one hand and with the second ring gear on the other hand, and a first clutch and a second clutch, with the aid of which in each case two elements of the planetary gear sets of the drive stage are shiftably coupled to each other, and a first brake and a second brake, with the aid of which in each case one element of the planetary gear sets of the drive stage is shiftably coupled to the housing, and the output stage including a Ravigneaux planetary gear set having a first Ravigneaux sun gear, a second
Ravigneaux sun gear, a Ravigneaux ring gear and a Ravigneaux planet carrier, on which two sets of Ravigneaux planet gears are rotatably mounted, namely one set of short planet gears and one set of stepped long planet gears having one larger and one smaller long planet stage, of which one long planet stage meshes with the short planet gears, one of the Ravigneaux sun gears meshing with the set of short planet gears, and the Ravigneaux ring gear meshing with one of the sets of Ravigneaux planet gears, and the other of the Ravigneaux sun gears meshing with the long planet stage [and] not meshing with the short planet gears,
a third clutch, with the aid of which one element of the Ravigneaux planetary gear set is shiftably coupled to the second connecting shaft, and a third brake, with the aid of which the first Ravigneaux sun gear is shiftably coupled to the housing.
The present invention is based on the basic idea of combining the two simple planetary gear sets of the output group to form one Ravigneaux planetary gear set and of transforming the fastest ring gear of the output group in the known transmissions to one of the sun gears of the Ravigneaux planetary gear set. Due to the very much smaller diameter of the sun gear compared to the ring gear, with an otherwise identical design, considerably lower maximum circumferential speeds arise, which in particular may be below the limiting value of 40 m/s, which is generally considered to be favorable.
The drive group may essentially be retained compared to the above-mentioned prior art; however, it may also be varied in moderation within the scope of the present invention. Variation options also exist within the scope of the present invention for the specific design of the output group.
It shall be noted at this point that, within the scope of the present description, the term “connect” or “connection” is used for fixed connections of two elements which are not detachable during the intended operation. Contrary to this, the term “couple” or “coupling” is used in a more general manner and includes both the above-mentioned connections and couplings which are detachable during the intended operation, the latter in each case being explicitly referred to as “shiftably coupled” if necessary. The term “shift element” within the scope of the present invention includes both “brakes,” which in each case shiftably couple a rotating element to the transmission housing, and “clutches,” which in each case shiftably couple two elements rotating relative to the transmission housing. This selection of terms shall be understood to be entirely independent of the design of the corresponding elements.
In particular, both the described brakes and the described clutches may be implemented as shiftable free wheels, multi-disk clutches, synchronizers or in another manner, for example. With respect to the expressions “sun gear,” “ring gear” and “planet carrier,” those skilled in the art will understand that these may refer both to the particular planetary gear set element and the associated shaft, the specific meaning in each case resulting from the context.
The preferred specific embodiments shall be described hereafter in the order of the axial position of the corresponding design engagement option from the transmission input to the transmission output.
Preferably it is provided that the input shaft is connected to the second sun gear and the second connecting shaft. Typically, this is the central shaft of the entire transmission system.
In one first specific embodiment, it is provided with respect to the connections of the planetary gear sets and the arrangement of the shift elements within the drive group that
the first connecting shaft is connected to the first ring gear, and the first planet carrier is connected to the second ring gear; the second sun gear ( 201 ) is shiftably coupled to the second planet carrier with the aid of the first clutch; the first ring gear is shiftably coupled to the second planet carrier with the aid of the second clutch; the second planet carrier is shiftably coupled to the housing with the aid of the first brake; and the first sun gear is shiftably coupled to the housing with the aid of the second brake.
Alternatively, it may be provided according to a second specific embodiment that
the first connecting shaft is connected to the second ring gear, and the second planet carrier is connected to the first ring gear; the first planet carrier is shiftably coupled to the second sun gear with the aid of the first clutch; the first planet carrier is shiftably coupled to the second ring gear with the aid of the second clutch; the first planet carrier is shiftably coupled to the housing with the aid of the first brake; and the first sun gear is shiftably coupled to the housing with the aid of the second brake.
Both variants are known from the prior art as a drive group, however in conjunction with an output group which is composed of two simple planetary gear sets.
The two connecting shafts form the output of the drive group and, at the same time, the input of the output group. Those skilled in the art will recognize that these will generally not involve separate shafts, but the customary planetary gear set shafts, which as the only shafts extending between the two groups merely fulfill the function of “connecting shafts” and are therefore referred to in this way here.
The first connecting shaft is preferably connected to the second Ravigneaux sun gear within the output group. In contrast, two preferred specific embodiments are provided for the connection of the second connecting shaft.
A first specific embodiment is characterized in that the Ravigneaux planet carrier is shiftably coupled to the second connecting shaft with the aid of the third clutch. Correspondingly, the output shaft is connected to the Ravigneaux planet carrier in this specific embodiment.
A second specific embodiment is characterized in that the Ravigneaux ring gear is shiftably coupled to the second connecting shaft with the aid of the third clutch. Correspondingly, the output shaft is connected to the Ravigneaux ring gear in this specific embodiment.
Each of the specific embodiments of the drive group discussed here may be combined with each of the specific embodiments of the output group discussed here to form a transmission system according to the present invention. It is thus conceivable to have different drive groups and different output groups available, and to combine them within the meaning of a modular transmission kit by connecting the particular shafts acting as connecting shafts.
If the transmission system according to the present invention is expanded by a fourth brake, an 11-speed transmission can be implemented. In particular, it is provided for this purpose that the drive group includes a fourth brake, with the aid of which the first planet carrier is shiftably coupled to the housing.
The following shifting tables show the activations of the shift elements necessary for setting the individual gears in a 9-speed transmission according to the present invention (Table 1) and in an 11-speed transmission according to the present invention (Table 2). The columns are in each case assigned to one shift element, B 1 denoting the first brake, B 2 the second brake, B 3 the third brake, B 4 the fourth brake, K 1 the first clutch, K 2 the second clutch, and K 3 the third clutch. “X” denotes the shift elements which are closed in the particular gear. Open shift elements are denoted by empty cells in the table.
TABLE 1
Mode
Gear
B1
B2
B3
K1
K2
K3
1st gear
X
X
X
2nd gear
X
X
X
3rd gear
X
X
X
4th gear
X
X
X
5th gear
X
X
X
6th gear
X
X
X
7th gear
X
X
X
8th gear
X
X
X
9th gear
X
X
X
Idle
X
X
Reverse
X
X
X
TABLE 2
Mode
Gear
B1
B2
B3
B4
K1
K2
K3
1st gear
X
X
X
2nd gear
X
X
X
3rd gear
X
X
X
4th gear
X
X
X
5th gear
X
X
X
6th gear
X
X
X
7th gear
X
X
X
8th gear
X
X
X
9th gear
X
X
X
10th gear
X
X
X
11th gear
X
X
X
Idle
X
X
Reverse
X
X
X
BRIEF DESCRIPTION OF THE DRAWINGS
Additional features and advantages of the present invention are derived from the following, specific description and the drawings.
FIG. 1 shows a first specific embodiment of a drive group of a transmission system according to the present invention;
FIG. 2 shows a second specific embodiment of a drive group of a transmission system according to the present invention;
FIG. 3 shows a third specific embodiment of a drive group of a transmission system according to the present invention;
FIG. 4 shows a first specific embodiment of an output group of a transmission system according to the present invention;
FIG. 5 shows a second specific embodiment of an output group of a transmission system according to the present invention;
FIG. 6 shows a third specific embodiment of an output group of a transmission system according to the present invention;
FIG. 7 shows a fourth specific embodiment of an output group of a transmission system according to the present invention;
FIG. 8 shows a fifth specific embodiment of an output group of a transmission system according to the present invention; and
FIG. 9 shows one specific embodiment of a transmission system according to the present invention, composed of one drive group according to FIG. 1 and one output group according to FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
Identical reference numerals in the figures indicate identical or analogous elements.
FIGS. 1 through 3 show different specific embodiments of drive groups within a transmission system according to the present invention.
FIGS. 4 through 8 show different specific embodiments of output groups within a transmission system according to the present invention.
FIG. 9 shows, purely by way of example, a transmission system according to the present invention, composed of one drive group according to FIG. 1 and one output group according to FIG. 4 . Those skilled in the art will understand that each of the shown drive groups in combination with each of the shown output groups results in a transmission system according to the present invention. The graphic representation of each of the possible combinations may thus be dispensed with. The illustration according to FIG. 9 shall suffice as a representative example.
The drive group according to FIG. 1 includes two simple planetary gear sets, namely a first planetary gear set 10 and a second planetary gear set 20 . First planetary gear set 10 includes a first sun gear 101 , a first ring gear 102 and a first planet carrier 103 , on which a set of first planet gears is rotatably mounted, which mesh with first sun gear 101 on the one hand and with first ring gear 102 on the other hand. Second planetary gear set 20 includes a second sun gear 201 , a second ring gear 202 and a second planet carrier 203 , on which a set of second planet gears is rotatably mounted, which mesh with second sun gear 201 on the one hand and with second ring gear 202 on the other hand. Planetary gear sets 10 , 20 are situated coaxially and axially adjoining each other. The input-side interface of the drive group is formed by the transmission input shaft. The output-side interface of the drive group is formed by two connecting shafts, namely first connecting shaft CON 1 and second connecting shaft CON 2 .
Input shaft 1 is connected to second sun gear 201 . The same is connected at the same time to second connecting shaft CON 2 , so that input shaft 1 , second sun gear 201 and second connecting shaft CON 2 together form the central shaft of the drive group.
This central shaft is shiftably coupled to second planet carrier 203 via a first clutch K 1 . At the same time, second planet carrier 203 is shiftably coupled to the housing via a first brake B 1 . Moreover, second planet carrier 203 is shiftably coupled to first ring gear 102 via a second clutch K 2 . First ring gear 102 is additionally connected to first connecting shaft CON 1 .
In addition to this shiftable coupling, a fixed coupling also exists between planetary gear sets 10 , 20 , namely a connection between first planet carrier 103 and second ring gear 202 . First sun gear 101 is shiftably coupled to the housing via a second brake B 2 . In this configuration, the drive group according to FIG. 1 may be used in combination with any of the output groups described hereafter to create a transmission system according to the present invention, in particular a 9-speed transmission according to the present invention. The connection of the groups takes place in each case via connecting shafts CON 1 and CON 2 , as is indicated by way of example in FIG. 9 .
A further shiftable coupling, which is optionally provided within the scope of the present invention to implement an 11-speed transmission according to the present invention, is shown with a dashed line in FIG. 1 . First planet carrier 103 is shiftably coupled to the housing with the aid of the brake referred to here as fourth brake B 4 .
The drive group according to FIG. 2 represents a pure isomorphism to the drive group of FIG. 1 . In particular, the axial sequence of planetary gear sets 10 , 20 is inverted. All connections within the drive group correspond to those of the specific embodiment of FIG. 1 , so that reference may be made to the description above.
Contrary to the specific embodiment of FIG. 1 , the drive group according to FIG. 3 has a fixed connection between second planet carrier 203 and first ring gear 102 . First brake B 1 shiftably couples first planet carrier 103 to the housing, while second brake B 2 , as is also the case in the specific embodiment according to FIG. 1 , shiftably couples first sun gear 101 to the housing. First clutch K 1 shiftably couples first planet carrier 103 to second sun gear 201 .
Second clutch K 2 shiftably couples first planet carrier 103 to second ring gear 202 , which is fixedly connected to first connecting shaft CON 1 . As is also the case in the specific embodiment of FIG. 1 , second connecting shaft CON 2 is connected to input shaft 1 and second sun gear 201 . In addition, reference may be made to the description above with respect to FIG. 1 , an equivalent arrangement of a fourth brake B 4 not being possible in this specific embodiment due to the inaccessibility of the second planet carrier.
FIG. 4 shows a first specific embodiment of an output group, which may be connected to any of the drive groups of FIGS. 1 through 3 to create a transmission system according to the present invention. The connection is created via connecting shafts CON 1 and CON 2 ; in each case first connecting shaft CON 1 of the drive group is to be connected to first connecting shaft CON 1 of the output group, and second connecting shaft CON 2 of the drive group is to be connected to second connecting shaft CON 2 of the output group. All other shown output groups are also based on this concept, so that each shown output group may be combined with each shown drive group to form a transmission system according to the present invention.
The output group according to FIG. 4 includes a Ravigneaux planetary gear set 30 having a first Ravigneaux sun gear 311 , a second Ravigneaux sun gear 312 , a Ravigneaux ring gear 302 and a Ravigneaux planet carrier 303 . One set of short planet gears 331 and one set of long planet gears 332 are rotatably mounted on Ravigneaux planet carrier 303 . Long planet gears 332 are designed as stepped planet gears, having one larger stage, i.e., one stage having a larger diameter, and one smaller stage, i.e., one stage having a smaller diameter. In the specific embodiment shown in FIG. 4 , short planetary gear set 331 meshes with the smaller stage of long planets gears 332 . First Ravigneaux sun gear 311 , which is shiftably coupled to the housing via a third brake B 3 , meshes with the set of short planet gears 331 . Second Ravigneaux sun gear 312 , which is fixedly connected to first connecting shaft CON 1 , meshes with the larger stage of long planet gears 332 . Ravigneaux ring gear 302 is fixedly connected to transmission output shaft 2 . A third clutch K 3 shiftably couples Ravigneaux planet carrier 303 to second connecting shaft CON 2 . In the shown specific embodiment, Ravigneaux planetary gear set 30 is oriented with its small long planet stage in the direction of the drive group.
FIG. 5 shows a second specific embodiment of an output group, which differs from that of FIG. 4 only in that Ravigneaux ring gear 302 does not mesh with the larger, but with the smaller stage of long planet gears 332 . In addition, reference may be made to the description above with respect to FIG. 4 .
FIG. 6 shows a third specific embodiment of an output group, in which Ravigneaux planetary gear set 30 is axially reversed, i.e., oriented with its larger long planet stage in the direction of the drive group. Correspondingly, first Ravigneaux sun gear 311 meshes with the larger long planet stage, and second Ravigneaux sun gear 312 meshes with short planet gears 331 . In this specific embodiment, Ravigneaux ring gear 302 also meshes with short planet gears 331 . In addition, reference may be made to the description above with respect to FIG. 4 .
FIG. 7 shows a fourth specific embodiment of the output group, which differs from the specific embodiment shown in FIG. 6 only in that, instead of Ravigneaux planet carrier 303 , Ravigneaux ring gear 302 is shiftably coupled to second connecting shaft CON 2 via third clutch K 3 . Correspondingly, Ravigneaux planet carrier 303 , instead of Ravigneaux ring gear 302 , is connected to output shaft 2 here. In this specific embodiment, Ravigneaux ring gear 302 meshes with the small stage of long planet gears 332 .
FIG. 8 shows a fifth specific embodiment of an output group, which differs from that of FIG. 7 only in the point of contact of the Ravigneaux ring gear, which meshes with the large stage of long planet gears 332 here, instead of with the small stage. In addition, this specific embodiment corresponds to that of FIG. 7 .
FIG. 9 shows a transmission system according to the present invention composed of one drive group according to FIG. 1 and one output group according to FIG. 4 , which is provided purely by way of example and representatively of all remaining combinations of drive and output groups, which those skilled in the art are able to readily carry out. In particular, connecting shafts CON 1 and CON 2 of the drive and output groups assigned to each other merely have to be connected to each other for such a combination.
Naturally, the specific embodiments discussed in the specific description and shown in the figures represent only illustrative exemplary embodiments of the present invention. In light of the present disclosure, those skilled in the art are provided with a wide range of variation options.
LIST OF REFERENCE NUMERALS
1 input shaft
2 output shaft
10 first planetary gear set
101 first sun gear
102 first ring gear
103 first planet carrier
20 second planetary gear set
201 second sun gear
202 second ring gear
203 second planet carrier
30 Ravigneaux planetary gear set
311 first Ravigneaux sun gear
312 second Ravigneaux sun gear
302 Ravigneaux ring gear
303 Ravigneaux planet carrier
331 short planet gears
332 long planet gears
B 1 first brake
B 2 second brake
B 3 third brake
B 4 fourth brake
K 1 first clutch
K 2 second clutch
K 3 third clutch
CON 1 first connecting shaft
CON 2 second connecting shaft | The invention relates to a 9-speed transmission made up of two simple planetary gear sets including a drive group and an output group designed as a Ravigneaux set having six shift elements, namely three clutches and three brakes, certain specific embodiments being expandable to form an 11-speed transmission by adding a fourth brake. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application Serial No. 60/095,842, filed Aug. 7, 1998.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a carabiner combined with at least one useful folding tool. More specifically, the invention is directed to locking or nonlocking carabiners that are used in combination with ropes by mountaineers to provide useful tools which are predominately folded into the device such as a knife, a saw, a can opener, Phillips or flat head screwdrivers, a bottle cap opener, a saw, an Allen wrench, a claw-shaped ripping hook, a pair of pliers, and a pair of scissors.
2. Description of the Related Art
Carabiners are well known for their utility and safety to people engaged in mountaineering and rock climbing. Carabiners are a type of fastener used to attach rope or to restrain or restrict climbing ropes in their movement. The carabiner is generally a metallic loop made up of a body in the form of a hook or C-shaped of which the rear, the straight, and the central portions are extended by curved loops, one at the top and one at the bottom, the free ends of which are connected, to close the loop by a gate. The gate is pivotally mounted to permit passage of rope into the loop and lockable to ensure the rope remains in place in the loop.
Although conceptually not complex, carabiners have been the object of improvements by generations of experienced users to extend their utility and to improve their safety. The related art of interest will be discussed in the order of perceived relevance to the present invention.
U.S. Pat. No. 5,270,909 issued on Dec. 14, 1993, to Richard S. Weiss et al. describes an openable carabiner-type handle attachment for a 6-volt battery equipped flashlight or a mug. The lock is spring-loaded and totally dissimilar in structure to the lock of the present invention. There is neither a suggestion or a teaching that a combination of folding tools can be substituted for the battery or mug to be carried.
U.S. Pat. No. 5,329,675 issued on Jul. 19, 1994, to Andrew McLean et al. describes a carabiner with a thumb grip. The thumb grip is attached as a fin or rib extending from the loop. A person's thumb may rest on the thumb grip, thereby contacting the loop in a particularly handy position. This allows a person to orient or feel the carabiner during use. The carabiner device is distinguishable for not including any tools.
U.S. Pat. No. 4,122,569 issued on Oct. 31, 1978, to Thomas H. Hitchcock describes an integrated universal tool comprising a crescent wrench having its handle formed in parallel rails to contain three blades which are kept from pivoting out by a sliding keeper. The middle blade is a knife with a saw tooth edge at one end, a V-shaped notch in the middle, a curved recess shear blade and a crimping pin proximate the opposite end, and a flat blade screwdriver at the opposite end. One sideward blade comprises a flat blade screwdriver at one end, a cooperating V-shaped notch for stripping sheathed wires, a crimping wire notch proximate the opposite end, and a cooperating curved shear blade at the opposite end. The other sideward blade comprises a Phillips screw-driver at one end, a crimping notch, and a curved shear blade at the opposite end. The combination tool is distinguishable for its linear construction of the slotted crescent wrench handle and a sliding keeper.
European Patent Application No. E.P.0. 0 619 167 A1 published on Mar. 19, 1994, for Carl V. Elsener, Sr. describes a Swiss folding blade knife and tool combination. The device comprises a handle into which fold a knife blade, a Phillips screwdriver, two combination bottle cap openers and flat head screwdrivers, and other elongated tools not describable. The combination knife and tool combination device is distinguishable as having a non-loop
U.S. Pat. No. 1,187,842 issued on Jun. 20, 1916, to Eilef Kaas describes a combination tool comprising a pair of detachable side flanges removable by press-buttons and containing two saws, a gimlet, a file, a button lock, a bodkin, a corkscrew, a punch, a screwdriver, a can opener, a tape measure and pointer, a knife, and a combination nail and brush hinged from an arm containing an ear spoon. The multiple tool is distinguishable for its non-loop structure.
U.S. Pat. No. 5,122,844 issued on May 25, 1993, to George C. Sessions et al. describes a pocket tool with retractable pliers jaws, cutting jaws or scissors and a pair of channel-shaped handles. The pivotally mounted ancillary tools include a knife blade, a serrated blade, a pair of scissors, a bottle opener, a pointed shaft, a flat head screwdriver, and a lanyard receiving hole. The pocket tool is distinguishable for its folding structure.
U.S. Pat. No. 5,553,340 issued on Sep. 10, 1996, to James D. Brown, Jr. describes a utility tool for making adjustments or repairs of a power chain saw. A hexagonal socket is present on the closed end of a cylindrical case member. The opposite open end has a loop and tunnels for a file, a flat head screwdriver and a pair of tweezers. A slot holds a pivoting slide member which contains other pivoting out tools such as a Phillips screwdriver, a star wrench, a flat head screwdriver, a knife blade, a second knife blade with a scooped end, and a combination wire tool with a file, a wire for cleaning oil holes, and a blunt edge for gapping sparkplugs. The utility tool is distinguishable for its pivoting slide member with tools and encased tools.
Great Britain Patent Application No. 9237 published on Aug. 29, 1896, for Rudolph Teichmann describes a combination hand tool for cyclists comprising movable jaw driven by a screw attached to a grooved handle containing the pivoting tools. The accessory tools comprise a tire valve removal tool, a file and pricker combination, an air tire lifter, a spanner, a hexagonal wrench, and a hooked pin forcer. The combination hand tool is distinguishable for lacking a loop structure.
Sweden Patent Application No. 106,956 published on Mar. 23, 1943, for P. E. J. Larsen describes a combination hand tool comprising a pair of angled jaw pliers having a cutter region and a serrated crushing region in the jaws. The pivoting tools from the opposite in the grooved handle include a saw, a knife blade, and a combination flat head screwdriver, a can opener and a bottle cap opener. The tool is distinguishable for failing to have a loop structure.
There is a need in the art of mountaineering for tools which are effective for their intended use as well as being safe and handy. Moreover, none of the above patents, taken either singly or in combination, is seen to describe the instant invention as claimed.
SUMMARY OF THE INVENTION
According to the present invention, an improved carabiner and tool combination device comprises a body forming a portion of a loop and a gate completing the loop, wherein the body includes a folding knife. The folding knife comprises an elongated storage slot which is integral with the carabiner body. A knife blade is pivotally mounted at one end on a pivot pin to move between a blade open position outside the storage slot and a blade closed position within the storage slot. A gate is connected to the carabiner body and is hingewise pivoted between an open position and a closed position. The body and gate form a closed loop when the gate is in the closed position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a carabiner with four tools, each in the open position.
FIG. 2 is a side view of a carabiner in a closed tool position.
FIG. 3 is a an exploded view of the knife-blade locking pin assembly.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 1 and 2, a combination locking or nonlocking carabiner and tool device 10 is formed into a curvilinear prolate loop body circumscribing an opening 12 , through which the fingers may pass. It should be noted that the device 10 can be grasped by either inserting the fingers through the opening 12 or around the entire device 10 . The opening 12 is formed from the combination of a carabiner body 14 defined by handle 20 a, upper arm 20 b, lower arm 20 c, and gate 30 . Preferably, the body 14 is comprised of mating halves 21 a and 21 b, for ease of manufacturing and assembly, wherein a cavity may be formed for the accommodation of the tools and features as described below. Alternatively, the body 14 can be a unitary body.
Gate 30 is conventional and pivotally mounted on gate pivot pin 32 which is spring-loaded and swings between a gate closed position as illustrated in FIGS. 1 and 2 and a gate open position (not shown). Gate 30 is locked by rotating a knurled and internally threaded gate lock 34 in the closed gate position. Preferably, the arms 20 b and 20 c are ergonomically configured to include a prolapsed portion integrally formed by the gate 30 . The prolapse is conformed to the fleshy portion of the palm of the hand below the thumb, thus permitting the carabiner to be comfortably held in the palm during its function as either a carabiner or the handle of an extended tool.
Within the carabiner body 14 is contained a folding knife comprising a handle 20 a, a pivotally mounted knife blade 40 , an elongated storage slot 42 , and first pivot pin 44 . Blade 40 pivots on first pivot pin 44 between an open blade position as shown in FIG. 1, and a closed blade position as depicted in FIG. 2 . Knife blade 40 is ready as a cutting tool in the open blade position. In addition, the back of the blade 40 has a smooth portion 36 and a serrated sawing portion 38 to form a continuous profile with the prolapsed upper arm 20 b of the carabiner body 14 . In the closed blade position, blade 40 is safely contained in an elongated slot 42 .
As is shown in FIG. 1 the device 10 can contain additional tools which are useful to a mountaineer and are particularly advantageous to have readily at hand. Can opener 46 is shown pivotally mounted on the first pivot pin 44 . Knife blade 40 and can opener 46 pivot independently on a first pivot pin 44 inserted through apertures in both mating halves 21 a and 21 b of carabiner body 14 .
Two additional optional tools are shown in FIG. 1. A generic tool 52 is shown pivotally mounted on second pivot pin 54 , as is a generic tool 56 . Each tool 52 and 56 pivots about a second pivot pin 54 between an open tool position as shown in FIG. 1 and a closed tool position shown in FIG. 2, in which they are contained in elongated slot 42 . The width of elongated slot 42 is defined by the number and size of tools contained therein in the closed position. Tools 46 , 52 and 56 can be selected from a group of tools which are useful to have at hand including a second knife blade, a bottle cap opener, a can opener, a saw, a flat head screw driver, a Phillips head screwdriver, an Allen wrench, a claw-shaped ripping hook tool, pliers, and scissors. In particular, the combination of a knife blade 40 and tool 46 selected as a can opener has been found to be useful. In another embodiment, the combination of a knife blade 40 and a tool 46 as a can opener with tool 52 and tool 56 selected as a flat head screwdriver and a Phillips head screw-driver has been found to be especially useful and handy.
Conventional Phillips-head screw- drivers have a crossed blade head in which each of the two crossed blades is identical. In an alternate configuration, one narrower or minor blade is combined with a larger or major blade to produce a Phillips head screwdriver having a flatter overall aspect. This type of Phillips head screwdriver fits particularly well into confined storage such as elongated storage slot 42 , and is preferred in the combination carabiner device 10 shown in FIG. 1 .
An additional tool is shown in FIG. 1 . Bottle cap opener 58 is shown integral with lower loop 20 a, and is generally defined as a notch with a sufficient lip 64 to act as a bottle opener. Bottle cap opener 58 provides an additional tool without the space limitation imposed by elongated slot 42 . Bottle cap opener 58 is particularly handy because it does not require manual opening and is always readily at hand. Bottle cap opener 58 is also easily usable even when blade 40 or any one of tools 46 , 52 and 56 is in the open position.
Also shown in FIG. 2 is aperture 60 in the lower arm 20 c. Aperture 60 extends through lower arm 20 c, and allows for the passage therethrough of suspension means 62 which is shown as a lanyard, but can be a key ring, key chain, leather lace, shoe lace, and the like useful means.
In FIG. 2, the combination carabiner and tool device 10 has two features which are configured for manipulation with the thumb of the right hand as an example. The features can be positioned on the opposite side of the tool for left-handed users. Attached to knife blade 40 is a thumb ridge 41 which assists in the movement of blade 40 from the blade closed position as shown in FIG. 2 to the blade open position shown in FIG. 1 . Thumb ridge 41 is made of solid rubber or a polymer, and has a surface having a coefficient of friction which is easily engaged by the thumb even when wet with perspiration, slime and mud, and coated with dust or a glove. Thumb ridge 41 can be attached to a flat blade surface or for better adhesion, can fill a shallow pocket in the blade surface and extend above the surface as shown for maximum frictional contact with the thumb. The size of thumb ridge 41 is not critical, but it must be small enough not to interfere with the use of the knife and carabiner. Alternatively, thumb ridge 41 can overlap the back edge of the knife blade 40 to afford the versatility for either right- or left-handed persons.
Also shown in FIG. 2 is a triangular lock release button 70 which is manually operated by the thumb of the right hand. The triangular shape is exemplary as any shape which can be tactilely felt to aid in locating the geometrically different shaped button even in the dark. Alternatively, the lock release button 70 can be positioned on the opposite side for the convenience of left-handed users.
In FIG. 3, an exploded view of an exemplary locking pin assembly 66 of the invention is illustrated. Lock release button 70 is shown to protrude through a triangular slot 68 in the upper arm 20 b so that it is readily accessible to the right thumb. Retaining means 71 holds the lock release button 70 within the body. In this situation, retaining means 71 is a flange unitary with lock release button 70 . Alternatively, retaining means 71 can be a collar, split ring, pin, tab or the like for accomplishing this purpose. Lock release button 70 is attached to an elongated shaft 73 formed of two parts, a lesser diameter shaft 72 and greater diameter shaft 74 . In this preferred example, the lock release button 70 and the elongated shaft 73 are a unitary piece formed from a single piece of metal. In the alternative, they can be formed separately and assembled by welding.
Within the lower end of greater diameter shaft 74 is spring cavity 76 which holds coiled spring 78 . Coiled spring 78 urges the locking pin assembly 66 against the undersurface of upper arm 20 a. The locking pin assembly 66 is entirely contained in pin assembly cavity 80 , the lower end of which cavity is a surface within the body of upper arm 20 a.
The function of locking pin assembly 66 is to releasably lock blade 40 into the open blade position. In the open blade position, the greater diameter shaft 74 has a cross-sectional area sufficient to substantially fill arcuate slot 40 s in blade 40 . The greater diameter shaft 74 , being held in an offset but coplanar arrangement by the surface of blade 40 during closed and semi-open angular positions of blade 40 , is forced upward by spring 78 as the slot 40 s passes directly overhead, thus permitting shaft 74 to align in the same plane as knife blade 40 . As a result, blade 40 is prevented from further rotational movement and is restrained from pivoting about the first pivot pin 44 .
The locking pin assembly 66 provides releasable locking of blade 40 . When the-lock is to be released, the lock release button 70 is manually pushed in, forcing the greater diameter shaft 74 downward, and freeing greater diameter shaft 74 from slot 40 s in blade 40 . As a result, blade 40 is free to pivot about the first pivot pin 44 from an open blade position to a closed blade position inside elongated slot 42 . Alternatively, by placing an outwardly biasing coil spring 78 about lesser diameter shaft 72 , the same purpose can be achieved.
Conventional locking knife assemblies such as liner locks, liner locks with slide button actuators and lockbacks can be employed in the present invention.
Materials of construction for the combination carabiner and tool device of the invention can be stainless steel or high quality alloy steel known for impact resistance and for being able to be machined to close tolerances. A manufacturer can also use metals in combination with plastic materials and other conventional materials of construction. Hence, it is to be understood that the present invention is not limited to the sole embodiments described above, but encompasses any and all embodiments within the scope of the following claims. | A combination carabiner and tool device comprises a curvilinear handle and a lockable gate to form a loop. In the handle is a folding knife and additional useful tools at both ends. A push button lock releasably holds the knife blade in the blade open position. The knife blade is pivoted into position and releasably locked by manipulation with the user's thumb. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. patent application Ser. No. 61/176,443 entitled “Power Monitoring System”, filed May 7, 2009, the entirety of which is incorporated herein by reference for all purposes.
BACKGROUND
[0002] Electricity is becoming more expensive while use of electricity continues to increase. Tracking and minimizing usage of electricity is a difficult task. For example, many electronic devices continue to consume electricity even when turned off. Low power factors in a home or other facility also increase the demand on municipal power systems, causing spikes in electrical current and requiring that the power systems be capable of supplying electricity at the spike level rather than just the average current level actually consumed.
SUMMARY
[0003] The present invention provides a power monitoring system that may be used in a home or other location to monitor and control electricity consumption while controlling various devices such as lights and appliances. The power monitoring system may also include power factor monitoring and correction.
[0004] An embodiment of the power monitoring system includes a client device and a server device. The client device includes a power meter, a client-side microcontroller or, for example, an application specific integrated circuit (ASIC) or similar types of devices, circuits, implementations, etc., and a client-side wireless transceiver. The term microcontroller refers herein to microcontrollers, microprocessors, ASICs of any type and form, state machines, integrated circuits that perform similar and/or the same functions, etc. The client-side microcontroller reads power usage statistics from the power meter and transmits them to the server, or other client, device. The server device includes a server-side microcontroller that receives the power usage statistics from the client device. Communication transactions between clients and servers may occur over one or more wireless and/or wired mediums, including, but not limited to, over-the-air, over-the-powerlines, or over-additional-external-wiring. Communication transactions with the end-user occur through a software application interface, hosted on the server, which is accessible over public and private LAN/WAN infrastructures, through general web browsers or custom software applications. The server includes the LAN/WAN hardware interface. The server-side microcontroller includes a software application that reports the power usage statistics via Internet. The server device also includes a server-side wireless transceiver and an Internet interface.
[0005] In an embodiment of the power monitoring system, the client device also includes a driver circuit connected to the client-side microcontroller. The client device also includes a power input connected to the driver circuit, and a load output connected to the driver circuit. The client-side microcontroller is adapted to receive control commands from the server device and to configure the driver circuit based at least in part on the control commands.
[0006] In an embodiment of the power monitoring system, the client device also includes a light meter connected to the client-side microcontroller. The client-side microcontroller is adapted to configure the driver circuit based on a combination of the control commands and on an ambient light measurement from the light meter. In some embodiments, the light meter is an independent device.
[0007] In an embodiment of the power monitoring system, the client device also includes a motion detector connected to the client-side microcontroller. The client-side microcontroller is adapted to configure the driver circuit based on a combination of the control commands and on a signal from the motion detector. In some embodiments, the motion detector is an independent device.
[0008] In an embodiment of the power monitoring system, the driver circuit is adapted to drive a resistive load.
[0009] In an embodiment of the power monitoring system, the driver circuit is adapted to drive an inductive load.
[0010] In an embodiment of the power monitoring system, the client device also includes a client-side power line transceiver connected to the client-side microcontroller, and the server device also includes a server-side power line transceiver connected to the server-side microcontroller.
[0011] In an embodiment of the power monitoring system, the power usage statistics may include average input voltage, average input current, real-time input voltage, real-time input current, average output voltage, average output current, real-time output voltage, real-time output current, real power, apparent power, power factor, associated peak and root mean square (RMS) values, (if appropriate) dimming level, and on/off status.
[0012] In an embodiment of the power monitoring system, the server-side microcontroller is adapted to read electricity cost data from a power company.
[0013] In an embodiment of the power monitoring system, the server-side microcontroller is adapted to reduce electricity costs by causing the client device to configure the driver circuit to reduce power to the load output during peak electricity periods.
[0014] In an embodiment of the power monitoring system, the server-side microcontroller is adapted to receive commands from the power company to configure the driver circuit to reduce power to the load output.
[0015] In an embodiment of the power monitoring system, the server-side microcontroller is adapted to report power usage statistics for a plurality of client devices.
[0016] In an embodiment of the power monitoring system, the software application is adapted to enable grouping of a plurality of client devices and concurrent control of client device groups.
[0017] In an embodiment of the power monitoring system, the software application is adapted to enable scheduling of client device control.
[0018] In an embodiment of the power monitoring system, the software application is adapted to control client devices in response to events triggered by remote sensors.
[0019] In an embodiment of the power monitoring system, the client device also includes at least one manual control input connected to the client-side microcontroller. The client-side microcontroller is adapted to configure the driver circuit based on the manual control input.
[0020] In an embodiment of the power monitoring system, the client device also includes a power factor correction circuit connected to the power meter.
[0021] An embodiment of the power monitoring system also includes sensors such as light sensors, sound sensors, motion sensors, vibration sensors, liquid presence sensors, liquid flow sensors, magnetic sensors, position sensors, and orientation sensors.
[0022] In an embodiment of the power monitoring system, the software application is adapted to simulate occupancy by randomized control of the client device.
[0023] Another embodiment provides a power monitoring and control system, including a client device and a server device. The client device includes a driver circuit with a power input and a load output. The client device also includes a power meter, a light meter, and a client-side microcontroller. The client-side microcontroller is adapted to read power usage statistics from the power meter and to transmit them to the server device. The client-side microcontroller is also adapted to receive control commands from the server device and to configure the driver circuit based at least in part on the control commands and on an ambient light measurement from the light meter. The client device also includes a client-side wireless transceiver and a client-side power line transceiver. The server device includes a server-side microcontroller that is adapted to receive the power usage statistics from the client device. The server-side microcontroller includes a software application that is adapted to report the power usage statistics and to receive control commands via Internet. The server-side microcontroller is adapted to transmit the control commands to the client device. The server device also includes a server-side wireless transceiver, a server-side power line transceiver, and an Internet interface connected to the server-side microcontroller.
[0024] This summary provides only a general outline of some particular embodiments. Many other objects, features, advantages and other embodiments will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] A further understanding of the various exemplary embodiments may be realized by reference to the figures which are described in remaining portions of the specification. In the figures, like reference numerals may be used throughout several drawings to refer to similar components.
[0026] FIG. 1 depicts a block diagram of a system for monitoring power usage and status and for controlling electrical devices.
[0027] FIG. 2 depicts a block diagram of a client-side portion of a system for monitoring power usage and status and for controlling electrical devices.
[0028] FIG. 3 depicts a block diagram of a server-side portion of a system for monitoring power usage and status and for controlling electrical devices.
DESCRIPTION
[0029] A power monitoring system is disclosed herein that monitors and controls electricity consumption. The power monitoring system disclosed herein may be used in conjunction with a sophisticated power grid if desired, enabling a user to shift consumption of electricity to off-peak periods as well as to minimize overall electricity consumption. The power monitoring system includes one or more power meters, such as a watthour meter, that may be installed in a home or other facility to monitor overall power consumption, and installed in every outlet, every light dimmer, every switch, etc., or in selected locations. The power meters may be adapted merely to monitor power usage or may be adapted to control power usage as well by dimming or reducing the power output through the power meter in any suitable manner. For example, the power meters may employ phase clipping, amplitude reduction, or any other suitable technique to reduce power output.
[0030] The results from the power meters may be accessed and viewed via any suitable interface. In one embodiment, the power meters may be accessed using a web server that gathers data from the power meters and makes the data available on a local area network (LAN) or Internet connection using a web browser application on a computer, personal digital assistant (PDA) or cellular telephone or by other wireless means.
[0031] The power consumption reported by the power monitoring system may be compared with the main electricity meter to the house or other facility if desired and allow various levels of decision making to take place along with auditing and power/energy management control, data analysis, and evaluation, etc.
[0032] Some embodiments of the power monitoring system enable cooperation with the power company to automatically reduce power consumption during peak power consumption periods by automatically dimming lights and automatically turning off power to non-essential devices. Configuration of these power consumption settings or preferences may be stored in a file on a server in the home or in any other suitable device. In some embodiments, information may be retrieved from the power company defining peak and non-peak hours. Information may also be transmitted from the power company to the power monitoring system during brownout periods, either automatically minimizing power consumption in the home by reducing power through selected power meters in the power monitoring system or turning off electricity through power meters to nonessential devices including browning down/out appropriate types of electrical energy consumers. This cooperation may also be voluntary by configuring power consumption settings for each of a number of power conditions from the power company. The power monitoring system may thus include a complex infrastructure for controlling and monitoring power consumption in a home or other location, while remaining simple to access and configure using a web browser or other interface. For example, in addition to the consumption settings discussed above, the power monitoring system may measure and display voltage and/or current waveforms, power factor information, etc., for the entire home as well as for individual outlets and switches. In addition, the power monitoring system can detect the position and setting of the dimmers and switches connected to the system including remotely detecting the manually set dimming level of all dimmers attached to the system. Top power consumers in the home may be identified, for example by graphically displaying the power used by refrigerators, washers and dryers, stoves, audio/visual equipment, computers, lighting, etc. Various power/energy consumption rates may be entered into the system with the system having a selected priority process for determining which electrical power consumers/appliances in the house should be turned off or dimmed depending on the details of the power/energy pricing rates and schedules. The power monitoring control system could also include secure means to provide electronic forms of payment to, for example, the utility company(ies). In addition, the detailed power usage for the customer could be stored on the customer's mass storage, the utilities' mass storage or a third party's mass storage facilities. Such storage of information could also be used to provide a basis for rental/lease fee arrangements where an equipment provider could lease the power monitoring system to a customer in return for a percentage of the energy savings and associated costs that the customer benefits from having the power monitoring and control system.
[0033] The power monitoring system may also include power factor correction, either globally with, for example, a bank of capacitors at the power mains to a building or locally at each device or outlet. This smooths the power consumption, reduces reactive power losses, and assists in reducing current spikes and helping prevent overheating and power waste in power lines.
[0034] The power monitoring system may also minimize power consumed by devices when in a standby mode such as televisions and other audio/visual equipment. The power monitoring system may be configured to fully power down the equipment at certain time periods, or manually by a command through the web browser interface or using a button or other interface on the power meter device itself, or by turning off power when electricity is being consumed but falls under a predetermined threshold level or by using remote sensors such as motion, voice, audio, visual, etc that are wireless and wired connected to the system. Electricity may then be fully restored by a command through the interface or using a button on the power meter device.
[0035] The power monitoring system also provides remote access to power usage in the home via the web browser interface, enabling the user, for example and not limited to, to control and to turn lights on and off, to determine whether a device has been left on by monitoring actual power usage through an associated power meter, and to turn off power to a device if it has been left on and to, for example, determine if a light has ceased to work or burned out. Radios or other devices may be turned on remotely when away from the home to simulate occupancy of the home. Such turning on may also be done in conjunction with various types of sensors including but not limited to light, sound, motion, visual, audio, vibration, liquid, spill and displacement, magnetic, etc. sensors. This type of activation of lights and sound generating devices to simulate occupancy may also be programmed and/or randomized using the web browser interface in some embodiments.
[0036] In some embodiments, the power monitoring control system may also include sensors and/or detectors to indicate whether doors or windows are closed and/or locked, including a sensor or set of sensors on a garage door indicating whether the garage door is in a vertical or horizontal position to report whether the garage door is open or closed, along with video cameras, sound and motion sensors and/or detectors, general security detectors and/or sensors, and sensors and/or detectors to monitor water flow or potential water leaks or some subset of the above. The potential list of sensors and/or detectors displayed above is meant to provide examples of possible configurations and is in no way meant to be limiting for the present invention.
[0037] The power monitoring system may be used to regulate access to computers, television and games for children, enabling power outlets only during scheduled times.
[0038] In summary, the power monitoring system is a monitoring as well as control system, in enough depth to enable power consumption comparisons with the main kilowatt hour meter for a building or dwelling, whether residential or industrial, in some embodiments. The power monitoring system may in some embodiments include a link to the utility company to download price rates during various time periods, peak and off times, seasonal rates, etc., displaying the cost of actual power consumption and enabling control power to devices based on these scheduled rates. For example, and interface to the power monitoring system may be included in devices such as dishwashers, washing machines, dryers, and other such appliances, turning them on and initiating a wash cycle during off times to benefit from lower electricity rates. It may also include other systems such as air conditioners and heating, ventilation and air conditioning (HVAC) systems in general including the controls and vents for such, refrigerators, and refrigeration units, and the other such appliances and electronics that can are amenable to, for example, being dimmed or browned out. It can also be used to monitor water and fluid based systems and provide appropriate feedback, alerts, or control depending on the details of the particular implementation.
[0039] A block diagram of a power monitoring system 10 according to one embodiment is illustrated in FIG. 1 . A client device 12 is connected to a load 14 which may be any electrical device or devices, such as a light or appliance. The client device 12 is connected with a power source such as being plugged into a residential power socket or connected to a battery to power the load 14 . The client device 12 communicates wirelessly with a server device 16 , which includes an Internet interface 20 and a software application that may be accessed for example by web browsers. In one embodiment, the software application comprises a web application. The server device 16 may be connected to a desktop computer 22 through a router 24 , or to a laptop computer 26 , (as an example) a mobile phone 30 which could also be a smart phone, a personal digital assistant, a remote control, etc.), or any other Internet enabled device, whether through a wired or wireless connection. In one example, the wireless connection between the client device 12 and the server device 16 uses the IEEE 802.15.4 standard for low-rate wireless personal area networks (LR-WPANs).
[0040] The client device 12 is illustrated in more detail in the block diagram of FIG. 2 . A microcontroller (MCU) 50 controls drive circuitry or a driver circuit 52 which powers a load output 54 . Note that microprocessors and/or microcontrollers (e.g., 50 ) described herein may replaced in various embodiments with other suitable control devices, such as state machines, digital logic, analog and digital logic, application specific integrated circuits (ASICs), gate arrays, configurable logic devices (CLDs), etc. A power meter 56 measures power usage statistics from the drive circuitry 52 and reports them to the microcontroller 50 , which in turn reports them to the server device 16 . The power usage statistics may be retrieved from the server device 16 by a web interface on any suitable device such as a home computer 22 , laptop computer 26 or mobile phone 30 , etc. The power usage statistics may be stored in a static memory 60 in the client device 12 and transmitted to the server device 16 using a wireless transceiver 62 , a power line transceiver 64 , a wired connection or any other desired connection mechanism. Software/firmware may also be stored in the static memory 60 to be executed by the microcontroller 50 . The client device 12 may also include manual buttons enabling all functions performed in the client device 12 to be manually operated, such as dimming or turning on and off the power to the load.
[0041] The drive circuitry 52 may be customized to drive specific types of electrical loads, e.g., duty cycle control of resistive loads such as lighting, or on-off control of inductive loads such as appliances, motors, etc. The power usage statistics may include measuring both average and real-time input voltage and current, output voltage and current, etc. The microcontroller 50 is able to derive, save and report real power (W), apparent power (VA), the power factor (PF), the dynamic power factor or true power factor even during dimming of lights, where statistics like min, max, average and trending may be reported along with other information. The present invention can also perform the functions and operations of a typical thermostat.
[0042] The server device 16 is illustrated in more detail in the block diagram of FIG. 3 . A microcontroller 80 hosts software for communications networks such as a wireless transceiver 82 and power line transceiver 84 used to communicate with client devices (e.g., 12 ) and Ethernet, WiFi,
[0043] USB or other systems 86 for communicating with users. The microcontroller 80 also hosts software for a software application providing a user interface. Because the software application is hosted in the server device 16 , no software or drivers are required to be installed on user devices such as a home computer 22 , laptop computer 26 or mobile phone 30 other than a web browser. The server device 16 also includes static memory 90 to store power usage statistics and to meet other data storage needs. The software application enables users to organize, control and read data from wireless client devices. Organization of client devices may be realized through visual grouping in the software application, which allows logical control of multiple devices. Device functions may be assigned to various forms of automatic control, including scheduling and response to remote sensing events. The software application may be accessed with any type of web-enabled device, whether locally or abroad.
[0044] While illustrative embodiments have been described in detail herein, it is to be understood that the concepts disclosed herein may be otherwise variously embodied and employed. | A power monitoring system is disclosed which enables monitoring of power consumption and optionally control of power delivery. An embodiment of the power monitoring system includes a client device and a server device. The client device includes a power meter, a client-side microcontroller, and a client-side communication transceiver, for transacting with other clients or servers. The client-side microcontroller reads power usage statistics from the power meter and transmits them to the server device. The server device includes a server-side microcontroller that receives the power usage statistics from the client device. Some embodiments of the server-side microcontroller include a LAN/WAN interface, for public or private network access, and a software application that reports the power usage, and offers control opportunities to users on those networks. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application claims priority to and is a continuation of U.S. patent application Ser. No. 13/034,678 entitled “Thermostat Battery Recharging During HVAC Function Active and Inactive States” filed on Feb. 24, 2011.
U.S. patent application Ser. No. 13/034,678 claims the benefit of the following commonly assigned applications: U.S. Prov. Ser. No. 61/415,771 filed Nov. 19, 2010; U.S. Prov. Ser. No. 61/429,093 filed Dec. 31, 2010.
The subject matter of this patent application also relates to the subject matter of the following commonly assigned applications: U.S. Ser. No. 12/881,430 filed Sep. 14, 2010; U.S. Ser. No. 12/881,463 filed Sep. 14, 2010; U.S. Ser. No. 12/984,602 filed Jan. 4, 2011; U.S. Ser. No. 12/987,257 filed Jan. 10, 2011; U.S. Ser. No. 13/034,674 filed on Feb. 24, 2011; and U.S. Ser. No. 13/034,666 filed on Feb. 24, 2011. Each of the above-referenced patent applications is incorporated by reference herein.
COPYRIGHT AUTHORIZATION
A portion of the disclosure of this patent document may contain material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND
This invention generally relates to control systems for heating, ventilation and air conditioning (HVAC) systems. More particularly, embodiments of this invention relate to thermostats having jumper-free designs and/or isolation circuitry.
As is known, for example as discussed in the technical publication No. 50-8433, entitled “Power Stealing Thermostats” from Honeywell (1997), early thermostats used a bimetallic strip to sense temperature and respond to temperature changes in the room. The movement of the bimetallic strip was used to directly open and close an electrical circuit. Power was delivered to an electromechanical actuator, usually relay or contactor in the HVAC equipment whenever the contact was closed to provide heating and/or cooling to the controlled space. Since these thermostats did not require electrical power to operate, the wiring connections were very simple. Only one wire connected to the transformer and another wire connected to the load. Typically, a 24 VAC power supply transformer, the thermostat, and 24 VAC HVAC equipment relay were all connected in a loop with each device having only two external connections required.
When electronics began to be used in thermostats the fact that the thermostat was not directly wired to both sides of the transformer for its power source created a problem. This meant either the thermostat had to have its own independent power source, such as a battery, or be hardwired directly from the system transformer. Direct hardwiring a “common” wire from the transformer to the electronic thermostat may be very difficult and costly. However, there are also disadvantages to using a battery for providing the operating power. One primary disadvantage is the need to continually check and replace the battery. If the battery is not properly replaced and cannot provide adequate power, the electronic thermostat may fail during a period of extreme environmental conditions.
Since many households did not have a direct wire from the system transformer (such as a “common” wire), some thermostats have been designed to derive power from the transformer through the equipment load. The methods for powering an electronic thermostat from the transformer with a single direct wire connection to the transformer is called “power stealing” or “power sharing.” The thermostat “steals,” “shares” or “harvests” its power during the “OFF” periods of the heating or cooling system by allowing a small amount of current to flow through it into the load coil below its response threshold (even at maximum transformer output voltage). During the “ON” periods of the heating or cooling system the thermostat draws power by allowing a small voltage drop across itself. Hopefully, the voltage drop will not cause the load coil to dropout below its response threshold (even at minimum transformer output voltage). Examples of thermostats with power stealing capability include the Honeywell T8600, Honeywell T8400C, and the Emerson Model 1F97-0671. However, these systems do not have power storage means and therefore always rely on power stealing or must use disposable batteries.
U.S. Pat. No. 4,174,807 discusses the use of a rechargeable battery in an autocycling control circuit for heating and/or air conditioning systems. However, the battery is only used in the event of a power failure and then only to keep the digital clock and timing sequence program from being disrupted.
U.S. Pat. No. 6,566,768 and U.S. Pat. No. 5,903,139 discuss the use of power stealing in combination with a capacitor used to store power. The discussed systems, however lack the ability to power steal from HVAC systems having two power transformers, such as the case when an existing HVAC heating system is subsequently upgraded to add air conditioning and a second power transformer is installed. Additionally, the discussed systems do not have the capability to charge a battery.
SUMMARY
According to some embodiments a thermostat is provided for controlling one or more HVAC functions in an HVAC system. The thermostat includes a rechargeable battery; charging circuitry adapted and arranged to recharge the battery; and control circuitry adapted and arranged to control the one or more HVAC functions using power from the rechargeable battery. According to some embodiments, the thermostat also includes power harvesting circuitry adapted and arranged to harvest power from the HVAC system in cases where no common wire is available to the thermostat, and to supply power to the charging circuit for recharging the battery.
The power harvesting circuitry is preferably adapted and arranged to automatically select harvesting power from a power source among two or more available power sources. According to some embodiments, the power harvesting circuitry is adapted and arranged to harvest power from a circuit of the HVAC functions during times when the HVAC functions are active or inactive. During power harvesting from a circuit of an HVAC function when the HVAC function is active, the power harvesting circuitry, according to some embodiments, repeatedly charges and discharges one or more capacitive and/or magnetic elements to store electrical energy for use by the charging circuit and/or other operations in the thermostat. The power harvesting circuitry can includes solid state switching components and circuitry adapted and arranged to quickly open and close one or more circuits controlling the one or more HVAC functions.
According to some embodiments, the charging circuitry is adapted to charge the battery such that longer cycle life is preferred over higher charge capacity, such as controlling the ratio of charge current to total capacity, and/or limiting the float voltage.
As used herein the terms power “harvesting,” “sharing” and “stealing” when referring to HVAC thermostats all refer to the thermostat are designed to derive power from the power transformer through the equipment load without using a direct or common wire source directly from the transformer.
As used herein the term “HVAC” includes systems providing both heating and cooling, heating only, cooling only, as well as systems that provide other occupant comfort and/or conditioning functionality such as humidification, dehumidification and ventilation.
As used herein the term “thermostat” includes any device, instrument and/or system for controlling at least some aspect of an HVAC system. While it is very common for a thermostat to control an HVAC system primarily based on temperature, the term includes controlling devices, for example, that control an HVAC system based on other parameters such as humidity.
As used herein the term “residential” when referring to an HVAC system means a type of HVAC system that is suitable to heat, cool and/or otherwise condition the interior of a building that is primarily used as a single family dwelling. An example of a cooling system that would be considered residential would have a cooling capacity of less than about 5 tons of refrigeration (1 ton of refrigeration=12,000 Btu/h).
As used herein the term “light commercial” when referring to an HVAC system means a type of HVAC system that is suitable to heat, cool and/or otherwise condition the interior of a building that is primarily used for commercial purposes, but is of a size and construction that a residential HVAC system is considered suitable. An example of a cooling system that would be considered residential would have a cooling capacity of less than about 5 tons of refrigeration.
As used herein the term “common wire” when referring to HVAC systems refers to a direct wire from an HVAC power transformer that is in addition to the power or return wire to the transformer. Thus, power can be drawn from a circuit including the common wire and the power or return wire without risk of switching on or off relays, switches and/or contactors for operating various HVAC systems since those switching means are not in series in such a circuit.
As used herein the term “silent” or “silently” when referring to thermostat operation and/or control means that any sound made by the thermostat is generally inaudible to the human ear at a range of greater than 1 meter.
It will be appreciated that these systems and methods are novel, as are applications thereof and many of the components, systems, methods and algorithms employed and included therein. It should be appreciated that embodiments of the presently described inventive body of work can be implemented in numerous ways, including as processes, apparata, systems, devices, methods, computer readable media, computational algorithms, embedded or distributed software and/or as a combination thereof. Several illustrative embodiments are described below.
BRIEF DESCRIPTION OF THE DRAWINGS
The inventive body of work will be readily understood by referring to the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 is a diagram of an enclosure with an HVAC system, according to some embodiments;
FIG. 2 is a diagram of an HVAC system, according to some embodiments;
FIG. 3 is a block diagram of some circuitry of a thermostat, according to some embodiments;
FIGS. 4A-C schematically illustrate the use of auto-switching connectors being used to automatically select a source for power harvesting, according to some embodiments;
FIG. 5 is a schematic of a half-bridge sense circuit, according to some embodiments;
FIGS. 6A-B are schematics showing the high voltage buck, bootstrap LDO and battery LDO power circuitry, according to some embodiments; and
FIG. 7 shows a battery charging circuit and rechargeable battery, according to some embodiments.
DETAILED DESCRIPTION
A detailed description of the inventive body of work is provided below. While several embodiments are described, it should be understood that the inventive body of work is not limited to any one embodiment, but instead encompasses numerous alternatives, modifications, and equivalents. In addition, while numerous specific details are set forth in the following description in order to provide a thorough understanding of the inventive body of work, some embodiments can be practiced without some or all of these details. Moreover, for the purpose of clarity, certain technical material that is known in the related art has not been described in detail in order to avoid unnecessarily obscuring the inventive body of work.
FIG. 1 is a diagram of an enclosure with and HVAC system, according to some embodiments. Enclosure 100 , in this example is a single-family dwelling. According to other embodiments, the enclosure can be, for example, a duplex, an apartment within an apartment building, a light commercial structure such as an office or retail store, or a structure or enclosure that is a combination of the above. Thermostat 110 controls HVAC system 120 as will be described in further detail below. According to some embodiments, the HVAC system 120 is has a cooling capacity less than about 5 tons.
FIG. 2 is a diagram of an HVAC system, according to some embodiments. HVAC system 120 provides heating, cooling, ventilation, and/or air handling for the enclosure, such as a single-family home 100 depicted in FIG. 1 . The system 120 depicts a forced air type heating system, although according to other embodiments, other types of systems could be used such as hydronic, in-floor radiant heating, heat pump, etc. In heating, heating coils or elements 242 within air handler 240 provide a source of heat using electricity or gas via line 236 . Cool air is drawn from the enclosure via return air duct 246 through fan 238 and is heated heating coils or elements 242 . The heated air flows back into the enclosure at one or more locations via supply air duct system 252 and supply air grills such as grill 250 . In cooling an outside compressor 230 passes gas such as freon through a set of heat exchanger coils to cool the gas. The gas then goes to the cooling coils 234 in the air handlers 240 where it expands, cools and cools the air being circulated through the enclosure via fan 238 . According to some embodiments a humidifier 254 is also provided. Although not shown in FIG. 2 , according to some embodiments the HVAC system has other known functionality such as venting air to and from the outside, and one or more dampers to control airflow within the duct systems.
Thermostat 110 controls the HVAC system 120 through a number of control circuits. In particular, there are often separate control systems for heating and cooling. The heating system can include a low voltage, for example 24 VAC, operated gas valve which controls the flow of gas to the furnace; the cooling system includes a contactor having a low-voltage coil and high-voltage contacts which control energizing of the compressor; and the circulation system includes a fan relay having a low-voltage coil and high-voltage contacts which control energizing of the fan which circulates the conditioned air. The electrical power for energizing such low-voltage operated devices is provided either by a single transformer 260 for both heating and cooling, or by two separate transformers 260 for heating and 262 for cooling. Often, a single transformer is provided when the heating and cooling system is installed as a complete unit. If the cooling system is added to an existing heating system, sometimes an additional transformer is used.
According to some embodiments, the thermostat 110 is split into two parts: a head unit 270 and a backplate 286 . The head unit 270 contains a main processor 272 , storage 274 (such as flash storage), local area wireless networking 276 , and display and user interface 278 . Also included are environmental sensors such as temperature, humidity and/or pressure. A rechargeable battery 282 and power management subsystems 284 are also included as will be described in further detail herein. The head unit 270 is removable by the user and can be connected to a computer for configuration.
The backplate 286 installs on the wall and interfaces with the HVAC wiring 264 . Backplate 286 provides power to the head unit 270 and also facilitates control of the attached HVAC systems, which in FIG. 2 is heating and cooling but could include other functions such as humidification, dehumidification and ventilation. According to some embodiments, backplate 286 also include a cellular wireless interface. Components within backplate 286 will be described in further detail herein.
FIG. 3 is a block diagram of some circuitry of a thermostat, according to some embodiments. Circuitry 300 , according to some embodiments, is a backplate of a thermostat. A number of HVAC wires can be attached using HVAC terminals 312 . One example of which is the W1 terminal 314 . Each terminal is used to control an HVAC function. According to some embodiments, each of the wires from the terminals W1, W2, Y1, Y2, G, O/B, AUX and E is connected to a separate isolated FET drive within 310 . The common HVAC functions for each of the terminals are: W1 and W2 heating; Y1 and Y2 for cooling; G for fan; O/B for heatpumps; and E for emergency heat. Note that although the circuitry 300 is able control 8 functions using the isolated FET drives 310 , according to some embodiments, other functions, or fewer functions can be controlled. For example circuitry for a more simply equipped HVAC system may only have a single heating (W), and single cooling (Y) and a fan (G), in which case there would only be three isolated FET drives 310 . According to a preferred embodiment, 5 FET drives 310 are provided, namely heating (W), cooling (Y), fan (G), auxiliary (AUX) and compressor direction (O/B). Not shown are the circuit returns such as RH (return for heat) and RC (return for cooling). According to some embodiments the thermostat can control a humidifier and/or de-humidifier. Further details relating to isolated FET drives 310 are described in co-pending U.S. patent application Ser. No. 13/034,674, entitled “Thermostat Circuitry for Connection to HVAC Systems,” filed on even date herewith which is incorporated herein by reference.
The HVAC functions are controlled by the HVAC control general purpose input/outputs (GPIOs) 322 within MCU 320 . MCU 320 is a general purpose microcontroller such as the MSP430 16-bit ultra-low power MCU available from Texas Instruments. MCU 320 communicates with the head unit via Head Unit Interface 340 . The head unit together with the backplate make up the thermostat. The head unit has user interface capability such that it can display information to a user via an LCD display and receive input from a user via buttons and/or touch screen input devices. According to some embodiments, the head unit has network capabilities for communication to other devices either locally or over the internet. Through such network capability, for example, the thermostat can send information and receive commands and setting from a computer located elsewhere inside or outside of the enclosure. The MCU detects whether the head unit is attached to the backplate via head unit detect 338 .
Clock 342 provides a low frequency clock signal to MCU 320 , for example 32.768 kHz. According to some embodiments there are two crystal oscillators, one for high frequency such as 16 MHz and one for the lower frequency. Power for MCU 320 is supplied at power input 344 at 3.0 V. Circuitry 336 provides wiring detection, battery measurement, and buck input measurement. A temperature sensor 330 is provided, and according to some embodiments and a humidity sensor 332 are provided. According to some embodiments, one or more other sensors 334 are provided such as: pressure, proximity (e.g. using infrared), ambient light, and pyroelectric infrared (PIR).
Power circuitry 350 is provided to supply power. According to some embodiments, when the thermostat is first turned on with insufficient battery power, a bootstrap power system is provided. A high voltage low dropout voltage regulator (LDO) 380 provides 3.0 volts of power for the bootstrap of the MCU 320 . The bootstrap function can be disabled under MCU control but according to some embodiments the bootstrap function is left enabled to provide a “safety net” if the head unit supply vanishes for any reason. For example, if the head-unit includes the re-chargeable battery 384 and is removed unexpectedly, the power would be lost and the bootstrap function would operate. The input to this Bootstrap LDO 380 is provided by connectors and circuitry 368 that automatically selects power from common 362 (highest priority), cool 366 (lower priority); or heat (lowest priority) 364 .
In normal operation, a 3.0 volt Primary LDO 382 powers the backplate circuitry and itself is powered by VCC Main. According to some embodiments, high voltage buck 360 is provided as a second supply in the backplate. The input to this supply is the circuitry 368 . According to some embodiments, the high voltage buck 380 can supply a maximum of 100 mA at 4.5 v. According to some embodiments, the VCC main and the Primary LDO 382 can be powered by a rechargeable battery (shown in FIG. 7 ) in cases where there is no alternative power source (such as the high voltage buck or USB power, for example).
FIGS. 4A-C schematically illustrate the use of auto-switching connectors being used to automatically select a source for power harvesting, according to some embodiments. The connectors 362 , 364 , and 366 are connectors as shown in FIG. 3 . For further details regarding preferred automatically switching connectors, see co-pending U.S. patent application Ser. No. 13/034,666, entitled “Thermostat Wiring Connector” filed on even date herewith and incorporated herein by reference. The connector 362 is used for connection to an HVAC “C” (common) wire and includes two switched pairs of normally closed secondary conductors 410 and 412 . The connector 366 is used for connection to an HVAC “Y” (cooling) wire and includes one switched pair of normally closed secondary conductors 454 . The connector 364 is used for connection to an HVAC “W” (heating) wire. Note that although not shown in FIGS. 4A-C , one or more additional pairs of switched secondary conductors can be provided with any of the connectors 362 , 366 and 365 , such as could be used for the purpose of electronically detecting the presence of an HVAC system wire to the connector. Power harvesting circuitry 460 is used to supply power to the thermostat and is also connected to the Rc wire 462 (or according to other embodiment the Rh wire). For example, the power harvesting circuitry 460 can include the HV buck 360 and Bootstrap LDO 380 as shown in and described with respect to FIGS. 3 and 6A -B.
FIG. 4A shows the case of the switches 454 , 410 and 412 when no C wire and no Y wire is attached. In this case all of the switches 454 , 410 and 412 are closed and the power harvesting circuitry 460 is connected at input 464 with the W wire via circuit paths 420 , 422 and 426 . FIG. 4B shows the case of the switches 454 , 410 and 412 when no C wire is attached but there is a Y wire attached. In this case switches 410 and 412 are closed but switch 454 is opened due to the presence of the Y wire. In this case the power harvesting circuitry 460 is connected at input 464 with the Y wire via circuit paths 424 and 428 . FIG. 4C shows the case of the switches 454 , 410 and 412 when both C and Y wires are attached. In this case all the switches 454 , 410 and 412 are open and the power harvesting circuitry 460 is connected at input 464 with the C wire via circuit path 430 . Note that the case of a connection of C and W wires and no Y wire is not shown but that in this case the W wire would not be connected to circuitry 420 since switch 410 would be open. Thus, through the use of circuitry and the connectors shown, the power harvesting circuitry is automatically switched so as to use connections to C, Y and W wires in decreasing order of priority. Preferably, the C wire is the highest priority as this ordinarily provides the best power source, if available. Note that according to some embodiments, the Y and W priorities are reversed to make W higher priority than Y.
FIG. 5 is a schematic of a half-bridge sense circuit, according to some embodiments. Circuit 500 provides voltage sensing, clipped to 3.0 volts, for presence detection and current sensing. At inputs 502 , 504 and 506 are the 24 VAC waveforms from three of the HVAC circuits. In the case shown in FIG. 5 , inputs 502 , 504 and 506 are for HVAC W1, HVAC Y1 and HVAC G, respectively. The sense input bias buffer 550 is provided as shown. Note that a voltage divider is used in each case that takes the voltage from 24 volts to approximately 4 volts. Clamp diodes 520 a , 520 b and 520 c ensure that the voltage goes no higher or lower than the range of the microcontroller 320 (shown in FIG. 3 ). The Sense outputs 530 , 532 and 534 are connected to the microcontroller 320 so that the microcontroller 320 can sense the presence of a signal on the HVAC lines. The circuits are repeated for the other HVAC lines so that the microcontroller can detect signals on any of the HVAC lines.
FIGS. 6A-B are schematics showing the high voltage buck, bootstrap LDO and battery LDO power circuitry, according to some embodiments. FIG. 6A shows the input 464 from the connector selected power, which corresponds to input 464 to power circuitry 460 in FIG. 4 . The diodes 632 are used to rectify the AC power signal from the HVAC power transformer wire that is selected by the connector circuitry shown in FIG. 4 . When the thermostat is installed in a building having two HVAC power transformers, such as may be the case when an existing HVAC heating-only system is upgraded to add an HVAC cooling system. In such cases, there are two power wires from the HVAC system, often called “Rh” the power wire directly from the heating system transformer, and “Rc” the power wire directly from the cooling transformer. Input 462 is from a terminal connected to the Rc wire. According to some embodiments, the Rc and Rh terminals are switched using automatic switching or other jumperless design, as shown and described in co-pending U.S. patent application Ser. No. 13/034,674, entitled “Thermostat Circuitry for Connection to HVAC Systems,” filed on even date herewith and which is incorporated herein by reference.
Rectified input 624 is input to the high voltage buck circuit 610 , according to some embodiments. In buck circuit 610 , which corresponds to high voltage buck 360 in FIG. 3 , the voltage on the input capacitors 612 , 614 and 616 of high voltage buck 610 can be measured by the MCU 320 (of FIG. 3 ) at node 620 , allowing the MCU to momentarily open the W1 or Y1 contacts during an “enabled” or “on” phase in order to recharge the buck input capacitors 612 , 614 and 616 and continue power harvesting. According to some embodiments, the same HVAC circuit (e.g. heating or cooling) is used for power harvesting, whether or not there is more than one HVAC function in the system. According to some other embodiments, when the thermostat is used with an HVAC system having two circuits (e.g. heating and cooling), the system will power harvest from the non-activated circuit. In cases where a common wire is available from the HVAC power transformer, the system preferably does not power harvest at all from the heating and cooling circuits. According to some embodiments, the step down converter 630 is a high efficiency, high voltage 100 mA synchronous step-down converter such as the LTC3631 from Linear Technology. According to some embodiments, inductor 642 is a 100 uH power inductor such as the MOS6020 from Coilcraft. According to some embodiments, one or more other types of elements in addition to or instead of input capacitors 612 , 614 and 616 are used to store electrical energy during power harvesting when the HVAC function is active (or “on”). For example, magnetic elements such as inductors and/or transformers can be used.
In order to control the HVAC functions, the HVAC function wire is shorted to the return or power wire. For example, in the case of heating, the W wire is shorted to the Rh (or R or Rc depending on the configuration). In the case of cooling the Y wire is shorted to the Rc (or R or Rh depending on the configuration). By shorting these two wires, the 24 VAC transformer is placed in series with a relay that controls the HVAC function. However, for power harvesting, a problem is that when these wires are shorted, there is no voltage across them, and when open, there is no current flow. Since Power=Voltage*Current, if either quantity is zero the power that can be extracted is zero. According to some embodiments, the power harvesting circuitry allows power to be taken from the two wires in both the states of HVAC—the HVAC “on” and the HVAC “off”.
In the HVAC “off” state, some energy can be harvested from these two wires by taking less energy than would cause the of the relay to turn on, which would cause the HVAC function to erroneously turn on. Based on testing, it has been found that HVAC functions generally do not turn on when (0.040 A*4.5V)=0.180 watts is extracted at the output. So after the input diodes, capacitors, and switching regulator, this allows us to take 40 mA at 4.5 volts from these wires without turning on the HVAC system.
In the HVAC “on” state, the two wires must be connected together to allow current to flow, which turns on the HVAC relay. This, however, shorts out the input supply, so our system does not get any power when the HVAC “on” switch is closed. To get around this problem, the voltage is monitored on the capacitors 612 , 614 and 616 at the input switching power supply node 620 . When the voltage on these capacitors “C in ” drops close to the point at which the switching power supply would “Drop out” and lose output regulation, for example at about +8 Volts, the HVAC “on” switch is turned off and C in , is charged. During the time that C in , is charging, current is still flowing in the HVAC relay, so the HVAC relay stays on. When the C in , capacitor voltages increases some amount, for example about +16 Volts, the HVAC “on” switch is closed again, C in begins to discharge while it feeds the switching regulator, and current continues to flow in the HVAC relay. Note that C in , is not allowed to discharge back to the HVAC “on” switch due to input diodes 632 . When the voltage on C in drops to about +8 Volts the HVAC “on” switch is turned off and the process repeats. This continues until the system tells the HVAC “on” switch to go off because HVAC is no longer needed. According to some embodiments, the ability of the HVAC “on” switch to turn on and off relatively quickly is provided by circuitry 450 as shown in and described with respect to FIG. 4 of co-pending U.S. patent application Ser. No. 13/034,674, entitled “Thermostat Circuitry for Connection to HVAC Systems,” filed on even date herewith, which is incorporated herein by reference.
According to some embodiments, one or more alternative power harvesting techniques are used. For example, rather than having the HVAC “on” switch turn on when the voltage on C in reaches a certain point, it the system might turn off the “HVAC “on” switch for a predetermined period of time instead. According to some embodiments, power harvesting is enhanced by synchronizing the power harvesting with the AC current waveform.
FIG. 6B is a schematic of high voltage low dropout voltage regulators used to provide bootstrap power and battery, according to some embodiments. The bootstrap LDO circuitry 680 , and battery LDO circuitry correspond to the bootstrap LDO 380 and battery LDO 382 in FIG. 3 respectively. Rectified input 624 is input to bootstrap circuit 680 . According to some embodiments, regulator 670 is low-dropout linear regulator such as the TPS79801 from Texas Instruments. The output power 690 is provided to the backplate at 3.0V. The bootstrap disable signal 680 can be used to disable the bootstrap power unit, as shown. The input 660 comes from VCC main, which can be, for example, from the rechargeable battery. According to some embodiments, the low dropout regulator 662 is a low quiescent current device designed for power-sensitive applications such as the TLV70030 from Texas Instruments.
FIG. 7 shows a battery charging circuit 700 and rechargeable battery, according to some embodiments. The charger 710 is used to charge the lithium-ion battery 750 . In general, li-ion battery capacity depends on what voltage the battery is charged to, and the cycle life depends on the charged voltage, how fast the battery is charged and the temperature during which the battery is charged. Ordinarily, Li-ion batteries are charged at about 4.2V. In some cases the charging voltage is even higher in an attempt to gain greater capacity, but at the expense of decreased cycle life. However, in the case of the rechargeable battery 750 for use with a wall-mounted thermostat, a greater cycle life is preferred over capacity. High capacity is generally not needed since charging power is available via the power harvesting circuitry, and greater cycle life is preferred since user replacement may be difficult or unavailable. Thus, according to some embodiments, a low charging speed, low final float voltage and reduced charging temperature range is preferred. According to some embodiments, a final float voltage of between 3.9V and 4.1V is used. According to some embodiments a final float voltage of less than 4.0V is used, such as 3.95V. According to some embodiments, the ratio of charge current to total capacity “C” is also controlled, such as charging the battery to 0.2 C (0.2 times the rated capacity) to provide better cycle life than a higher ratio. According to some embodiments, using a lower charging current aids in avoiding unintended tripping of the HVAC relay.
According to some embodiments, charger 710 is a USB power manager and li-ion battery charger such as the LTC4085-3 from Linear Technology. Backplate voltage 720 is input to charger 710 . The circuitry 730 is used to select the charging current. In particular the value of resistor 732 (24.9 k) in parallel with resistor 734 (16.9 k) in combination with the inputs Double Current 738 and High Power 728 are used to select the charging current. If High Power 728 and Double Current 738 are both set to 0, then the charging current is 8.0 mA; if the High Power 728 is set to 0 and Double Current 738 is set to 1, then the charging current is 19.9 mA; if the High Power 728 is set to 1 and Double Current 738 is set to 0, then the charging current is 40.1 mA; and if the High Power 728 and Double Current 738 are both set to 1, then the charging current is 99.3 mA. Resistor 736 is used to set the default charge current. In the case shown, a 220 k resistor set the default charge current to 227 mA. According to some embodiments, a charge temperature range of 0-44 degrees C. is set via the Thermistor Monitoring Circuits.
According to some embodiments, the thermostat is capable of being powered by a USB power supply. This could be supplied by a user, for example, by attaching the thermostat via a USB cable to a computer or another USB power supply. In cases there a USB power supply is available, it is selected as the preferred power source for the thermostat and can be used to recharge the rechargeable battery. According to some embodiments, a charge current of about 227 mA is used when a USB supply source is available; a charge current of about 100 mA is used when an HVAC common wire is present; and a charge current of between about 20-40 mA is used when power is harvested from an HVAC heating and/or cooling circuit.
Although the foregoing has been described in some detail for purposes of clarity, it will be apparent that certain changes and modifications may be made without departing from the principles thereof. It should be noted that there are many alternative ways of implementing both the processes and apparatuses described herein. Accordingly, the present embodiments are to be considered as illustrative and not restrictive, and the inventive body of work is not to be limited to the details given herein, which may be modified within the scope and equivalents of the appended claims. | A thermostat and related methods are described for controlling one or more functions, such as heating and cooling in an HVAC. According to some embodiments the thermostat includes a switching circuit for controlling an HVAC function, where closing the switching circuit activates the HVAC function. The thermostat may also include power harvesting circuitry adapted and arranged to harvest power from the HVAC system, where during times when the HVAC function is active the switching circuit opens for a time interval. The power harvesting circuitry may harvest power from the HVAC system during the time interval, and the time interval may be short enough that the HVAC function remains activated without interruption during the time interval. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to integrated circuit manufacture and more particularly to a method of manufacturing wafer slice starting material which incorporates an extrinsic gettering technique.
2. Description of the Relevant Art
Methods of gettering a silicon substrate are well known. Gettering is used to remove lifetime reducing contaminants (usually heavy metals) from regions of the circuit where their presence would degrade device performance. Most all the transition metals, such as gold, copper, iron, titanium, nickel, etc., are reported as possible lifetime reducing contaminants. It is desirable to reduce the presence of such contaminants in the active regions in order to reduce reverse junction leakage, improve bipolar transistor gain, and increase refresh time in dynamic metal oxide semiconductor (MOS) memories.
Lifetime reducing contaminants (heavy metals) may be introduced into a semiconductor substrate in a number of ways. First, heavy metal contaminants may be derived from processing equipment during wafer fabrication. For example, delivery lines are often made of stainless steel. Thus heavy metal atoms comprising stainless steel species may be introduced into a semiconductor substrate during wafer fabrication. The semiconductor substrate may also receive heavy metal ions during diffusion, ion implantation, chemical vapor deposition (CVD), plasma etching, and sputtering operations.
Second, heavy metal atoms are often derived from the conductive material placed on the frontside and backside surfaces of a semiconductor substrate. Frontside surface conductive material, generally referred to as "metallization", inherently uses heavy metal materials such as titanium and tungsten to enhance silicide growth and interconnect conductivity. A coating of gold is typically placed on the backside surface of a semiconductor substrate during the final stages of device fabrication to provide power supply conductivity to the semiconductor substrate, and also as an aid to bonding of the backside surface to the chip package. Heavy metals placed on the frontside and backside surfaces may migrate to the active regions and deleteriously effect circuit operations.
Gettering within the bulk of a semiconductor substrate is typically used to trap contaminants such as heavy metals at sites away from device active regions. There are two common forms of gettering: intrinsic gettering and extrinsic gettering.
Intrinsic gettering involves forming gettering sites in the bulk of a semiconductor substrate, generally below the active regions near the frontside surface of the semiconductor substrate. In silicon substrates (wafers) manufactured using the Czochralski (Cz) method, intrinsic gettering generally includes an initial denuding step (for wafers without silicon epitaxial layers) followed by a nucleation step, and then a precipitation step. Denudation, nucleation, and precipitation, in combination, form lattice dislocations in the silicon bulk below the active regions. The dislocations serve to trap heavy metal ions at the dislocation sites, away from the overlying active regions.
Extrinsic gettering, on the other hand, generally involves gettering near the backside surface of a silicon substrate. There are several methods used to perform extrinsic gettering. Two common methods include (i) diffusing phosphorous into the backside surface of a silicon wafer, and/or (ii) depositing polycrystalline silicon (polysilicon) on the backside surface of a silicon wafer. Diffusion processes utilizing extrinsic gettering techniques such as backside phosphorous diffusion and polysilicon deposition is described in Runyan, et al., Semiconductor Integrated Circuit Processing Technology, (Addison-Wesley Publishing Co., 1990), pp. 428-442; and, DeBusk, et al., "practical Gettering in High Temperature Processing", Semiconductor International, (May 1992) (both of which are herein incorporated by reference).
Extrinsic gettering is the subject of this application. Deposited doped polysilicon has become the standard gate electrode material for MOS transistors. In common silicon gate MOS processes, a gate polysilicon layer is deposited over a gate oxide layer early in the device fabrication process. An extrinsic gettering technique may take place before gate polysilicon is deposited, or may be combined with wafer fabrication steps after gate polysilicon deposition. As defined herein, initial semiconductor fabrication occurs prior to deposition of a layer of gate polysilicon. On the other hand, process-induced (or "in-process") extrinsic gettering techniques are combined with standard wafer fabrication operations which occur after gate polysilicon deposition.
Gettering techniques employed during initial semiconductor fabrication are potentially more effective than in-process techniques. Gettering sites produced during initial semiconductor fabrication have an opportunity to trap mobile contaminants away from the active device areas of the frontside surface of the silicon substrate before the wafer is subjected to any contaminants arising from normal processing flow. Any contaminants brought about by the process tool, or by operator involvement, will be obviated by the presence of pre-existing gettering sites.
Current backside surface phosphorous diffusion techniques involve placing silicon wafers on-edge in a wafer boat, and inserting the wafer boat into a diffusion furnace containing n-type dopants (i.e., phosphorous). Thus both the frontside and backside surfaces of silicon wafers are subjected to phosphorous ions in a diffusion furnace.
It is well known that "outgassing" of phosphorous impurities, introduced into the backside surface of a silicon wafer in an extrinsic gettering process, may contaminate active device regions on the frontside surface during subsequent processing steps such as thermal oxidation.
In common silicon gate MOS processes, phosphorus backside gettering is typically incorporated into wafer fabrication following deposition of the gate polysilicon layer over the gate oxide layer. The phosphorus, diffused into both the frontside and backside surfaces of the wafer, may thus provide extrinsic gettering at the backside surface as well as lower the electrical resistivity of the polysilicon layer at the frontside surface. The deleterious effects of any outgassing of phosphorus atoms from the backside surface during subsequent thermal processing steps are thus mitigated.
As with diffusion, conventional oxidation and polysilicon deposition processes typically involve placing silicon wafers on-edge in a wafer boat. Silicon wafers in the wafer boat may then be subjected to an oxidation or polysilicon deposition process. Thus both the frontside and backside surfaces of silicon wafers are simultaneously subjected to the same oxidation, or polysilicon deposition process ambient.
In a wafer fabrication process employing a process-induced extrinsic phosphorus gettering technique, phosphorus diffusion may occur after gate oxide growth and gate polysilicon deposition. During the gate oxide growth and gate polysilicon deposition processes, oxide and polysilicon layers are commonly formed on both sides of a silicon wafer. Gate oxides are typically about 100 angstroms thick. Phosphorous ions, however, cannot easily diffuse through an oxide layer more than about 70 angstroms thick. For this reason, any gate oxide and polysilicon layers deposited prior to phosphorus diffusion must be removed from the backside surface of a silicon wafer so that the backside silicon surface can receive backside phosphorous gettering.
A protective masking material must be placed on the frontside surface of a silicon wafer in order to remove the polysilicon and underlying gate oxide on the backside surface. The protective masking material (e.g., polymerized photoresist) prevents wet etch removal of the underlying polysilicon at the frontside surface of the silicon wafer while allowing removal of exposed polysilicon and gate oxide on the backside surface. Following the stripping of the photoresist from the frontside surface, a hydrofluoric acid solution is then used to remove the gate oxide layer from the backside surface of the silicon wafer.
The above steps of coating the frontside surface of a silicon wafer with photoresist, baking the photoresist, removing polysilicon, photoresist and oxide on the backside surface is not only time consuming, but also involves numerous expensive and caustic materials. Additionally, use of photoresist during early stages of wafer processing may reduce the effectiveness of subsequent photolithography and selective polysilicon removal. Still further, any additional use of photoresist should be avoided in a cleanroom environment since photoresist, and the removal thereof, is a relatively "dirty" procedure which can compromise cleanroom integrity.
It would thus be advantageous to provide an extrinsic gettering technique that may be employed during initial semiconductor fabrication, prior to high-temperature thermal cycles such as anneals which may increase the mobilities of contaminants. Not only would the steps of removing polysilicon and gate oxide from the backside surface of a wafer be eliminated, but the steps of coating the frontside surface with photoresist, baking the photoresist, and removing the photoresist would also be eliminated.
SUMMARY OF THE INVENTION
The problems outlined above are in large part solved by the wafer slice material manufacturing method of the present invention. Employing an extrinsic gettering technique during initial semiconductor fabrication, the method optimizes extrinsic gettering during semiconductor fabrication. Extrinsic gettering occurs prior to any high-temperature thermal cycles such as anneals which may increase the mobilities of contaminants.
The method of the present invention involves (i) subjecting a frontside and a backside surface of a silicon substrate to a source of phosphorus atoms, (ii) depositing one or more thin films on the frontside and backside surfaces of the silicon substrate, and (iii) removing all thin films from the frontside surface along with a layer of silicon to a depth of about 10.0 μm at the frontside surface of the silicon substrate. It is estimated that removing the layer of silicon to a depth of about 10.0 μm at the frontside surface of the silicon substrate also removes at least 99 percent of the phosphorus atoms introduced onto and into the frontside surface.
The final polishing step of a typical silicon wafer manufacturing process removes a layer of silicon to a depth of about 10.0 μm at the frontside surface of the silicon wafer. Thus the wafer slice material manufacturing method of the present invention may easily be incorporated into a standard silicon wafer manufacturing process. In this case, the steps of (i) subjecting a frontside and a backside surface of a silicon substrate to a source of phosphorus atoms and (ii) depositing one or more thin films on the frontside and backside surfaces of the silicon substrate may be carried out prior to the final polishing step of a typical silicon wafer manufacturing process. The final polishing step may accomplish step (iii) of the wafer slice material manufacturing method of the present invention, removing all thin films from the frontside surface along with a layer of silicon to a depth of about 10.0 μm at the frontside surface of the silicon substrate.
The thin films formed on the backside surface of the silicon substrate remain, preventing outgassing of dopant impurities during subsequent thermal processing steps. A thin film of polysilicon formed over the backside surface may provide an additional source of extrinsic gettering.
Phosphorous introduction onto and into the backside surface occurs prior to any barrier material, such as an oxide, being formed at backside surface. In a wafer fabrication process employing a process-induced extrinsic phosphorus gettering technique, phosphorus diffusion may occur after gate oxide growth and gate polysilicon deposition. In this case, a protective masking material must be placed on the frontside surface of a silicon wafer in order to remove the polysilicon and underlying gate oxide on the backside surface. Coating the frontside surface of a silicon wafer with photoresist, baking the photoresist, removing polysilicon, photoresist and oxide on the backside surface is not only time consuming, but also involves numerous expensive and caustic materials. Additionally, use of photoresist during early stages of wafer processing may reduce the effectiveness of subsequent photolithography and selective polysilicon removal. Still further, any additional use of photoresist should be avoided in a cleanroom environment since photoresist, and the removal thereof, is a relatively "dirty" procedure which can compromise cleanroom integrity.
Dopant impurities may be introduced through ion implantation of chemical diffusion. Unlike chemical diffusion where large numbers of wafers are processed in parallel, ion implantation involves processing of silicon substrates in series. Ion implantation and other slower alternative processes involving serial operations have been rejected in favor of processes in which many silicon substrates may be processed in parallel. The method of the present invention thus allows for high manufacturing throughput.
Broadly speaking, the present invention contemplates a method for manufacturing wafer slice starting material which optimizes extrinsic gettering of a silicon substrate. First, the frontside and backside surfaces of a silicon substrate are subjected to dopant materials. A layer of phosphorus pentoxide (P 2 O 5 ) formed during a diffusion process involving phosphorus ions may then be removed from the frontside and backside surfaces of the silicon substrate. One or more thin films are then formed on both the frontside and backside surfaces to prevent dopant materials from leaving the backside surface and being deposited on or into the frontside surface of the silicon substrate during subsequent thermal processing steps. All thin films are then removed from the frontside surface along with a layer of the silicon substrate immediately below the frontside surface to a depth of about 10.0 μm. It is estimated that removing the layer of silicon about 10.0 μm in depth at the frontside surface of the silicon substrate also removes at least 99 percent of the phosphorus atoms introduced onto and into the frontside surface.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings in which:
FIG. 1a is a partial cross-sectional view of a monolithic silicon substrate with a frontside surface and a backside surface.
FIG. 1b is a partial cross-sectional view of the silicon substrate of FIG. 1a undergoing a phosphorus diffusion operation and showing layers of phosphorus pentoxide (P 2 O 5 ) on the frontside and backside surfaces resulting the thermal diffusion operation.
FIG. 1c is a partial cross-sectional view of the silicon substrate of FIG. 1b following deposition of capping layers of polysilicon or silicon nitride over the P 2 O 5 layers on the frontside and backside surfaces.
FIG. 1d is a partial cross-sectional view of the silicon substrate of FIG. 1c following removal of the capping layer, the P 2 O 5 layer, and some of the silicon substrate at the frontside surface.
FIG. 2a is a partial cross-sectional view of a monolithic silicon substrate with a frontside surface and a backside surface.
FIG. 2b is a partial cross-sectional view of the silicon substrate of FIG. 2a undergoing a phosphorus diffusion operation and showing layers of phosphorus pentoxide (P 2 O 5 ) on the frontside and backside surfaces resulting the thermal diffusion operation.
FIG. 2c is a partial cross-sectional view of the silicon substrate of FIG. 2b following removal of the P 2 O 5 layers from the frontside and backside surfaces.
FIG. 2d is a partial cross-sectional view of the silicon substrate of FIG. 2c following deposition of capping layers of polysilicon or silicon nitride on the frontside and backside surfaces.
FIG. 2e is a partial cross-sectional view of the silicon substrate of FIG. 2d following removal of the capping layer and some of the silicon substrate at the frontside surface.
FIG. 3a shows a partial cross-sectional view of a monolithic silicon substrate with a frontside surface and a backside surface.
FIG. 3b is a partial cross-sectional view of the silicon substrate of FIG. 3a undergoing a phosphorus diffusion operation and showing layers of phosphorus pentoxide (P 2 O 5 ) on the frontside and backside surfaces resulting the thermal diffusion operation.
FIG. 3c is a partial cross-sectional view of the silicon substrate of FIG. 3b following deposition of capping layers of polysilicon or silicon nitride over the P 2 O 5 layers on the frontside and backside surfaces.
FIG. 3d is a partial cross-sectional view of the silicon substrate of FIG. 3c following deposition of oxide layers over the capping layers on the frontside and backside surfaces.
FIG. 3e is a partial cross-sectional view of the silicon substrate of FIG. 3d following removal of the oxide layer, the capping layer, the P 2 O 5 layer, and some of the silicon substrate at the frontside surface.
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 thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1a shows a partial cross-sectional view of a monolithic silicon substrate 10 with a frontside surface 12 and a backside surface 14. Silicon substrate 10 may have a lattice structure arranged in any of several possible orientations (e.g., <111> or <100>).
The first step in a wafer slice manufacturing method which optimizes extrinsic gettering includes subjecting silicon substrate 10 to n-type phosphorus ions. FIG. 1b shows both frontside surface 12 and backside surface 14 of silicon substrate 10 being subjected to phosphorus ions 15. Phosphorus ions 15 diffuse onto or into frontside surface 12 and onto and into backside surface 14 of silicon substrate 10. The phosphorus ions 15 which diffuse into exposed backside surface 14 of silicon substrate 10 provide an extrinsic gettering source at backside surface 14.
The diffusion of phosphorus ions is preferably carried out in a diffusion furnace according to common diffusion techniques. Common diffusion techniques involve placing silicon wafers on-edge in a wafer boat, and inserting the wafer boat into a diffusion furnace. Thus both frontside surface 12 and backside surface 14 are simultaneously subjected to phosphorous ions.
During the thermal diffusion operation, thin layers of phosphorus pentoxide (P 2 O 5 ) may be formed on both frontside surface 12 and backside surface 14 of silicon substrate 10. Such P 2 O 5 layers may be formed in a diffusion furnace containing phosphine (PH 3 ) and oxygen (O 2 ) through the following reaction:
2PH.sub.3 +4.sub.2 →P.sub.2 O.sub.5 +3H.sub.2 O
Alternately, the P 2 O 5 layers may be formed in a diffusion furnace containing phosphorus oxychloride (POCl 3 ) and oxygen (O 2 ) through the following reaction:
4POCl.sub.3 +3O.sub.2 →2P.sub.2 O.sub.5 +6Cl.sub.2
FIG. 1b shows a P 2 O 5 layer 16a formed on frontside surface 12 of silicon substrate 10, and a P 2 O 5 layer 16b formed on backside surface 14 of silicon substrate 10 during thermal diffusion.
As frontside surface 12 and backside surface 14 of silicon substrate 10 are subjected to phosphorus ions 15, areas of high phosphorus ion concentration 18a and 18b are created. As shown in FIG. 1b, area of high phosphorus concentration 18a includes P 2 O 5 layer 16a and extends through frontside surface 12 and into substrate 10. Similarly, area of high phosphorus concentration 18b includes P 2 O 5 layer 16b and extends through backside surface 14 and into substrate 10.
Regarding area of high phosphorus concentration 18a, phosphorus ion concentration is highest in P 2 O 5 layer 16a and at frontside surface 12 of silicon substrate 10, and decreases with increasing depth from frontside surface 12 into substrate 10. Similarly, regarding area of high phosphorus concentration 18b, phosphorus ion concentration is highest in P 2 O 5 layer 16b and at backside surface 14 of silicon substrate 10, and decreases with increasing depth from backside surface 14 into substrate 10.
The second step in a wafer slice manufacturing method which optimizes extrinsic gettering preferably involves the formation of capping layers of polysilicon or silicon nitride over P 2 O 5 layers 16a and 16b. FIG. 1c shows a capping layer 20a over P 2 O 5 layer 16a on frontside surface 12 of silicon substrate 10, and a capping layer 20b over P 2 O 5 layer 16b on backside surface 14 of silicon substrate 10.
Capping layers 20a and 20b of polysilicon (Si) may be formed according to common CVD procedures in a CVD chamber containing silane (SiH 4 ) and at temperatures typically between 600° C. and 650° C. through the following reaction:
SiH.sub.4 +(heat)→Si+2H.sub.2
Capping layers 20a and 20b of silicon nitride (Si 3 N 4 ) may be formed according to common CVD procedures in a CVD chamber containing dichlorosilane (SiH 2 Cl 2 ) and ammonia (NH 3 ) and at temperatures typically between 700° C. and 750° C. through the following reaction:
3SiH.sub.2 Cl.sub.2 +4NH.sub.3 →Si.sub.3 N.sub.4 +9H.sub.2 +3Cl.sub.2
Capping layers 20a and 20b may be formed simultaneously over P 2 O 5 layers 16a and 16b, respectively, by placing silicon substrate 10 on-edge in a wafer boat, and inserting the wafer boat into a CVD chamber.
When capping layer 20a and P 2 O 5 layer 16a are removed in the next step, capping layer 20b over P 2 O 5 layer 16b will serve to seal P 2 O 5 layer 16b and backside surface 14 of silicon substrate 10, thus preventing dopant materials from outgassing from area of high phosphorus concentration 18b and contaminating the frontside surface during subsequent thermal processing steps.
The next step in a wafer slice manufacturing method which optimizes extrinsic gettering involves the removal of capping layer 20a, P 2 O 5 layer 16a, and some of silicon substrate 10 from frontside surface 12 down to a depth of about 10.0 μm. FIG. 1d shows silicon substrate 10 after removal of capping layer 20a, P 2 O 5 layer 16a, and some of silicon substrate 10 at frontside surface 12 down to a depth of about 10.0 μm. A new frontside surface 22 is formed which is about 10.0 μm below original frontside surface 12. Capping layer 20b over P 2 O 5 layer 16b on backside surface 14 of silicon substrate 10 remains, as does area of high phosphorus concentration 18b.
A plasma dry etch process may be used to remove capping layer 20a, P 2 O 5 layer 16a, and some of silicon substrate 10 at frontside surface 12 down to a depth of about 10.0 μm. Alternately, capping layer 20a, P 2 O 5 layer 16a, and some of silicon substrate 10 at frontside surface 12 down to a depth of about 10.0 μm may be removed by a mechanical grinding, lapping, buffing, or polishing process. If desired, a chemical etchant may be added to the mechanical grinding, lapping, buffing or polishing technique to enhance the process.
With the removal of some of silicon substrate 10 at frontside surface 12 down to a depth of about 10.0 μm, forming new frontside surface 22, it is estimated that at least 99 percent of the phosphorus atoms introduced onto and into frontside surface 12 of silicon substrate 10 are removed. As mentioned above, capping layer 20b of polysilicon or silicon nitride over remaining P 2 O 5 layer 16b serves to seal P 2 O 5 layer 16b and backside surface 14 of silicon substrate 10, thus preventing dopant materials from outgassing and contaminating frontside surface 12 during subsequent thermal processing steps.
In a second embodiment, P 2 O 5 layers formed on the frontside and backside surfaces of silicon substrate 10 may be removed prior to deposition of capping layers. FIGS. 2a-2e will be used to describe the steps involved in this second embodiment.
FIG. 2a shows a partial cross-sectional view of a monolithic silicon substrate 10 with a frontside surface 12 and a backside surface 14. Silicon substrate 10 may have a lattice structure arranged in any of several possible orientations (e.g., <111> or <100>). FIG. 2b illustrates both frontside surface 12 and backside surface 14 of silicon substrate 10 being subjected to phosphorus ions.
Silicon substrate 10 is preferably subjected to phosphorus ions in a diffusion furnace according to common diffusion procedures using phosphine (PH 3 ) or phosphorus oxychloride (POCl 3 ). Common diffusion techniques involve placing silicon wafers on-edge in a wafer boat, and inserting the wafer boat into a diffusion furnace. As shown in FIG. 2b, both frontside surface 12 and backside surface 14 are simultaneously subjected to phosphorous ions. P 2 O 5 layers 16a and 16b may be formed simultaneously on frontside surface 12 and backside surface 14, respectively, during the thermal diffusion process.
As frontside surface 12 and backside surface 14 of silicon substrate 10 are subjected to phosphorus ions 15, areas of high phosphorus ion concentration 18a and 18b are created. As shown in FIG. 2b, area of high phosphorus concentration 18a includes P 2 O 5 layer 16a and extends through frontside surface 12 and into substrate 10. Similarly, area of high phosphorus concentration 18b includes P 2 O 5 layer 16b and extends through backside surface 14 and into substrate 10.
FIG. 2c depicts the next step of removing the P 2 O 5 layers from both the frontside and backside surfaces. Specifically, FIG. 2c illustrates silicon substrate 10 after removal of P 2 O 5 layer 16a from frontside surface 12 and P 2 O 5 layer 16b from backside surface 14. P 2 O 5 layers 16a and 16b may be removed using wet or dry chemical etch processes.
After removal of P 2 O 5 layer 16a from frontside surface 12, a portion of area of high phosphorus concentration 18a remains as phosphorus region 24a. Similarly, after removal of P 2 O 5 layer 16b from backside surface 14, a portion of area of high phosphorus concentration 18b remains as phosphorus region 24b.
According to a subsequent step, FIG. 2d shows a capping layer 26a of polysilicon or silicon nitride formed on frontside surface 12 of silicon substrate 10, and a capping layer 26b of polysilicon or silicon nitride formed on backside surface 14 of silicon substrate 10. Capping layers 26a and 26b are preferably formed simultaneously over the exposed surfaces of phosphorous layers 24a and 24b using a CVD process.
The next step in a second embodiment of a wafer slice manufacturing method which optimizes extrinsic gettering involves plasma removal of capping layer 26a and some of silicon substrate 10 at frontside surface 12 down to a depth of about 10.0 μm. Alternatively, capping layer 26a and part of silicon substrate 10 may be removed using a mechanical technique. FIG. 2e shows silicon substrate 10 after removal of capping layer 26a and some of silicon substrate 10 at frontside surface 12 down to a depth of about 10.0 μm. A new frontside surface 22 is formed which is about 10.0 μm below original frontside surface 12. Capping layer 26b on backside surface 14 of silicon substrate 10 remains, as does phosphorus region 16b. As mentioned above, it is estimated that at least 99 percent of the dopants are removed with the upper layer of silicon.
The backside capping layer 26b of polysilicon or silicon nitride remains over backside surface 14 to prevent dopant materials from outgassing and contaminating the new frontside surface 22. A capping layer 26b of polysilicon, in direct contact with backside surface 14 of silicon substrate 10, may serve to provide an additional source of extrinsic gettering at backside surface 14.
It shall be noted that phosphorus atoms located on and in P 2 O 5 layer 16b were subsequently removed when P 2 O 5 layer 16b was removed in the second embodiment. Accordingly, the level of extrinsic gettering provided by the second embodiment may be lower than the level provided by the first embodiment in which P 2 O 5 layer 16b remains in place. Also as a direct result, the required thickness of capping layer 26b used to seal backside surface 14 in the second embodiment may be less than the required thickness of capping layer 20b of the first embodiment.
FIGS. 3a-3e will be used to describe the steps involved in a third embodiment. FIG. 3a shows a partial cross-sectional view of a monolithic silicon substrate 10 arranged in one of several possible orientations. FIG. 3b depicts both frontside surface 12 and backside surface 14 of silicon substrate 10 being subjected to phosphorus ions 30.
Silicon substrate 10 is preferably subjected to phosphorus ions in a diffusion furnace according to common diffusion procedures using phosphine (PH 3 ) or phosphorus oxychloride (POCl 3 ). Common diffusion techniques involve placing silicon wafers on-edge in a wafer boat, and inserting the wafer boat into a diffusion furnace. Thus both frontside surface 12 and backside surface 14 are simultaneously subjected to phosphorous ions. P 2 O 5 layers 33a and 33b may be formed simultaneously on frontside surface 12 and backside surface 14, respectively, during the thermal diffusion process.
Phosphorus regions 32a and 32b are formed as silicon substrate 10 is subjected to phosphorus ions. Phosphorus region 32a includes P 2 O 5 layer 33a, frontside surface 12, and extends through frontside surface 12 into substrate 10. Similarly, phosphorus region 32b includes P 2 O 5 layer 33b, backside surface 14, and extends through backside surface 14 into substrate 10. Phosphorus ion concentration is highest in and on P 2 O 5 layers 33a and 33b, and on frontside surface 12 and backside surface 14 of silicon substrate 10. Phosphorus ion concentration decreases with increasing depth into silicon substrate 10 from frontside surface 12 and from backside surface 14.
The next step in the third embodiment of a wafer slice manufacturing method which optimizes extrinsic gettering involves the formation of capping layers of polysilicon or silicon nitride on P 2 O 5 layers 33a and 33b on frontside surface 12 and backside surface 14 of silicon substrate 10. FIG. 3c shows a capping layer 34a of polysilicon or silicon nitride on P 2 O 5 layer 33a on frontside surface 12 of silicon substrate 10, and a capping layer 34b of polysilicon or silicon nitride on P 2 O 5 layer 33b on backside surface 14 of silicon substrate 10. Capping layers 34a and 34b are preferably simultaneously formed according to common CVD procedures described hereinabove.
The next step in a third embodiment of a wafer slice manufacturing method which optimizes extrinsic gettering involves the formation of layers of silicon dioxide (oxide) on top of the capping layers. FIG. 3d shows an oxide layer 36a on capping layer 34a on P 2 O 5 layer 33a on frontside surface 12, and an oxide layer 36b on capping layer 34b on P 2 O 5 layer 33b on backside surface 14.
Oxide layers 36a and 36b are preferably simultaneously formed according to common CVD deposition procedures. Oxide layers 36a and 36b may be formed in a CVD chamber containing silane (SiH 4 ) and oxygen (O 2 ) at temperatures of less than about 500° C. through the following reaction:
SiH.sub.4 +O.sub.2 →SiO.sub.2 +2H.sub.2
The next step in a third embodiment of a wafer slice manufacturing method which optimizes extrinsic gettering includes the removal of oxide layer 36a, capping layer 34a, P 2 O 5 layer 33a, and some of silicon substrate 10 at frontside surface 12 down to a depth of about 10.0 μm. The oxide, capping layer, and substrate silicon may be removed using any chemical removal, mechanical removal, or a combination or chemical and mechanical removal techniques.
FIG. 3e shows silicon substrate 10 after removal of oxide layer 36a, capping layer 34a, P 2 O 5 layer 33a, and some of silicon substrate 10 at frontside surface 12 down to a depth of about 10.0 μm. The new frontside surface is estimated to be void of at least 99 percent of the phosphorous atoms introduced with phosphorous region 32a.
Removal of some of silicon substrate 10 at frontside surface 12 forms a new frontside surface 22 which is about 10.0 μm below the elevation of original frontside surface 12. Oxide layer 36b, capping layer 34b, and P 2 O 5 layer 33b on backside surface 14 of silicon substrate 10 remain, as does phosphorus region 32b. Oxide layer 36b and capping layer 34b serve to seal P 2 O 5 layer 33b and backside surface 14, preventing outgassing of dopant materials during subsequent thermal processing steps. As before, a capping layer 34b of polysilicon may provide an additional source of extrinsic gettering.
By achieving phosphorous diffusion into backside surface 14 of silicon substrate 10 prior to gate polysilicon deposition, the method of the present invention achieves extrinsic gettering at backside surface 14 during wafer slice manufacturing. Phosphorous atoms are introduced onto and into both frontside surface 12 and backside surface 14 of silicon substrate 10 through a variety of methods. One or more thin films are then formed over frontside surface 12 and backside surface 14 of silicon substrate 10. The thin films over frontside surface 12 are subsequently removed, along with some of silicon substrate 10 at frontside surface 12 down to a depth of about 10.0 μm. A new frontside surface 22 is formed which is about 10.0 μm below original frontside surface 12.
The thin films on backside surface 14 of silicon substrate 10 remain, one or more of which prevent outgassing of dopant impurities during subsequent thermal processing steps. A polysilicon capping layer over backside surface 14 of silicon substrate 10 may also provide an additional source of extrinsic gettering.
In addition, phosphorous introduction on and into backside surface 14 occurs prior to any barrier material, such as an oxide, being formed at backside surface 14, and also before substrate 10 undergoes any thermal cycles such as anneals which may increase the mobilities of contaminants.
Dopant impurities may be introduced through ion implantation or chemical diffusion. Unlike chemical diffusion where large numbers of wafers are processed in parallel, ion implantation involves processing of silicon substrates in series. Ion implantation and other slower alternative processes involving serial operations have been rejected in favor of processes in which many silicon substrates may be processed in parallel. The method of the present invention thus allows for high manufacturing throughput.
It will be appreciated to those skilled in the art after having the benefit of this disclosure that this invention is believed to be capable of applications with any integrated circuit embodied upon a silicon substrate. Furthermore, it is also to be understood that the form of the invention shown and described is to be taken as presently preferred embodiments. Various modifications and changes may be made to each and every processing step as would be obvious to a person skilled in the art having the benefit of this disclosure. It is intended that the following claims be interpreted to embrace all such modifications and change and, accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. | A method of manufacturing a silicon substrate which optimizes extrinsic gettering during semiconductor fabrication is provided in which phosphorous ions are diffused into the backside surface of a silicon substrate during wafer slice manufacture. Forming gettering sites at the backside surface prior to gate polysilicon deposition, extrinsic gettering is optimized. Initially, both the frontside and backside surfaces of a silicon substrate are subjected to dopant materials. Thereafter, at least one thin film is formed on both the frontside and backside surfaces. The thin films are then removed from the frontside surface along with a layer of the silicon substrate immediately below the frontside surface to a depth of about 10.0 μm. The final polishing step of a typical silicon wafer manufacturing process removes a layer of silicon to a depth of about 10.0 μm at the frontside surface of the silicon wafer, thus allowing the wafer slice material manufacturing method of the present invention to be easily be incorporated into a standard silicon wafer manufacturing process. It is estimated that at least 99 percent of the dopants introduced into the frontside surface are removed with the upper 10.0 μm of silicon. The thin films formed on the backside surface of the silicon substrate remain, preventing outgassing of dopant impurities during subsequent thermal processing steps. A polysilicon thin film formed over the backside surface may also provide an additional source of extrinsic gettering. | 2 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a closure comprising a snap hinge serving to connect the lower part of such closure to its lid.
Closures of the above-mentioned kind are known in the art. U.S. Pat. No. 4,487,324 OSTROWSKY/SEAQUIST, for example, discloses a closure having a snap hinge whereby two film hinges, lying in the main axis of rotation, are arranged on either side of a single spring element (hereinafter called "elastic" element). In contrast, DE-GMS 87 05 035--WEENER PLASTIK discloses a closure comprising an opposite arrangement of the snap hinge, wherein two elastic elements are arranged on either side of a single film hinge.
The concept of "surrounding border" is intended to embrace borders that do not completely run around the edge of the lid.
In both of the above named patents and particularly in the U.S. patent, parts of the lower part and lid, which are connected together by means of the film hinges, project relatively far outside of the closure. This results from the fact that both lower part and lid are, when being moulded, positioned relative to each other as indicated in FIG. 5 of the U.S. patent. Since, however, the mould for the lower part and lid have a specific wall thickness, the state of the art contemplated only the need to bridge such mould wall thicknesses by means of the sections that lead from both lower part and lid to the film hinge.
The same applies to U.S. Pat. No. 3,628,215--EVERBURG/AMERICAN OPTICAL--although the bridging sections, which had to exist due to the thicknesses of the mould wall, were not shown in all of the figures.
SUMMARY OF THE INVENTION
The present invention relates, therefore, to closures having a particularly attractive appearance, an aspect which requires, among other things, that the external profile of the elastic element, when the closure is in the closed position, so correspond to the external profile of adjacent sections of lower part and lid, that, ideally, a smooth, continuous external surface is formed, in contrast to U.S. Pat. No. 3,628,215--EVERBURG/AMERICAN OPTICAL, wherein the elastic element occupies the inside of the container when the lid is closed, the result of which being an aesthetically unpleasing groove that is visible from the outside.
Accordingly, the invention contemplates a small strip or two or more film hinge-strips, which are aligned with each other, serve as the film hinge.
The object of the present invention is the design of a closure wherein the film hinge, which lies in the main axis of rotation, cannot project to the outside when the closure is closed, a condition that applies equally when two or more film hinges are aligned in the main axis of rotation. It is proposed that a closure as described be so designed that, when the lid is closed, no part of the small strip is capable of projecting toward the outside. It is furthermore proposed that the closure comprising lid, lower part and hinge, nevertheless admit production in one moulding step.
In accordance with the invention, a single film hinge lies substantially in the outer faces of lower part and lid. In addition, two or more hinges, which are aligned together, are situated in flat sections of the outer faces of lower part and lid, that are located in the region of the hinge. In accordance with another aspect of the invention, the edges of the small strip or aligned small strips are also arranged in this manner.
It is proposed that, when the container is closed, no component or part of the small strip(s) which lead to the film hinge(s), will be able to protrude toward the outside. This advantage is enabled because sections of the lower part and the lid, which lead to the film hinge or film hinges, comprise inclined surfaces (bevelled edges). The inclination of the latter must be such that such edges are adjacent when the lid is closed and swung apart when the lid is opened.
In contrast to FIG. 5 of OSTROWSKY/SEAQUIST, the proposed design enables, when the lid is opened, the part of the articulated lid floor situated in the region of the film hinge to swing above the main axis of rotation. If the lid floor is flat or curved inwardly, the entire lid can be swung up over the main axis of rotation. Consequently, the lower part and the lid can be moulded in a mould that has no separation wall or walls between lower part and lid. These advantages will be described in the following disclosure with the aid of figures.
The expression "above" used herein relates to the closure when aligned vertically, for example, aligned uprightly over the mouth of a bottle.
If the bevelled edges rest on top of each other when in the closed position, the exact and correct positioning of the film hinge or film hinges, even when embodied as small strips, is ensured when the lid is in the closed position. Despite unavoidable play, the film hinge or film hinges are, when the bevelled edges are pressed together, positioned at the corner located between the outer faces of both lower part and lid. When the container is being closed, the small strips are completely pulled toward the inside, and are thus prevented from protruding even partially toward the outside.
The bevelled edges can be flat. However, such bevelled edges can have matching curvatures.
Steps arranged inside the bevelled edges, allow one of the parts (lower part or lid) during closure to pull the other part into its correct position. The steps in this embodiment are so designed that the part having the host stable construction will pull the other part into its correct position.
The above-mentioned steps can be formed by a raised section located on the bevelled edge of the lid and a recessed section located on the bevelled edge of the lower part, the effect of which being that, when the lid is snapped shut, the latter is pulled toward the inside relative to the rear wall of the lower part.
If the film hinge is constructed as a small strip, which is useful in the operation of some embodiments of the present invention, the entire width of the small strip will be pulled to the inside when the lid is closed, which prevents any part of the small strip from protruding to the outside when the closure is in the closed position.
Embodiment examples with further distinguishing features of the present invention will be described in greater detail with the aid of drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a proposed closure in the open position.
FIG. 2 shows a portion of a vertical cross section through the centre of a proposed closure and through the elastic element that is arranged in the middle thereof;
FIG. 3 shows a portion of the cross section of a snap hinge of a further embodiment of the proposed closure;
FIG. 4 shows with the lid in the open position, a cross section at right angles to the main axis of rotation through a section of the lower part and lid having bevelled edges comprising mating steps;
FIG. 5 shows the object of FIG. 4 in the closed position;
FIG. 6 shows a cross section of the open closure showing sections of the lower part and lid, which are connected together by means of a film hinge embodied as a small strip;
FIG. 7 shows the object of FIG. 6, in the closed position;
FIGS. 8 and 9 are perspective views of the proposed closure in both the closed and open positions wherein the lower part and lid have, up to sections located in the region of the hinge, the shape of cones having elliptical cross sections.
DETAILED DESCRIPTION
Closures of the type contemplated in the present invention are produced from elastic synthetic material, preferably polypropylene, which exhibits the rigidity required for such hinges.
The expression "snap hinge" is intended to convey the concept that the lid must, when being opened or closed, be moved past a certain dead point and be able to snap on its own accord out of such dead point, which is situated at a point situated in the lid's slew path, into either the open position or closed position end then to remain in such position.
The closure illustrated in FIGS. 1 and 2 comprises a lower part 1 and a lid 3 which, as FIG. 1 shows, is surrounded on three sides by a border 5. Floor 4 of the lid connects via a snap hinge 6 to the rear wall 2 of the lower part. The snap hinge comprises two film hinges 8, which, lying to the outside, align with each other in a common main axis of rotation 10. Both lower part and lid have an indentation which, being located between the two film hinges 8, accommodates an elastic element 14 that connects via linear articulations 16 and 18 to floor 4 of the lid and rear wall 2 of the lower part respectively.
Lower part 1 comprises a flat rear wall 2 having an outer face 2a into which both film hinges 8 fall, while floor 4 of lid 3 has a flat outer face 4a into which both film hinges also fall. Outer faces 2a and 4a of rear wall and lid respectively also accommodate linear articulations 16 and 18, which have the same design as the film hinges but which are, for the purpose of being distinguished from the film hinges that sit in the main axis of rotation, named "linear articulations".
Rear wall 2 of the lower part extends on either side of elastic element 14 upwardly beyond floor 20 of the lower part and ends in inclined faces 22 whose arrangement is such that their upper edge, which lies in outer face 2a, coincides with the position of film hinge 8. Bevelled edge 24 of floor 4 of the lid is so arranged that its leading edge (pointing to the left in FIG. 2) lies in outer face 4a of the lid floor and also coincides with the position of film hinge 8. A variety of conventional embodiments can be contemplated for film hinge or film hinges 8. The latter can be embodied as a thin notch or as a narrow strip; their inner and/or outer faces can be so curved that the convex side of the bend as shown in FIG. 2 or 3 faces left toward the top. The inclined surface shown in FIG. 3, which is formed by the two bevelled edges 22 and 24, can feature between such bevelled edges a groove which acts as a weakened zone.
Elastic element 14 can, depending on the external profile of the closure, have a curvature, (FIG. 2) or be angular (FIG. 3). The size of the angle can range from 60° to approximately 120°. It is essential in any case, however, that the design of lower part, lid and elastic element be such that the injection mould need not have a separation wall or separation walls between lower part 1 and lid 3 and that the moulded closure can, following the injection moulding process, be removed without difficulty in a more or less vertical direction from the mould, as suggested by FIG. 2.
This can be achieved in particular if both lid and lower part have bevelled edges arranged as described above. One consequence of this arrangement is that, for example, a lid having a flat floor 4 as shown in FIGS. 1 or 2 as well as a lid having an inwardly curved floor lies, when in the open position, above the main axis of rotation 10, while similar prior art lids are forced to lie at least partially below the film hinge.
FIG. 4 illustrates a special embodiment of both inclined surfaces. The latter comprise, in the rear wall 2 and in floor 4 of the lid, steps whose shapes complement each other. Provided on the lid is a raised section 26, whose profile suggests a step that rises at an obtuse angle from bevelled edge 24. Provided on lower part 2 is a recessed section 28 which, in similar fashion, meets bevelled edge 22 at an obtuse angle and is thus able to mate with raised section 26.
When the lid is closed, raised section 26 mates with recessed section 28 in such a manner that the step faces, whereat both sections merge with the bevelled surfaces and which are shown oriented vertically in FIG. 5, are able to come to rest against each other. By this means, the lid is pulled toward the inside, which prevents any part of film hinge 8 from protruding toward the outside.
As FIGS. 6 and 7 show, the film hinge can also be embodied as a small strip 30. It must be ensured that the main axis of rotation 10 occupy a point (identified in the figure by a cross) and lie within a region of play at one of the edges of the small strip. This can be accomplished if the lid, as is also shown in FIGS 2 and 3, have across practically its entire thickness (more particularly over its thickness minus the thickness of the small strip) a bevelled edge 24a. In contrast, rear wall 2 of the lower part has only a shortened bevelled edge 22a, which is situated on the inner side of the rear wall, as well as a rim surface 32 that runs at an angle to the rear wall. The left-hand edge of the small strip meets the corner formed at the junction of rim surface 32 and outer face 2a of the rear wall. The right-hand edge of the small strip indicated in FIG. 6 joins outer face 4a of the lid floor as well as the lower extremity of bevelled edge 24 a. When the lid is closed, bevelled edges 22a and 24a come to rest against each other (FIG. 7) which enables small strip 30 to be pulled completely inward, the result of which being that no portion of the small strip can protrude toward the outside when the lid is in the closed position.
As FIGS. 8 and 9 show, the present invention can be used in conjunction with closures comprising curved external walls and shaped as a cone having elliptical cross sections. It is, however, essential that the lower part comprise in the region of the hinge a flattened section 34 whose width is at least as great as the integral length of the hinge in the direction of the main axis of rotation 10. Projecting upwardly from floor 20 of the lower part are two protrusions 36, each of which comprises a bevelled face 22b, of the kind described above, both of which connect to a bevelled face 24b of the lid via a film hinge 8 which sits in the main axis of rotation 10. Bevelled faces 24b extend across the entire thickness of lid floor 4b in a fashion analogous to that shown in FIG. 3. Floor 4b of the lid has, up to the longitudinal extremities of the hinge, a surrounding border 38. When the lid is closed, as in FIG. 8, the lower edge of border 38 comes to rest on top of floor 20 of the lower part, while bevelled faces 22b and 24b come to lie against each other.
Inclined faces 22 and 24 can, as is shown particularly well in FIG. 3, be flat. They can also be curved, which is to say, have jacket surfaces that are parallel to the main axis of rotation. It is preferable that such curvatures mate together when the lid is closed.
The present invention can also be used in conjunction with closures wherein only a single film hinge is arranged in the middle of the closure and is flanked by two elastic elements.
The present invention can also be used in conjunction with arrangements wherein more than two elastic elements and/or film hinges are arranged side by side in the main axis of rotation, an arrangement which, for example, can be essential in the design of box-shaped containers.
The closures can, if required, also be moulded conventionally by using dies or pushers and then be removed from the mould in a suitable manner. | A snap hinge closure has a lid which pivots about a main axis of rotation with film hinges aligned therewith. When the lid is closed, no parts of the hinge project beyond the surfaces of the closure. | 4 |
FIELD OF THE INVENTION
The present invention relates to a hybrid demolition shear and a hybrid concrete pulverizing apparatus and methods of their manufacture and use.
BACKGROUND
In the field of construction demolition, one of the principal measures of performance is the amount of scrap material that can be moved from a demolition site within a given period of time. Several factors affect this work rate.
One factor is the ability of demolition equipment to shear or pulverize the scrap metal material as efficiently as possible. Generally, it is most advantageous to use a shearing tool or pulverizer head whose operation is not interrupted by required equipment or accessory changes.
As an example of devices of the prior art, U.S. Pat. No. 4,670,983 simply provides for a mounting aperture from which a magnet might be removably hung and then removed, as needed. However, operating systems like these typically require that a magnetic lifting unit be stored or placed separate from the demolition machine, and installed in a discrete operation while the demolition tool is taken temporarily out of service. The magnetic lifting unit must then be connected to a source of power and then operated in a discrete operation in which already sheared material is moved from the position where it has been sheared into pieces or pulverized to yield smaller metal or metal-bearing pieces for removal from the demolition site.
Another factor is access and mobility within a demolition site that is typically a complex landscape of constantly changing and disorganized piles of material. It is most beneficial to be able to create and negotiate paths through the material. This requires demolition equipment to be as mobile as possible to be able to navigate the downed building material, and to be able to move and remove waste from the demolition site.
Another aspect of demolition site operation is the need to have demolition equipment that can maintain continuous operation to demolish, pick, place and remove waste material following shearing and/or pulverizing of the demolition target structure, without requiring the operator to interrupt operations to dismantle and reassemble or reconfigure the demolition machine for respective shearing and/or pulverizing steps and subsequent picking, placement and removal steps, in sequence, such as would be the case in the operation of a shearing head arm that is adapted to be used as a support for a magnet that must be hung and removed for magnetic pick, place and removal functions following shearing (as described in U.S. Pat. No. 4,670,983, hereby incorporated herein by reference). Such a device requires the operator to cease shearing operations, position the arm to accept a hung magnetic lifter, and leave the cab of the vehicle to hang the magnetic lifter and attach its power source. The operation must then be reversed following use of the magnetic lifter, in order to reinitiate shearing operations.
Such an arrangement also has the disadvantage of lacking articulation and the degrees of freedom typically associated with hydraulic arm linkages, as U.S. Pat. No. 4,670,983 calls only for the magnet to be hung from the hydraulic arm by a chain of other flexible support.
In addition, a demolition site does not lend itself to the temporary dismantling and/or storage of large portions of a demolition machine. Accordingly, it is advantageous to provide demolition equipment that can operate within limited space while being able to demolish, pick, place and remove waste material following shearing and/or pulverizing of the demolition target structure.
It is therefore beneficial to be able to provide demolition equipment that can continuously operate through discrete sequences of respective shearing and/or pulverizing steps and subsequent picking, placement and removal steps, without the need to reconfigure, reassemble or re-mount respective tool heads or the like.
Other arrangements in the prior art provide permanent magnets incorporated into boom arms, such as those described in U.S. Pat. Nos. 5,628,611 and 6,015,108, also hereby incorporated herein by reference. However, these references do not allow the advantage of readily moving the magnet into an effective position where the shearing occurs and metal scrap is released, without interference from portions of the shearing or pulverizing tool.
Accordingly, there remains a need for demolition equipment and methods able to address the concomitant problems of the need for high performance cutting and pulverizing tools within a complex and variable demolition site landscape, to be able to increase the efficiency in demolition site clean-up in terms of the amount of scrap material that can be processed and removed from a demolition site per unit time, as well as to provide lower operational costs.
In this regard, there also remains a need for combination shearing and magnetic lifting tools that more effectively allow the operator to alternatively deploy and store both the shearing or pulverizing tool into an effective position where the shearing occurs and metal scrap is released, without interference from portions of the shearing or pulverizing tool that may hinder the operator's natural and coordinated use of both the shearing or pulverizing tool and the lifting magnet.
SUMMARY OF THE INVENTION
The embodiments of the invention described herein address the shortcomings of the prior art.
In general terms, the present invention may be described as a shear tool or concrete pulverizer comprising pulverizing jaws, with a magnetic lifting attachment comprising a magnet and a hydraulic actuator adapted to move the magnet between a stored position and an active position with respect to the demolition tool by simultaneous movement of at least one of the jaws.
Demolition and Lifting Boom Arm Attachment
The present invention includes a magnetic lifting attachment to the boom structure and hydraulic system of a demolition machine, the boom structure and hydraulic system of a demolition machine comprising a demolition tool selected from the group consisting of shearing jaws and a concrete pulverizer comprising pulverizing jaws, and a hydraulic actuator adapted to actuate the demolition tool, the magnetic lifting attachment attached to the boom structure and comprising a magnet and a hydraulic actuator adapted to move the magnet between a stored position and an active position with respect to the demolition tool by simultaneous movement of at least one of the jaws.
In a preferred embodiment as applied to a concrete pulverizer tool head, the magnet may be incorporated into a moveable portion of the tool that is stationary when the tool head is being used, such as by incorporating or attaching the magnet to the stationary jaw of a set of pulverizer jaws, such that the stationary jaw is moved from an active position to a stored position while the magnet conversely is moved from a stored position to an active position.
Shearing or Pulverizing Demolition Tool and Lifting Boom Arm for a Demolition Machine
The present invention includes a shearing and lifting boom arm for a demolition machine, comprising: (a) an articulating boom arm bearing: (1) a demolition tool selected from the group consisting of (i) shearing jaws and (ii) a concrete pulverizer comprising pulverizing jaws, and a hydraulic actuator adapted to actuate the demolition tool; and (2) a magnetic lifting attachment comprising a magnet and a hydraulic actuator adapted to move the magnet between a stored position and an active position with respect to the demolition tool by simultaneous movement of at least one of the jaws.
The present invention includes a shearing and lifting boom arm that may be used in applications that do not require a vehicle base.
The active position may be any position where the magnet may be operated without interference from the demolition tool, typically and preferably the active position is below the demolition tool, although it might also be positioned beyond or actively astride the demolition tool head.
Likewise, the stored position may be any position where the magnet may be stored so as not to interfere or restrict the operation of the demolition tool, and typically and preferably may be selected from the group consisting of either (1) alongside the articulating arm and (2) above and behind the active position of the demolition tool and beneath the articulating arm.
Shearing or Pulverizing Demolition Tool and Magnetic Lifting Demolition Machine
The present invention also includes a shearing and lifting demolition machine comprising a vehicle base having an articulating arm, the articulating arm bearing: (1) a demolition tool selected from the group consisting of (a) shearing jaws and (b) a concrete pulverizer comprising pulverizing jaws, and a hydraulic actuator adapted to actuate the demolition tool; and (2) a magnetic lifting attachment and a hydraulic actuator adapted to move the magnetic lifting attachment between a stored position and an active position with respect to the demolition tool by simultaneous movement of at least one of the jaws (the stored and active positions as described above).
Method of Heavy Demolition Using Shearing or Pulverizing Demolition Tool and Lifting Boom Arm for a Demolition Machine
The present invention further includes a method of heavy demolition, the method comprising the steps: (a) operating a shearing and lifting machine at a site where scrap material is located, the shearing and lifting machine comprising a vehicle base having an articulating arm, the articulating arm bearing: (1) a demolition tool selected from the group consisting of (i) shearing jaws and (ii) a concrete pulverizer comprising pulverizing jaws, and a hydraulic actuator adapted to actuate the demolition tool; and (2) a magnet and a hydraulic actuator adapted to move the magnet between a stored position and an active position with respect to the demolition tool by simultaneous movement of at least one of the jaws; and (b) demolishing the scrap material with the demolition tool so as to obtain sheared scrap material; followed by (c) lifting the sheared scrap material with the magnet.
Typically, the magnet is moved from the active position to the stored position prior to demolishing the scrap material with the demolition tool. The magnet normally is moved from the stored position to the active position prior to lifting of the sheared scrap material with the magnet.
Once lifted, the scrap material may be transported, typically from the demolition site for further processing or transport, by action of the vehicle base.
The method may also include the step of moving the sheared scrap material with the magnet, followed by releasing the sheared scrap material from the magnet, in order to facilitate further processing or transport of the scrap material.
Following use of the magnetic lifter, the method typically will include the step of de-energizing the magnet and moving the magnet from the active position to the stored position following the release of the sheared scrap material from the magnet, to permit further use of the demolition tool.
In a preferred embodiment, the method of the present invention comprises the steps: (a) operating a shearing or pulverizing and lifting machine at a site where scrap material is located, the shearing/pulverizing and lifting machine comprising a vehicle base having an articulating arm, the articulating arm bearing: (1) a demolition tool selected from the group consisting of (i) shearing jaws and (ii) a concrete pulverizer comprising pulverizing jaws, and a hydraulic actuator adapted to actuate the demolition tool; and (2) a magnet and a hydraulic actuator adapted to move the magnet from a stored position to an active position with respect to the demolition tool by simultaneous movement of at least one of the jaws; and (b) demolishing the scrap material with the demolition tool so as to obtain sheared scrap material (or material freed from the concrete); followed by (c) moving the magnet from the stored position to the active position; (d) lifting the sheared/freed scrap material with the magnet; (e) transporting the scrap material lifted by the magnet by action of the vehicle base; and (f) releasing the sheared/freed scrap material from the magnet; and (g) de-energizing the magnet and moving the magnet from the active position to the stored position.
Using the hydraulic controls governing the demolition tool and the magnetic lifter, the operator is able to perform the steps of the method of the present invention without leaving the relative safety of the vehicle cab, and is therefore able to perform demolition much more safely and efficiently.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of a demolition machine, showing the magnetic lifter in the stored position, which may be adapted as a demolition shear or concrete pulverizer machine apparatus in accordance with one embodiment of the present invention.
FIG. 2 is a side elevation view of a demolition machine, showing the magnetic lifter in the active position, which may be adapted as a demolition shear or concrete pulverizer machine apparatus in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the foregoing summary, the following describes a preferred embodiment of the present invention which is considered to be the best mode thereof. With reference to the drawings, the invention will now be described in detail with regard for the best mode and preferred embodiment.
FIG. 1 is a side elevation view of a demolition machine, showing the magnetic lifter in the stored position, which may be adapted as a demolition shear or concrete pulverizer machine apparatus in accordance with one embodiment of the present invention. The device of the present invention may be mounted upon and/or adapted to commercial demolition equipment known and used in the art, such as those commercially available from Kubota of Osaka, Japan (also Kubota Manufacturing of America of Gainesville, Ga., U.S.A.) or Case Construction Equipment, Inc. of Racine, Wis., USA.
FIG. 1 shows smaller machine tractor carrier vehicle 1 bearing machine boom 2 bearing the machine arm 3 that may bear a shearing head or a concrete pulverizing demolition tool, in this case a pulverizing demolition tool head having a moving jaw 4 and a stationary jaw 5 , moving jaw 4 being actuated by hydraulic actuator 6 , so as to move along direction line A. This may be done through the use of hydraulic actuators and their control systems known and used in the art.
The shearing heading or concrete pulverizing demolition tool that may be used in accordance with the present invention may be those commercially available from The Stanley/LaBounty Company of Two Harbors, Minn., and such as those described in U.S. Pat. Nos. RE35,432; 7,354,010; 7,311,126; 7,306,177; 7,284,720; 7,284,718; 7,284,330; 7,255,295; 7,216,575; 7,121,489; 7,108,211; 6,994,284; 6,926,217; 6,839,969; 6,119,970; 6,061,911; and 5,894,666, all of which are hereby incorporated herein by reference. Additional concrete pulverizing demolition tools are described in U.S. Pat. Nos. 5,704,560; 6,129,298; 6,439,317; and 7,407,017, also hereby incorporated herein by reference.
FIG. 1 shows the magnetic lifter 7 in the stored position, the magnetic lifter 7 being moveably linked, in this embodiment, to the stationary jaw 5 , so as to be moveable between its stored position and its active position, as shown in FIG. 2 , so as to move along direction line B. It will be understood that the displayed embodiment allows for the movement of the stationary jaw 5 from its active position (i.e., coincidentally, the magnetic lifter's stored position) to its own stored position as shown in FIG. 2 .
FIG. 2 shows the magnetic lifter 7 in the active position, having been moved along direction line B. In this embodiment, it will be appreciated that the magnet is moved into an effective position where the shearing occurs and metal scrap is released, without interference from portions of the shearing or pulverizing tool that may hinder the operator's natural and coordinated use of both the shearing or pulverizing tool and the lifting magnet. This allows the operator to more efficiently shear/pulverize scrap material and then readily place the magnet for lifting without having to reposition the boom or arm in order to deploy the magnet into a position to pick and lift the newly cut or pulverized material.
However, it will be understood that, in other embodiments, the magnetic lifter may be reversibly moved between its stored position to its active position with simultaneous movement of any other potential obstructive or interference structure, depending upon the particular design and layout of the demolition tool. For instance, a demolition machine may be provided with a shearing head that has no discrete active and stored positions, and wherein the magnetic lifter is deployed by moving the entire shearing head upward or to one side.
In the preferred embodiment, the present invention may be reversibly moved between its stored position clear of the shearing head to its active position below or in front of the shearing head.
For instance, the present invention may be used with or adapted from shearing tool heads commercially available from the Stanley/LaBounty Company of Two Harbors, Minn., and may be used in the hybrid and retrofit machine applications of the present invention.
For instance, for bucket linkage shears, the tractor vehicle (“excavator”) weight and corresponding attachment weight are normally as follows:
(1) EXCAVATOR WEIGHT
(2) ATTACHMENT
(3) JAW
JAW
APPROXIMATE 3rd Member
WEIGHT APPROXIMATE
OPENING
DEPTH
MODEL
(lbs)
(m tons)
(lbs)
(kg)
(in)
(mm)
(in)
(mm)
BLS 40
40,000-65,000
18-30
2,900
1,315
15-18
381-457
18
457
BLS 80
70,000-100,000
32-45
3,500
1,588
17-20
432-508
19.5
495
In a preferred embodiment, the demolition tool of the present invention may be placed upon a relatively lighter shearing demolition machine having a weight less than or equal to about 65,000 pounds with a shearing head that is capable of being attached to a relatively heavier shearing demolition machine having a weight greater than 65,000 pounds (i.e., replacing a shearing head weighing less than about 3,000 pounds with a reconfigured shearing head weighing more than about 3,000 pounds), a demolition machine better suited for more efficient demolition clean-up operations may be achieved with no diminishment in shearing performance.
The relatively larger shearing head is reconfigured so as to be able to be borne by and be operative upon the relatively smaller machine boom, as shown in FIG. 1 . This may be done by connecting the relatively larger shearing head with due regard to the balance and articulation required of the relatively smaller machine tractor vehicle 1 and relatively smaller machine boom 2 in combination to be able to accommodate the movement of the reconfigured relatively larger machine arm 3 , as well as with due regard to the placement and geometrical arrangement of the associated hydraulic actuators.
The present invention may be used with or adapted from known concrete pulverizers, and these tool heads may be commercially available from the Stanley/LaBounty Company of Two Harbors, Minn., and may be used in the hybrid and retrofit machine applications of the present invention. For concrete pulverizers, the tractor vehicle (“excavator”) weight and corresponding attachment weight are normally as follows:
# OF
(1) EXCAVATOR
(2) ATTACHMENT
(3) JAW OPENING
(4) STANDARD
STANDARD JAW
TEETH
WEIGHT
WEIGHT
(TIP TO TIP)
BACK JAW
DEPTH
UPPER/
(APPROX.)
(APPROX.)
(APPROX.)
WIDTH
(TIP TO THROAT)
MODEL
LOWER
(lbs.)
(M Tons)
(lbs.)
(Kg)
(in)
(mm)
(in)
(mm)
(in)
(mm)
CP 40
3/4
36-46,000
16-21
2,875
1,304
30
762
26
660
25
635
CP 60
3/4
46-65,000
21-29
3,000
1,361
36
914
29
737
27
686
CP 80
3/4
65-88,000
29-40
4,475
2,030
42
1,067
32.5
826
29
736
CP 100
3/4
88-111,000
40-50
6,150
2,790
48
1,219
33
838
35
889
CP 120
4/5
111-160,000
50-73
9,900
4,491
54
1,372
43.5
1,105
40
1,016
The preferred embodiment includes retrofitting a relatively lighter pulverizing demolition machine having a weight less than or equal to 65,000 pounds with a pulverizing head that is adapted to be attached to a relatively heavier pulverizing demolition machine having a weight greater than 65,000 pounds (preferably by replacing a pulverizing head weighing less than or equal to about 3,000 pounds with a pulverizing head weighing more than about 4,000 pounds (as may be selected from the above table). Preferred vehicle and tool weights are additionally described in U.S. Provisional Patent Application Ser. No. 61/397,599 which is hereby incorporated herein by reference.
The weight of the relatively lighter vehicles has been found to be sufficient to support the magnetic lifting of scrap material subject to shearing or resulting from pulverization.
In a preferred embodiment, the operation of the machine of the present invention typically involves shearing or pulverizing the scrap material at a site where scrap material is located to obtain sheared/freed scrap material, followed by moving the magnet from the stored position to the active position and lifting the sheared/freed scrap material with the magnet. The scrap material is then lifted by the magnet by action of the vehicle base and boom arm, and released from the magnet once moved to the desired position for further transport or processing. Thereafter, the magnet may be de-energized, and moved from the active position to the stored position.
In operation, the demolition machines of the present invention may be used in the conventional manner, but allows the operator to readily change the operation mode of the demolition machine from shearing or pulverizing to picking and removal, in order to demolish and remove scrap material without having to attach or reconfigure a magnet in a separate operation, and without leaving the cab of the vehicle.
In addition, the preferred hybrid weight machines have been found to offer the ideal combination of cutting force and nimble navigation within the demolition site environment, to best navigate through paths of rubble and with increased visibility toward demolished material scrap and workers on site. The combination of the invention also allows scrap material to be efficiently moved off the demolition site for transport and recycling.
While the invention has been described with a certain degree of particularity, it is manifest that many changes may be made in the details of construction and the arrangement of components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for the purposes of exemplification, but is to be limited only by the scope of the attached claims, including the full range of equivalency to which each element thereof is entitled. | The present invention is a magnetic lifting attachment to the boom structure and hydraulic system of a demolition machine, which includes a demolition tool selected from the group consisting of shearing jaws and a concrete pulverizer, and a hydraulic actuator adapted to actuate the demolition tool, the magnetic lifting attachment is attached to the boom structure and features a magnet and a hydraulic actuator adapted to move the magnet between a stored position and an active position with respect to the demolition tool by simultaneous movement of at least one of the jaws. | 4 |
The invention herein described was made in the course of or under a contract or subcontract with the Department of the Navy.
BACKGROUND OF THE INVENTION
This invention relates to RF (radio frequency) directional couplers and more particularly to a device for detecting incident or reflected waves.
The detection of the power of incident or reflected propagating RF waves depends on sampling of RF line voltage and RF line current and comparing vectorially two current derivatives of the line voltage and line current. The prior art systems have very poor sensitivity in the nulling or substraction process of the line voltage and line current energy sample in the reverse or reflected power indicating mode. The result is spurious residual output when sampling a transmission line terminated in a matched load or loads departing slightly from the transmission line characteristic impedance, causing the line VSWR (Voltage Standing Wave Ratio) to depart from a value of one-to-one. Such prior art devices when used to turn back the drive of a transmitter as a function of deteriorating antenna load impedance provide signals that falsely turn back the transmitter drive, particularly on AM modulation. It is desirable not to reduce transmitter drive until antenna load mismatch approaches a higher value that would seriously damage or degrade the transmitter.
BRIEF DESCRIPTION OF INVENTION
Briefly, a device for detecting the power of an incident or reflected wave comprises a capacitive pick-up element and a coupling loop positioned along one of the conductors of a transmission line. The capacitive pick-up element and the coupling loop are coupled to a summing capacitor. The capacitive pick-up element provides current through the summing capacitor in proportion to the line voltage, and the coupling loop provides current through the summing capacitor in proportion to the line current. The coupling loop is constructed of highly resistive material to maintain the phase and magnitude of the line current sample relative to the transmission line current essentially independent of frequency.
DETAILED DESCRIPTION OF INVENTION
A more detailed description follows in conjunction with the following drawings wherein,
FIG. 1 is a cross-sectional view of a power detector according to one embodiment of the present invention.
FIG. 2 is a schematic drawing of a portion of the detector of FIG. 1.
FIG. 3 is a vector diagram with the loop in FIG. 1 connected to monitor reflected or reverse power, and
FIG. 4 is a vector diagram with the loop in FIG. 1 connected to monitor forward power.
Referring to FIG. 1, a coaxial transmission line 11 couples RF signal waves from a source such as a transmitter (not shown) to an antenna or load (not shown). The transmission line 11 has a center conductor 19 and outer transmission line 11 has a center conductor 19 and outer coaxial conductor 21. A body 23 of dielectric material is spaced between the center conductor 19 and outer conductor 21. In the region of the coupler of the present invention, a portion of the material 23 is removed and a pair of capacitive pick-up elements 25 and 27 are mounted adjacent to the center conductor 19. The pick-up element 25 is a coaxial line having a center conductor 29 and a coaxial outer conductor 31 with the center conductor 29 spaced from the outer conductor 31 by a dielectric 33. The outer conductor 31 is mounted directly on the center conductor 19 of transmission line 11. Likewise, the capacitive pick-up element 27 is a coaxial line having a center conductor 35 and an outer conductor 37 spaced by a dielectric body 39. The outer conductor 37 is mounted directly on the center conductor 19 of transmission line 11. A coupling loop 45 is closely spaced parallel to pick-up element 25. The loop 45 extends approximately the same length along conductor 19 and occupies the region approximately adjacent to the pick-up element 25 to thereby have essentially the same distribution of phase along the coupling loop 45 as along the coaxial pick-up element 25. Similarly, a second coupling loop 47 is spaced parallel to pick-up element 27. The loop 47 extends approximately the same length along the conductor 19 and occupies the region approximately adjacent to the pick-up element 27.
The end 49 of pick-up element 25 nearest the antenna or load is coupled via lead 57 to a lumped element summing capacitor 50 at electrode 51 to thereby provide a reverse power pick-up element. The opposite electrode 52 of capacitor 50 is coupled to RF ground or a point of reference potential at the outer conductor 21 of coaxial transmission line 11. The end 55 of the loop 45 nearest the antenna or load is also coupled via lead 58 to capacitor 50 at electrode 51 to thereby provide a reverse power coupling loop. The opposite end 56 of loop 45 is coupled via lead 54 to outer conductor 21 of the transmission line 11. The RF voltage at the output representing reverse power is coupled to terminal 15 via lead 17 from electrode 51 of capacitor 50. The end 63 of pick-up element 27 nearest the source is coupled via lead 59 to a lumped element summing capacitor 65 at electrode 66 to thereby provide a forward power pick-up element. The opposite electrode 67 of capacitor 65 is coupled to RF ground or a point of reference potential at the outer conductor 21 of coaxial transmission line 11. The end 68 of loop 47 nearest the source is also coupled via lead 60 to capacitor 65 at electrode 66 to provide a forward power coupling loop. The opposite end 64 of loop 47 is coupled via lead 61 to outer conductor 21 of the transmission line 11. The RF voltage representing forward power is coupled to terminal 20 via lead 22 from electrode 66 of capacitor 65.
Referring to the schematic diagram of FIG. 2, and considering the reverse of reflected power coupling system in FIG. 1, the center conductor 19 is represented by conductor 79, the outer conductor 21 is represented by conductor 81, the distributed capacitance presented by capacitive pick-up element 25 is represented by capacitance 83, the lumped element summing capacitor 50 is represented by capacitance 85 and the mutual inductance (M) provided by the loop 45 closely spaced to the center conductor 19 of transmission line 11 is indicated by coils 90 and 91. The resistance 92 in FIG. 2 is the resistance of the coupling loop 45. In the embodiment shown in FIG. 1, the coupling loops 45 and 47 are made of a highly resistive material. The coupling loops 45 and 47 are, for example, 60 ohm 1/8 watt resistors which provide a very low Q (order of 0.2 to 0.1) series resonant circuit represented by elements 90, 92, and 85 in FIG. 2. Resistance 92 is proportioned with respect to coil 90 such that over a broadband of frequencies the impedance of this mesh is essentially resistive and of the value of resistor 92. The line current (I L ) in the transmission line is sampled by the loop 45 transformer action. The induced secondary voltage is represented by e x = -I L J ω M, where M is the mutual inductance between the line and the coupling loop 45. Since the impedance is essentially resistive (low Q), the induced loop current (I loop ) is essentially equal to e s /R.
The line voltage (E L ) is coupled by the capacitive pick-up element 25 which occupies substantially the same region as the coupling loop 45. The capacitor 83 represents this pick-up capacitance of element 25. The capacitors 83 and 85 form a voltage divider. The current through capacitor 85 which is a derivative of the line voltage is represented by I V which is equal to j E L /(X C 83 + X C 85) is the capacitive reactance of capacitor 83 and X C85 is the capacitive reactance of capacitor 85. The relative value of capacitance 85 compared to capacitance 83 is selected to maintain the magnitude of the current I V in capacitor 85 equal to the current sample from the loop (I loop ). The induced secondary voltage e s in the loop 45 for a transmission line VSWR (voltage standing wave ratio) of one-to-one lags the line current I L by 90°, and the current I V in capacitor 83 leads the line voltage by 90°. See FIG. 3. Accordingly, the current sample I V related to line voltage is 180° out of phase with the current sample I loop , which is related to line current over a broad range of frequencies. Thus, for a VSWR of one-to-one, the two currents, I loop and I V , flowing in capacitor 85 are of equal magnitude and are exactly 180° out of phase to provide a null and zero output. When the VSWR departs from a one-to-one ratio, reverse or reflected power flows causing a disparity in I loop - I V with a resulting net current flow in capacitor 85 proportional to the reverse or reflected power.
If the inductor 90 in FIG. 2 is wound the same way as inductor 91, the system can be made to read forward or incident power either by reversing the direction of inductor 90 with respect to inductor 91 or by exchanging the terminal end of the coupling loop to which the summing capacitor is connected, thus changing the sign of mutual inductance (M) to (-M). The forward or incident power coupling loop represented in FIG. 1 by element 47 is connected to summing capacitor 65 at the end 68 nearest the source. Likewise the pick-up element 27 is coupled to summing capacitor 65 at the end nearest the source. The direction of the loop current (I loop ) is reversed 180°. The loop current I loop is therefore for VSWR of one-to-one additive in phase with the current sample I V coupled by capacitive pick-up element 27. In the diagram of FIG. 2, pick-up element 27 is now represented by capacitor 83 and summing capacitor element 65 by capacitor 85. As illustrated by the vector diagram of FIG. 4, the loop current (I loop ) associated with the currents coupled to element 47 for a one-to-one VSWR is added in phase with the current I V associated with that coupled from pick-up element 27. The two currents add vectorially and produce an RF voltage output proportional to the forward or incident power. Since the capacitive pick-up element and the loop in each case (forward or reverse power coupling) occupy approximately the same space relative to the line sampled and are of distributed parameter construction and since the impedance of the loop circuit is of a low Q, a uniform phase relation between the line current and line voltage derivatives is provided over a wide range of frequencies. These factors have proved essential in the current and voltage sampling techniques to provide high discrimination between forward and reverse power detection. The magnitude RF voltage output taken across either of the summing capacitors (represented by capacitor 85 in FIG. 2) is equal to the vector addition of the loop current (I loop ) and the current sample I V times the reactance of capacitor 85. This RF voltage across terminals 95 and 97 may be coupled to an RF voltmeter by coupling terminal 95 to the voltmeter. Terminal 95 represents terminals 15 or 20 in FIG. 1. The output at terminal 95 in FIG. 2 may also be coupled to a detector and the varying D.C. voltage used to either control a meter or be used to control the gain of one or more stages of the source. | A device for detecting the power of incident or reflected waves along a transmission line is described which includes a capacitive pick-up element in series with a summing capacitor between the two conductors of the transmission line. The capacitive pick-up element provides a current sample through the summing capacitor in proportion to the line voltage. A coupling loop positioned in the approximate region of the capacitive pick-up element and in series resonance with the summing capacitor provides a current sample through the summing capacitor in proportion to the line current. The coupling loop is of highly resistive material to maintain the magnitude and phase of the developed line current sample relatively independent of frequency over a relatively broad range of frequencies. | 6 |
FIELD OF THE INVENTION
The invention relates to the general field of magnetic write heads with particular reference to an improved top pole piece.
BACKGROUND OF THE INVENTION
For high track density recording, tighter reader and writer track width control is the key ingredient for obtaining high yield. How to continue improving the writer track width by using a pole trim process together with a narrow pole width is a challenging task. The basic principle to having tighter pole width control is to have a thinner pole resist process so that photo CD (critical dimension) control can be further improved. Reducing the amount of pole material consumed during the pole trim process, without impacting performance, is the key factor associated with using a thinner pole resist.
There have been several proposals to utilize a plated S 2 (writer lower shield), a plated write gap, and a plated P 2 (top pole) in a single photo process thereby minimizing the extent of pole trim consumption. However, with this scheme the throat height definition is rather poor so this type of design creates magnetic flux leakage between pole and shield. So poor overwrite is a consequence of this type of design.
The present invention discloses an improved scheme that applies to both stitched writers and planar writers.
A routine search of the prior art was performed with the following references of interest being found:
In U.S. Pat. No. 6,594,112, Crue et al. disclose NiPd plating to more accurately define throat height. Alumina is used as the insulating material. In U.S. Pat. No. 6,621,659, Shukh et al. show alumina in the recess to define throat height.
SUMMARY OF THE INVENTION
It has been an object of at least one embodiment of the present invention to reduce the amount of pole material consumed during pole trimming.
Another object of at least one embodiment of the present invention has been to facilitate use of thinner photoresist during formation of the top pole.
Still another object of at least one embodiment of the present invention has been to improve heat dissipation by the write head.
A further object of at least one embodiment of the present invention has been to provide a process to manufacture said write head.
These objects have been achieved by using a plated NiPd write gap and self-aligning with a plated 24 KG pole material. Heat dissipation by the writer is thus improved since alumina has been replaced with nonmagnetic metal materials, such as Ru, leading to less pole tip protrusion which in turn leads to better writer track width control.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the starting point for the construction of the present invention.
FIGS. 2 and 3 show how lower pole and back pieces are to be separated.
FIGS. 4 and 5 show the formation, in automatic alignment, of the write gap and the lower pole piece.
FIG. 6 shows formation of the end piece.
FIGS. 7 and 8 are ABS views of FIG. 6 .
FIG. 9 shows the starting point for manufacturing a planar writer according to the teachings of the present invention.
FIGS. 10–13 illustrate the formation of the write coils and the lower pole structure.
FIGS. 14 and 15 show the formation of the top pole and end piece.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In this invention we disclose a plated NiPd write gap and a plated 24 KG P 2 in conjunction with a modified TH (throat height) definition method to overcome the poor TH definition problems associated with the prior art. The invention leads to a reduced amount of pole consumption by using a self-aligned plating process for the formation of the write gap and the top pole.
We begin a non-specific description of the present invention by referring to FIG. 1 . Seen there is read head 14 which is sandwiched between its shields 13 and 15 . Insulating layer 12 serves to isolate the top read shield 13 from lower write shield 11 .
The method of the present invention begins, as shown in FIG. 2 , with the deposition onto lower shield 11 of seed layer 21 which is characterized by having a magnetic moment of at least 24 kilogauss. Seed layer 21 could be CoFeN or CoFe and is deposited to a thickness between about 1,000 and 5,000 Angstroms. Then, as shown in FIG. 3 , trench 31 is formed in seed layer 21 . Trench 31 extends down as far as the top surface of shield 11 and has sloping sidewalls. The width of trench 31 will determine the throat depth of the writer.
Trench 31 is then just filled with layer of a non-magnetic metal 32 by means of sputtering. We have typically preferred ruthenium for metal 32 but other non-magnetic metals such as NiCu, Cu, Rh, or NiCr could also have been used.
Referring now to FIG. 4 , photoresist mold 41 is formed, as shown, and then write gap layer 51 is electroplated onto the floor of mold 41 . Gap layer 51 is preferably NiPd but similar materials such as NiP or Pt could also have been used. It is deposited to a thickness between about 700 and 1,500 Angstroms. The mold is positioned so that write gap layer 51 overlaps both seed layer 21 and non-magnetic metal layer 32 . Then, with the mold still in place, upper pole piece 52 is formed by electroplating onto write gap layer 51 (inside the mold). Upper pole piece 52 is made of a material such as CoNiFe and it is deposited to a thickness between about 2 and 4 microns. The structure, after removal of all photoresist is shown in FIG. 5 .
The general method concludes with the formation of back gap piece 61 that is in magnetic contact with seed layer 21 and with upper pole piece 52 , said back gap piece not overlapping the write gap layer. FIGS. 7 and 8 are ABS (air bearing surface) views of FIG. 6 and of FIG. 6 after its left edge has been planarized.
We will now disclose a process for a more specific embodiment of the present invention namely a the manufacture of a planar write. As noted earlier, the process is of a more general nature can, in general, be applied to write heads of any shape or design.
Referring now to FIG. 9 , the process begins with the provision of lower magnetic shield layer 112 on which is formed dielectric disc 16 . Lower coil 17 is then formed on disc 16 . Then, as shown in FIG. 10 , layer of ferromagnetic material 18 is deposited and patterned to form the bottom section of the lower pole which includes centrally located lower trench 42 on whose floor rests dielectric disc 16 and lower coil 17 .
Then, as seen in FIG. 11 , lower trench 42 is overfilled with insulating material 44 and then planarized, giving it the appearance seen in FIG. 12 , following which insulating layer 136 is deposited and patterned to form a lid that fully covers lower coil 17 as seen in FIG. 13 . Upper coil 137 is then formed on lid 136 and additional ferromagnetic material is deposited and patterned to complete formation of lower pole 18 which is then filled with insulation 138 .
The top (coplanar) surfaces of elements 11 and 138 in FIG. 13 are equivalent to the top surface of element 11 in FIGS. 1–5 . From this point the formation of the planar reader proceeds along the line previously recited for the general method:
Seed layer 21 , having a magnetic moment of at least 24 kilogauss, is deposited on the top surfaces of 11 and 138 and non-magnetic metal filled trench 32 is formed. Using a photoresist mold, as described earlier, top pole 52 is electro-formed on write gap layer 51 , said write gap layer overlapping both seed layer 21 and layer of a non-magnetic metal 32 , as shown in FIG. 14 .
To complete the structure, back gap piece 61 , that is in magnetic contact with the seed layer and with the upper pole piece and that does not overlap the write gap layer is formed, as shown in FIG. 15 .
We conclude by noting that the present invention, as disclosed above, offers the following advantages:
1. Less P 2 consumption due to self-aligned plated NiPd write gap and plated 24 KG pole material. 2. Thinner P 2 resist can be used and tighter control, both within a single wafer and from wafer to wafer can be expected. A thinner resist allows greater photo-processing latitude (depth of focus, for example) which in turn leads to better P 2 CD (critical dimension) control. 3. A modified TH definition process can further reduce the P 2 consumption. 4. Heat dissipation by the writer is improved by replacing alumina with nonmagnetic metal materials, such as Ru, NiCu, Cu; etc (layer 32 ), leading to less pole tip protrusion 5. Better writer track width control. 6. A simplified writer process. | For high track density recording, tighter reader and writer track width control are essential. This has been achieved by using a plated NiPd write gap which is self-aligned with a plated 23 KG pole material. Heat dissipation by the writer is thus improved since alumina has been replaced with nonmagnetic metal materials, such as Ru, leading to less pole tip protrusion which in turn leads to better writer track width control | 8 |
BACKGROUND OF THE INVENTION
(1). Field of the Invention
The present invention relates generally to office furniture and, more particularly, to a cubicle shield for providing shielding from lighting and ventilation.
(2). Description of the Prior Art
Cubicles have no ceilings and as such do not provide any controls to allow cubicle occupants or users to regulate and/or adjust light and/or ventilation within the cubicle. Some personnel using cubicles would like to reduce the light and/or ventilation reaching them. No prior art is directed to a movable, positionable overhead cubicle shield able to block light and/or ventilation. Thus, a need exists for a moveable, positionable overhead cubicle shield that can attenuate environmental parameters such as light and ventilation.
SUMMARY OF THE INVENTION
The present invention is directed to a shield for sheltering a cubicle inhabitant from environmental parameters, such as lighting or ventilation, by attenuating the environmental parameters. Additionally, the cubicle shield can be used as a support for images or designs.
Preferably, the present invention consists of a cubicle-mountable covering with or without a frame.
Accordingly, one aspect of the present invention is to provide a shield for sheltering a cubicle inhabitant from environmental parameters including an at least partially opaque covering suspended over the cubicle such that the environmental parameters are attenuated, and a frame for supporting the at least partially opaque covering, thereby providing protection for the cubicle inhabitant against environmental parameters.
These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment according to the present invention and mounted on a cubicle.
FIG. 2 is a perspective view of another embodiment of a cubicle shield constructed according to the present invention.
FIG. 3 is a perspective view of still another embodiment of a cubicle shield constructed according to the present invention.
FIG. 4 is a perspective view of an alternative embodiment of the present invention.
FIG. 5 is a top view of another alternative embodiment of the present invention.
FIG. 6 is a perspective view of yet another alternative embodiment of the present invention.
FIG. 7 is an uninstalled, flat view of a cubicle shield constructed according to the present invention.
FIG. 8 is an uninstalled, flat view of a cubicle shield constructed according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward,” “rearward,” “front,” “back,” “right,” “left,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting terms.
Referring now to the drawings in general, the illustrations are for the purpose of describing a preferred embodiment of the invention and are not intended to limit the invention thereto. As best seen in FIG. 1 , the shield, generally referred to as 10 , consists of a frame 15 and a covering 20 . These two components, namely the frame and covering, are preferably formed from separate elements in a preferred embodiment of the present invention, as shown in FIG. 1 . In an alternative embodiment of the present invention, the frame is provided and formed by the cubicle walls 25 , as shown in FIG. 2 . Alternatively, the cubicle shield is made using rigid materials that integrate both frame and covering components into a unitary, integral construction that requires only vertical support, as shown in FIG. 3 , which represents yet another embodiment of the present invention. In the embodiment illustrated in FIG. 3 , the thickness of the canopy material 30 is such that the rigidity of the canopy is adequate to make it self-supporting; the thickness required for the cubicle shield canopy to be self-supporting is dependent upon the type of canopy material selected and the properties of that material. In that embodiment, the integral, self-supporting cubicle shield, generally described as 10 in FIG. 3 , is formed of a rigid material that is pre-molded to the desired shape, making it self-supporting. This embodiment rests directly on the cubicle walls as illustrated. It may be additionally secured or fastened to the cubicle walls using fasteners, including but not limited to hook-and-loop fasteners, pins, clips, screws, and adhesives; note that this securement is not a requirement but advantageously provides additional securement in the event of impact to the cubicle structure or other vibration that might otherwise occur and potentially affect the original positioning of the shield resting on the cubicle itself.
In general, the present invention advantageously and usefully supplies diagonal screening or shadowing, i.e., preferably the shield is positioned with respect to the overhead light and the cubicle such that a shadow cast by the shield is at least as large or larger than the cross-sectional area of the shield and projects diagonally across the cubicle space, rather than projecting directly down or onto a smaller area or region. The shadowing effect provides a controllable effect on overhead lighting in order to provide individualized shading, which can be advantageous for preventing or reducing glare on a computer screen within the cubicle workspace as well as provide lower lighting within a cubicle space to a user who otherwise cannot dim or reduce the overhead lighting within an office environment without affecting other workers. Notably, where a group of cubicle users prefer shading or shadowing as provided by the present invention, a cubicle shield embodiment according to the present invention that provides coverage over a multiplicity of cubicles may be employed; otherwise, a cubicle shield embodiment that provides coverage over a single cubicle work space may be employed.
A framed cubicle shield embodiment according to the present invention is one in which the frame and covering are formed of at least two distinct components, as shown in FIGS. 1 , 4 , 5 , 6 and 7 . The frame component 15 supplies support to hold the at least partially flexible covering 20 in position. In the present invention, the frame may be self-supporting, or supported by a rod, wire or string that attaches to the ceiling above the cubicle. The frame is preferably constructed and positioned on a cubicle, when installed, to allow the cubicle shield to extend over at least one cubicle work space or area. At least two support members are required to form the frame in one embodiment of the present invention as illustrated in FIG. 1 , where in a preferred embodiment of a framed construction of a cubicle shield according to the present invention, three support members are used. The support members are formed of rigid or semi-rigid material for providing such support. In one embodiment of the present invention, the frame has a center arm 16 and 2 side arms 18 , as shown in FIG. 1 , that form an open-sided tetrahedron when opened and installed onto a cubicle. An uninstalled, flat view of this embodiment is shown in FIG. 7 . In this embodiment, the support members form an apex 22 and are attachable to the cubicle at apices 23 , 24 , and 25 in at least 3 non-rectilinear points, such that an open-sided tetrahedron is formed. Alternative shapes are also provided by the present invention, e.g., by changing the number and configuration of support members, without departing from the scope of the invention.
Alternatively, in another embodiment of a cubicle shield according to the present invention, a central support extends upward from cubicle wall intersection post with support members extending over one or more cubicles conjoining at the post. In such configurations, the covering or canopy may extend over a single cubicle, or over two or more cubicles. An example of this embodiment is shown in FIG. 4 , which illustrates an inverted canopy configuration, in which the covering 20 is suspended from the frame 15 mounted on a central support 45 . A normal, or non-inverted canopy or umbrella configuration, in which the covering drapes downwardly over the frame, is provided in yet another alternative embodiment according to the present invention. FIGS. 5 and 6 illustrate fan configurations, in which the frame members 15 radiate out from the central support 45 extending up from a cubicle post when installed on a cubicle.
The dimensions for the frame components may vary from a minimum of 1 foot to a maximum of 10 feet, depending upon the cubicle dimensions and the amount of shading or shadowing effect that is desired for a particular cubicle. In a 3-component frame, as shown in FIG. 7 , the two lateral frame components 18 are of approximately equal length, and the center frame component 16 is selectable to be approximately equal to, shorter, or longer than the lateral frame components, once again depending upon the amount of shading or shielding effect desired for a particular cubicle.
In a preferred embodiment according to the present invention, the support members are formed of at least semi-rigid material that is bendable. The support members may be segmented. The support members are removably attachable to a cubicle for providing support of the overall cubicle shield construction when it is installed on a cubicle.
The covering is formed of at least partially flexible covering material. The material is at least partially opaque to block light and provide the shading or shadowing effect described hereinabove. The covering material is preferably made of a fabric material, or a material that is assembled from components used for shades or blinds, including natural fibers or materials such as paper, cellulose, cotton, flax, rayon, bamboo, reeds, wood, and synthetic fibers, sheets, or materials, including nylon, polyester, polypropylene, PEEK, MYLAR, and the like, and may also be treated with a flame retardant or selected from a fire-resistant, flame retardant, or fire-proof material for enhanced safety. Where fabric is used, it may be woven, non-woven, or composite construction.
The cubicle shield according to the present invention is cubicle-mountable and additionally securable with fasteners, including but not limited to hook-and-loop fasteners, pins, clips, screws, adhesives, and the like. Where the shield is not self-supporting, attachment securement is preferred. Where the shield is self-supporting, such securement is desirable to further affix and confirm the position of the shield with respect to the cubicle as well as to provide safety assurances, e.g., that the shield will not fall onto a cubicle user if the cubicle is impacted and the shield is disrupted.
For an embodiment that requires securement or mounting onto a cubicle, i.e., for embodiments that are not self-supporting, the shield is preferably mounted on the side or top of the cubicle wall, or may be post-mounted. Preferably the shield is constructed of lightweight materials, such that no excessive stress is placed on the cubicle wall or post.
The present invention and various embodiments thereof thus provides a light and/or ventilation shield that also advantageously provides area for an overhead display not presently available with cubicles. Additionally, the cubicle shield can be used as a support or plane onto which art, photos, images, logos, advertisements, information, or designs are permanently or removably attached thereto or printed thereon.
Other embodiments of the present invention use the cubicle itself to provide the frame. Such an embodiment is a cubicle-framed, non-self-supporting cubicle shield, as shown in FIG. 2 . This embodiment uses an at least semi-rigid material as an at least partially flexible covering material that spans between two cubicle walls. The cubicle walls 25 provide lateral support to maintain the covering material 20 in a non-planar, arched, 3-dimensional shape. The material is at least partially opaque, to block light. The material can be made from plastic, such as from polyethylene, polystyrene, polycarbonate, and the like, or from composite material, such as paperboard or cardboard. The covering material is of unitary, integral construction of at least one layer of material, as shown in FIG. 8 . In FIG. 8 , an uninstalled view of a preferred embodiment, generally shown as 80 , is shown. This embodiment is a section of a circular plane with radius x=6 feet, radius y=2 to 3 inches, and arc a=135 degrees.
A variety of fasteners can be used, such as hook-and-loop, pins, screws, clips, adhesive, and the like. The covering material is side or top mountable on the cubicle wall, and the cubicle forms the supporting frame that holds the partially flexible material in the desired shape. The covering material is lightweight such as not to place undo stress on the cubicle wall or frame. The described embodiment thus provides a light and/or ventilation shield that also provides area for an overhead display.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. By way of example, the frame can be supported by a rod, wire or string that attaches to the ceiling above the cubicle. All modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims. | A shield for a cubicle including an at least partially opaque covering suspended over the cubicle such that the environmental parameters are attenuated, and a frame for supporting the at least partially opaque covering, thereby providing protection for the cubicle user against environmental parameters. Alternatively, a frameless shield may be provided. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to U.S. Provisional Application No. 61/672,908 filed Jul. 18, 2012. The aforementioned application is incorporated by reference in its entirety.
BACKGROUND
The present disclosure relates generally to protective helmets such as ballistic helmets or other helmets having a similar construction, such as a ballistic tactical helmet for use by law enforcement personnel, military field or combat helmets, or the like. More particularly, the present disclosure relates to a helmet edge trim and a helmet employing same with integral wiring for routing electrical power or signals to one or more electrical or electronic accessory devices or components attached or mounted to the helmet.
Commonly, a military ballistic helmet or the like is configured with mounts, brackets, or the like to carry one or more accessories or attachments, such as a flashlights, viewing optics and devices, such as a monocular, binoculars, monocular or binocular night vision (NVG) devices (including passive night vision devices and enhanced night vision (eNVG) devices), thermal imaging devices, cameras, friend or foe identification (IFF) systems, communications devices, and so forth.
To connect accessories to an electrical source, a wiring harness may be routed along the interior of the helmet. However, an internally routed wire harnesses may be subject to chemical attack due to perspiration, damaged through impact with the wearer's head, and so forth. In addition, an internally routed wiring harness may require one or more holes or vias through the ballistic material of the helmet, thus compromising the antiballistic properties of the helmet in these regions. Alternatively, a wire harness may be routed externally over the exterior surface of the helmet. However, external wiring harnesses may be cumbersome and susceptible to failure.
In addition, the number and complexity of helmet mounted components is increasing, with such components often including computer or microcontroller-based devices controlled through the use of electronic signals and sensors. This results in the need for larger and more complex wiring assemblies and poses difficulties in installing such devices while maintaining the ballistic integrity of the helmet.
Therefore, there exists a need for an improved helmet construction and method having an integrated accessory mounting and electrical interconnection device which could replace the wiring typically used for electrical power, data, and/or signal transmission and which would reduce wiring complexity, simplify helmet assembly and device attachment.
SUMMARY
A helmet system and method are provided that allow an electrical connection between one or more electrical or electronic components on the helmet by integrating a wiring harness or other flexible circuit between the edge trim and the brim of a helmet shell.
In preferred aspects, the helmet system and method allow a secure connection of helmet mounted accessories to the helmet without the need to run an exposed wiring harness over the exterior surface of the helmet shell and without the need to penetrate the ballistic shell with wiring vias. One advantage of the present development is that the edge trim with circuit components as described herein may be retrofit to any existing helmet by replacing existing edge trim with the edge trim as described herein, and may be adapted for use with any existing helmet design. It is to be understood that both the following detailed description is exemplary and explanatory only and are not restrictive of the invention.
In one aspect, a protective helmet includes an outer shell bounded by a peripheral edge and an edge trim attached to and extending around the peripheral edge. A wiring harness is disposed within the edge trim.
In a more limited aspect, the wiring harness is integral with the edge trim.
In another more limited aspect, the wiring harness is received between the peripheral edge and the edge trim.
In still another more limited aspect, the wiring harness comprises a plurality of conductive elements.
In another more limited aspect, the wiring harness is selected from a ribbon cable and a flexible circuit substrate carrying one or more printed circuit elements.
In yet another more limited aspect, the wiring harness comprises a flexible circuit substrate formed of a flexible polymer film having one or more conductive elements printed thereon.
In another more limited aspect the edge trim defines a channel receiving the peripheral edge.
In still another more limited aspect, the protective helmet includes one or more power connectors on the outer shell configured to attach to an electrical power source and one or more device connectors on the outer shell configured to connect to an electrically powered device. The wiring harness is electrically coupled to the one or more power connectors and the one or more device connectors.
In another more limited aspect, each of the one or more the power connectors includes a mechanical fastener for removably attaching a power source and further includes a first set of electrical contacts which is aligned with a second set of electrical contacts on the power source when the power source is attached.
In yet another more limited aspect, the power supply is selected from a battery and a battery pack.
In another more limited aspect, each of the one or more the device connectors includes a mechanical fastener for removably attaching a powered device and further including a first set of electrical contacts which is aligned with a second set of electrical contacts on the powered device when the powered device is attached.
In still another more limited aspect, the protective helmet further includes one or more powered devices selected from the group consisting of flashlights, illumination devices, passive night vision devices, enhanced night vision devices, thermal imaging devices, cameras, video recorders, and friend or foe identification (IFF) devices.
In another more limited aspect, the protective helmet further includes a mount attached to a front portion of the outer shell for positioning a viewing device in front of an eye of a user wearing the helmet.
In yet another more limited aspect, the protective helmet is a ballistic helmet.
In another more limited aspect, the outer shell comprises a ballistic shell formed of multiple plies of reinforcing fibers within a polymer matrix material.
In yet another more limited aspect, the edge trim is formed of a material selected from a molded polymer material and an extruded polymer material.
In another more limited aspect, the wiring harness includes a plurality of conductors for transmitting one or more of power, data signals, sensor signals, and communication signals.
In still another more limited aspect, the peripheral edge is unfinished.
In another more limited aspect, the edge trim is secured to the peripheral edge with a mechanical fastener.
In yet another more limited aspect, the edge trim is permanently secured to the peripheral edge with an adhesive.
In another more limited aspect, the adhesive is an epoxy adhesive.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention and together with the general description, serve to explain the principles of the invention, and are not to be construed as limiting the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be better understood by those skilled in the art by reference to the accompanying drawing figures, in which:
FIG. 1 is an isometric view, taken generally from the front and side, of an exemplary helmet in accordance with the present disclosure;
FIG. 2 is a front elevational view of the embodiment appearing in FIG. 1 ;
FIG. 3 is an exploded, isometric view of the embodiment appearing in FIG. 1 ;
FIGS. 4 and 5 are generally front and rear isometric views of the helmet embodiment appearing in FIG. 3 , with the electrical connectors removed;
FIG. 6 is front elevational view of the embodiment appearing in FIGS. 4 and 5 ;
FIG. 7 is an enlarged view of the region A appearing in FIG. 6 ;
FIG. 8 is an isometric view taken generally from the rear and side, illustrating the manner of attachment of accessories and a power supply;
FIG. 9 is an enlarged view of the front of the helmet, illustrating the manner of attachment of a bracket or shroud for attaching a night vision device, such as an NVG or eNVG, or other optical or viewing device;
FIG. 10 is a side cross-sectional view of the helmet embodiment appearing in FIGS. 4 and 5 ;
FIG. 11 is an enlarged view of the region C appearing in FIG. 10 ; and
FIG. 12 is a generally rear isometric view illustrating an exemplary electrical connector for electrically coupling the edge trim circuit to a power supply remotely located from the helmet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings wherein like reference numerals designate like parts throughout the several views, FIGS. 1-12 illustrate a helmet 100 , which may advantageously be a ballistic helmet although other helmet types are contemplated as well. The helmet 100 includes a shell 110 , which may be formed, e.g., by laying up multiple plies of a fiber reinforced composite material on a generally helmet-shaped pre-form. Such composite material may include fibers, e.g., polymer fibers such as aramid fibers (e.g., KEVLAR®) or other ballistic fiber impregnated with a polymer resin. Other ballistic and non-ballistic helmet types, including metal helmets, molded plastic helmets, etc., are also contemplated.
An edge trim member 120 is shaped to correspond to the peripheral edge 112 of the shell 110 and defines a groove or channel 122 sized to receive the unfinished edge 112 of the shell 110 . The edge trim member may be a molded construction or, alternatively, may be formed as an elongate strip by extrusion and cut to the appropriate length.
A wiring harness or circuit member 130 is received within the groove 122 . The circuit 130 may comprise a ribbon cable comprising a plurality of conductors 132 (5 conductors in the exemplary embodiment illustrated although other numbers of conductors are contemplated). Alternatively, the circuit member may comprise a flexible circuit substrate such as a flexible polymer film having conductive tracings formed thereon. In still further embodiments, the conductive elements may be formed directly in the edge trim member 120 , e.g., by molding the circuit elements within the edge trim or printing circuit elements directly on the edge trim member.
As best seen in FIG. 11 , the circuit member 130 is seated between the unfinished helmet brim 112 and the base of the groove 122 . The edge trim member 122 is secured to helmet shell 110 via an adhesive, e.g., an epoxy adhesive or the like, although other fasteners such as mechanical fasteners are also contemplated.
In the depicted embodiment, there appear four device connectors coupled to the edge trim member, including a front connector 140 , a rear connector 160 , and left and right side connectors 180 . It will be recognized, however, that other numbers of connectors, spacings, and electrical connector configurations are also contemplated.
The front mounting member 140 includes a bracket or shroud 142 adapted to attach a night vision goggle, enhanced night vision goggle, or other optical device (not shown) to be positioned in in front of one or both eyes of a user. In preferred embodiments, the bracket 142 is adapted to attach a pivoting mount which allows the user to selectively move the optical or viewing device between a lowered, operable position in front of the user's eyes and to a raised, stowed position on the helmet out of the line of sight of the viewer.
In the illustrated embodiment, the front connector 140 is secured to the edge trim member via threaded fasteners 144 which engage aligned openings 145 in the bracket 142 and openings 124 in the edge trim member. The openings 124 may be reinforced, e.g., via tapped metal inserts. In the illustrated embodiment, a bolt 146 passes through an opening 147 on the bracket 142 and an opening 114 in the shell 110 and receives a complimentary nut 148 to further secure the front connector 140 to the helmet 110 .
An electrical connector 150 is provided on the exterior surface of the front connector 140 . The electrical connector is positioned to align with a mating connector on a helmet mount (not shown) for attaching an optical/viewing device. The electrical connector 150 is adapted to connect to an electrical connector on a helmet mount, which in turn is electrically coupled to electrical contacts on a mounting shoe for the optical/viewing device. It will be recognized, however, that other arrangements are possible.
The electrical connector 150 includes contacts 151 , which are electrically coupled to protruding contacts 152 (see FIG. 9 ) on the inward facing surface of the front connector 140 . Each of the contacts 152 makes contact with a corresponding aligned contact 126 , e.g., flush or recessed contact pads, on the edge trim member 120 . The contacts 152 are preferably spring contacts, i.e., resiliently biased toward the contacts 126 to ensure a sold electrical connection therebetween.
The electrical connector 160 is adapted to receive a power supply, e.g., a battery or battery pack, 162 . The connector 160 is secured to the edge trim 120 via threaded fasteners 144 , which pass through openings 161 in the connector 160 and engage complimentary openings 124 in the edge trim 120 . The rear connector 160 includes a mounting shoe 164 , e.g., a dovetail type mounting shoe for receiving a complimentary female dovetail connector 166 on the power supply 162 . The power supply may also include a latch 168 to release the power supply 162 and replacing the power supply 162 with a new of newly charged power supply. It will be recognized that other connectors, such as a bayonet or other quick connect/disconnect type connectors on the battery pack and the rear connector are also contemplated. Electrical contacts 170 on the mounting shoe 164 align with corresponding contacts (not shown) on the power supply connector 166 .
The contacts 170 , in turn, are electrically coupled to corresponding spring contacts 152 . The spring contacts 152 , in turn, are coupled to aligned contacts 126 on the edge trim 120 (see FIG. 5 ). In alternative embodiments, as shown in FIG. 12 , the power supply 162 may be replaced with a connector 172 having a first end 174 mating with the connector 160 and a second end 176 mating with an electrical connector of a power supply, such as a power supply adapted to be worn by the user or incorporated into a garment worn by the user.
Left side and right side connectors 180 are secured to the edge trim member at the respective left and right sides of the helmet 110 via threaded fasteners 144 which pass through aligned openings 185 in the connectors and engage openings 124 in the edge trim member. The side connectors 180 as illustrated include a rail section 182 configured to allow clamping via a rail grabber 181 of an accessory device 183 to be attached.
In the illustrated embodiment, the side mounted accessory 183 is a flashlight, however, it will be recognized that all manner of accessories may be provided, including without limitation, friend/foe (IFF) transponders, cameras including video recording (e.g., DVR) devices, communication devices, and so forth. In the illustrated embodiment, the rail section conforms to the so-called Picatinny interface standard (e.g., MIL-STD-1938) although other mounting rails, brackets, etc., are contemplated as well.
The rail interface 182 includes contacts 184 which are electrically coupled to protruding contacts 152 (see FIG. 3 ) on the inward facing surface of the side connectors 180 . Each of the contacts 152 makes contact with a corresponding aligned contact 126 , e.g., flush or recessed contacts, on the edge trim member 120 . Again, the contacts 152 are preferably spring or otherwise resiliently biased contacts. The contacts 184 are adapted to provide an electrical coupling through the rail interface 182 and to the connectors 152 .
In addition to powering externally mounted devices, the edge trim circuit herein may also optionally be adapted to power in-helmet devices, such as devices embedded within the helmet or devices mounted within the interior of the helmet, i.e., between the used head and the interior surface of the shell. For example, the power supply attached via the connector 160 may supply power to a helmet recording system such as a monitor for recording and/or transmitting the shock profile or forces experienced by the helmet.
In the illustrated embodiment, the circuit is shown with five conductors, which may be used to provide power from the power supply to the attached devices, as well as data or control signals to record data or to allow one attached accessory device to operate or control another without the need for an external wired connection between the multiple devices.
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. | An improved helmet construction and method having a circuit carried within an edge trim member received over the unfinished edge of the helmet shell. A plurality of electrical connectors are provided at different locations on the helmet for providing power, data transmission, and/or signal transmission to one or more accessory devices on the helmet. | 0 |
FIELD OF THE INVENTION
This invention relates to a method for determining cure and/or detecting oxidation of spin-on dielectric polymers.
BACKGROUND OF THE INVENTION
The microelectronics fabrication industry is moving toward smaller geometries in its devices to enable lower power and faster speeds. As the conductor lines become finer and more closely packed, the requirements of the dielectrics between such conductors become more stringent. One class of materials being examined as a replacement for the standard dielectric material, silicon dioxide, is spin-on dielectric (SOD) polymers.
Unlike the traditional silicon dioxide dielectric layers, these dielectric layers are formed by applying a solution containing the oligomeric precursor to the dielectric polymer, spinning to evenly coat and to remove solvent, followed by curing of the polymer. Curing typically occurs by heating the coated substrate to initiate additional polymerization reaction and/or cross-linking. Achieving an adequate degree of cure is essential to minimizing change in mechanical or other properties later on during fabrication or even during use of a device having a SOD polymer. An undesirable oxidation reaction may also occur if cure conditions (such as exposure to oxygen or other oxidants) are not adequately controlled. Detection of such oxidation reactions may also be important to assuring quality control.
Fluorescence has been taught to measure cure, potentially in-situ, of various polymers with the addition of a fluorescent probe (see, e.g., U.S. Pat. No. 5,100,802 and WO86/07456). However, the addition of a probe molecule would be undesirable due to the need for purity and due to high processing temperatures in the microelectronics fabrication process. Intrinsic fluorescence has also been taught as a method for monitoring cure in polyurethanes, (see, e.g., Sun, et al., “Intrinsic Fluorescence Cure Sensor for Reaction Monitoring in Polyurethane,” Polymer Preprints , Vol. 35, No. 1, page 435, March 1994, and in polyester/styrene polymers (see, e.g., Grunden, et al., “Cure Monitoring of Styrene Containing Polymer Using UV-Reflection and Fluorescence Spectroscopies,” Polymer Preprints , Vol. 37, No. 1, March, 1996). However, it was unknown whether SOD polymers possessed this characteristic.
Various analysis methods have been examined to determine cure and oxidation of SOD polymers. FT-Raman analysis can be used to monitor cure of extent of cure, but this method is destructive to the sample. Refractive index may also provide some indication of cure, but it is not very sensitive to oxidation. FT-IR analysis can be used to detect oxidation but is ineffective at detecting cure of important SOD polymers.
Therefore, a need remains for an efficient and cost-effective manner for detecting extent of cure and/or oxidation for spin-on dielectrics.
SUMMARY OF THE INVENTION
The Applicants have discovered a method that not only enables monitoring on-line of SOD for extent of cure but would also allow for simultaneous examination for oxidation. Thus, this invention is a method comprising
preparing a sample by coating a thin film of a precursor material, which is free of fluorescent probe molecules onto a substrate and subjecting the precursor material to conditions to attempt to cause cure of the precursor to an organic, aromatic, polymer having a dielectric constant of less than 3.0,
exposing the sample to radiation having a wavelength in the range of 200 to 500 nm,
detecting a resulting emission of radiation, and comparing the emission to the emission for a known cured, non-oxidized standard for the polymer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph of the fluorescence emission spectra (emission intensity versus emission wavelength) of the polymeric reaction product of a cyclopentadienone functional compound and an aromatic acetylene functional compound cured in a nitrogen atmosphere.
FIG. 2 is a graph of the normalized ratios of emission intensity at two emission wavelengths versus time of cure for the polymeric reaction product of a cyclopentadienone functional compound and an aromatic acetylene functional compound cured in a nitrogen atmosphere.
FIG. 3 . is a graph of the fluorescence emission spectra of the polymeric reaction product of a cyclopentadienone functional compound and an aromatic acetylene functional compound cured in air.
FIGS. 4-6 are graphs of the normalized emission intensity at three wavelengths for cures occurring in air and nitrogen versus time for the polymeric reaction product of a cyclopentadienone functional compound and an aromatic acetylene functional compound.
FIGS. 7 and 8 are FT-IR spectra for samples of the polymeric reaction product of a cyclopentadienone functional compound and an aromatic acetylene functional compound cured in air and nitrogen atmospheres.
FIG. 9 is a graph normalized by forcing peak intensity to a maximum value showing peak emission versus excitation wavelength for CYCLOTENE™ BCB based resin at varying degrees of cure in nitrogen atmosphere.
FIG. 10 is a graph normalized by forcing peak intensity to a maximum value showing emission spectra for CYCLOTENE BCB based resin at varying degrees of cure in a nitrogen atmosphere.
FIG. 11 is a graph normalized by forcing peak intensity to a maximum value showing emission spectra for CYCLOTENE BCB based resin at varying degrees of cure in air.
FIG. 12 is a graph normalized by forcing peak intensity to a maximum value showing peak emission versus excitation wavelength for CYCLOTENE BCB based resin at varying degrees of cure in air.
FIG. 13 is a graph of emission intensity versus excitation wavelength for the polymeric reaction product of a cyclopentadienone functional compound and an aromatic acetylene functional compound cured in a nitrogen atmosphere.
FIG. 14 is a graph of the normalized ratios of emission intensity at two emission wavelengths versus time of cure for the polymeric reaction product of a cyclopentadienone functional compound and an aromatic acetylene functional compound cured in a nitrogen atmosphere.
FIG. 15 is a graph of emission intensity versus excitation wavelength for the polymeric reaction product of a cyclopentadienone functional compound and an aromatic acetylene functional compound cured in air.
DETAILED DESCRIPTION OF THE INVENTION
Generally, fluorescence behavior can be tested in two manners. First, in an excitation scan method, the wavelength of radiation applied to a sample is varied over a range of wavelengths and the sample is observed for emissions of radiation at one or more set wavelengths. This method maps the excited state for a fluorescent molecule, i.e., the excitation spectrum. However, preferably, an emission spectrum is obtained. In this second method, the wavelength of the radiation applied to a sample is held at a fixed value and the wavelengths of emission are collected over a range of wavelengths. This method maps the energy level for the ground state.
After obtaining the excitation or emission spectrum for the sample, that spectrum is compared to a spectrum for a sample having a known degree of cure and a known degree of oxidation. This comparison may reveal cure and/or oxidation in at least one of three manners—change in band wavelength position, change in band width, or change in band or peak intensity.
For the first two approaches, there is a shift in the wavelength where peak intensity occurs and/or a broadening of the peak or band. Alternatively, or in addition, the intensity of the emission at a given wavelength may have changed. A potential drawback of the latter method is that due to the inherent variability in determining absolute fluorescence intensities, the comparison of the test sample to the standard will need to be comparison of a normalized value for the test sample to a normalized value for the sample.
Thus, according to one preferred embodiment, a sample is exposed to radiation having an effective excitation wavelength, and the emission intensity is measured for at least three predetermined wavelengths. The first predetermined wavelength, referred to herein as the cure responsive wavelength, corresponds to a wavelength at which emission intensity is known to vary with cure. The second predetermined wavelength, referred to as the oxidation responsive wavelength, corresponds to a wavelength at which emission intensity is known to vary with oxidation. The third predetermined wavelength, referred to as the non-responsive wavelength, corresponds to a wavelength, which remains relatively unchanged with cure and oxidation reactions. The raw values for intensity at each of the cure responsive and oxidation responsive wavelengths are normalized by dividing the raw values of intensity for each by the value for intensity at the non-responsive wavelength to yield a cure intensity ratio and an oxidation intensity ratio. These ratios can then be compared to the cure intensity ratio and oxidation intensity ratio for at least one standard having a known degree of cure and oxidation. Thus, the degree of cure and oxidation can be estimated based on the difference in these ratios between the test sample and the standard. Use of more than one standard having different known degrees of cure and oxidation will provide more precise information about the degree of cure and oxidation.
According to a second embodiment, the first preferred embodiment is used except, rather than plotting emission wavelength versus intensity, the emission (detection) wavelength is held constant and the excitation wavelength is varied. Intensity of emission is then plotted against excitation wavelength and a similar normalization procedure as set forth in the first embodiment is used.
According to a third preferred embodiment, the detection wavelength is held constant but the excitation wavelength is varied and the intensity of emission at the detection wavelength for the various excitation wavelengths is determined. The excitation wavelength, which causes the maximum (i.e., peak) emission intensity, is determined and is compared to the excitation wavelength, which causes the peak emission intensity for at least one standard having a known degree of cure and oxidation. The difference in peak wavelength will indicate how close the sample is to the degree of cure and oxidation in the standard. This method avoids the necessity of normalization, but suffers from the fact that the effect of cure reaction on peak shift could be negated or enhanced by the effect of the oxidation reaction on peak shift, thereby yielding confusing results. In fact, unless there is more than one peak that can be analyzed, this method is less accurate in providing simultaneous cure and oxidation information. There is an analogous fourth method, which bases the determination of degree of cure and oxidation on peak shift but holds excitation wavelength constant and plots intensity of emission versus emission wavelength. This method suffers from the same drawback that, unless there is more than one peak, the separate effects of cure and oxidation may be difficult to determine.
According to a fifth embodiment, a sample is exposed to radiation having an effective excitation wavelength, the emission spectra is obtained. Band width of a select peak or band is measured at half the band height and compared to that for a standard having a known degree of cure and oxidation. The difference in band width will indicate how close the sample is to the known degree of cure and oxidation. There is an analogous method, which base varies the excitation wavelength and measures emission at a set wavelength. The plot obtained is a plot of emission intensity versus excitation wavelength. A similar band width measurement can be made and compared to band width for a standard.
Which methods (excitation scan vs. emission scan and peak shift, width or intensity) are more appropriate may depend upon the characteristics of a specific SOD.
Applicants believe the method of this invention would be useful in simultaneously detecting cure and oxidation of various aromatic SOD polymers. Preferably, the SOD polymer is an organic polymer having no, or substantially no, Si atoms in the backbone. Polyarylenes are especially preferred. Examples of polyarylenes include the poly(arylene ethers) (i.e., PAE resins—Air Products) that are described in EP 0 755 957 B1, Jun. 5, 1999 and/or the FLARE resins made by Allied Signal Corp. (see N. H. Hedricks and K. S. Y Liu, Polym. Prepr. (Am. Chem. Soc., Div. Polym. Chm.) 1996, 37(1), pages 150-1; also J. S. Drage, et al., Material Res. Soc, Symp. Proc. (1997), Volume 476 (Low Dielectric Constant Materials III), pages 121-128 and those described in U.S. Pat. Nos. 5,115,082; 5,155,175; 5,179,188 and 5,874,516 and in PCT WO91/09081; WO97/01593 and EP 0755957-81. Alternatively, the polyarylene may be as disclosed in WO97/10193. Preferably, however, the polyarylene is the reaction product of a cyclopentadienone functional compound and an aromatic acetylene functional compound, as disclosed in those disclosed in U.S. Pat. No. 5,965,679, incorporated herein by reference. Fluorescence analysis for simultaneous detection of cure and oxidation for these latter preferred polyarylenes works particularly well as these polymers display peaks at distinct wavelengths for oxidation and cure, respectively.
The precursors (i.e., curable oligomer or polymer) are preferably of the general formula:
[A] w [B] z [EG] v
wherein A has the structure:
and B has the structure:
wherein EG are end groups having one or more of the structures:
wherein R 1 and R 2 are independently H or an unsubstituted or inertly-substituted aromatic moiety and Ar 1 , Ar 2 and Ar 3 are independently an unsubstituted aromatic moiety or inertly-substituted aromatic moiety, M is a bond, and y is an integer of three or more, p is the number of unreacted acetylene groups in the given mer unit, r is one less than the number of reacted acetylene groups in the given mer unit and p+r=y−1, z is an integer from 0 to about 1000; w is an integer from 0 to about 1000 and v is an integer of two or more.
Such oligomers and polymers can be prepared by reacting a biscyclopentadienone, an aromatic acetylene containing three or more acetylene moieties and, optionally, a polyfunctional compound containing two aromatic acetylene moieties. Such a reaction may be represented by the reaction of compounds of the formulas
(a) a biscyclopentadienone of the formula:
(b) a polyfunctional acetylene of the formula:
(c) and, optionally, a diacetylene of the formula:
wherein R 1 , R 2 , Ar 1 , Ar 2 , Ar 3 and y are as previously defined.
The definition of aromatic moiety includes phenyl, polyaromatic and fused aromatic moieties. Inertly-substituted means the substituent groups are essentially inert to the cyclopentadienone and acetylene polymerization reactions and do not readily react under the conditions of use of the cured polymer in microelectronic devices with environmental species, such as water. Such substituent groups include, for example, F, Cl, Br, —CF 3 , —OCH 3 , —OCF 3 , —O—Ph and alkyl of from one to eight carbon atoms, cycloalkyl of from three to about eight carbon atoms. For example, the moieties, which can be unsubstituted or inertly-substituted aromatic moieties, include:
wherein Z can be: —O—, —S—, alkylene, —CF 2 —, —CH 2 —, —O—CF 2 —, perfluoroalkyl, perfluoroalkoxy,
wherein each R 3 is independently —H, —CH 3 , —CH 2 CH 3 , —(CH 2 ) 2 CH 3 or Ph. Ph is phenyl.
For these preferred SODs, i.e., the reaction product of cyclopentadienone functional compound and aromatic acetylene compounds—an emission spectrum is preferably attained after applying radiation having a wavelength in the preferred range of 300 to 450 nm, more preferably 300 to 400 nm, and most preferably 330 to 390 nm. The cure responsive emission wavelength is in the range of about 380 to 440 nm, preferably in the range of 390 to 400 nm and/or 420 to 430 nm. The oxidation responsive wavelength is in the range of 500 to 650 nm, preferably 520 to 550 nm. The non-responsive wavelength is preferably in the range of 460 to 500 nm, more preferably 470 to 480 nm. To ensure a substantial degree of cure, the cure intensity ratio at wavelengths in the range 390 to 400 nm is preferably less than about 0.5 or in the range 420 to 430 nm less than about 1.4. The oxidation intensity ratio is preferably less than about 0.5 for oxidation responsive wavelengths in the range of 520 to 550 nm.
The methods outlined may also be applicable to BCB based polymers, which are the reaction product of monomers comprising
(a) a cyclobutarene monomer having the formula:
wherein
B 1 is a n-valent organic linking group, preferably comprising ethylenic unsaturation,
Ar 1 is a polyvalent aromatic or heteroaromatic group and the carbon atoms of the cyclobutane ring are bonded to adjacent carbon atoms on the same aromatic ring of Ar 1 ;
m is an integer of 1 or more;
n is an integer of 1 or more; and
R 1 is a monovalent group. The preferred BCB based polymers are the reaction product of the monomer (a) and has the formula
wherein
each R 3 is independently an alkyl group of 1-6 carbon atoms, trimethylsilyl, methoxy or chloro; preferably R 3 is hydrogen;
each R 4 is independently a divalent, ethylenically unsaturated organic group, preferably an alkenyl of 1 to 6 carbons, most preferably —CH 2 ═CH 2 —;
each R 5 is independently hydrogen, an alkyl group of 1 to 6 carbon atoms, cycloalkyl, aralkyl or phenyl; preferably R 5 is methyl;
each R 6 is independently hydrogen, alkyl of 1 to 6 carbon atoms, chloro or cyano, preferably hydrogen;
n is an integer of 1 or more; and
each q is an integer of 0 to 3, some of which are commercially available under the trade name CYCLOTENE from The Dow Chemical Company.
BCB based polymers show an excitation wavelength peak shift to lower wavelengths with cure or an emission wavelength peak shift to higher wavelengths with cure. If oxidation is also occurring, the shift in peak emission wavelength to higher wavelengths is much larger. The width of the emission and excitation bands can also be used to detect oxidation since the width of these bands becomes much broader with oxidation.
The fluorescence spectrum of SOD films can advantageously be obtained by using flexible fiber optic probes attached to the fluorimeter. The center of the fiber optic bundle carries the excitation light to the sample, while the emitted light is returned to the emission monochromator of the fluorimeter via an outer ring of bundled fibers. This arrangement is advantageous since (1) it provides a very small area of the sample to be probed for cure and oxidation, (2) it allows the remote measurement of cure and oxidation, and (3) it allows for easy incorporation of the fluoresence emission technique to be automated into a tool capable of mapping the cure and oxidation across a sample. Spatial resolution of cure and oxidation can provide valuable feedback on curing tools (hot plates, vertical tube furnaces), in order to determine their temperature uniformity, as well as the quality of the nitrogen purge environment, in addition to ensuring uniformity in physical properties to improve device yield and performance. The feedback could also be used to increase cure time and/or temperature if the emission indicates incomplete cure.
EXAMPLES
Example 1
Fluorescence Emission Measurements of the Reaction Product of A Biscyclopentadienone Compound and A Trifunctional Aromatic Acetylene
An oligomer solution made by the reaction of 3,3′-(oxydi-1,4-phenylene)bis(2,4,5-triphenylcyclopentadienone) and 1,3,5-tris(phenylethynyl)benzene in gamma-butyrolactone was later diluted with cyclohexanone and was spin coated on silicon substrates. The coated wafers were baked for 90 seconds at 320° C. on a nitrogen blanketed hot plate to remove residual solvent, and then placed on a nitrogen blanketed hot plate at 400° C., for 2, 5, 10, 20 and 30 minutes. Fluorescence emission spectra, as shown in FIG. 1, were collected on the samples using a Spex Fluorolog fluorimeter with front-face reflection optics, with excitation at 355 nm. The fluorescence spectra were normalized by the intensity of the band near 475 nm.
The normalized fluorescence spectra showed two bands that changed with cure time—one at 397, the other at 428 nm. As shown in FIG. 2, the plot of the normalized ratios I428/I475 and I397/I475 showed a decrease with cure time from 2 to 30 minutes, with a larger percentage change in the I397/I475 ratio. Either band or both bands can be used to quantitate cure.
Example 2
Fluorescence Emission Spectra of Oxidation
Films were prepared as in Example 1, except that the 400° C. hot plate cures were done in air, not under nitrogen. The fluorescence spectra were collected as in Example 1, and were likewise normalized by the intensity of the 475 nm band. As shown in FIG. 3, the normalized fluorescence spectra of films cured in air showed a large increase with cure time in the intensity of a band near 530 nm and a lesser increase in a shoulder near 630 nm. The bands at 428 and 397 nm also grew in intensity with cure time, as noted in example 1, because the polymer was curing, to some extent, even in the presence of oxygen. As shown in FIG. 4, the intensity ratio I530/I478 was relatively independent of cure time for films cured in nitrogen, but showed a sharp increase for films cured in air. As shown in FIGS. 5 and 6, the ratios I428/I478 and I397/I478 also showed a decrease with cure time in both air and nitrogen, but the decrease was much larger for cures in air than in nitrogen. Thus, the oxidation can be quantified by measuring the normalized ratio I530/I478, or by the ratios I428/I478 or I397/I478.
Verification that the changes in the fluorescence spectra were due to oxidation and not some other degradative process is given by the FT-IR spectra of the films. Transmission FT-IR spectra of the films cured in air and nitrogen were collected using a Nicolet Model 800 FT-IR spectrometer. As shown in FIGS. 7 and 8, the bands in the infrared spectrum near 1675 and 1740 cm-1, which grow in intensity during the cure in air (but not in nitrogen), were assigned to carbonyl groups, which were formed during the oxidation of the polymer. While the oxidation of the films could be monitored quantitatively by the growth of the 1675 cm-1 band in the FT-IR spectrum, the changes in the fluorescence emission spectrum were more sensitive in detecting oxidation than were FT-IR. The change in absorbance at 1675 cm-1 for a film oxidized at 400° C. for 30 minutes was approximately 0.005 absorbance unit for a 0.3 micron thick film. This was detectable by modem FT-IR spectrometers, but required significant signal averaging to detect a small increase in the baseline at 1675 cm-1 over the noise background. Alternatively, the same film oxidized at 400° C. for 30 minutes showed an increase in normalized fluorescence intensity at 530 nm by almost a factor of three (192,400 to 596,690), which was easily detectable, with little additional signal averaging.
Thus, the fluorescence emission spectrum of the films showed distinctive changes, which could be used to monitor both the cure and oxidation of the polymer. The changes in the spectrum due to cure were primarily found in the bands at 428 and 397 nm, while the oxidation of the polymer produced changes primarily at 530 nm. These regions of the fluorescence emission spectrum were sufficiently separated in wavelength that measurement of both the extent of cure and the detection and quanitification of oxidation could be accomplished in the same experimental measurement. This combination of cure and oxidation analysis is an advantage in time and money over conventional techniques, which require two separate methods for cure and oxidation (for example, RI for cure and FT-IR for oxidation).
Example 3
Fluorescence Measurements of CYCLOTENE BCB Based Resin Cure
The degree of cure of CYCLOTENE films can be monitored by either the excitation or emission spectra. Excitation spectra were collected for CYCLOTENE 3022 films prepared by spin-coating CYCLOTENE 3022-63 formulation on silicon substrates. The coated wafers were placed in a N 2 -purged convection oven, and three different cure schedules were run to achieve different cure levels of the CYCLOTENE film. The cure schedules used were 150° C. for 30 minutes (to remove solvent), 210° C. for 30 minutes (soft cure) and 250° C. for 60 minutes (standard hard cure). Fluorescence excitation spectra were collected on the samples using a Spex Fluorolog fluorimeter with front-face reflection optics, with the emission collected at 370 nm.
In FIGS. 9 and 10, the peak intensity was forced to the maximum value for plotting and comparison purposes. The spectra in FIG. 9 show that the peak in the excitation spectrum shifts to the blue with increasing cure. The peak moves from 344 nm after solvent removal to 337 nm for the 250° C./60 minutes standard hard cure. This shift in peak position is easier to detect than a change in the absolute value of the fluorescence emission, and is an advantage of using this method. Emission spectra with excitation at 335 nm, shown in FIG. 10, also showed differences, which can be used as an indicator of cure. With increasing cure, the band at 370 nm decreases, while the shoulder at 390 nm increases. This resulted in a shift of the emission maximum to longer wavelengths. The relative peak height (I370/I390) of the two bands (or emission maximum) can, therefore, be used as an indicator of cure.
Example 4
Fluorescence Measurements of CYCLOTENE BCB Based Resin Oxidation
CYCLOTENE films were prepared as in Example 3, except that the 400° C. hot plate cures were done in air, not under nitrogen. The fluorescence emission spectra were collected as described in Example 3. As with FIGS. 9 and 10, in FIG. 11, the peak intensity was forced to the maximum value for plotting and comparison purposes. Since the magnitude of the curve for 60 minutes at 250° C. was very small, more noise was seen in this curve as it is forced to maximum for comparison purposes. The peak in the emission spectra, as shown in FIG. 11, was progressively shifted further to the red (i.e., higher wavelengths) with increased oxidation, from 371 nm to 475 nm. This was significantly larger than the shift in emission maximum with cure under nitrogen (371 to 389 nm in Example 3). Note also that the width of the emission band in FIG. 11 was affected by oxidation—the more oxidation, the broader the band. Therefore, monitoring the position of the emission maximum and/or band width can be used to determine the extent of oxidation of CYCLOTENE films in-situ.
The fluorescence excitation spectra were also collected for these samples. As shown in FIG. 12, the excitation spectra shifts to the red (higher wavelengths) with increased oxidation. This shift was larger and in the opposite direction from the excitation maximum for cure in nitrogen. Again, however, band width can be another useful indicator to distinguish between cure and oxidation.
Example 5
Fluorescence Excitation Measurements of the Reaction Product of A Biscyclopentadienone Compound and A Trifunctional Aromatic Acetylene
Films were prepared as described in Example 1. Excitation spectra were collected on the samples using a Spex Fluorolog 1680 0.22 nm double spectrometer with front-face reflection optics, with emission collected at 536 nm. The excitation spectra were normalized by the intensity of the band near 355 nm. These spectra, shown in FIG. 13, reveal two bands change with cure time—one at 327 nm, the other at 340 nm. The plot of the normalized ratios I340/I355 and I337/I355 in FIG. 14 shows a decrease with cure time from 2 to 30 minutes, with a larger percentage change in the I327/I475 ratio. Both or either band can be used to quantitate cure.
Example 6
Fluorescence Excitation Spectra of Oxidation
Films were prepared as in Example 5, except that the 400° C. hot plate cures were done in air, not under nitrogen. The excitation spectra were collected as in Example 5, and were likewise normalized by the intensity of the 355 nm band. The normalized excitation spectra of the films cured in air (see FIG. 15) showed a decrease in the intensity of bands near 327 and 340 nm, as was seen in the samples cured under nitrogen in Example 5, since the polymer was still curing to some extent even in the presence of oxygen. However, there was also a decrease with cure time in a band near 275 nm, and increases with cure time in the intensity of bands near 375, 400, 450 and 475 nm. The oxidation of these polymers, therefore, can be quantified by measuring the normalized ratios I375/I355, I400/I355, I450/I355 or I475/I355. | This invention is a method comprising preparing a sample by coating a thin film of a precursor material, which is free of fluorescent probe molecules onto a substrate and subjecting the precursor material to conditions to attempt to cause cure of the precursor to an organic, aromatic, polymer having a dielectric constant of less than 3.0, exposing the sample to radiation having a wavelength in the range of 200 to 500 nm, detecting a resulting emission of radiation, and comparing the emission to the emission for a known cured, non-oxidized standard for the polymer. | 7 |
BACKGROUND OF THE INVENTION
[0001] Narrowing of cerebral blood vessels (NCBV) or cerebral vasospasm is a pathological condition that frequently develops after subarachnoid hemorrhage and leads to impairment of cerebral blood flow, cerebral oxygen delivery and subsequent cerebral ischemia and stoke. It affects up to 60% of patients with hemorrhage after rupture of intracranial aneurysms.
[0002] Cerebral vasospasm has a number of symptoms that develop gradually, including depressed level of consciousness, numbness, weakness, visual loss and increased intracranial pressure; it is usually detected by means of transcranial Doppler ultrasound and cerebral angiography. Current methods of treating cerebral vasospasm or its symptoms have been only partially successful and the approaches to prevent cerebral vasospasm so far have not been effective. Common treatments include so-called “triple H” therapy (hypertension, hypervolemia and hemodilution), intraarterial infusion of smooth muscle relaxants (papaverine, verapamil) and endovascular balloon angioplasty; prophylactic measures include calcium channel blocker administration (nimodipine). All these measures, however, do not eliminate the risks of cerebral ischemia and only marginally improve clinical outcome.
[0003] Cerebral vasospasm is a decrease in diameter of arterial vessels that supply the brain. Its frequency and to some extent severity appear to be directly related to the amount of blood in the subarachnoid space. It appears that such narrowing may, at least in the beginning, be sympathetically mediated and therefore, sympathetic blockade may theoretically prevent cerebral vasospasm development. Such blockade on systemic level, however, would be worsening the brain perfusion as it would result in lowering the patient's blood pressure.
[0004] Cerebral vasospasm typically develops between 1 and 21 days after subarachnoid hemorrhage. Therefore, all interventions to prevent and treat cerebral vasospasm preferably should be done within this timeframe.
[0005] Spinal cord stimulation (SCS) is an established modality that is widely used to treat all kinds of chronic pain, primarily neuropathic in origin. It has also been successfully used to treat most severe cases of peripheral vascular disease and intractable angina. In the latter two applications, SCS effect is not limited to pain relief but also results in vasodilatation, similar to previous experience with surgical sympathectomy.
[0006] Multiple animal experiments [7-14] have shown augmentation of cerebral blood flow (CBF) with cervical SCS. Level of stimulation seemed to have direct effect on the blood flow, with stimulation of upper levels (C1-3) generating higher flow values.
[0007] Isono et al. [9] postulated that CBF is increased from cervical SCS mainly through a central pathway. Using a cat model, they showed that CBF augmentation with cervical SCS is no longer observed after sectioning of the dorsal columns at the cervicomedullary junction. Later, Patel et al. [12] obtained the same results using rat model. The Patel group also showed lack of changes in CBF after resection of superior cervical ganglion while using SCS.
[0008] Visocchi [27] has demonstrated that SCS can either increase, decrease or has no effect in CBF. The difference correlated mainly with the stimulated level of the spinal cord. Thoracic stimulation had low effect and sometimes even decreased CBF. Cervical stimulation more frequently produced CBF augmentation (61%). In another article [28], Visocchi et al. found that vasoconstriction of carotid arteries with sympathetic trunk stimulation were attenuated by cervical SCS. In this experiment they used rabbit model to observe CBF changes with SCS alone, sympathetic trunk stimulation alone and simultaneous spinal cord and sympathetic trunk stimulation.
[0009] Patel et al. observed that increase in CBF with SCS is in direct relation with specific sympathetic receptors [11]. Their experiments demonstrated that either sympathetic ganglion blocker or al-adrenergic receptor blocker can abolish the response to SCS, but the same result does not happen with α or β-adrenergic receptor blockers.
[0010] The use of spinal cord stimulation for the treatment for cerebral vasospasm after SAH with SCS has been tried in different animal models. Ebel et al. [7] found increased blood flow in rats with SAH and SCS compared to control groups. Visocchi et al. [29] described prevention of early vasospasm in rabbits treated with SCS after induced SAH.
[0011] Recently, Lee et al. [10] showed the vasodilatation effect of SCS in the basilar artery of rats 5 days after induction of SAH. Radiotracer studies, laser Doppler flowmetry and histologic photomicrographs were used to prove these changes in the delayed spasm.
[0012] The effect of SCS on CBF in humans was first described by Hosobuchi in 1985 [30]. He found that SCS at upper cervical levels can increase CBF. The same result was not found with stimulation of thoracic levels. Later, he tested cervical SCS for patients with symptomatic cerebral ischemia in three patients (one with anterior and two with posterior circulation occlusion) [17]. Although good results were obtained, further studies were needed to confirm its clinical application.
[0013] Takanashi and Shinonaga [19] published the only article found in the literature related to the use of SCS for cerebral vasospasm in humans. Ten SAH patients with secured cerebral aneurysm (Hunt Hess grade 2 to 4 and Fisher) were implanted with percutaneous epidural cervical leads (C1-2). The stimulation was continuous and started on day 5 (±1) post bleeding for 10 to 15 days. The results were analyzed by the amount of increment in CBF with Xenon computed tomography and cerebral angiography before and after stimulation. CBF was significantly increased in the distribution of the middle cerebral artery. Four patients presented with angiographic vasospasm and 3 were reported with clinical vasospasm. One patient died and the overall outcome was good or excellent in 7. No major adverse effect was attributed to the use of SCS. The data analysis correlated increase in CBF with SCS. The electrodes were positioned all the way up to C1-2, with the intention of reaching the highest degrees of CBF augmentation.
SUMMARY OF THE INVENTION
[0014] The present invention is based on the discovery that spinal cord stimulation can be used for purposes other than pain management. The present inventors have identified spinal cord stimulation for both the treatment and prevention of cerebral vasospasm.
[0015] For example, in one aspect, the invention provides a method of preventing cerebral vasospasm in a subject having had a subarachnoid hemorrhage, the method comprising providing an electrical impulse generator capable of generating a predetermined electrical signal, wherein the electrical impulse generator is operatively coupled to a stimulation lead having an implantable electrode portion, wherein the electrical impulse generator is arranged to deliver the predetermined electrical signal to the electrode portion; selecting an implant location adjacent a lower cervical spinal region; surgically implanting the stimulation lead and positioning the electrode portion of the stimulation lead in an area adjacent to the implant location with the electrode portion disposed behind the spinal cord in the lower cervical spinal region, such that the stimulation lead is positioned to deliver the predetermined electrical signal from the electrical impulse generator to the selected implant location; and activating the electrical impulse generator for a predetermined period of time to generate the predetermined electrical signal to prevent cerebral vasospasm in the subject.
[0016] In another aspect, the invention provides a method of treating cerebral vasospasm in a subject having had a subarachnoid hemorrhage, the method comprising providing an electrical impulse generator capable of generating a predetermined electrical signal, wherein the electrical impulse generator is operatively coupled to a stimulation lead having an implantable electrode portion, wherein the connector the electrical impulse generator is arranged to deliver the predetermined electrical signal to the electrode portion; selecting an implant location adjacent an upper cervical spinal region; surgically implanting the stimulation lead and positioning the electrode portion of the stimulation lead in an area adjacent to the implant location and positioning the electrode portion behind the spinal cord in the upper cervical spinal region, such that the stimulation lead is positioned to deliver the predetermined electrical signal from the electrical impulse generator to the selected implant region; and activating the electrical impulse generator for a predetermined period of time to generate the predetermined electrical signal to prevent cerebral vasospasm in the subject.
[0017] In yet another aspect, the invention provides a method of applying spinal cord stimulation in a subject having had a subarachnoid hemorrhage, the method comprising providing an electrical impulse generator capable of generating a predetermined electrical signal, wherein the electrical impulse generator is operatively coupled to a stimulation lead having an implantable electrode portion, wherein the connector the electrical impulse generator is arranged to direct the predetermined electrical signal toward the electrode portion; assessing whether the subject has a presence of a cerebral vasospasm or an absence of a cerebral vasospasm; selecting a first implant location in an upper cervical spinal region based on the presence of cerebral vasospasm, and selecting a second implant location in a lower cervical spinal region based on the absence of cerebral vasospasm; surgically implanting the stimulation lead and positioning the electrode portion of the stimulation lead in an area behind the spinal cord adjacent the selected first or second implant location, such that the stimulation lead is positioned to deliver the predetermined electrical signal from the electrical impulse generator to the selected first or second implant location; and activating the electrical impulse generator for a predetermined period of time to generate the predetermined electrical signal to treat or prevent cerebral vasospasm in the subject.
[0018] In another aspect, the invention provides a method of applying spinal cord stimulation in a subject having had a subarachnoid hemorrhage, the method comprising providing an electrical impulse generator capable of generating a desired electrical signal, the electrical impulse generator operatively coupled to an implantable electrode and arranged to send the desired electrical signal toward the electrode; providing the electrode with a plurality of contacts, including a first group of contacts and a second group of contacts; assessing whether the subject has a presence or an absence of a cerebral vasospasm; implanting the electrode in a selected area adjacent the spine with the first group of contacts disposed adjacent a first desired location adjacent an upper cervical spinal region of the subject, and with the second group of contacts disposed adjacent a lower cervical spinal region of the subject; and activating the electrical impulse generator to deliver the desired electrical signal to only the first group of contacts based on the presence of cerebral vasospasm and activating the electrical impulse generator to deliver the electrical signal to only the second group of contacts based on the absence of cerebral vasospasm.
[0019] The predetermined electrical signal should be supplied in an effective amount to treat (or prevent) cerebral vasospasm. As used herein “effective amount” is variable among subjects but generally corresponds within a rate range of approximately 2 to 1000 pulses per second, a pulse width range of approximately 10 to 500 milliseconds, an amplitude range of approximately up to 10 volts, and electrode polarity set in monopolar, bipolar, tripolar or more complex pattern.
[0020] In one embodiment, the methods described herein comprise performing a partial removal of ligamentum flavum at a removal location and implanting the stimulation lead through the removal location. In another embodiment, the methods described herein comprise performing a partial laminectomy and implanting the stimulation lead through the partial laminectomy.
[0021] In some embodiments, the methods described herein comprise selecting the implant location adjacent to vertebra(e) in the lower cervical spinal region. In one embodiment, the lower cervical spinal region comprises one or more vertebra(e) at levels C3-C7. In another embodiment, the lower cervical spinal region comprises one or more vertebra(e) at levels C3-C5.
[0022] In other embodiments, the methods described herein comprise selecting the implant location adjacent to vertebra(e) in the upper cervical spinal region. In one embodiment, the upper cervical spinal region comprises one or more vertebra(e) at levels C1-C4. In another embodiment, the upper cervical spinal region comprises one or more vertebra(e) at levels C1-C3.
[0023] In some embodiments, the methods described herein comprise arranging the electrical impulse generator to cause the predetermined electrical signal to have an impulse frequency within the range of 2-3,000 Hz. In other embodiments, the impulse frequency generated is selected from the group consisting of 2, 5, 25, 50, 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, 2500, 2600, 2700, 2800, 2900, 3000 Hz or more or any range therebetween.
[0024] In some embodiments, the stimulation lead is inserted at a vertebral position below or at the level of T1/T2 into an epidural space and advanced in a superior direction, substantially parallel to a longitudinal direction of the epidural space, until the electrode portion reaches a desired position relative to the cervical segments of the spinal cord.
[0025] In some embodiments, an apparatus and method disclosed herein is used to electrically stimulate selected level of the spinal cord within the epidural space of a patient to at least decrease the sympathetic tone in the cranial region and produce focal vascular relaxation of cerebral arteries of a patient.
[0026] In some embodiments, an apparatus and method disclosed herein is for the prevention and treatment of arterial vasospasm following the subarachnoid hemorrhage through continuous stimulation of the cervical spinal cord.
[0027] In some embodiments, the spinal cord stimulation described herein is administered to a subject in need thereof for a period of time selected from the group consisting of 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 6 hours, 8 hours, 12 hours, 24 hours, 2 days, 3 days, 4 days, 5 days, 6 days, 7 days, 8 days, 9 days, 10 days, 11 days, 12 days, 13 days, 14 days, 15 days, 16 days, 17 days, 18 days, 19 days, 20 days, 21 days, or longer if warranted by the subject's condition.
BRIEF DESCRIPTION OF THE FIGURES
[0028] FIG. 1 a is a partial sectional side view illustrating a percutaneous stimulation lead insertion technique for a purpose of stimulating the cervical spinal cord to prevent or treat arterial vasospasm.
[0029] FIG. 2 is a partial sectional side view of a human body having a laminotomy stimulator lead positioned within the cervical spinal canal in accordance with the present invention.
[0030] FIG. 3 is a schematic view of one embodiment of a spinal cord stimulator to practice the invention;
[0031] FIG. 4 is a cross sectional view of the spine
DETAILED DESCRIPTION OF THE INVENTION
[0032] Cerebral vasospasm is a serious complication that occurs following an aneurysmal subarachnoid hemorrhage (SAH). Its presentation and demographics have already been established [1,2], but the complete understanding of its pathophysiology remains unclear. The aim of treatment usually is to maintain uninterrupted brain oxygenation using multimodality approaches [3,4].
[0033] Spinal cord stimulation (SCS) is an accepted method of treatment of chronic refractory pain due to central and peripheral problems [5,6]. The effects of cervical SCS on cerebral blood flow (CBF) are well known based on experimental investigations [7-14], and its vasodilatory effect on peripheral arteries is widely used in clinical settings in treatment of peripheral vascular disease [15]. Possible indications for the treatment of cerebrovascular conditions and brain tumors are now under investigation with initial results appearing quite promising [16-20].
[0034] The inventors have discovered that the location of SCS along the axis of the cervical spinal cord correlates with the prophylactic and therapeutic effects of this modality on cerebral vasculature, specifically on management of the SAH related arterial vasospasm.
[0035] FIG. 3 is schematic view of one embodiment of a spinal cord stimulator 30 that can be used to practice the invention. FIG. 3 shows an electrical impulse generator 32 . The electrical impulse generator 32 may incorporate a controller or any suitable processor 38 . The electrical impulse generator 32 may be any suitable spinal cord stimulator that provides an electrical impulse to the spine. For example, electrical impulse generator 32 may comprise a single stimulation lead 34 or may comprise a plurality of stimulation leads. The electrical impulse generator 32 is operatively coupled to a stimulation lead 34 having an implantable electrode portion 36 , wherein the electrical impulse generator 32 is arranged to deliver the predetermined electrical signal to the electrode portion 36 .
[0036] The implantable electrode portion 36 may be any suitable electrode including: intravascular, transcutaneous, intracutaneous, patch-type, cuff-type, tape-type, screw-type, barb-type, metal, wire, balloon-type, basket-type, umbrella-type or suction-type electrodes. Guided or steerable catheter devices comprising electrodes may be used alone or in combination with the implantable electrode portion 36 . For example, a catheter comprising one or more wire, metal strips or metal foil electrodes or electrode arrays may be inserted adjacent the spine. The implantable electrode portion 36 may be oriented in any fashion along the catheter device, including longitudinally or transversely. Various techniques such as ultrasound and fluoroscopy may be used to facilitate positioning of the electrodes.
[0037] All or a portion of the implantable electrode portion 36 may be placed in any suitable manner for providing stimulation to the spine. The stimulation lead 34 may be placed invasively or non-invasively. In one embodiment, all or a portion of the implantable electrode portion 36 is implanted adjacent the spine. Alternatively, all or a portion of the implantable electrode portion 36 is implanted adjacent specific vertebrae.
[0038] As set forth in FIG. 4 , the spinal cord is divided into specific neurological segments. The cervical spinal cord is divided into eight levels (C1-C8) and contributes to different functions in the neck and arms.
[0039] In one embodiment, the implantable electrode portion 36 is implanted in the cervical spinal region at the C1-C3 level. In another embodiment, the implantable electrode portion 36 is implanted in the cervical spinal region at the C3-C5 level. In some embodiments, the implantable electrode portion 36 comprises a single contact so that electrical stimulation can be carried out on one specific area (or contact point) of the spinal cord. In some embodiments, the implantable electrode portion comprises multiple contacts ( 36 a - 36 j ) so that electrical stimulation can be carried out on more than one area (or contact points) of the spinal cord simultaneously or sequentially. For example, in some embodiments, a first group of contacts is disposed adjacent a first desired implant location adjacent an upper cervical spinal region of the subject and a second group of contacts is disposed adjacent a lower cervical spinal region of the subject and the electrical impulse generator 32 is activated to deliver the desired electrical signal to only the first group of contacts based on the presence of cerebral vasospasm and activating the electrical impulse generator 32 to deliver the electrical signal to only the second group of contacts based on the absence of cerebral vasospasm. In other embodiments, the electrical impulse generator 32 is activated to deliver the desired electrical signal to both the first and second groups of contacts. In one embodiment, electrical stimulation is carried out at both the C1-C3 and C3-C5 levels. Alternatively, the implantable electrode portion 36 is/are a guided or steerable electrode which allows its position to be adjusted during the medical procedure. Different electrode positions are accessible through various access openings along the spinal cord. The implantable electrode portion 36 may be positioned endoscopically through a percutaneous port, through an incision in the spine, placed on the skin or in combinations thereof. The present invention includes various electrodes, catheters and electrode catheters suitable for spinal cord stimulation.
[0040] In one embodiment of the present invention, the location of the implantable electrode portion 36 is chosen to elicit maximum stimulation to the spinal cord while preventing current spread to adjacent tissues. Furthermore, a non-conductive material such as plastic may be employed to sufficiently enclose the electrodes of all the configurations to shield them from the surrounding tissues and vessels, while exposing their confronting edges and surfaces for positive contact with the spinal cord, or the spinal cord coverings.
[0041] In some embodiments, the electrical impulse generator 32 incorporates a neuro stimulator 42 . For example, FIG. 3 shows a nerve stimulation lead at 44 . Electrodes used to stimulate a nerve such as the vagal nerve may be, for example, non-invasive, e.g., clips, or invasive, e.g., needles or probes. The application of an electrical stimulus to the right or left vagal nerve may include, but is not limited to bipolar and/or monopolar techniques. Different electrode positions are accessible through various access openings, for example, in the cervical or thorax regions. Nerve stimulation lead 44 may be positioned through a thoracotomy, sternotomy, endoscopically through a percutaneous port, through a stab wound or puncture, through a small incision in the neck or chest, through the internal jugular vein, the esophagus, the trachea, placed on the skin or in combinations thereof. Electrical stimulation may be carried out on the right vagal nerve, the left vagal nerve or to both nerves simultaneously or sequentially. The present invention may include various electrodes, catheters and electrode catheters suitable for vagal nerve stimulation to temporarily stop or slow the beating heart alone or in combination with other heart rate inhibiting agents.
[0042] Nerve stimulation implantable electrodes 46 may be endotracheal, endoesophageal, intravascular, transcutaneous, intracutaneous, patch-type, balloon-type, cuff-type, basket-type, umbrella-type, tape-type, screw-type, barb-type, metal, wire or suction-type electrodes. Guided or steerable catheter devices comprising electrodes may be used alone or in combination with the nerve stimulation implantable electrodes 46 . For example, a catheter comprising one or more wire, metal strips or metal foil electrodes or electrode arrays may be inserted into the internal jugular vein to make electrical contact with the wall of the internal jugular vein, and thus stimulate the vagal nerve adjacent to the internal jugular vein. Access to the internal jugular vein may be via, for example, the right atrium, the right atrial appendage, the inferior vena cava or the superior vena cava. The catheter may comprise, for example, a balloon which may be inflated with air or liquid to press the electrodes firmly against the vessel wall. Similar techniques may be performed by insertion of a catheter-type device into the trachea or esophagus. Additionally, tracheal tubes and esophageal tubes comprising electrodes may be used.
[0043] Nerve implantable electrodes 46 may be oriented in any fashion along the catheter device, including longitudinally or transversely. Various techniques such as ultrasound, fluoroscopy and echocardiography may be used to facilitate positioning of the electrodes. If desired or necessary, avoidance of obstruction of blood flow may be achieved with notched catheter designs or with catheters which incorporate one or more tunnels or passageways.
[0044] In some embodiments, the spinal cord stimulation described herein is administered to a subject in need thereof for a period of time selected from the group consisting of 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 6 hours, 8 hours, 12 hours, 24 hours, 2 days, 3 days, 4 days, 5 days, 6 days, 7 days, 8 days, 9 days, 10 days, 11 days, 12 days, 13 days, 14 days, 15 days, 16 days, 17 days, 18 days, 19 days, 20 days, 21 days, or longer if warranted by the subject's condition.
[0045] The implantable electrode portion 36 may be in communication with a controller 38 as shown in FIG. 3 . The controller 38 may thus be used to process the pulses being transmitted from the implantable electrode portion 36 . The controller 38 may store information about the pulses being generated. The controller 38 may also be used to control or monitor the level or duration of spinal stimulation that occurs.
[0046] Electrical impulse generator 32 may incorporate one or more switches to facilitate regulation of the various components by the surgeon. One example of such a switch is a foot pedal. The switch may also be, for example, a hand switch, or a voice-activated switch comprising voice-recognition technologies. The switch may be incorporated in or on one of the surgeon's instruments, such as surgical site retractor, or any other location easily and quickly accessed by the surgeon.
[0047] Electrical impulse generator 32 may also include a display 40 . Electrical impulse generator 32 may also include other means of indicating the status of various components to the surgeon such as a numerical display, gauges, a monitor display or audio feedback. Electrical impulse generator 32 may also include one or more visual and/or audible signals used to prepare a surgeon for the start or stop of spinal cord stimulation and/or cardiac stimulation.
[0048] Any commercially-available spinal cord stimulator can be used as the electrical impulse generator to practice the invention. In one embodiment, the electrical impulse generator 32 is a commercially-available neurostimulation device more commonly used for the management of chronic pain and include the SYNERGY, INTREL, RESTORE, RESTORE-ADVANCED, RESTORE-PRIME, PRIME-ADVANCED, RESTORE-ULTRA, X-TREL, and MATTRIX neurostimulation systems from Medtronic, Inc. The percutaneous leads and electrodes in this system are either quadripolar (4 contacts), such as the PISCES-QUAD, PISCES-QUAD PLUS and the PISCES-QUAD COMPACT, VERIFY, or octapolar (8 contacts) such as the OCTAD, OCTAD COMPACT and the OCTAD SUBCOMPACT lead-electrode system. The surgical leads themselves are quadripolar, such as the RESUME II Lead-electrode system, the RESUME TL Lead-electrode system and the ON-POINT PNS Lead-electrode system, or octapolar, such as the SPECIFY Lead-electrode system, the 2×4 HINGED Lead-electrode system, or hexadecimapolar (16 contacts), such as SPECIFY 5-6-5 Lead-electrode system, to create multiple stimulation combinations and a broad area of paresthesia. These neurostimulation systems and associated lead-electrode systems are described in U.S. Pat. Nos. 6,671,544; 6,654,642; 6,360,750; 6,353,762; 6,058,331; 5,342,409; 5,031,618 and 4,044,774, each of which is incorporated herein by reference. Other commercially available systems that may useful for the practice of this invention as described herein include the rechargeable PRECISION Spinal Cord Stimulation System (Advanced Bionics Corporation, Sylmar, Calif.; which is a Boston Scientific Company) which can drive up to 16 electrodes (see e.g., U.S. Pat. Nos. 6,735,474; 6,735,475; 6,659,968; 6,622,048; 6,516,227 and 6,052,624); the GENESIS, GENESIS XP, EON, EON MINI and RENEW Spinal Cord Stimulators available from Advanced Neuromodulation Systems, Inc. (Plano, Tex.; see e.g., U.S. Pat. Nos. 6,748,276; 6,609,031 and 5,938,690); and the Vagus Nerve Stimulation (VNS) Therapy System available from Cyberonics, Inc. (Houston, Tex.; see e.g., U.S. Pat. Nos. 6,721,603 and 5,330,515).
[0049] Electrical impulse generators may also be classified based on their source of power, which includes: battery powered, radio-frequency (RF) powered, or a combination of both types. For battery powered electrical impulse generators, an implanted, non-rechargeable or RF-recharged battery is usually used as the source of power. The battery, an optional RF-receiving coil and the leads with their electrodes are all surgically implanted and thus the electrolytic device, other than the optional transmitting coil, is completely internal. The settings of the totally implanted electrical impulse generator can be controlled by the patient through an external magnet. The lifetime of the implant, when powered by a non-rechargeable battery, is generally limited by the duration of battery life and ranges from two to four years depending upon usage and power requirements. For RF-powered electrical impulse generators, the radio-frequency is transmitted from an externally worn source to an implanted passive receiver, which charges usually an implanted rechargeable battery, but may optionally charge a capacitor, such as an electrochemical supercapacitor. Since the source of power for the transmitting coil can be the grid, or a readily rechargeable battery, or a replaceable non-rechargeable battery, the radio-frequency system provides greater power and can power electrodes generating electrochemically a greater amount or flux of the pain-relieving oxidant or its precursor; or it can power a greater number of oxidant generating electrodes; or it can power electrodes having a greater area at which more oxidant is generated. Specific earlier disclosed examples include an electrical impulse generator that has a battery power source contained within to supply power over an eight hour period in which power may be replenished by an external radio frequency coupled device (see, for example, U.S. Pat. No. 5,807,397, incorporated herein by reference) or an electrical impulse generator which is controlled by an external transmitter using data signals and powered by radio frequency (see, for example, U.S. Pat. No. 6,061,596, incorporated herein by reference).
[0050] In one embodiment, the electrical impulse generator generates an impulse frequency within the range of 2-3,000 Hz. In other embodiments, the impulse frequency generated is selected from the group consisting of 2, 5, 25, 50, 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, 2500, 2600, 2700, 2800, 2900, 3000 Hz or more or any range therebetween.
[0051] The superior cervical ganglion serves as the most important source of sympathetic input to the brain. Although most of the ganglion is formed by branches of the first four cervical nerves, the sympathetic part is formed by preganglionic fibers that originate from the lateral column at the upper thoracic levels, leaving the spinal cord with the thoracic spinal nerves, traveling through the sympathetic chain until they reach the superior ganglion, where they synapse with postganglionic nerves [21]. Accompanying the internal carotid artery, the sympathetic nerves enter the skull. Because of the difference in growth rate between the spinal cord and the bony spine, the upper level of the thoracic spinal cord is located at the level of C7.
[0052] It seems quite clear that morphologic changes occur in the cerebral vessels after SAH, and the inflammatory response and local chemical agents are responsible for the induction of vasospasm [22]. The sympathetic system also plays an important role in the pathogenesis of this process [23,24]. Interestingly, this has been indirectly supported by Yasargil [24] who suggested separating the vessel wall from the adventitial sympathetic nerve plexus during the surgery for aneurysm repair.
[0053] Naredi et al. [25] found increased sympathetic activity in patients with nontraumatic SAH. The total body norepinephrine spillover into plasma was approximately 3 fold higher after 48 h compared to the control groups. Further supporting this explanation for vasospasm origin, the higher levels were present between the 7th and 10th days after bleeding right around the empirically observed peak incidence of vasospasm occurrence. The numbers returned to normal in approximately 6 months of follow up. Trying to decrease of influence by the environmental factors, one of the control groups was formed by patients under clinical investigation for refractory pain that underwent catheterization in the intensive care unit.
[0054] The effects of cervical sympathectomy on vasospasm were demonstrated by Faleiros et al. [26]. The authors submitted rabbits to SAH by injection of autologous blood into the cisterna magna. The diameter of the basilar artery after the hemorrhage was analyzed by angiography in animals with bilateral sympathectomy of the superior cervical ganglion alone, bilateral sympathectomy of the superior plus inferior cervical ganglion, and control groups.
[0055] The sympathectomy of the superior cervical ganglion seemed to protect the animals from vasospasm. Treggiari et al. [23] performed cervical sympathetic blockade to treat nine patients with clinical cerebral vasospasm confirmed by angiography. They observed improvement in cerebral perfusion in all angiograms after the blockade, even though the caliber of the vessels did not change. The authors attributed this to a decreased peripheral resistance. One patient died of complications of initial hemorrhage and other 2 died from consequences of severe vasospasm.
[0056] The main concern with the scientific explanation of the CBF augmentation with SCS is the lack of clear understanding of the mechanisms for vasospasm development and resolution. It is possible that more central, medullary mechanisms are responsible for immediate vasospasm after SAH [31] and for subsequent vasodilatation needed for vasospasm treatment. At the same time, pure sympathetic pathways that originate in lower cervical spinal cord or in the cervicothoracic junction and travel through the sympathetic ganglion to the cerebral vessels along the wall of the carotid arteries may be responsible for development of delayed vasospasm that results in major post-SAH morbidity.
[0057] The experimental and initial clinical data do support the idea that upper cervical SCS facilitates CBF in patients with vasospasm and improved outcome. Superior cervical sympathectomy, on the other hand, seems to prevent vasospasm from development. Clinical results of Takanashi and Shinonaga [19] suggest possible augmentation in CBF that may be used as treatment for vasospasm, and not as its prophylaxis, contrary to what is postulated in the title of their publication. Animal data seem to support this concept as well [11]. However, in order to prevent the delayed vasospasm, one needs to create functional sympathectomy, either by literally removing or blocking the sympathetic ganglia or by applying SCS to the lower segments of the cervical spinal cord.
[0058] Based on the thorough literature review, we hypothesize that in order to prevent the SAH-related delayed vasospasm, SCS should target the lower cervical segments, but once the vasospasm is present, the patient may receive additional benefit and possibly improve clinical outcome by CBF augmentation and treatment of the vasospasm by stimulation of the upper cervical spinal cord.
[0059] At this point it is difficult to say whether SCS interacts with the lateral column of the medulla at those parameters that are normally used for pain treatment, but due to the limited data it would be impossible to exclude this possibility.
[0060] Benefits of vasospasm prevention have not yet been established since there were no studies comparing results in patients at risk of vasospasm that received or did not receive SCS before the vasospasm starts. If this is turns to be true and poses no additional risk to the patient, dedicated placebo-controlled randomized clinical studies in humans will be required to prove our hypothesis. We suggest implanting longer electrode arrays that would cover both lower and upper cervical segments. Lower cervical SCS may then be used during the first 5-6 days after the SAH for true vasospasm prophylaxis and the additional 10-14 days of SCS to the upper cervical segments to treat vasospasm in those who develop it despite the prophylactic SCS application.
Example 1
[0061] Cervical spinal cord stimulation after acute aneurvsmal subarachnoid hemorrhage. The following Example establishes the feasibility and safety of prolonged cervical spinal cord stimulation (SCS) in the setting of acute aneurysmal subarachnoid hemorrhage (aSAH), as well as to evaluate clinical effects of cervical SCS in a small group of selected aSAH patients. The study was undertaken in preparation for a larger scale randomized trial of SCS for prevention of cerebral arterial vasospasm following aSAH.
[0062] Material and methods: A single arm non-randomized prospective study of cervical SCS in aSAH patients was performed in University of Illinois at Chicago. Standard percutaneous 8-contact SCS electrodes were implanted under an Investigational Device Exemption protocol in 12 consecutive patients that satisfied the following inclusion criteria: (1) age 18-65, (2) angiography-confirmed aSAH within 3 days prior to the electrode implantation, (3) Hunt/Hess (H&H) grade 2-4, (4) Fischer grade 2-4, (5) no history of previous cervical spine surgery, and (6) ability to obtain informed consent from the patient or family. All electrodes were inserted using percutaneous approach under general anesthesia immediately upon completion of the definitive surgical or endovascular procedure to secure the ruptured aneurysm. SCS was then delivered for the soonest of either 14 consecutive days or until the patient's discharge. Daily vital signs, laboratory values, transcranial Doppler, computed tomography and angiography results were recorded along with the information on presence of clinical vasospasm and all interventions aimed at vasospasm prevention and treatment.
[0063] Results: Mean age of implanted patients was 49 years (range—27-62), average H&H grade—2.9, average Fisher grade—3.3. Three had aneurysms coiled and 9—clipped. One patient developed multisystem failure and expired on post-operative day 11. In two patients, electrode was inadvertently pulled out on days 7 and 13 after the implantation. There were no complications related to the electrode insertion or to SCS during the entire study period. The angiographic vasospasm was observed in 6 out of 12 patients, and clinical vasospasm—in 2 out of 12; no patient suffered any vasospasm-related neurological complication. Both incidences were smaller than predicted based on the patients' Fisher and H&H grades.
[0064] Conclusion: The data presented herein demonstrates that cervical spinal stimulation is both a safe and feasible approach for treatment. Our data indicate that despite high level of acuity in patients after aSAH, general severity of medical condition, impaired level of consciousness, frequent patient re-positioning, need in multiple tests and variety of monitors, SCS electrodes may be safely implanted and maintained for the two-week period.
[0065] All of the above U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet, are incorporated herein by reference, in their entirety.
[0066] From the foregoing it will be appreciated 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.
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[0097] [31] Cetas J S, Lee D, Alkayed N, Heinricher M M. Coupled control of pain and cerebral blood flow in the medulla. In: New horizons in functional neurosurgery, Program of 2008 ASSFN meeting, Vancouver, BC, 2008. p. 81. | The present invention relates to a method of prevention and treatment of narrowing of cerebral blood vessels after subarachnoid hemorrhage, and in particular, to a method of applying electrical energy through electrical stimulation electrodes particularly positioned in the cervical region of a patient to affect the sympathetic tone of the blood vessels supplying the brain. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for creating monocrystalline piezoresistors in the surface of a semiconductor substrate, in which at least one dopant is introduced into the resistance area and in which the resistance area is provided with an electrically insulating sheathing.
2. Description of Related Art
It is known that monocrystalline piezoresistors may be created in a monocrystalline silicon layer by doping the resistance area. Such monocrystalline piezoresistors have a high sensitivity to mechanical stress and also have long-term stability. These piezoresistors are therefore used for signal detection in a number of micromechanical sensor elements, for example, acceleration, force or pressure sensor elements.
In a temperature range below 160° C., piezoresistors in monocrystalline silicon are electrically insulated already just by the depletion zone of the pn-junction between the resistance area and the surrounding silicon. However, with an increase in the ambient temperature, leakage currents occur at this pn-junction. Such piezoresistors are therefore used for measuring purposes only up to an ambient temperature of approximately 160° C. to a maximum of 200° C. At higher temperatures, the leakage currents occurring at the pn-junction lead to an unacceptable distortion of the measurement results.
Published German patent application document DE 10 2008 043 084 A1 proposes embedding the piezoresistor in an oxide area in order to reliably insulate a monocrystalline piezoresistor electrically from the adjacent silicon material, even at higher ambient temperatures. According to published German patent application document DE 10 2008 043 084 A1, the silicon environment of the piezoresistor is therefore initially etched to make it porous, and then the porous etched silicon material is oxidized.
BRIEF SUMMARY OF THE INVENTION
Alternative possibilities for creating an electrically insulating sheathing for a piezoresistor in a semiconductor material are proposed with the present invention, so that such a piezoresistor may also be used in the high-temperature range, i.e., for measurements at ambient temperatures higher than 200° C.
According to the present invention, the resistance area is initially delineated laterally by at least one circumferential, essentially vertical trench and then undercut by etching over the entire area. Next an electrically insulating layer is created on the wall of the trench and the undercut area, so that this electrically insulating layer is electrically insulated from the adjacent semiconductor material.
In contrast with the method described in published German patent application document DE 10 2008 043 084 A1, the method according to the present invention may be applied to different semiconductor materials and is not limited to monocrystalline silicon. Thus not only monocrystalline piezoresistors may be created and electrically insulated in a monocrystalline silicon layer but also piezoresistors may be created in other semiconductor materials. Materials other than silicon oxide are also used in particular for implementation of a thermally stable electrical insulation of the piezoresistors. As in the case of published German patent application document DE 10 2008 043 084 A1, the insulating layer surrounding the piezoresistor is created exclusively with the aid of standard surface micromechanical methods, which are readily controllable, according to the present invention.
The electrically insulating layer should sheath the piezoresistor as thoroughly as possible, at least on the substrate side, to ensure that even at higher temperatures, leakage currents do not occur at any point between the piezoresistor and the adjacent semiconductor material. The resistance area must therefore be undercut by etching throughout the entire area. The etching attack required for this purpose is advantageously performed over the vertical trench delineating the resistance area laterally. The resistance area is then undercut by etching in an isotropic etching step in which the base area of the trench is widened. This variant of the method results in completely undercutting the resistance area only if the lateral extent of the resistance area is small enough in relation to the isotropic widening of the trench.
Otherwise it is advisable to also create trench openings within the cohesive resistance area, these openings extending to beneath the resistance area. These trench openings are then widened in the base area in an isotropic etching step together with the circumferential trench, so that the resistance area is undercut by etching starting from the edge area and also in the central area at the same time.
In the method according to the present invention, it is important to be sure that the resistance area remains mechanically connected to the semiconductor substrate despite the circumferential trench and complete undercutting. The mechanical connection may be implemented at points in the form of webs, for example, between the resistance area and the surrounding semiconductor substrate. In this case, the webs should be formed from an electrically insulating material if at all possible.
In a preferred variant of the method according to the present invention, the mechanical connection of the resistance area is ensured with the aid of the trench mask. The trench mask is therefore not opened completely in the area of the circumferential trench to be created but instead is merely provided with perforations through which the etching attack of the trench process takes place. The distance and size of the perforation openings here are selected in such a way that the perforation area of the trench mask is completely undercut by etching during the trench process. In this procedure, the resistance area is held by the trench mask until it is again bound to the semiconductor substrate by the electrically insulating layer created on the wall of the trench and the undercut area. Therefore, in this case, no additional measures are necessary for electrical insulation of the mechanical connection of the resistance area in this case. An oxide layer is preferably created on the substrate surface as the trench mask, which is easily structured accordingly.
As already mentioned, the trench and the undercut area may essentially be coated with any electrically insulating material to electrically insulate the resistance area, for example, coating it with silicon nitride or silicon carbide. An oxide layer is preferably created on the wall of the trench and the undercut area because standard methods such as thermal oxidation and/or CVD (chemical vapor deposition) methods may be used for this.
In most cases, the trench and the trench openings, if necessary, are filled at least to the extent that a closed planar surface is formed. In the simplest case, this may be continued for coating the wall of the trench and the undercut area until the trench and the trench openings are sealed with the coating material, at least superficially.
In the case of a larger opening area of the trench and the trench openings, a first oxide layer may also be created initially in the area of the trench, the trench openings, if necessary, and the undercut area and then a polysilicon layer being deposited thereon which is subsequently oxidized in an additional method step.
Within the context of the manufacturing method according to the present invention, the substrate surface is usually also coated with the electrically insulating material with which the piezoresistor is sheathed on the substrate side. Therefore, not only the piezoresistor but also the entire substrate surface is protected very well from environmental influences. For contacting the piezoresistor, terminal pads may then be formed easily in a metal layer which extends over corresponding contact openings in this passivation layer of electrically insulating material. With regard to a particularly good media resistance, it has proven advantageous if the terminal pads are formed from a noble metal such as platinum or gold. This also prevents Kirkendall voiding in particular, which occurs at the connection of aluminum pads to gold bond wires at higher temperatures.
In a particularly advantageous layout variant, in which a resistance area is provided with two metal contacts on opposite end sections of the resistance area, these end sections are designed to be wider than the central area of the resistance area, to better transmit any mechanical stresses in the area of the piezoresistor and in particular the connecting area to the adjacent semiconductor substrate.
The method according to the present invention is based initially only on the formation of an electrical insulation between a monocrystalline piezoresistor, which has been created in the surface of a semiconductor substrate, and the adjacent semiconductor material. Depending on the function of the component equipped with such a piezoresistor, additional layers are created on this monocrystalline layer and processed.
A preferred field of application for monocrystalline piezoresistors is the detection of mechanical stresses in a micromechanical component structure, for example, in the diaphragm of pressure sensors and microphones or in bending beams of an acceleration sensor, a balance and a force sensor or a torsion sensor. Since the piezoresistors according to the present invention are created in the substrate surface, they are on the diaphragm surface or on the surface of the bending beam and are thus at the greatest possible distance from the neutral fiber of the micromechanical measurement structure. This contributes significantly toward an increase in measurement sensitivity. Signal detection in the case of yaw-rate sensors or actuators, for example, micromirrors, may also be mentioned here as possible applications.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a through 1 d show a schematic sectional diagram through a substrate 10 according to individual method steps of a first variant of the method according to the present invention for creating a piezoresistor.
FIGS. 2 a through 2 d each show a schematic sectional diagram through a substrate 20 according to individual method steps of a second method variant.
FIGS. 3 a , 3 b illustrate a method variant for filling the trenches on the basis of schematic sectional diagrams through the structured substrate 20 .
FIGS. 4 a to 4 c show three different resistor layouts.
FIG. 5 shows a schematic sectional diagram through a first pressure sensor element 50
FIG. 6 shows a schematic sectional diagram through a second pressure sensor element 60 .
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 a through 1 d illustrate a method for creating piezoresistors in the surface of a semiconductor substrate 10 , which is preferably monocrystalline, so that the piezoresistors are also monocrystalline. Semiconductor substrate 10 may be a silicon wafer, for example, having any basic doping. In the simplest case, this substrate doping forms the doping of resistance area 11 . If resistance area 11 is to be provided with another doping, the entire substrate surface may be doped accordingly. Structured doping is not absolutely necessary because resistance area 11 is electrically insulated from the adjacent substrate material on all sides with the aid of the method according to the present invention. For this purpose, an essentially vertical circumferential trench 12 around resistance area 11 is initially introduced into the substrate surface, which laterally delineates resistance area 11 and extends to the depth of resistance area 11 . Base area 13 of this trench 12 is then widened in an isotropic etching step until resistance area 11 is completely undercut by etching, so that resistance area 11 is still connected mechanically to semiconductor substrate 10 only at points, for example, by webs. FIG. 1 a shows semiconductor substrate 10 after the etching mask, which is necessary for the trench process and the isotropic etching step, has been removed. The mechanical connection of resistance area 11 to semiconductor substrate 10 is not shown here.
The substrate surface and the wall of trench 12 and of undercut area 13 are then provided with an electrically insulating layer 14 , as shown in FIG. 1 b . In the exemplary embodiment depicted here, electrically insulating layer 14 is an oxide layer created by thermal oxidation. The thermal oxidation process is continued until trench 12 is closed at least at the surface, as shown in FIG. 1 c . As a result of this self-stopping oxidation process, resistance area 11 is completely surrounded by an electrically insulating material. In the present exemplary embodiment, a residual cavity 17 remains beneath the closed substrate surface laterally from resistance area 11 due to the geometry of trench 12 .
FIG. 1 d shows semiconductor substrate 10 having piezoresistor 11 which was created in this way and has been provided with metal contacts 18 . For this purpose, oxide layer 14 was opened in the area of piezoresistor 11 . The corresponding contact holes were defined here with the aid of a passivation layer 15 in a photolithographic process and were then etched by a wet chemical method. However, they may also be opened by plasma etching. Aluminum metallization, for example, was then applied, and metal contacts 18 were then structured out of the metallization. However, metal contacts of a noble metal, for example, Pt or Au, are to be preferred from the standpoint of achieving a particularly good media resistance of the piezoresistor.
FIGS. 2 a through 2 d illustrate one variant of the method described above, in which the mechanical bonding of resistance area 21 is accomplished with the aid of trench mask 26 .
This method variant also begins with a monocrystalline silicon substrate 20 . To create an essentially vertical trench 22 which laterally delineates resistance area 21 , the substrate surface was initially masked with an oxide layer 26 , which was provided with a perforation 261 in the area of trench 22 to be created. Accordingly, the etching attack of the trench process and also of the subsequent isotropic etching step for undercutting of resistance area 21 takes place through perforation 261 in oxide layer 26 . The distance and size of the perforation openings were selected in such a way that a cohesive trench 22 surrounding resistance area 21 in the form of a ring is created during the trench process. FIG. 2 a shows silicon substrate 20 with the essentially vertical trench 22 , whose base area 23 has been widened to the extent that resistance area 21 is completely undercut by etching.
In contrast with the method variant described above in conjunction with FIGS. 1 a through 1 d , trench mask 26 is not removed here but remains on the substrate surface even during the subsequent oxidation process, as illustrated in FIG. 2 b.
FIG. 2 b shows structured silicon substrate 20 after the wall of trench 22 and undercut area 23 have been provided with a first oxide layer 24 for electrical insulation of resistance area 21 .
As shown in FIG. 2 c , perforation 261 in trench mask 26 is closed only then by applying another passivation 25 . This may be, for example, a nitride layer, which is deposited on the surface of the component in a CVD method.
Cavity 27 in the area of trench 22 , 23 of this encapsulated structure is then filled by thermal oxidation in a second oxidation step. FIG. 2 d shows that the process of thermal oxidation in the present exemplary embodiment was continued until cavity 27 was completely oxidized. Since this method step usually also affects the extent and location of the perforation openings in trench mask 26 , a discussion of the perforation has been omitted here.
FIGS. 3 a and 3 b illustrate another possibility for filling cavity 27 in the area of trench 22 , 23 . To accelerate the filling process by thermal oxidation, polysilicon is deposited after the first oxidation step and also penetrates into cavity 27 through perforation 261 in trench mask 26 . Accordingly, a polysilicon layer 29 is formed not only on trench mask 26 but also on first oxide layer 24 within cavity 27 , as shown in FIG. 3 a.
In a subsequent oxidation step, this polysilicon layer 29 is oxidized, as shown in FIG. 3 b . Cavity 27 may be filled comparatively rapidly due to the material added by deposition of polysilicon.
While FIGS. 1 through 3 show only sections through substrate 10 and 20 in a stage of the manufacturing process, FIGS. 4 a through 4 c show top views of a monocrystalline silicon substrate 40 illustrating various possible layouts for piezoresistors created in this way.
In the case of FIG. 4 a , a piezoresistor 41 in the form of a relatively narrow doped area 41 resembling a section of a printed conductor is formed in the surface of substrate 40 . The doping of resistance area 41 may be selected arbitrarily. In the case of a sensor element without any additional circuit elements, the substrate doping may be simply taken over. If a different doping is necessary, the entire substrate surface may easily be doped accordingly because resistance area 41 is sheathed completely by electrically insulating oxide 44 on the substrate side. This shows with dotted lines a residual cavity 47 beneath the closed surface in the area of the trench, which was created for lateral delineation of resistance area 41 and was filled with oxide 44 . Piezoresistor 41 is contacted via two metal contacts 48 , which are situated on opposite ends of resistance area 41 .
In contrast with the variant shown in FIG. 4 a , resistance area 411 , which resembles a section of a printed conductor, is relatively wide in the case of FIG. 4 b . Trench openings 422 , which are situated in the form of a grid and are filled with electrically insulating oxide 44 in the same way as circumferential trench 421 , are discernible within this cohesive resistance area 411 . Resistance area 411 is undercut here by isotropic widening of the base area of circumferential trench 421 and also of trench openings 422 . FIG. 4 b illustrates that electrically insulated piezoresistors of an arbitrary lateral extent may be implemented according to the present invention by introducing trench openings within the cohesive resistance area.
FIG. 4 c shows a piezoresistor 412 whose terminal areas 4 on the end are widened in the form of a wedge in comparison with central area 5 . Grid-type trench openings 422 are formed here only inside these terminal areas 4 , which are widened in the form of a wedge, these trench openings being filled with oxide 44 just like circumferential trench 421 . Metal contacts 48 in the terminal areas of piezoresistor 412 are adapted to the wedge shape of terminal areas 4 and are also wedge-shaped.
This resistance layout having a widened restraint of the piezoresistor permits improved transmission and detection of surface stress. This has proven to be advantageous in diaphragm sensors, for example, because the surface stress here is to be detected with the aid of piezoresistors. The improved transmission of surface stress is based on the fact that the lateral compressive stress in the surroundings of the piezoresistor, which may be attributed to the different thermal expansion coefficients of the semiconductor material and the oxide, has the lesser effect on the surface stress in the area of the piezoresistor the wider its restraint is.
As already mentioned at the outset, monocrystalline piezoresistors sheathed with an electrically insulating material and therefore electrically insulated from the adjacent substrate material are particularly suitable for signal detection with micromechanical pressure sensor elements which are to be used in the high-temperature range. For signal analysis, the piezoresistors may be connected in a Wheatstone bridge, for example. FIGS. 5 and 6 each illustrate such a pressure sensor element having monocrystalline piezoresistors in the diaphragm area.
Pressure sensor element 50 shown in FIG. 5 was implemented with arbitrary doping, starting from a silicon substrate 51 . The doping required for the piezoresistors is advantageously selected as substrate doping. In any case, structured doping for the piezoresistors is not necessary here. The front side of substrate 51 was initially processed according to the method described above to create monocrystalline piezoresistors 53 in diaphragm area 52 . Accordingly, piezoresistors 53 are adjacent to the substrate surface and embedded in an oxide area 54 , so that they are insulated from substrate 51 laterally and downward. An oxide layer 55 having contact openings in the area of piezoresistors 53 is formed on the substrate surface. The connecting lines and terminal pads 56 for piezoresistors 53 are implemented here in a metallization applied to oxide layer 55 and extending over the contact openings. A passivation layer 57 , which is open only in the area of terminal pads 56 , forms the seal.
Only then was diaphragm 52 exposed starting from the back of substrate 51 . A method known from bulk micromechanics such as anisotropic etching using KOH or TMAH or trenching was used for this purpose. Sensor element 51 shown here is used for differential pressure measurement because pressure is applied to diaphragm 52 on both sides, as indicated by arrows 1 and 2 . If cavern 58 beneath diaphragm 52 is sealed under defined pressure conditions, for example, by hermetically sealed anodic bonding of glass on the back of sensor element 50 , then sensor element 50 may also be used for absolute pressure measurement.
The bulk micromechanical methods may also be performed using an etch stop; for example, an SOI wafer on whose oxide layer the process is stopped may be used in trenching. A pn-etch stop may be used in KOH etching.
Only surface micromechanical methods were used to manufacture pressure sensor element 60 shown in FIG. 6 . A diaphragm 62 was initially formed in a monocrystalline n-epitaxial layer 3 above a p-silicon substrate 61 . Next, a cavern 68 was created in the p-silicon substrate beneath diaphragm 62 . Only then was the method according to the present invention used to create monocrystalline piezoresistors 63 embedded in silicon oxide 64 in the diaphragm surface. Here again, piezoresistor 63 of pressure sensor element 60 is adjacent to the surface of monocrystalline n-epitaxial layer 3 . An oxide layer 65 having contact openings in the area of piezoresistors 63 is formed on the surface of n-epitaxial layer 3 . Connecting lines and terminal pads 66 for piezoresistors 63 are implemented in a metallization applied to oxide layer 65 and extending over the contact openings. A passivation layer 67 , which is open only in the area of terminal pads 66 , forms the seal. | An electrically insulating sheathing for a piezoresistor and a semiconductor material are provided such that the piezoresistor is able to be used in the high temperature range, e.g., for measurements at higher ambient temperatures than 200° C. A doped resistance area is initially laterally delineated by at least one circumferential essentially vertical trench and is undercut by etching over the entire area. An electrically insulating layer is then created on the wall of the trench and the undercut area, so that the resistance area is electrically insulated from the adjacent semiconductor material by the electrically insulating layer. | 6 |
This is a continuation-in-part of application Ser. No. 07/988,292 filed Dec. 8, 1992, now U.S. Pat. No. 5,335,562.
BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates to transmissions. More particularly, the present invention relates to multi-speed rear wheel drive transmissions.
II. Description of the Prior Art
Typically, most rear wheel drive transmissions are constructed with a short input shaft which transmits driving torque from a source such as an engine through a pair of gears known as a headset, to a countershaft. The countershaft is located parallel to the input shaft and is positioned amid a plurality of driving gears. An output shaft, having a plurality of driven output gears surrounding the shaft, is located parallel to the countershaft. Each of the driven output gears surrounding the output shaft is in mesh with a corresponding driving gear from the plurality of gears on the countershaft. Usually the output shaft is coaxial with the input shaft. A number of axially reciprocating synchronizers are coupled to the output shaft or countershaft to engage one of the speed gears on one side and another of the speed gears on its other side. One of the speed gears on the output shaft is a reverse gear which is in mesh with the driving gear on the countershaft through an idler gear. Most often, the output shaft is coaxial with the input shaft with one of the synchronizers arranged to engage, in one position, the input shaft directly to the output shaft to effect one of the speed changes.
With the typical headset multi-speed transmission, all of the driving and driven speed gears are in continuous motion when the vehicle is stationary, the transmission is in neutral, the driving source, or engine, is running and the clutch is engaged. Invariably, the driving source, or engine, generates angular accelerations in the power output characteristics that induce rotational harmonics of the drive train. The rotational harmonics of the rotating gears of the typical headset multi-speed transmission cause a considerable noise problem commonly referred to as "neutral roll-over noise".
With the typical headset transmission design, the torque of the driving source or engine is multiplied by the headset gear ratio. Hence, all of the speed gears that transmit torque in the power flow sequence after the headset must have an adequate face width to transmit the multiplied torque. Since the torque multiplication is transmitted through a single driving gear on the countershaft to an engaged driven gear on the output shaft, the countershaft and output shaft have to be sized and supported to withstand considerable deflection forces.
When shifting gears in a conventional headset transmission, the activated synchronizer must speed up or slow down the revolutions (rpm) of all of the speed gears, countershaft, input shaft and clutch disc. The shift sequence, first to second, third to fourth, third to second, etc. determines the magnitude of the rpm changes affected at the speed gears, countershaft, input shaft and clutch disc. The rpm changes of these rotating masses create a different amount of reflected inertia at the activated synchronizer, which results in the need of different synchronizer sizes to produce an acceptably low shift effort. Recently, double and triple cone synchronizers have been used to reduce shift effort.
Vehicles equipped with a typical headset multi-speed transmission cannot be towed without restrictions and/or the risk of serious damage to the transmission when the rear wheels of the vehicle are in contact with the pavement, the transmission is in neutral and the drive train clutch is engaged to the stationary driving source or engine. Under these conditions, the rotation of the output shaft may cause serious damage to bearings, journals, or thrust surfaces, since the rest of the transmission components are in a stationary state and adequate lubrication of the bearings, journals, gear meshes, or thrust surfaces does not occur. To avoid such damage, towing under these conditions is typically restricted to speeds of no greater than 30 miles per hour and for distances of 50 miles or less.
SUMMARY OF THE INVENTION
The present invention is directed to overcoming the various disadvantages outlined relative to the prior art headset transmission. With the transmission of the invention, neutral roll-over noise is eliminated. The gear face widths are minimized and reduced. Shaft deflections and, thus, the diameter of the shafts can be reduced. The required synchronizer capacity and size is the same in all positions and, thus, size is minimized. Vehicles containing the transmission can be towed with the transmission in neutral without restrictions since lubrication of the bearings, journals, and thrust surfaces occurs.
The multi-speed transmission of this invention is particularly designed for rear wheel drive vehicles and includes a driven input shaft. A first series of driving speed gears surrounds the input shaft. A number of single sized synchronizers are coupled to the input shaft and arranged operatively to couple with one of two of the series of driving speed gears. A countershaft arranged parallel to the input shaft has a series of driven speed gears meshing with different ones of the driving speed gears on the input shaft. One of the driven speed gears on the countershaft can be engaged with the reverse driving speed gear on the input shaft through an idler gear. An output shaft is arranged coaxial with the input shaft and is parallel with the countershaft. The countershaft is coupled to the output shaft by a driving output gear fixed to the countershaft in mesh with a driven output gear fixed to the output shaft. The driving output gear and driven output gear are referred to as a final drive set, hence, the arrangement of the invention is referred to as a final drive, multi-speed rear wheel drive transmission.
With the foregoing arrangement of the invention, all of the driving and driven gears are stationary when the vehicle is stationary, the transmission is in neutral, the driving source or engine is running, and the clutch is engaged. Therefore, neutral roll-over noise is eliminated.
With the foregoing arrangement of the invention, there is no headset torque multiplication, therefore, the face widths of the speed gears can be reduced. Likewise, shaft deflections are reduced permitting a reduction in shaft diameters.
With the foregoing arrangement of the invention, the inertias of the speed gears and the countershaft are no longer a factor during synchronization because these inertias are now directly coupled to the drive shaft through the final drive gear mesh and become a part of the vehicle inertia. Therefore, each of the synchronizers can be of the same minimum size. The minimum size is dictated by the size of the gears which the synchronizers act upon. This results in a synchronizer which, even for the smallest gear, is larger than needed to produce acceptably low shift efforts.
Vehicles equipped with the transmission of the foregoing arrangement of the invention can be towed without restrictions and/or the risk of serious damage to the transmission when the vehicle wheels are in contact with the pavement, and the transmission is in neutral and the drive train clutch is engaged to the stationary driving source or engine. This is possible since rotation of the transmission output shaft induces rotation of the countershaft through the final drive gear mesh and all of the gears within the transmission, which results in oil splash and lubrication to bearings, journals, gear meshes and thrust surfaces.
Also disclosed is a first alternative preferred embodiment of a final drive transmission having an engagement device disposed between a synchronizer and gear to dampen "in-gear" or "drive rattle" noise. Because the final drive transmission provides excess synchronizer capacity, it is possible to add an engagement device without increasing the capacity of the synchronizer. Also disclosed is an input shaft mounted lubrication fluid pump. The pump forces fluid through an axial bore in the input shaft for delivery to radially disposed outlet passages. The continuously rotating input shaft generates centrifugal force to deliver lubricating fluid through the outlet passages to the synchronizers and gears.
A second preferred embodiment is also disclosed for eliminating in-gear or drive rattle noise. In the second alternative embodiment, the first and second drive gears are fixedly mounted to the input shaft. The corresponding driven gears and a synchronizer are mounted on the countershaft. The remaining speed gear pairs are mounted on the input shaft and the countershaft in the manner of a final drive transmission.
Finally, a third preferred alternative embodiment of the final gear transmission having a power take-off assembly is disclosed. The transmission includes a drive gear splined to the input shaft and a driven gear mounted for rotation on a countershaft. Apertures are provided on either side of the housing opposite the driven gear for mounting a conventional power take-off assembly.
BRIEF DESCRIPTION OF THE DRAWING
The advantages of the present invention will be more apparent from the following detailed description when considered in connection with the accompanying drawing wherein:
FIG. 1 is a schematic view of a typical headset multi-speed rear wheel drive transmission according to the prior art;
FIG. 2 is a schematic view of a transmission according to a preferred embodiment of the invention;
FIG. 3 is an elevational view, partially in section, of a transmission according to the preferred embodiment of the invention;
FIG. 4 is a schematic view of the reverse gears and idler gear assembly according to the preferred embodiment of the invention;
FIG. 5 is an elevational view, partially in section, of a transmission constructed according to a first alternative embodiment of the invention;
FIG. 6 is a partial elevational view of a synchronizer and engagement device according to the first alternative embodiment of the invention taken from inset 6 of FIG. 5;
FIG. 7 is a fragmentary view of the engagement device of the first alternative embodiment in accordance with the invention;
FIG. 8 is a fragmentary view of a belleville washer positioned as an alternative engagement device in accordance with the invention;
FIG. 9 is a cross-sectional view of an oil pump in accordance with the first alternative embodiment of the invention;
FIG. 10 is a schematic view of a second alternative embodiment of a transmission according to the invention;
FIG. 11 is an elevational view, partially in section, of a third alternative embodiment of a transmission according to the invention; and
FIG. 12 is a cross-sectional view of the third embodiment of the transmission having a power take-off assembly according to the invention taken along lines 12--12 of FIG. 11.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawing, and particularly to FIG. 1, a prior art six speed headset transmission 10 is shown. A headset transmission is a transmission which includes an input shaft 12 journalled in bearing 14 which carries a driving gear 16 which is in mesh with driven gear 18 coupled to countershaft 20 journalled at its ends in bearings 22 and 24. Countershaft 20 carries a number of driving gears integrally formed with the shaft or coupled to the shaft. These driving gears 26, 28, 30, 32, 34, and 38, are respectively, the reverse, first, second, third, fourth, and sixth gears of the transmission and are in constant mesh with driven speed gears 40, 42, 44, 46, 48, and 52 surrounding an output shaft 54 journalled at its ends in bearings 56 and 58. Bearing 56 can be a bearing internally contained in input shaft 12. Synchronizers 60, 62, 64 and 66 are coupled to output shaft 54 for reciprocal axial movement to selectively engage adjacent gears on either side by the use of inter-engaging splines and known principals of synchronizer design. For example, synchronizer 62 can be moved to the right as seen in FIG. 1 to engage first gear 42 with the output shaft 54, or it can be moved to the left to engage second gear 44 with the output shaft 54.
Likewise, synchronizer 66 can be moved to the right as viewed in FIG. 1 to engage sixth gear 52 with the output shaft 54, or can be moved to the left to engage input shaft 12 directly with the output shaft 54 for a 1:1 ratio, which in this case serves as the fifth gear.
It can be seen that all of the gears on both the countershaft 20 and output shaft 54 are in continuous movement through the gears 16 and 18, therefore, when the transmission is in neutral, the complete gear set is rotating. This rotation causes neutral roll-over noise. Since there is an engine torque multiplication created by the driving input gear 16 and the driven countershaft gear 18, the gears on the output shaft 54 and the countershaft 20 must have adequate face width to transfer the engine torque from the input shaft 12 to the output shaft 54. For this same reason, countershaft 20 and the output shaft 54 must be sized and supported to withstand considerable deflection forces. Furthermore, during synchronization, each of the gear meshes 40-26, 42-28, 44-30, 46-32, 48-34, 52-38, and 16-18 create different amounts of reflected inertia, requiring that the individual synchronizers 60, 62, 64 and 66 be sized to best handle the work required to effect the speed changes through the gears on either side of the individual synchronizer.
Referring now to FIGS. 2 and 3, the transmission 70, according to the invention, has an input shaft 71 extending through the wall of a front housing 75 terminating within a rear housing 120. A series of driving speed gears surround the input shaft 71 and are supported for rotation about the input shaft 71 by coaxial needle bearings 83 (FIG. 2). The driving speed gears 72, 74, 76, 78, 80 and 82 constitute, respectively, the reverse, first, second, third, fourth, and sixth gears of the transmission. The driving speed gears are in constant mesh with driven gears 87, 88, 90, 92, 94, and 96 mounted on the countershaft 100. A final drive pinion gear 98 on the countershaft 100 is in constant mesh with the driven output gear 84 on an output shaft 86. Thus, the first gear 74 is the smallest of the gears.
The input shaft 71 is supported by a conventional bearing 112, such as a ball bearing or a tapered roller bearing, in the front housing 75 and by bearing 114 on the other end at the output shaft 86. The output shaft 86 is supported by spaced opposed tapered roller bearings 116 and 118 in the rear housing 120. Countershaft 100 is supported at its ends by bearing 122 and bearing 124.
Synchronizers 102, 104, 106 and 108 are coupled to the input shaft 71 for reciprocal axial movement to selectively engage adjacent gears on either side by the use of inter-engaging splines. For example, the synchronizer 106 can be moved to the right as viewed in FIG. 2 to engage first gear 74, or it can be moved to the left to engage second gear 76. Likewise, synchronizer 102 can be moved to the left as viewed in FIG. 2 to engage sixth gear 82 or to the right to engage the input shaft 71 directly with the output shaft 86 for a 1:1 ratio, which in this case serves as the fifth gear. The synchronizers 102, 104, 106 and 108 are actuated through the shift mechanism 110, not described in this disclosure.
As shown in FIG. 4, an idler gear 89, mounted on a shaft 91, is in mesh with driving gear 72 and driven gear 87 to provide a reverse gearing when the synchronizer 104 is moved for engagement with driving gear 72. As is known in the art, the shaft 91 is supported by bearings (not shown) in a parallel alignment with the input shaft 71 and countershaft 100.
With the present invention, all gears are idle when the vehicle is stationary, the transmission is in neutral, the engine is running and the clutch is engaged, therefore, neutral roll-over noise is eliminated. This results in a cost savings for clutch disc design since a pre-damper stage is no longer required. Also, the elimination of the pre-damper stage reduces drive line clunk.
Since in the power flow sequence there is no engine torque multiplication created by a gear mesh ahead of the gear meshes formed by the speed gears on the input shaft 71 and the mating gears on the countershaft 100, the face widths of the gears on the input shaft 71 and countershaft 100 can be reduced compared to the prior art design, thereby, reducing the overall length of the transmission. The only gears that will transmit multiplied engine torque are the final drive pinion 98 and gear 84. Thus, these are the only gears that will have face widths comparable to the prior art design.
With the lower torque load carried by the speed gears along with adequate bearing support provided by bearings 112, 114, 116, 118, 122 and 124, the deflections of input shaft 71 and countershaft 100 are reduced allowing reduction in shaft diameters.
It can also be seen with the present invention that the inertias of the speed gears and the countershaft are no longer a factor during synchronization because these inertias are now directly coupled to the drive shaft through the final drive gear mesh and become part of the vehicle inertia. Therefore, synchronizers 102, 104, 106 and 108 can be of the same optimum size since the work they must perform during the synchronization of any speed change involves changing the speed of only the input shaft, synchronizer assembly and clutch disc inertias.
A first alternative preferred embodiment of a final drive transmission according to the invention is shown in FIGS. 5-9. The transmission 170 includes an engagement device positioned to reduce in-gear rattle, and a centrifugal oil pump assembly. As shown in FIG. 5, the transmission 170 has an input shaft 171 having a series of driving speed gears 72, 74, 76, 78, 80 and 82 supported for rotation by coaxial needle bearings 83. The driving speed gears are in constant mesh with driven gears 87, 88, 90, 92, 94, and 96. Each driven gear has a synchronizer cone 132 mounted on countershaft 100. A final drive pinion gear 98 on the countershaft 100 is in constant mesh with the driven output gear 84 on the output shaft 86. The input shaft 171 and the countershaft 100 are supported as discussed above. Synchronizers 103, 104, 106, and 108 are splined to the input shaft 171.
As best shown in FIG. 6, the synchronizer 103 has a hub 126 splined to the input shaft 171. The hub 126 supports a sleeve 128 which is axially movable by way of a gear shift linkage 130 between the synchronizer clutch gears 132 of the speed gears 74 and 76. Cone surfaces 134 are formed at either end to correspond to matching cone surfaces 136 formed on the synchronizer clutch gears 132 of the speed gears 74 and 76. A spring loaded ball 138 is mounted in the hub to apply an indexing load to the cone surfaces 134. As discussed above, the cone surfaces of the synchronizer of a conventional transmission are required to handle the reflected inertias of the speed gears, countershaft, input shaft, and clutch disc and, accordingly, are increased in size or number of cones to attain acceptably low shift efforts. In the final drive transmission according to the invention there is no reflected inertia effect from the speed gears and countershaft. Therefore, minimum size synchronizers are required, restrained by the minimum dimension of the cone on the speed gears. The minimum size of each cone is limited by the diameter of the speed gear necessary to encircle the input shaft. This results in synchronizer sizes larger than necessary to produce low shift effort, even for the largest of the rpm changes during shifting. The synchronizer size, accordingly, may be of the same minimal size for all of the gears.
It has been found that the final drive transmission may be subject to certain gear rattle when the transmission is engaged. This noise is referred to as in-gear or drive rattle noise. Drive rattle noise occurs because gears on the input shaft which are not engaged by the synchronizer are not subject to load and have a tendency to rattle. This appears to be particularly true of the low speed gear 74. Accordingly, an engagement device may be mounted to engage the gears. As best shown in FIG. 7, a ring 140 having a friction producing arm 141 is mounted to the synchronizer 103. An annular groove 142 is formed on radially extending side surfaces 144 of the hub 126 of the synchronizer 103. The groove 142 is disposed opposite a radial surface 146 of adjacent gear 74. The ring 140 and arm 141 are unitarily formed of suitable resilient material such elastomer or rubber as that used for oil seals. The arm 141 extends to engage the gear 74 and prevent rattling during operation of the transmission 170. Because the synchronizer 103 has excess capacity, the addition of friction to the gear may be had without any need for increasing the size of the synchronizer 103 as would be required in a headset transmission. This size synchronizer has more capacity than necessary to produce a low shift effort for even the largest of the rpm changes during shifting. The engagement device is shown mounted between synchronizer 103 and gears 74 and 76 because it has been found that these gears are particularly susceptible to in-gear rattle. The engagement device may be used with synchronizers 104, 106 and 108 if desired.
In FIG. 8 is shown an alternative engagement device in the form of a belleville washer 150 disposed between radial surface 144 of the hub 126 of the synchronizer 103 and radial surface 146 of gear 74. The washer 150 places a force on the gear 74 to maintain the position of gear during operation of the transmission and prevent rattle.
As shown in FIGS. 5 and 9, the transmission 170 includes a lubricating fluid pump assembly. Lubricating fluid is pumped from a sump 152 through a filter 154 and a conduit 156 by a gerotor pump 157 mounted around the input shaft 171. The gerotor pump 157 includes a housing 158 and an outer rotor 159 in mesh around an inner rotor 161 fixedly attached to the input shaft 171. Pumping chambers 163 are formed between rotor lobes 165 of the rotors 159, 161. Fluid is drawn into the pumping chamber 163 through an inlet 166 and delivered from the pumping chamber 163 to an outlet passage 104 in the housing 158. A conventional pressure relief valve 162 is provided in the housing 158 for relieving excess pressure in the pumping chamber 163. As best shown in FIG. 5, the fluid is carried from the outlet passage 164 through a radial bore 183 through a centrally disposed axial bore 185 in the input shaft 171. A series of radially disposed outlet passages 187 extend from the axial bore to each synchronizer 103, 104, 106, and 108. An axial bore 189 also extends through the output shaft 86 to a radial passage 191. Fluid is delivered underneath the synchronizer hubs and then outwardly by centrifugal force to lubricate the cones of the synchronizer, adjacent gears and needle bearings. Likewise, fluid is pumped axially by the gerotor pump through the axial bore 189 of the output shaft 86 to provide fluid for lubrication to the opposed taper roller bearings through radial passage 191. Because conventional lubrication systems lubricate the transmission by passing the teeth of the gears through fluid in the sump, the sump must include sufficient oil to cover the teeth of the gears. Because the pump assembly of the present invention does not require the gear teeth to traverse through the fluid in the sump 152, it is possible to have a much lower level of fluid in the sump 152 than known in conventional transmissions.
A second alternative embodiment of a transmission 270 is shown schematically in FIG. 10. The second preferred embodiment includes a final drive transmission having two gear pair, such as first drive gear 272 and a second drive gear 274, fixedly attached to the input shaft 271 and corresponding driven gears 287, 288 supported by needle bearings 83 on countershaft 200 and connectable to the countershaft 200 by way of a synchronizer 202. Two or four gear pairs could be arranged in this fashion, with the drive gears fixedly attached to the input shaft and the corresponding driven gears supported by the needle bearings on the countershaft and connectable to the countershaft by the way of synchronizers. All other aspects of the transmission according to the second preferred embodiment are the same as disclosed above for the preferred embodiment of the invention.
A third alternative embodiment of the final drive transmission 370 adapted for use with a conventional power take-off (PTO) assembly 310 is shown in FIGS. 11 and 12. As known in the art, the PTO assembly 310 includes a clutch and control mechanism to selectively deliver power from the transmission 370 to a shaft (not shown) for powering auxiliary equipment such as hydraulic motors. Housing 312 is provided with a pair of apertures 314 disposed on either side of the countershaft 100. The conventional power take-off assembly 310 is mounted on a desired side of the transmission housing 312 by bolting the PTO assembly 310 onto the housing 312 over the aperture 314. A plate 316 is bolted to the housing 312 to cover the other aperture 314. A drive gear 318 is splined to the drive shaft 71 and a driven gear 320 is mounted on needle bearings 83 to the countershaft 100. The driven gear 320 is positioned opposite the apertures 314 to permit meshing engagement with a driven gear 322 of the PTO assembly 310. In this way, the final drive transmission can be provided with a power take-off assembly on either side of the housing.
Although a six speed transmission is shown herein, it is clearly within the scope of the invention to encompass a seven speed transmission.
Towing restrictions for the vehicle are no longer required, since the final drive gear set is in constant mesh and connected to the drive shaft. This enables the countershaft and speed gears to turn when the transmission is in neutral, the vehicle rear wheels are in contact with the pavement, and the clutch is engaged to the stopped engine. The turning countershaft gears provide the oil splash required to lubricate the needle bearings, support bearings, journals, gear meshes and thrust surfaces.
The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows. | A multi-speed rear wheel drive transmission having synchronizers and a plurality of gears rotatable on the input shaft provides for the elimination of neutral roll-over noise and optimization of common reduced size synchronizers. Gear face widths are also reduced along with shaft diameters to further optimize the transmission design. Towing restrictions are no longer required in vehicles utilizing this design. The input shaft is coaxial with the output shaft and may be connected by synchronizer to the output shaft. A countershaft is in continuous meshing contact with the output shaft. Also disclosed is a device for correcting in-gear rattle, as well as a lubricating pump assembly utilizing an axial bore in the input shaft. Finally, a transmission with a power take-off assembly is disclosed. | 5 |
RELATED APPLICATION
The present application claims priority to U.S. provisional patent application No. 60/916,099, filed on May 4, 2007; all of the foregoing patent-related document(s) are hereby incorporated by reference herein in their respective entirety(ies).
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to attack-resistant panes (see DEFINITIONS section) and to barriers (see DEFINITIONS section) and unanchored barriers (see DEFINITIONS section).
2. Description of the Related Art
Attack-resistant panes are conventional. An attack resistant pane may be ballistic resistant, blast resistant, or both. The degree of ballistic resistance is sometimes rated under one of the following standards: (i) “Ballistic Resistant Protective Materials NIJ Standard 0108.01” by the National Institute of Justice of the U.S. Department of Justice (published at http:///www.eeel.nist.gov/oles/Publications/NIJ-0108.01.pdf as of May 3, 2008 and herein incorporated by reference); and (ii) “Bullet-resisting Equipment UL 752” by Underwriters' Laboratories (published at http://ulstandardinfonet.ul.com/scopes/scopes.asp?fn=0752.html as of May 3, 2008 and herein incorporated by reference). The degree of blast resistance is sometimes rated under the following standard: GSA Testing Standard (published at the following websites (i) http://www.govsupply.com/Products/GSATest.cfm; (ii) http://www.govsupply.com/Docs/TestReports/GSATestingStandardMemorandum.pdf; and (iii) http://www.govsupply.com/Docs/TestReports/GSATestingStandard.pdf as of May 3, 2008 and are herein incorporated by reference.) It is noted that these standards of ballistic resistance and blast resistance are applicable not just to attack resistant panes, but more broadly to any attack resistant panel, such as an opaque panel. Conventionally, attack resistant panes are made of acrylic or glass, often reinforced with polycarbonate. Conventionally, attack resistant panes are usually a couple inches thick, but may be thinner depending on material used, degree of blast resistance required, degree of ballistic resistance desired and application. Conventional applications of attack resistant panes include external windows of buildings, internal windows of buildings and military vehicle windows.
Barriers and unanchored barriers are conventional. For example, one well known type of barrier, commonly used to direct vehicular traffic flow, is called a Jersey barrier. One conventional anchored barrier is the security bollard.
U.S. Pat. No. 7,104,720 (“Humphries 1”) discloses a traffic noise barrier including a longitudinal barrier portion and panels. The panels may be made of a transparent material, such as PARAGLASS SOUNDSTOP acrylic sheet available from CYRO Industries. The transparent panels of the barrier of Humphries 1 are not disclosed to be attack-resistant.
US published patent application 2004/0255769 (“Drackett”) discloses a mobile personal gunfire shield. The Drackett shield is attack-resistant, but it is not a barrier.
US published patent application 2005/0265780 (“Humphries 2”) discloses a crashworthy traffic noise barrier including a longitudinal barrier portion, upstanding posts, longitudinal beams and panels. The panels may be reinforced with plastic threads, walls or net, and are designed to remain attached to the barrier, even in the event of a crash. The panels may be made of a transparent material, such as a cast acrylic glass panel with embedded plastic threads. The transparent panels of the barrier of Humphries 2 are not disclosed to be attack-resistant.
Description Of the Related Art Section Disclaimer: To the extent that specific publications are discussed above in this Description of the Related Art Section, these discussions should not be taken as an admission that the discussed publications (for example, published patents) are prior art for patent law purposes. For example, some or all of the discussed publications may not be sufficiently early in time, may not reflect subject matter developed early enough in time and/or may not be sufficiently enabling so as to amount to prior art for patent law purposes. To the extent that specific publications are discussed above in this Description of the Related Art Section, they are all hereby incorporated by reference into this document in their respective entirety(ies).
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to barriers that include attack resistant pane(s). In this way, a person behind the barrier can be protected when they are outside. More specifically, the person behind the barrier is protected, at least to some extent, from both: (i) vehicular attacks; and (ii) blast (for example, bombs) and/or ballistic (for example, bullet) attacks. Also, the protected person can see what is happening across the barrier because of the attack-resistant pane(s). Also, if the barrier is unanchored then it can be moved from place to place, for example, by heavy equipment, so that the same barrier can be re-deployed at different locations on an as-needed basis. Preferably, the barrier also includes framing pieces that secure the attack-resistant pane(s) to the body of the barrier, with the framing pieces being covered on one side by an attack-resistant material (preferably, hardened steel).
Various embodiments of the present invention may exhibit one or more of the following objects, functional features and/or advantages:
(1) pre-existing non-attack-resistant barriers (for example, standard jersey barriers) can be retrofit to be used in preferred attack-resistant barriers according to the present invention;
(2) a ballistic/blast resistant barrier is provided that is able to be implemented quickly, such as in dangerous situations;
(3) a ballistic/blast resistant barrier is provided that affords complete ballistic/blast resistant coverage to the entire body of an individual or team without restricting vision;
(4) a ballistic/blast resistant barrier is provided that may be conveniently broken down (and set-up) for ease of transport and maintenance;
(5) armor panels that may be slid into or out of the bracket assembly facilitate convenient break-down and set-up of the unit, or repair or replacement of damaged armor sections;
(6) superior protection from ballistic impacts;
(7) superior protection from blast forces; and
(8) superior protection from vehicle impacts.
According to one aspect of the present invention, an attack-resistant barrier includes a barrier member, a cap and an upper wall. The barrier member is shaped as a Jersey barrier and includes a relatively narrow cap engaging portion and a relatively wide lower portion. The cap includes: (i) a barrier engaging portion shaped and located to wrap around the cap engaging portion; and (ii) a trough. The upper wall defines an attack side major surface and a protected side major surface. The upper wall includes: (i) a lower edge region mechanically connected to the trough; (ii) at least one attack-resistant pane having multiple pane edges; (iii) multiple channel members shaped and located to wrap around at least some of the pane edges; and (iv) multiple armor strips shaped and located on at least the attack side major surface as a facing over at least a portion of the channel members.
According to another aspect of the present invention, an attack-resistant barrier includes: a barrier member, and an attack-resistant wall. The barrier is adapted to act as a barrier (see DEFINITIONS section). The attack-resistant wall is mechanically connected to the barrier. The attack-resistant wall includes: at least one attack-resistant pane, and an attack-resistant opaque portion located around at least a portion of the attack-resistant pane.
According to another aspect of the present invention, an attack-resistant barrier includes a barrier member, an attack-resistant wall, attack resistant pane(s), channel members and armor strips. The barrier member is adapted to act as a barrier. The attack-resistant wall is mechanically connected to the barrier. The attack-resistant wall defines an attack side major surface and a protected side major surface. The attack-resistant wall includes: (i) at least one attack-resistant pane having multiple pane edges; (ii) multiple channel members shaped and located to wrap around at least some of the pane edges; and (iii) multiple armor strips shaped and located on at least the attack side major surface as a facing over at least a portion of the channel members.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more fully understood and appreciated by reading the following Detailed Description in conjunction with the accompanying drawings, in which:
FIG. 1 is a front view that illustrates a barrier according to a first embodiment of the present invention;
FIG. 2 is a rear view of the first embodiment barrier; and
FIG. 3 is a top view of the first embodiment barrier;
FIG. 4 is a front view of a barrier according to a second embodiment of the present invention; and
FIG. 5 is a side view of a barrier according to a third embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 to 3 show barrier 10 , including: base unit 11 ; and upper wall 12 . The base unit includes: cap 13 ; barrier portion 14 ; trough 15 ; and cut-outs 16 . The upper wall includes attack-resistant panes 17 ; C-shaped channel 20 ; double C-channel members 21 ; and armor strips 22 . The barrier portion of barrier 10 is shaped as a conventional Jersey barrier. The cap is engaged with the top of the barrier portion. The upper wall extends from the top of the cap in the upwards direction. Preferably, the barrier portion itself is pre-existing. For example, a pre-existing Jersey barrier could be retrofit with a cap and an upper wall. Even if the barrier portion itself is new, it may be made according to a pre-existing and/or mass produced barrier design. Barrier 10 may be conveniently broken down (and set-up) for ease of transport and maintenance.
Barrier portion 14 is preferably composed of a material, such as metal, plastic, ceramic or a composite material. Upper wall 12 is removably interconnected to the cap. A series of holes (not shown) around the perimeter of the cap allow for the cap to be permanently secured to the barrier portion by fasteners (not shown), such as lags, anchor bolts, “drop ins,” or the like. The weight of the cap and its wrap-around engagement with the top of the barrier portion also help provide reliable securement of the cap and upper wall to the barrier portion. In some embodiments the weight and/or friction may be sufficient to secure the cap and eliminate the need for separate fasteners in this mechanical connection. This is important because the barrier is meant to protect against vehicular impacts, as well as ballistic and/or blast impacts.
The cut-outs in the top of the cap allow the barrier to be moved after the cap is installed to form the base unit. Preferably, the heavy concrete barrier portion has lifting grips (not shown) for lifting, where the lifting grips align with the cut-outs in the cap so that the grips protrude through the cut-outs and/or can be accessed through them. For example, these lifting grips may take the form of metal bars or wire loops anchored in the concrete of the barrier portion.
Trough 15 is formed as a separate piece that is attached to the rest of the cap and is considered to form a part of the finished cap. Preferably the trough is welded to the rest of the cap, but other types of mechanical connections may be possible. Alternatively, the trough could be formed as a single unitary piece with the rest of the cap. The trough is used to hold the upper wall. A series of holes (not shown) under the trough allow for the drainage of any moisture that otherwise may build up in the trough.
The attack-resistant panes 17 are composed of an attack-resistant material, such as plastic, acrylic, glass, polycarbonate-reinforced acrylic and/or polycarbonate reinforced glass. Alternative embodiments of the present invention may include only a single pane and/or have pane(s) of substantially different geometries than panes 17 . Some trade names of suitable materials (which may be registered trademarks in some jurisdictions) are: Armortex; Frag-Stop; Hygard and Acryshield. Manufacturers of suitable attack-resistant pane materials include: North American Specialty Glass, Trumbauersville, Pa. USA and SABIC Innovative Plastics (formerly GE Plastics).
For handgun rounds we use a laminated polycarbonate/acrylic generally supplied by SABIC Innovative Plastics (formerly GE Plastics) The panes are secured to each other and to the cap by framing pieces 20 , 21 , 22 (sometimes referred to as a support network) to form the upper wall. It is this upper wall that makes the plain old barrier into an attack-resistant barrier, according to the present invention, because the attack-panes provide some degree of blast and/or ballistic protection, while still allowing protected people on one side of the barrier to see what is going on the other side of the barrier.
The support framework includes a C-shaped channel 20 located at each side end the upper wall 12 , as shown in FIG. 1 . Channel 20 is mechanically connected to the trough portion of the cap by an appropriate fastener. The bracket assembly further includes H-shaped double C-channel members 21 , which are also attached to the trough by an appropriate fastener. These members 21 interconnect the ballistic/blast resistant transparent armor panels. Both the channels 20 and the members 21 are preferably made of a material that is rigid, but still relatively easy to form and shape, such as plain carbon steel. Channels 20 and members 21 do not need to be made from blast resistant and/or ballistic resistant material (sometimes referred to as armor), which is good because these pieces are difficult to manufacture from armor material.
Preferably, channels 20 and members 21 include a gasket within their channels interposed over at least a part of the surface area that interfaces with the panes. The gasket can help absorb mechanical shocks due to vehicle impacts, ballistic impacts and/or blast forces. Preferably, the gasket is made of rubber. Because of the C and H shapes of the pieces 20 and 21 , the panes may be slid into or out of the support framework. This facilitates convenient break-down and set-up of the unit, or repair or replacement of damaged armor sections. A soap solution may be used to lubricate the panes when they are slid into and/or out of the support framework.
The surfaces of pieces 20 , 21 facing at least one major surface of the upper wall (called the attack side) are covered with a facing in the form of armor strips 22 . As their name implies, the armor strips are, because of their thickness and material choice, blast and/or ballistic resistant. Alternatively the armor strip facing can be used at both major surfaces of the upper wall. Armor strips 22 are made of hardened steel. Alternatively, the armor strips can be made of other materials, such as metal, plastic, ceramic or a composite material. The armor strips are used to cover gaps (or shield seams) between the panes 17 . These armor strips are welded to channels on the front of the barrier and fit over the trough at the bottom of the panes.
Preferably the framing pieces, armor strips and trough are mechanically connected by welding at their mechanical interfaces, but other types of mechanical connections may be possible.
Between the thick concrete barrier, the attack resistant panes, and the armor strips, barrier 10 forms a wall that is blast and/or ballistic resistant comprehensively over its entire major surface area. This is important because it is undesirable to have a bullet and/or shrapnel get through any chink in the armor. This provides comprehensive protection to the people behind the barrier (sometimes referred to as the protected side). Because the upper wall makes barrier 10 significantly taller than a plain Jersey barrier, a person's entire body can be protected from forces that are vectoring substantially parallel to the ground. This provides good protection to the front of a person standing on the protected side.
The panes, armor strips and barrier portion (sometimes collectively called the armored components) should at least provide a degree of ballistic resistance or blast resistance so that the barrier a be considered to be attack resistant, unlike the barrier of Humphries 2, discussed above. More preferably, for ballistic resistant barriers, the armored components should be rated at least NIJ-I (see National Institute of Justice Standards discussed above), which is considered sufficient to stop a bullet from a .22 caliber gun. Even more preferably, for ballistic resistant barriers, the armored components should be rated at least UL Threat Level One (see Underwriters' Laboratories Standards discussed above), which is considered sufficient to stop a bullet from a 9 mm caliber gun.
Barrier 10 is not anchored to the ground, which means that it is “portable” (see Definitions section). It is the mass and shape of the Jersey barrier portion that really makes barrier 10 a barrier (see DEFINITIONS section), as opposed to a mere attack-resistant wall. Alternatively, some barriers according to the present invention could be anchored to the ground and/or pre-existing man-made structures, with the anchoring helping the barrier to act as a barrier.
FIG. 4 shows attack-resistant barrier 100 , including flange 102 ; fastener 104 ; opaque portion 106 ; and attack-resistant windows 108 . The flange and fasteners show an alternative, although not necessarily preferred, structure for attaching an attack-resistant device to the top of a barrier, such as a Jersey barrier. Preferably, the opaque portion is ballistic resistant and/or blast resistant. In fact, the use of opaque materials may result in a higher degree of ballistic resistance and blast resistance due to the decreased use and surface areas of substantially transparent attack-resistant material.
FIG. 5 shows attack-resistant barrier 200 , including concrete portion 202 ; end post 220 ; and fasteners 222 . Although not shown, a front view of barrier 200 would look much like components 17 , 20 and 21 of barrier 10 , except that these components extend over flat surface 204 of concrete portion 202 . As shown in FIG. 5 , the concrete portion has been modified from the standard Jersey barrier shape to provide a flat mounting surface for the attack resistant device. Instead of fitting over the barrier portion as a cap, the attack resistant device is mounted to a major surface of the barrier by fasteners 222 , potentially providing additional strength in the connection between the barrier portion and the attack-resistant device portion. The use of armor panels (not shown but similar to panels 17 ) allows light to pass thru the attack-resistant barrier in the direction of arrow L so that people protected by the barrier can see through it to the unprotected side.
DEFINITIONS
The following definitions are provided to facilitate claim interpretation:
Present invention: means at least some embodiments of the present invention; references to various feature(s) of the “present invention” throughout this document do not mean that all claimed embodiments or methods include the referenced feature(s).
First, second, third, etc. (“ordinals”): Unless otherwise noted, ordinals only serve to distinguish or identify (e.g., various members of a group); the mere use of ordinals implies neither a consecutive numerical limit nor a serial limitation.
Attach-resistant pane: Any substantially transparent window that is at least substantially resistant to ballistic and/or blast type forces; attack-resistant panes include, but are not limited to bullet-proof windows, bullet-proof shields and vehicles with bullet-proof windshields; attack-resistant panes may be made of any attack-resistant pane material now know or to be developed in the future.
Barrier: any device having suitable mass and/or anchoring and a shape such that it cannot be moved by a reasonable strong individual person; barriers include, but are not limited to: concrete barriers, Jersey barriers, Earth filled barriers, liquid filled barriers, barriers with outer walls of canvas, sand-packed barriers, gravel-filled barriers, plastic walled barriers, gel filled barriers and/or barrier designs to be developed in the future.
Mechanically connected: Includes both direct mechanical connections, and indirect mechanical connections made through intermediate components; includes rigid mechanical connections as well as mechanical connection that allows for relative motion between the mechanically connected components; includes, but is not limited, to welded connections, solder connections, connections by fasteners (for example, nails, bolts, screws, nuts, hook-and-loop fasteners, knots, rivets, force fit connections, friction fit connections, connections secured by engagement added by gravitational forces, quick-release connections, pivoting or rotatable connections, slidable mechanical connections and/or magnetic connections.
Vehicle barrier: any device having suitable mass and/or anchoring and a shape such that it is capable of at least substantially impeding the motion typical automobile across the barrier by physical interference between the typical automobile and the barrier; many barriers can stop even larger vehicles, but this is not necessarily required.
Unanchored Barrier: any barrier that is not anchored to the ground and/or a man-made structure.
To the extent that the definitions provided above are consistent with ordinary, plain, and accustomed meanings (as generally shown by documents such as dictionaries and/or technical lexicons), the above definitions shall be considered supplemental in nature. To the extent that the definitions provided above are inconsistent with ordinary, plain, and accustomed meanings (as generally shown by documents such as dictionaries and/or technical lexicons), the above definitions shall control. If the definitions provided above are broader than the ordinary, plain, and accustomed meanings in some aspect, then the above definitions shall be considered to broaden the claim accordingly.
To the extent that a patentee may act as its own lexicographer under applicable law, it is hereby further directed that all words appearing in the claims section, except for the above-defined words, shall take on their ordinary, plain, and accustomed meanings (as generally shown by documents such as dictionaries and/or technical lexicons), and shall not be considered to be specially defined in this specification. In the situation where a word or term used in the claims has more than one alternative ordinary, plain and accustomed meaning, the broadest definition that is consistent with technological feasibility and not directly inconsistent with the specification shall control.
Unless otherwise explicitly provided in the claim language, steps in method steps or process claims need only be performed in the same time order as the order the steps are recited in the claim only to the extent that impossibility or extreme feasibility problems dictate that the recited step order (or portion of the recited step order) be used. This broad interpretation with respect to step order is to be used regardless of whether the alternative time ordering(s) of the claimed steps is particularly mentioned or discussed in this document. | A barrier that includes attack resistant pane(s) (see DEFINITIONS section). In this way, a person behind the barrier can be protected when they are outside. More specifically, the person behind the barrier is protected, at least to some extent, from both: (i) vehicular attacks; and (ii) blast (for example, bombs) and/or ballistic (for example, bullet) attacks. Also, the protected person can see what is happening across the barrier because of the attack-resistant pane(s). Also, if the barrier is unanchored then it can be moved from place to place, for example, by heavy equipment, so that the same barrier can be re-deployed at different outdoor locations (or indoor locations) on an as-needed basis. Preferably, the barrier also includes framing pieces that secure the attack-resistant pane(s) to the body of the barrier, with the framing pieces being covered on one side by an attack-resistant material (preferably, hardened steel). | 5 |
BACKGROUND
If a user is viewing a three-dimensional (3D) computer aided design (CAD) model in a web browser, user manipulation of the model (such as rotation in the X, Y or Z direction) typically requires that one or more new images of the model be generated on a server and transmitted to the user's web browser for display. This results in latency since the user's browser must request a new image from the server, wait for the server to generate the image, and then receive the image from the server. This latency undermines real-time user interaction with the 3D model.
SUMMARY
In general, one or more aspects of the subject matter described in this specification can be embodied in one or more methods that include obtaining a plurality of distinct pre-computed images of a three-dimensional drawing where each of the plurality of images result from applying a constrained operation to the drawing to alter the appearance of the drawing where the operation is constrained to a single axis, a predetermined degree of application, or both. First input is accepted to apply the constrained operation to the drawing such that the drawing is in a first state. One of the pre-computed images whose appearance is closest to the drawing in the first state is selected. The selected image is caused to be displayed. Other embodiments of this aspect include corresponding systems, apparatus, and computer program products.
These and other embodiments can optionally include one or more of the following features. The constrained operation is one of: rotation about a single axis, scaling according to a predetermined scaling factor, or translation along a single axis. During accepting of the first input, displaying an animation that changes in response to the first input and provides a visual indication of how the drawing will appear based on the first input. The animation is of a cube. Selecting one of the pre-computed images and causing display of the pre-computed image occurs during the accepting. An additional plurality of pre-computed images of a three-dimensional drawing is obtained where the additional plurality of images result from applying the constrained operation to the drawing to alter the appearance of the drawing. The obtaining an additional plurality of pre-computed images does not include obtaining an image that is in the plurality of pre-computed images. The plurality of pre-computed images are obtained from a file. The selected image is displayed in a web browser.
In general, one or more aspects of the subject matter described in this specification can be embodied in one or more methods that include obtaining a plurality of distinct pre-computed images of a three-dimensional drawing where the plurality of images includes three sets of images, and where each image in a given set are of the drawing rotated a first number of degrees about a distinct axis for the given set. First input is accepted to rotate the drawing a second number of degrees about a first axis such that the drawing is in a first orientation and where the first input is constrained to be about the first axis. One of the pre-computed images for the first axis is selected that shows the drawing in an orientation that is closest to the first orientation. The selected image is caused to be displayed. Other embodiments of this aspect include corresponding systems, apparatus, and computer program products.
These and other embodiments can optionally include one or more of the following features. During accepting of the first input, displaying an animation that changes in response to the first input and provides a visual indication of how the drawing will be oriented based on the first input. The animation is of a cube. The first number of degrees is inclusively between one and thirty. The second number of degrees is inclusively between 1 and 360. Selecting one of the pre-computed images and causing display of the pre-computed image occurs during the accepting. An additional plurality of pre-computed images of a three-dimensional drawing are obtained where the additional plurality of images includes three sets of images, and where each image in a given set are of the drawing rotated a first number of degrees about a distinct axis for the given set based on the first orientation of the drawing. The obtaining an additional plurality of pre-computed images does not include obtaining an image in the plurality of pre-computed images. The plurality of pre-computed images are obtained from a file. The selected image is displayed in a web browser.
Particular implementations of the subject matter described in this specification can be implemented to realize one or more of the following advantages. A server pre-computes a set of “filmstrip” images of a 3D model that anticipate manipulation of the model by a user. The images are pre-cached at a client so that they can be displayed immediately as the user manipulates the model. The client then selects the appropriate pre-computed image from the pre-fetched filmstrip to display to the user, rather than making a request to the server. Model manipulations are constrained so that there is not a large or unbounded set of images to pre-compute. When the user invokes an orbit command, a wire frame cube is displayed over the model image in the client's user interface and updated immediately even though the associated effect on the model has not been computed. This gives the user an indication as to how the model will be reoriented as a result of the mouse interaction. For example, when a user drags the mouse, the cube rotates so that the user understands how much rotation will be applied to the model. Once a user orbits along a particular axis, only a subset of the filmstrip set needs to be updated to prepare for subsequent orbits.
The details of one or more implementations of the invention are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the invention will become apparent from the description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an example user interface for presenting a three-dimensional drawing.
FIG. 2 illustrates examples of rotation in 3D space.
FIGS. 3A-B illustrate animated rotation indicators.
FIG. 4 is a flowchart of an example method for updating a drawing.
FIG. 5 is a flowchart of an example method for updating a drawing in response to a rotation operation.
FIG. 6 illustrates an example system for generating pre-computed images.
FIG. 7 is a schematic diagram of a generic computer system.
Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
FIG. 1 illustrates a user interface 100 for presenting a 3D drawing 102 created by a CAD program or other program. Users can interact with the drawing 102 and the user interface 100 using an input device, such as a mouse, a trackball, a microphone (e.g., voice commands), a keyboard, a camera (e.g., gestures), other suitable device, or combinations of these. The user interface 100 includes a toolbar 104 , which includes buttons 106 - 116 . The buttons 106 - 116 can be selected by the user to manipulate and/or interact with the drawing 102 . A “file” button 106 can be used to open or load a drawing (e.g., the drawing 102 can be loaded from a file, or can be received from a network resource, such as from an Internet web server). The user interface 100 can be displayed, for example, on a client computer connected to a network. The user interface 100 can include other user controls, such as drop-down menus, for example. In various implementations, the user interface 100 is presented in a web browser. However, the user interface 100 can be presented by other software applications.
The user can perform operations to change the appearance of the drawing 102 . For example, the user can use “zoom” buttons 108 - 110 to scale the drawing 102 larger or smaller. The user can also select a “fit” button 112 to scale the drawing 102 to fit inside the user interface 100 . As another example, the user can select a “pan” button 114 to translate the drawing 102 to a new location within the user interface 100 . As a fourth example, the user can select an “orbit” button 116 to orbit (i.e., rotate) the drawing 102 about an axis, resulting in the drawing 102 being displayed in a different orientation.
Zoom, pan, and orbit operations can be constrained, to limit the number of possible changes to the drawing 102 's appearance given a user input. For example, the zoom operation can be constrained to allow a user to zoom in or zoom out by a fixed factor (e.g., zoom operations can be limited to zooming in or out by factors of 10%). The pan operation can be constrained to allow a user to move the drawing 102 in increments of a predetermined amount (e.g., in increments of 100 pixels) from its current location. Likewise, orbit operations can be constrained to be in increments of a fixed number of degrees (e.g., 10 degrees), about a single axis of rotation. For example, rotation operations can be constrained to rotate about one of three axes of reference in three-dimensional space (e.g., a horizontal X axis 118 , a vertical Y axis 120 , and a Z axis 122 which is perpendicular to the user interface 100 ). Pan operations can also be constrained so that the drawing 102 can be translated only along one of the X, Y, and Z axes 118 - 122 . Other constraints are possible.
FIG. 2 illustrates examples of rotation in three-dimensional space. As discussed above, a user can, using constrained orbit operations, rotate a drawing about one of the X, Y, and Z axes 118 - 122 . As discussed above, rotations can also be constrained to be by a certain number of degrees. In some implementations, rotation about the X axis 118 can be performed by selecting a drawing object and dragging with the mouse in a vertical fashion (i.e., up and/or down). The selected drawing object can then rotate about the horizontal X axis 118 in response to the vertical dragging. For example, drawing objects 202 a - d illustrate the progression of a rotation of the drawing 102 about the X axis 118 , such as in response to a downward dragging of the mouse.
In some implementations, a rotation about the Y axis 120 can be performed by selecting a drawing object and dragging with the mouse in a horizontal fashion (i.e., left and/or right). The selected drawing object can then rotate about the vertical Y axis in response to the horizontal dragging. For example, drawing objects 204 a - d illustrate the progression of a rotation of the drawing 102 about the Y axis 120 , such as in response to a leftward dragging of the mouse.
In some implementations, a selected drawing object can be rotated about the Z axis 122 by dragging with a mouse in an area that is outside of the selected drawing object. For example, in some implementations, a circle is drawn around the selected drawing object, and dragging along or outside of the circle can result in the rotation of the drawing object about the Z axis 122 . For example, the drawing objects 206 a - d illustrate the progression of a rotation of the drawing 102 about the Z axis 122 .
If rotation operations (or pan or zoom operations) performed on the drawing 102 are constrained, a server computer (e.g., a server that sends image data to render in the user interface 100 ), can pre-compute a set of images, where the pre-computed images represent the possible outcomes of a next operation on the drawing 102 . That is, the pre-computed images represent the drawing 102 after operations have been performed. The server can generate a set of pre-computed images by applying all allowable constrained operations on a selected drawing object. For example, in one implementation, a set of pre-computed images includes 106 images, including 36 images for all possible rotations (using 10 degree increments) of a drawing about the X axis 118 , 35 images for all possible rotations about the Y axis 120 , and 35 images for all possible rotations about the Z axis 122 (for the rotations about the Y and Z axes 120 - 122 , the starting image is the same as for the rotation about the X axis 118 , so 35 images are included for each of the Y and Z axes 120 - 122 , rather than 36). The images 202 a - d , 204 a - d , and 206 a - d illustrate a sampling of the images that could be included in a set of images pre-computed for the drawing 102 .
The set of pre-computed images can be sent to a client that is displaying the user interface 100 . For example, a user can select the file button 104 and request to load the drawing 102 from a server computer (e.g., by entering a resource name which identifies the drawing 102 as being stored on a server computer). The server computer can send the drawing 102 and can also send a set of pre-computed images corresponding to the drawing 102 . The set of pre-computed images can be combined (e.g., into a single image) before sending. A combined image can be thought of as like a “filmstrip”, where a single filmstrip includes multiple images.
In response to a user rotating the drawing 102 , the client can determine the axis about which the drawing 102 was rotated, and the number of degrees that the drawing 102 was rotated. The client can select and display the pre-computed image that most closely resembles the effect of the rotation operation. For example, if the user rotates the drawing 102 forty degrees clockwise about the Y axis 120 , the client can determine which pre-computed image most closely represents the drawing 102 after such a rotation. The drawing 102 can be replaced with the selected pre-computed image.
If the pre-computed images are combined when sent from the server (e.g., in a filmstrip), the identified pre-computed image can be cropped from the set of images and then displayed in the user interface 100 . The client can crop identified images after each operation, or the client can extract individual images from the combined image after receipt of the combined image (e.g., after receipt of the combined image (and possibly before operations are performed) the client can extract individual images, and for example, store the individual images in client memory, and then, after an operation, display an identified individual image).
The server can generate pre-computed images by applying operations that are equally separated from one another (e.g., rotations about an axis that are all ten degrees apart from one another), or the server can cluster more pre-computed images closer to the current position of the drawing 102 . For example, the server can apply rotation operations that are five degrees apart (e.g., 5, 10, 15, 20, 25, 30) for the first thirty degrees of rotation from the current position of the drawing 102 , and then perform rotations that are further spaced apart (e.g., 10 degrees apart) for rotation values that are more than thirty degrees rotated from the current position of the drawing 102 .
In some implementations, an operation amount (e.g., rotation, zoom or pan amount) performed using the user interface 100 may not coincide exactly with the operation amounts performed by the server to generate the pre-computed images. For example, a rotation operation performed using the user interface 100 may be fluid and may accept a rotation value of a high degree of precision, such as a client user rotating the drawing 102 by 8.2 degrees. The server may have generated pre-computed images that are ten degrees apart. The client can identify a pre-computed image that most closely represents the performed operation. For example, the client can identify the pre-computed image corresponding to a 10 degree rotation. The client can “round” (e.g., round up) to find the nearest pre-computed image. In cases where two pre-computed images most closely representing the client operation are equally different from the client operation, the client can choose to select either the upper or lower operation value. For example, the user may rotate the drawing 102 by 15 degrees, the server may have generated pre-computed images rotated by 10 and 20 degrees, and the client can choose either the 10 or 20 degree rotation. In some implementations, the user interface 100 restricts client operations to operation amounts that coincide exactly with operation amounts used by the server to pre-compute images.
After a pre-computed image is displayed, the server can generate and send a new set of pre-computed images to prepare for subsequent operations. The server can determine which images need to be generated, and can generate and send only those images that are needed. For example, some of the needed pre-computed images may be included in the previously-sent filmstrip. By way of illustration, if a user rotates a drawing about the X axis 118 , the server may need to regenerate and send images corresponding to a subsequent rotation about the Y or Z axes 120 - 122 , but the current images corresponding to the rotation about the X axis 118 may not need to be regenerated.
FIGS. 3A-3B illustrate animated rotation indicators. The drawing objects 204 b-d illustrate a rotation of the drawing object 102 about the Y axis 120 . A cube 302 can be displayed as a user rotates the drawing object 102 , to provide a visual indication of how the drawing will be oriented based on the rotation. For example, as a user begins to drag the mouse (e.g., the user can drag leftward to rotate the drawing object 102 about the Y axis 120 ), the cube 302 can appear. As the user continues to drag with the mouse, the cube 302 can rotate in a direction that corresponds to the dragging. For example, if the user drags the drawing object 204 b to the left, the cube 302 can rotate to the left, in an amount indicative of how much the user has dragged. When the user releases the mouse, the cube 302 can disappear, and a pre-computed image can be displayed, where the pre-computed image is closest to the drawing 102 rotated in the amount that the cube was rotated.
As another example, the drawing objects 202 b - d illustrate a rotation of the drawing object 102 about the X axis 118 . A cube 304 can provide a visual indication of how the drawing will appear based on the downward rotation. For example, as the user drags downward, the cube 304 can rotate downward, in an amount representing the amount the user has dragged. An indicator other than a cube can be used, such as another shape, or an indicator which displays a numerical value indicating the amount of rotation that will be applied. Although an animated indicator for rotation is illustrated, other animated indicators are possible, and for other operations such as for scaling or translation.
In some implementations, a circle 306 can also appear while the user is performing a rotation. For example, the circle 306 can appear after the user selects the orbit button 116 . The circle 306 can be used to allow the user to rotate about the Z axis 122 . For example, if a user selects the circle 306 , or presses and holds the mouse outside of the circle 306 , and then drags, for example in a clockwise or counter-clockwise motion, the selected drawing object (e.g., 202 b ) can rotate about the Z axis 122 .
FIG. 4 is a flowchart of an example method 400 for updating a drawing. A plurality of distinct pre-computed images of a three-dimensional drawing is obtained, where each of the plurality of images result from applying a constrained operation to the drawing to alter the appearance of the drawing where the operation is constrained to a single axis, a predetermined degree of application, or both (step 402 ). For example, a server computer can generate pre-computed images by applying a zoom operation to the drawing 102 , where each zoom operation changes the size of the drawing 102 by a different factor (e.g., zoom operations can reduce the drawing 102 by 5%, 10%, 15%, etc, and can enlarge the drawing 102 by 5%, 10%, 15%, etc.). The server computer can send the pre-computed images to a client computer that is displaying the user interface 100 .
Next, a first input to apply the constrained operation to the drawing such that the drawing is in a first state is accepted (step 404 ). For example, a user can select the drawing 102 in the user interface 100 and then select the zoom in button 108 . The user interface 100 can determine a zoom factor to apply (e.g., 10%) in response to the selection of the zoom in button 108 . One of the pre-computed images whose appearance is closest to the drawing in the first state is then selected (step 406 ). For example, a pre-computed image that most closely matches the drawing 102 enlarged by the determined factor (e.g., 10%) can be selected from the pre-computed images received from the server. The selected image is then displayed (step 408 ). For example, the drawing 102 can be removed from the user interface 100 , and the identified pre-computed image can be displayed in the user interface 100 .
FIG. 5 is a flowchart of an example method 500 for updating a drawing in response to a rotation operation. First, a plurality of distinct pre-computed images of a three-dimensional drawing is obtained, where the plurality of images includes three sets of images, and where each image in a given set are of the drawing rotated a first number of degrees about a distinct axis for the given set (step 502 ). For example, a server computer can generate a set of pre-computed images by applying rotation operations to the drawing 102 , rotating the drawing 102 about each of the X, Y and Z axes 118 - 122 , where each rotation is 10 degrees offset from the previous rotation. The set of generated pre-computed images can include 36 distinct images generated from rotations about the X axis 118 , 35 images generated from rotations about the Y axis 120 , and 35 images generated from rotations about the Z axis 122 . The generated images can be sent from the server computer to a client computer displaying the user interface 100 .
A first input is then accepted to rotate the drawing a second number of degrees about a first axis is accepted, such that the drawing is in a first orientation and where the first input is constrained to be about the first axis (step 504 ). For example, a user viewing the user interface 100 can select the drawing 102 , and then select the orbit button 116 , and then drag with the mouse to indicate a rotation operation about a particular axis (such as dragging left to indicate a rotation operation about the Y axis 122 , or dragging down to indicate a rotation about the X axis 118 ). The user interface 100 can determine the amount of rotation represented by the drag operation.
One of the pre-computed images for the first axis that shows the drawing in an orientation that is closest to the first orientation is then accepted (step 506 ). For example, a pre-computed image that most closely matches the drawing 102 rotated by the determined amount (e.g., 50 degrees) can be selected from the pre-computed images received from the server. The selected image is then displayed (step 508 ). For example, the drawing 102 can be removed from the user interface 100 , and the identified pre-computed image can be displayed in the user interface 100 .
FIG. 6 illustrates an example system 600 for generating pre-computed images. A server computing device 602 can communicate with a client computing device 604 across one or more networks 606 . The one or more networks 606 can include a local area network (LAN), a wide area network (WAN), the Internet, or combinations of these. The server 602 includes an image generator 608 and a set of pre-computed images 610 . The image generator 608 can, given a drawing (e.g., drawing 102 ), generate the set of pre-computed images 610 by applying an operation (e.g., zoom, pan, rotation) to the drawing. (In some implementations, if the image generator 608 has previously pre-computed images for another client, the previously pre-computed images can be used instead of regenerating them.) For example, the server 602 can generate the pre-computed images 610 by applying a zoom operation to the drawing 102 , where each zoom operation changes the size of the drawing 102 by a different factor (e.g., zoom operations can reduce the drawing 102 by 5%, 10%, 15%, etc, and can enlarge the drawing 102 by 5%, 10%, 15%, etc.). As another example, the server 602 can generate the pre-computed images 610 by applying rotation operations about the X, Y, and Z axes 118 - 122 . The set of pre-computed images 610 can be sent to the client 604 across the network 608 . The client 604 can store the received image data in an image cache 612 .
The client 604 includes input/output devices, such as a keyboard and mouse 614 and a display device 616 . The client includes a drawing graphical user interface (GUI) component 618 . The drawing GUI component 618 can render images on the display 616 , such as rendering a drawing 620 in an interface 100 on the display 616 . For example, in response to a user performing an operation (e.g., pan, zoom, rotation) on the drawing 620 , the drawing GUI component 618 can identify the degree of application of the operation (e.g., amount of zoom or pan, or amount and axis of rotation), and can identify an image in the image cache 612 which most closely matches the effect of the operation, and can display the identified image in the display 616 .
FIG. 7 is a schematic diagram of a generic computer system 700 . The system 700 can be used for practicing operations described in association with the techniques 400 and 500 . The system 700 can include a processor 710 , a memory 720 , a storage device 730 , and input/output devices 740 . Each of the components 710 , 720 , 730 , and 740 are interconnected using a system bus 750 . The processor 710 is capable of processing instructions for execution within the system 700 . Such executed instructions can implement one or more components of system 600 , for example. In one implementation, the processor 710 is a single-threaded or multi-threaded processor. The processor 710 is capable of processing instructions stored in the memory 720 or on the storage device 730 to display graphical information for a user interface on the input/output device 740 .
The memory 720 is a computer readable medium such as volatile or non volatile random access memory that stores information within the system 700 . The memory 720 could store data structures representing pre-computed images, for example. The storage device 730 is capable of providing persistent storage for the system 700 . The storage device 730 may be a floppy disk device, a hard disk device, an optical disk device, or a tape device, or other suitable persistent storage means. The input/output device 740 provides input/output operations for the system 700 . In one implementation, the input/output device 740 includes a keyboard and/or pointing device. In another implementation, the input/output device 740 includes a display unit for displaying graphical user interfaces.
The input/output device 740 can provide input/output operations for a CAD system. The CAD system can be, for example, AutoCad™, Autodesk Freewheel™, Autodesk Architectural Desktop™ or Autodesk Building Systems™, available from Autodesk, Inc., of San Rafael, Calif., or another CAD application or other software application. The CAD system can include computer software components that manage three-dimensional drawings. Examples of such software components include the drawing GUI component 618 , which can be persisted in storage device 730 , memory 720 or can be obtained over a network connection 606 , to name a few examples.
Implementations of the subject matter and the functional operations described in this specification can be implemented in digital electronic circuitry, or in computer software, firmware, or hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them. Implementations of the subject matter described in this specification can be implemented as one or more computer program products, i.e., one or more modules of computer program instructions encoded on a computer-readable medium for execution by, or to control the operation of, data processing apparatus. The computer-readable medium can be a machine-readable storage device, a machine-readable storage substrate, a memory device, a composition of matter effecting a machine-readable propagated signal, or a combination of one or more of them. The term “data processing apparatus” encompasses all apparatus, devices, and machines for processing data, including by way of example a programmable processor, a computer, or multiple processors or computers. The apparatus can include, in addition to hardware, code that creates an execution environment for the computer program in question, e.g., code that constitutes processor firmware, a protocol stack, a database management system, an operating system, or a combination of one or more of them. A propagated signal is an artificially generated signal, e.g., a machine-generated electrical, optical, or electromagnetic signal, that is generated to encode information for transmission to suitable receiver apparatus.
A computer program (also known as a program, software, software application, script, or code) can be written in any form of programming language, including compiled or interpreted languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. A computer program does not necessarily correspond to a file in a file system. A program can be stored in a portion of a file that holds other programs or data (e.g., one or more scripts stored in a markup language document), in a single file dedicated to the program in question, or in multiple coordinated files (e.g., files that store one or more modules, sub-programs, or portions of code). A computer program can be deployed to be executed on one computer or on multiple computers that are located at one site or distributed across multiple sites and interconnected by a communication network.
The processes and logic flows described in this specification can be performed by one or more programmable processors executing one or more computer programs to perform functions by operating on input data and generating output. The processes and logic flows can also be performed by, and apparatus can also be implemented as, special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit).
Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read-only memory or a random access memory or both. The essential elements of a computer are a processor for performing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto-optical disks, or optical disks. However, a computer need not have such devices. Moreover, a computer can be embedded in another device, e.g., a mobile telephone, a personal digital assistant (PDA), a mobile audio player, a Global Positioning System (GPS) receiver, to name just a few. Computer-readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media and memory devices, including by way of example semiconductor memory devices, e.g., EPROM, EEPROM, and flash memory devices; magnetic disks, e.g., internal hard disks or removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.
To provide for interaction with a user, implementations of the subject matter described in this specification can be implemented on a computer having a display device, e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor, for displaying information to the user and a keyboard and a pointing device, e.g., a mouse or a trackball, by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including acoustic, speech, or tactile input.
Implementations of the subject matter described in this specification can be implemented in a computing system that includes a back-end component, e.g., as a data server, or that includes a middleware component, e.g., an application server, or that includes a front-end component, e.g., a client computer having a graphical user interface or a Web browser through which a user can interact with an implementation of the subject matter described is this specification, or any combination of one or more such back-end, middleware, or front-end components. The components of the system can be interconnected by any form or medium of digital data communication, e.g., a communication network. Examples of communication networks include a local area network (“LAN”) and a wide area network (“WAN”), e.g., the Internet.
The computing system can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.
While this specification contains many specifics, these should not be construed as limitations on the scope of the invention or of what may be claimed, but rather as descriptions of features specific to particular implementations of the invention. Certain features that are described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.
Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.
Thus, particular implementations of the invention have been described. Other implementations are within the scope of the following claims. For example, the actions recited in the claims can be performed in a different order and still achieve desirable results. | The present disclosure includes, among other things, systems, methods and program products for pre-computing image manipulations. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based on and claims priority under 35 USC §119 from Japanese Patent Application No. 2007-224489 filed Aug. 30, 2007.
BACKGROUND
[0002] (i) Technical Field
[0003] The present invention relates to a hologram reading apparatus, a hologram reading method, a hologram recording apparatus and a hologram recording method.
[0004] (ii) Related Art
[0005] Some of hologram recording techniques employ the so-called coaxial-type recording technique in which a hologram recording medium is irradiated with reference light and signal light as a single beam to thereby record a hologram formed by the interference between the reference light and the signal light in the hologram recording medium. One of the advantages resulted from the employment of the coaxial-type recording technique is that the hologram recording/reading apparatus can be miniaturized.
[0006] FIG. 6 shows a part of an optical system constituting a hologram recording/reading apparatus 2 in a related art. As shown in FIG. 5 , the hologram recording/reading apparatus 2 is configured in a manner that a spatial light modulator 25 irradiates a hologram recording medium 100 with spatial-modulated reference light and spatial-modulated signal light as the same beam to thereby record date therein. On the other hand, in the case of reading data, only the reference light serving as a reading beam is irradiated to the hologram recording medium 100 to thereby reproduce a reproduction beam, then an iris 45 shields a reference light portion of the reproduction beam and a filter 47 disposed at the focal plane of a Fourier transform lens 46 extracts a desired spatial frequency band of the signal light. A light receiving element 50 reads data based on the extracted desired spatial frequency band of the signal light.
SUMMARY
[0007] According to an aspect of the invention, there is provided a hologram reading apparatus including:
[0008] a holding unit that holds a hologram recording medium in which data page is recorded by irradiating as a single beam both reference light and signal light which are modulated by a spatial light modulator, wherein the spatial light modulator includes a first pixel area for modulating the reference light and a second pixel area for modulating the signal light based on data page to be recorded, and a pitch of pixels in the first pixel area is different from that in the second pixel area;
[0009] a Fourier transform lens that subjects reproduction light, which is reproduced by irradiating the reference light to the hologram recording medium, to a Fourier transformation;
[0010] a filter disposed on a Fourier transform plane of the reproduction light by the Fourier transform lens, wherein the filter shields the reference light at a first spatial frequency band and transmits the signal light at a second spatial frequency band, based on that the reference light and the signal light which are included in the reproduction light differ from each other in distance of image formation positions of a spatial frequency component thereof; and
[0011] a reading unit that receives the reproduction light transmitted through the filter and reads the data page modulated to the signal light included in the reproduction light.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Embodiments of the present invention will be described in detail based on the following figures, wherein:
[0013] FIG. 1 is a diagram showing a hologram recording/reading apparatus according to an exemplary embodiment;
[0014] FIG. 2 is a diagram showing a spatial light modulator;
[0015] FIG. 3 is a diagram showing the focal plane of a lens and a filter;
[0016] FIG. 4 is a diagram showing the focal plane of a lens and a filter;
[0017] FIGS. 5A-5B are diagrams showing the focal plane of a lens and a filter; and
[0018] FIG. 6 is a diagram showing a part of a hologram recording/reading apparatus in a related art,
[0019] wherein description of some reference numerals and signs are set forth below.
1 hologram recording/reading apparatus 2 hologram recording/reading apparatus (related art) 10 light source 12 shutter 14 half wave plate 16 polarizing plate 18 enlarging/collimating optical system 20 mirror 22 polarization beam splitter 24 spatial light modulator 25 spatial light modulator (related art) 26 , 28 lens 30 , 32 Fourier transform lens 34 filter 36 , 38 Fourier transform lens 40 medium holding portion 42 , 44 Fourier transform lens 45 iris 47 filter 50 light receiving element 60 filter 61 band-pass filter 100 hologram recording medium 200 reference light pixel area 300 signal light pixel area 400 0-order DC component 410 primary-order DC components of signal light 510 primary-order DC components of reference light
DETAILED DESCRIPTION
[0048] Hereinafter, an exemplary embodiment of the invention will be explained with reference to drawings.
[0049] FIG. 1 is a diagram showing a hologram recording/reading (reproducing) apparatus 1 according to an exemplary embodiment. As shown in FIG. 1 , the hologram recording/reading apparatus 1 includes a light source 10 , a shutter 12 , a half wave plate 14 , a polarizing plate 16 , an enlarging/collimating optical system 18 , a mirror 20 , a polarization beam splitter 22 , a spatial light modulator 24 , lenses 26 , 28 and Fourier transform lenses 30 , 32 constituting a relay lens system, a filter 34 , a Fourier transform lens 36 for focusing reference light or both the reference light and signal light in a hologram recording medium 100 , a Fourier transform lens 38 for relaying transmitted light (reproduction light) transmitted through the hologram recording medium, a medium holding portion 40 for holding the hologram recording medium 100 , Fourier transform lenses 42 , 44 constituting the relay lens system, a filter 60 and a light receiving element 50 .
[0050] The light source 10 irradiates coherent light acting as a light source of the signal light and the reference light for recording hologram. As the coherent light, a light source such as a laser beam having been known conventionally may be employed. As the laser beam, a laser beam of a waveform (for example, a green laser etc. having a wavelength of 532 nm) having the sensitivity at the optical recording layer of the hologram recording medium 100 may be employed.
[0051] The shutter 12 is provided on an optical path of the laser beam irradiated from the light source 10 . The laser beam is interrupted in accordance with the opening/closing of the shutter 12 . The laser beam passed through the shutter 12 further passes the half wave plate 14 and the polarizing plate 16 and so is adjusted in its light intensity and polarization direction.
[0052] The laser beam passed through the polarizing plate 16 is converted into collimated light with a diameter by the enlarging/collimating optical system 18 . The laser beam thus converted into the collimated light by the enlarging/collimating optical system 18 enters into the polarization beam splitter 22 .
[0053] The polarization beam splitter 22 transmits p-polarized light of the incident laser beam and reflects s-polarized light thereof. The laser beam reflected by the polarization beam splitter 22 enters into the spatial light modulator 24 .
[0054] The spatial light modulator 24 polarizes and modulates the laser beam entered from the polarization beam splitter 22 in accordance with a pattern according to recording information. The recording information is represented by a pattern image of bright and dark in which digital data “0”, “1” is made correspond to “bright”, “dark”, respectively. The laser beam having alight intensity modulation pattern subjected to the light intensity modulation enters again into the polarization beam splitter 22 . In this case, since the polarization beam splitter 22 transmits the p-polarized light, the light modulated by the spatial light modulator 24 transmits the polarization beam splitter 22 .
[0055] FIG. 2 shows an example of the configuration of the spatial light modulator 24 . As shown in FIG. 2 , the spatial light modulator 24 according to the embodiment is arranged to include reference light pixel area 200 for modulating the reference light and signal light pixel area 300 for modulating the signal light in a manner that the signal light pixel area 300 is disposed at the center portion and the reference light pixel area 200 is disposed at the outer periphery of the signal light pixel area 300 .
[0056] Each of the reference light pixel area 200 and the signal light pixel area 300 is configured by a plurality of pixels and each of the pixels is intensity-modulated into bright or dark in accordance with two-dimensional image data for modulating the reference light and the signal light. In FIG. 2 , the painted pixels in each of the reference light pixel area 200 and the signal light pixel area 300 represent “dark” pixels. In FIG. 2 , the painted pattern representing the “dark” pixels is differentiated between the reference light pixel area 200 and the signal light pixel area 300 merely for the sake of the explanation, and actually each of the color and pattern of the “dark” pixels is not differentiated therebetween.
[0057] The pixels contained in the signal light pixel area 300 generate a two-dimensional image obtained by coding data page to be recorded and subject the signal light to the spatial modulation. Also, the reference light pixel area 200 may generate a two-dimensional image obtained by coding a random pattern and subject the reference light to the spatial modulation. The reference light is not necessarily modulated. However, when the reference light is subjected to the random modulation with a period almost same as that of the data page pattern, the reference light can be irradiated uniformly at the time of data page recording, whereby the overlapping of the signal light and the reference light is made large at the hologram recording area and hence data page can be recorded with good accuracy.
[0058] The spatial light modulator 24 according to the embodiment is characterized in that the pitch of the pixels contained in the reference light pixel area 200 differs from the pitch of the pixels contained in the signal light pixel area 300 . That is, supposing that the pitch of the pixels contained in the reference light pixel area 200 is d 1 and the pitch of the pixels contained in the signal light pixel area 300 is d 2 , d 1 is smaller than d 2 in this embodiment. The pitch of the pixels means a distance between the adjacent pixels contained in each of the pixel areas of the spatial light modulator 24 . In this manner, since the pitch of the pixels for modulating the reference light and the pitch of the pixels for modulating the signal light in the spatial light modulator 24 are differentiated, the distance of each of the 0-order component and the primary-order component is differentiated between the reference light and the signal light. That is, the distance between the image formation positions of bright spots on the Fourier transform plane is differentiated between the reference light and the signal light. The embodiment simultaneously performs the cutting of the reference light and the extraction of a desired frequency band of the signal light by utilizing the difference of the distance between the image formation positions. This process will be explained later.
[0059] Recording light including the signal light and the reference light each subjected to the spatial modulation by the spatial light modulator 24 is relayed by the lenses 26 , 28 constituting the relay lens system and entered into the Fourier transform lens 30 . The recording light is focused by the Fourier transform lens 30 so as to pass the filter 34 . A frequency band of the recording light is cut when passing through the filter 34 . Since the frequency band of the recording light is cut by the filter 34 , the recording more effectively utilizing the hologram recording medium 100 can be realized. The filter 34 may be constituted by a low pass filter for passing the DC component of the primary or less-order of the spatial frequency component of the reference light and the signal light. In this case, the radius of the transmission portion of the filter 34 is set to be fλ/d 1 (the pitch of the pixels of the reference light) or more.
[0060] The recording light passed through the filter 34 is converted into collimated light again by the Fourier transform lens 32 and entered into the Fourier transform lens 36 for focusing the recoding beam in the hologram recording medium 100 .
[0061] The Fourier transform lens 36 focuses the reference light and the signal light in the hologram recording medium 100 which is held by the medium holding portion 40 . Then, hologram (interference fringe) formed by the interference between the reference light and the signal light at the position where the reference light and the signal light are focused is recorded in an optical recording layer of the hologram recording medium 100 . The aforesaid explanation is a recording process for recording data page in the hologram recording medium 100 .
[0062] Next, the explanation will be made as to a process of reading (reproducing) the data page recorded in the hologram recording medium 100 by the hologram recording/reading apparatus 1 .
[0063] First, in the hologram recording/reading apparatus 1 , only the reference light is irradiated to the hologram recording medium 100 . The irradiated reference light is diffracted by the hologram formed in the hologram recording medium 100 and so reproduction light is obtained. The reproduction light thus obtained includes the reference light and the signal light irradiated at the time of forming the hologram.
[0064] Since the hologram recording medium 100 is a recording medium of a transmission type, the reproduction light transmits the hologram recording medium 100 , then is relayed by the Fourier transform lens 38 and enters into the Fourier transform lens 42 . The filter 60 is disposed on the focal plane of the Fourier transform lens 42 .
[0065] FIG. 3 shows an example of the focal plane of the Fourier transform lens 42 (hereinafter called a Fourier transform plane) disposed at the filter 60 . As shown in FIG. 3 , a 0-order DC component 400 of the signal light is located at the center of the Fourier transform plane, and primary-order DC components 410 of the signal light are located around the 0-order DC component. Further, primary-order DC components 510 of the reference light are located on the outside of the primary-order DC component of the signal light. In this embodiment, a spot distance L 1 of the reference light can be represented by the following expression (1) and a spot distance L 2 of the signal light can be represented by the following expression (2), where d 1 represents the pitch of the pixels of the reference light pixel area 200 and d 2 represents the pitch of the pixels of the signal light pixel area 300 in the spatial light modulator 24 , f represents the focal distance of the lens, and λ represents the wavelength of the coherent light. The spot distance means a distance between the 0-order component and the primary-order component.
[0000] L 1= fλ/d 1 (1)
[0000] L 2= fλ/d 2 (2)
[0066] When the filter 60 is configured as a low pass filter having a transmission portion with a radius r satisfying the relation of L 2 <r<L 1 and is disposed at the Fourier transform plane, as shown in FIG. 3 , the reference light can be cut from the reproduction light and only the signal light having the desired frequency band (the primary or less-order DC component) can be transmitted and extracted. When the wavelength λ of the coherent light is 532 nm, the focal distance f of the lens is 100 mm, the pitch d 1 of the pixels of the reference light is 20 μm, the pitch d 2 of the pixels of the signal light is 24 μm, L 1 becomes 2.217 mm and L 2 becomes 2.66 mm. When the filter is configured as a low pass filter having a radius r of 2.5 mm, the reference light can be cut from the reproduction light and the spatial frequency band of the primary or less-order DC component of the signal light can be extracted.
[0067] Since the filter 34 does not remove the reference light, the radius of the filter 34 is is set to be larger than L 1 . That is, in the aforesaid numerical example, the primary-order DC component of each of the reference light and the signal light can be transmitted by setting the radius of the filter 34 to 2.7 mm
[0068] The reproduction light (signal light) transmitted through the filter 60 is relayed by the Fourier transform lens 44 and focused on the light receiving element 50 . The light receiving element 50 reads the recorded data page modulated in the signal light based on the light intensity modulation pattern of the signal light.
[0069] In the hologram recording/reading apparatus 1 according to the embodiment described above, since filter 60 simultaneously performs both the removal of the reference light from the reproduction light and the extraction of the desired frequency band of the signal light, as compared with the hologram recording/reading apparatus 2 of the related art shown in FIG. 6 , the iris 45 and the Fourier transform lenses 42 , 44 constituting the relay lens system can be eliminated and so the further miniaturization of the optical system can be realized.
[0070] The invention is not limited to the aforesaid embodiment.
[0071] For example, the filter disposed at the focal plane of the Fourier transform lens 42 is not limited to the low pass filter shown in FIG. 3 . The filter may be configured as a band-pass filter, like a filter 61 shown in FIG. 4 , which cuts the 0-order DC component of the signal light but transmits the frequency band including the primary-order DC component of the signal light. In this case, supposing that the transmission portion of the filter 61 is configured as a square shape in a manner that the size of each side of the outer periphery thereof is S 1 and the size of each side of the inner periphery thereof is S 2 , the following expressions are satisfied.
[0000] L 2< S 1/2< L 1, R spot< S 2/2< L 2
[0000] In this case, Rspot represents the radius of the spot. Of course, the filter disposed at the Fourier transform plane of the Fourier transform lens 42 is not limited to the configuration shown in the drawings and may be configured to have various shapes accorded to the desired spatial frequency band of the signal light to be transmitted.
[0072] Further, although in the aforesaid embodiment, the pitch (d 1 ) of the pixels of the reference light pixel area is set to be smaller than the pitch (d 2 ) of the pixels of the signal light pixel area, the pitch (d 1 ) of the pixels of the reference light pixel area is set to be larger than the pitch (d 2 ) of the pixels of the signal light pixel area. In this case, according to the aforesaid expressions (1) and (2), the spot distance L 2 of the signal light becomes longer than the spot distance L 1 of the reference light on the Fourier transform plane. FIG. 5A shows the Fourier transform plane in this case. As also clear from FIG. 5A , the primary-order components 410 of the signal light locate at the outside of the primary-order components 510 of the reference light. In this case, when a filter 62 configured as shown in FIG. 5B is disposed at the focal plane of the Fourier transform lens 42 , the reference light can be cut and only the spatial frequency band including the primary-order components 410 of the signal light can be transmitted. Supposing that the size of each side of the outer periphery of the transmission portion of the filter 62 is S 3 and the size of each side of the inner periphery thereof is S 4 , S 3 and S 4 satisfy the relation of 2 L 1 <S 3 <2L 2 <S 4 <4L 1 . For example, when the wavelength λ of the coherent light is 532 nm, the focal distance f of the lens is 100 mm, the pitch d 1 of the pixels of the reference light is 24 μm, the pitch d 2 of the pixels of the signal light is 20 μm, L 1 becomes 2.66 mm and L 2 becomes 2.217 mm. In this case, when the filter 62 is configured as a band pass filter having S 3 of 6.7 mm and S 4 of 5 mm, the reference light can be eliminated from the reproduction light and the spatial frequency band including the primary-order DC component of the signal light can be extracted.
[0073] Further, although the aforesaid embodiment is arranged in a manner that the hologram recording/reading apparatus 1 performs both the recording and reading of hologram, a hologram recording apparatus for recording hologram and a hologram reading apparatus for reading hologram may be provided separately, of course. | A hologram reading apparatus includes: a unit holding a hologram recording medium in which data page is recorded by irradiating as a single beam both reference light and signal light modulated by a spatial light modulator including a first pixel area for modulating the reference light and a second pixel area for modulating the signal light, a pitch of pixels in the first pixel area being different from that in the second pixel area; a Fourier transform lens subjecting reproduction light to a Fourier transformation; a filter disposed on a Fourier transform plane of the reproduction light by the Fourier transform lens, the filter shielding the reference light at a first spatial frequency band and transmitting the signal light at a second spatial frequency band; and a reading unit receiving the reproduction light transmitted through the filter and reading the data page modulated to the signal light included in the reproduction light. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 11/942,821 filed on Nov. 20, 2007 now U.S. Pat. No. 7,866,513, which is a continuation of International patent application PCT/FR2006/050228 filed on Mar. 14, 2006 which designates the United States and claims priority from French patent application 0551309 filed on May 20, 2005, the content of which is incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a device for dispensing and intaking a liquid or semi-liquid product, preferably pharmaceutical or cosmetic, by means of a dosage chamber of a pump body.
BACKGROUND OF THE INVENTION
Such devices are usually designed for dispensing measured amounts of a liquid product, and for watertight sealing of the neck of a bottle containing said liquid product to be dispensed.
Devices of this type exist forming a pump and comprising a pump body, a piston mounted fixed in the pump body, a dosage chamber with variable volume into which the end of the piston opens, the chamber communicating with the outside by means of a release valve enclosed in a push button, allowing a dose of product to be dispensed when it is pressed. In addition, the end of the piston is closed by a valve or a second valve for intaking the liquid product in the chamber.
Such devices have certain disadvantages, in particular in the pharmaceutical field, since the doses of product dispensed can vary from one spray to the next, while the dispensing of accurate doses is required.
Furthermore, when such devices are implemented on bottles without air intake, for example with deformable walls, the pump must have sufficient suction power to reduce the volume of the container. This demand is difficult to meet, which can affect the precision of the doses of product dispensed.
Moreover, such devices are very sensitive and their reliability is not always guaranteed. The manufacturer must ensure that the elements forming the pump are centred and aligned around the axis of symmetry of said pump, at the risk of malfunctions that can result in incomplete doses and/or reduced suction power. In addition, when activating the pump, the user must make sure to press the centre of the push button, in order not to cause the compression elements to move off centre and to avoid breaking the seal between the valve and the dosage chamber.
Furthermore, the known devices entail problems when priming the pump. Indeed, due to their design, it is difficult to vent the air contained in the dosage chamber before using the dispenser for the first time.
SUMMARY OF THE INVENTION
The present invention makes it possible to solve the disadvantages of such pumps.
It relates in particular to a device designed to be installed independently on a bottle with varying capacity, which is to say a flexible bottle, or deformable bag, or on a bottle with a mobile scraper, or on a rigid bottle with constant capacity, requiring an air intake or not.
The device according to the invention comprises a piston which is mounted fixed in the pump body and which has one end engaged in a watertight manner in the chamber, the end of the piston being covered by an elastically deformable membrane.
According to the invention, the membrane comprises:
on the one hand, a transversal wall forming an intake valve being provided with a central supply orifice, capable of being blocked in a watertight manner by a projecting element forming a valve seat on the end of the piston, and on the other hand, a cylindrical attachment skirt equipped with at least one sealing peripheral lip in sliding contact with the inner wall of the chamber; the skirt forming a valve by deformation in contact with a boss provided on the inner wall of the chamber, for releasing the air compressed by the piston in the chamber when priming the pump.
Thus manufactured, the device according to the invention guarantees the venting of the air contained in the chamber, which allows the pump to be primed before its first use.
According to a first embodiment of the device according to the invention, the boss consists of at least one axial rib projecting from the inner wall of the chamber.
In order to improve the watertightness, the bottom face of the transversal wall of the membrane advantageously comprises an annular pad centred on the central orifice, and coming to rest against the projecting element of the end of the piston in the valve closing position.
According to one advantageous alternative embodiment, the device according to the invention comprises an element for connecting the piston to the pump body, equipped with a bearing for retaining the membrane.
Moreover, according to another alternative embodiment, the retaining bearing comprises means for snap-fitting the skirt of the membrane. The snap-fitting means preferably consist of a peripheral groove, made in the lateral wall of the element and cooperating with a snap-fitting bead provided on the inner wall of the skirt.
According to a further alternative embodiment, the connection element is an independent part, designed to be added to the bottom part of the pump body.
According to yet another alternative embodiment, the connection element comprises a transversal wall forming a bottom, designed to block the body at the bottom.
It is advantageously provided for the connection element to comprise a cylindrical bore in which a product intake tube is inserted.
The connection element preferably comprises an axial supply conduit, communicating at the bottom with the cylindrical bore.
Moreover, it is advantageously provided for the connection element to comprise a peripheral shoulder against which the bottom edge of the skirt of the membrane comes to a stop.
It is advantageously provided for the watertight peripheral lip to be made in the proximity of the peripheral shoulder. This makes it possible to improve the watertightness of the device by limiting any radial movement of the membrane, which can offset the projecting element in relation to the central orifice of the membrane.
According to yet another embodiment, the device according to the invention comprises an expansion cavity in which the projecting element of the end of the piston is inserted. This cavity is hermetically sealed at the bottom by the projecting element and at the top by the membrane.
Finally, it is advantageously provided for the projecting element to consist of a ball mobile between a valve closing position and an opening position in which it allows the liquid product to enter the chamber.
The device according to the invention preferably comprises elements for centring the projecting element in the axis of the intake orifice.
Thus manufactured, the device according to the invention guarantees not only easy and quick priming of the pump before its first use, but also a perfect seal between the end of the piston and the dosage chamber, regardless of the pressing force and the manner in which the users exerts this force on the push button, or of the area of the push button which the user presses to activate the pump.
The device of the invention has a particularly useful application in the field of pump sprayers in which the spray cooperates with a valve having an end needle valve.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objectives and advantages of the invention will become apparent from the following description made in reference to FIGS. 1 to 8 , wherein:
FIG. 1 shows, in a partial section view, a device according to the invention mounted in a pump;
FIG. 2 depicts an embodiment of a membrane which comprises a device according to the invention, in a profile view;
FIG. 3 shows a second embodiment of the device according to the invention, in a profile view, the membrane being shown partially in order to illustrate various elements of the device according to the invention;
FIG. 4 shows, in a section view, the device shown in FIG. 3 mounted in a pump body, at the time of priming the pump;
FIG. 5 shows, in a section view, the device of FIGS. 3 and 4 before priming the pump;
FIG. 6 is a section view of the device of FIG. 5 according to the plane E-E shown in FIG. 5 ;
FIG. 7 is a section view of the device of FIG. 5 according to the plane D-D shown in FIG. 5 ; and
FIG. 8 is a section view of the device of FIG. 5 according to the plane C-C shown in FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
The device described below is particularly suitable for dispensing a pharmaceutical product, such as a medicine, contained in a bottle container.
It should, however, be understood that the device according to the invention does not only apply to dispensing a pharmaceutical product, and that it relates to any device corresponding to the definition of the invention capable of being used in any type of pump body.
For this purpose, two embodiments of the device according to the invention are presented below.
FIG. 1 depicts a first embodiment of the device according to the invention, and FIGS. 3 to 8 depict a second embodiment.
Regardless of the embodiment shown in the figures, the device according to the invention is designed for dispensing a dose of liquid or semi-liquid product, via a dosage chamber 1 of a pump body 2 .
In a standard manner, as shown in FIG. 1 for example, the pump body 2 comprises a hollow cylinder 21 with dimensions allowing it to accommodate the device according to the invention.
The hollow cylinder 21 is open at a first end to accommodate an exhaust system, not shown in detail in the figures, which is equipped in particular with a push button 22 and which comprises the dosage chamber 1 .
The push button 22 is mounted mobile between a pressed position and a released inactive position in a guiding sleeve 23 assembled in the hollow cylinder 21 of the pump body 2 .
A compression spring 24 in the sleeve provides, in this case, the elastic return of the push button 22 from its pressed position to its inactive position.
The first end of the hollow cylinder 21 comprises a flange 26 for hooking on the neck of the bottle container. It is possible to provide an annular seal 27 , under the hooking flange 26 , to guarantee the seal with the neck of the bottle. Moreover, an outer girder 28 makes it possible in this case to crimp the pump on the bottle container.
In order to facilitate the understanding of the figures, neither the bottle container nor the liquid product are shown.
A second end of the cylinder 21 of the pump body is closed around a conduit 25 providing the connection for the end of an intake tube 76 of a liquid product contained in the bottle container on which the pump is mounted.
As shown in FIG. 1 , the device according to the invention, which is mounted in the pump body 2 , comprises in particular a piston 3 .
The piston 3 which is mounted fixed in the bottom of the pump body 2 , comprises a top end 31 inserted in a watertight manner in the chamber 1 .
The end 31 of the piston is covered by an at least partially elastically deformable membrane 4 , which is more particularly shown in FIG. 2 .
The membrane 4 comprises, on the one hand, a deformable transversal wall 41 forming an intake valve being provided with a central supply orifice 42 , capable of being blocked in a watertight manner by a projecting element 5 forming a valve seat on the end of the piston 3 (see FIG. 3 ).
On the other hand, the membrane 4 comprises a cylindrical attachment skirt 43 , provided with at least one and in this case two peripheral sealing lips 44 , in sliding contact with the inner wall of the chamber 1 .
Where applicable, the skirt 43 can be made from a different material which is more rigid than that of the wall 41 .
It is provided for the peripheral lips to be made at the bottom of the cylindrical skirt of the membrane, in order to guarantee an optimum seal which is explained in greater detail below.
The membrane 4 allows the introduction of a liquid product in the dosage chamber 1 , when a depression is created in this chamber 1 . Indeed, the deformable nature of its wall 41 allows it to lift, separating from the projecting element under the pressure of the liquid, unblocking the orifice 42 and thus allowing the liquid to penetrate into the dosage chamber.
According to the invention, the skirt 43 forms a valve by deformation of at least the lips 44 in contact with a boss 6 provided on the inner wall of the chamber 1 , for releasing the air compressed by said piston 3 in the chamber 1 when priming the pump.
As shown in FIG. 1 , the boss consists in this case of at least one axial rib 6 projecting on the inner wall of the chamber 1 .
The axial rib 6 comprises a channel 61 which is longitudinal and has a very narrow cross-section, allowing the passage of the air expelled from the dosage chamber 1 when priming the pump.
FIG. 4 shows, in particular, the shape taken on by the membrane 4 when the piston 3 is pressed into the dosage chamber.
It is noted that the rib 6 crushes the sealing lips 44 without breaking the seal of the liquid product. Indeed, the supporting contact between the groove 6 and the lips 44 does not create a passage for the liquid. Only the channel 61 forming a capillary guarantees the release of the air compressed during the initial phase of priming the pump, said release taking place by passing around the sealing lips 44 and towards the outside of the chamber 1 .
In order to improve the watertightness of the intake valve between the membrane 4 and the end of the piston, the bottom face of the transversal wall 41 comprises an annular pad 45 centred on said central orifice 42 , and coming to rest against the projecting element 5 .
As shown more particularly in FIG. 3 , in a partial section view, the device according to the invention comprises an element 7 guaranteeing the connection of the piston 3 to the pump body 2 .
The connection element 7 is provided with a bearing 71 for retaining the membrane 4 .
The retaining bearing 71 comprises means for snap-fitting the skirt 43 of the membrane 4 . These snap-fitting means consist of a peripheral groove 72 , made in the lateral wall of the element 7 and cooperating with a snap-fitting bead 73 provided on the inner wall of the skirt 43 .
The connection element 7 in this case is made as a separate part from the pump body 2 , which is designed to be inserted through the top opening and accommodated in the bottom part of said body.
The connection element 7 comprises a base 74 made in the shape of a disc, which guarantees the positioning and coaxial setting of the element.
It is provided to make at least one radial recess 79 in the thickness of the disc, cooperating with a rivet (not shown in the figures) projecting from the bottom of the pump body, which prevents all rotation of said device according to the invention when the latter is correctly arranged on the bottom of the pump body.
It should be understood that, according to one variation, not shown, the connection element 7 can be added to the bottom part of the pump body 2 , so that the transversal wall 74 forms a bottom blocking said body 2 at the bottom.
As can be seen in FIG. 5 in particular, the connection element 7 comprises, at the bottom, a cylindrical bore 75 in which the tube 76 for intaking the liquid product is inserted ( FIGS. 1 and 4 ).
Moreover, the connection element 7 comprises, at the top, an internal conduit 77 for supplying the product to the chamber 1 , the supply conduit communicating with the cylindrical bore 75 ( FIGS. 1 , 4 and 5 ).
As shown in FIGS. 4 and 5 , the connection element 7 also comprises a peripheral shoulder 78 against which the bottom edge of the skirt 43 of the membrane 4 comes to a stop.
As can be seen in particular in FIG. 3 , an expansion cavity 8 is provided on the end of the piston 3 under the membrane 4 , the cavity 8 being hermetically sealed by the projecting element 5 and by the membrane 4 .
The liquid product is introduced in this cavity before penetrating into the dosage chamber 1 .
As can be seen in the figures, the projecting element 5 of the end of the piston 3 is inserted in the cavity 8 .
According to the first embodiment shown in FIG. 1 , the projecting element 5 consists of a mobile ball 5 resting between centring elements 51 in the valve closing position.
As can be seen in FIG. 1 , the top end of the supply conduit 77 is made to form a race 9 ( FIG. 1 ) in the shape of a truncated cone, providing support and centring of the ball 5 .
According to this embodiment, in the valve closing position, the ball blocks both the end of the supply conduit 77 and the orifice of the membrane 4 . It is thus immobilised between the race and the membrane. Thus, the ball prevents any liquid from entering the cavity 8 , and any liquid from entering the dosage chamber.
According to another embodiment shown, for example in FIG. 4 or 5 , the top end of the connection element 7 comprises slots delimited in this case by two tabs 52 provided on the bearing 71 , designed to extend the conduit 77 . The tabs 52 maintain the projecting element 5 centred in the axis of the conduit 77 and at a distance from its end. The projecting element 5 is thus presented in the shape of a full cylinder with a diameter that is substantially equal to or slightly greater than, the distance separating the two tabs 52 , so that the projecting element is immobilised between the two tabs 52 .
According to this embodiment, even if the projecting element 5 only blocks the orifice of the membrane, the liquid can enter the expansion cavity 8 .
The cavity 8 can thus be used as a chamber for treating the liquid product. For this purpose, it is possible to insert a chemical or biological agent in such cavity, with which the liquid product can interact by mutual contact or dispersion. This agent can be contained in the material forming the projecting element 5 or on the walls of the cavity 8 .
In order better to visualise the space filled by the liquid in the valve closing position, FIGS. 6 to 8 each show section views of the end of the piston according to several transversal planes. These figures each depict the zones filled by the liquid when the projecting element 5 blocks the orifice 42 of the membrane 4 .
FIG. 8 is a section view according to the plane C-C shown in FIG. 5 . FIG. 8 shows the liquid (in grey) filling the supply conduit 77 .
FIG. 7 is a section view according to the plane D-D shown in FIG. 5 . This figure shows that the liquid fills the entire free volume of the cavity 8 located under the projecting element 5 and on either side of the projecting element 5 , between the centring tabs 52 .
Finally, FIG. 6 is a section view according to the plane E-E shown in FIG. 5 . This figure shows that the liquid fills the entire free volume of the cavity 8 located on either side of the projecting element 5 , between the centring tabs 52 .
The centring tabs 52 guarantee that the projecting element 5 is always centred on the axis of the supply conduit 77 , and also on the axis of the orifice 42 , to guarantee a regular flow of the liquid and optimum watertightness at the level of the orifice 42 of the membrane 4 .
Moreover, the actual position of the peripheral sealing lips 44 on the skirt 43 of the membrane 4 reinforces the sealing capacity of the membrane. Indeed, the closer these lips 44 are to the shoulder, the smaller the risk of the membrane 4 moving and being offset in relation to the axis of the supply conduit.
Also, maximum watertightness is guaranteed by the combination of the sealing lips 44 positioned near the shoulder 78 , on the one hand, and the centring elements 51 (or 52 ) of the projecting element 5 forming a valve seat on the end of the piston, on the other hand.
The preceding description clearly explains how the invention makes it possible to guarantee the watertightness at the intake of the dosage chamber, by guaranteeing the radial setting of the membrane 4 when a user presses the push button of the pump.
In addition, the preceding description clearly describes the means providing the venting of the air contained in the dosage chamber when priming the pump.
An advantageous combination of these typical characteristics of the device according to the invention offers the pharmaceutical and/or cosmetic industry a pump:
that dispenses accurate doses of a liquid product, thanks to the improved watertightness between the membrane and the dosage chamber when the pump is not being used; and which is easily primed thanks to the means implemented to vent the air contained in the dosage chamber before a first use. | A device for dispensing and receiving a liquid or semi-liquid product via a dosage chamber of a pump body. The device includes a piston which is fixably mounted in the pump body and is provided with an end sealingly engaged into the chamber. The piston end is provided with a membrane forming an intake valve allowing the introduction of the product in the dosage chamber and including at least one sealing peripheral lip in sliding contact with an inner wall of the dosage chamber. The device includes a connection element wholly within the pump body for connecting the piston to the pump body. The connection element is an independent part from the membrane and the pump body and is connected to a bottom part of the pump body over a conduit extending up from the bottom part of the pump body. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to a sum current transformer having a wound, lapped core of high-permeability, soft-magnetic material for acquiring the current of current conductors passing through the core, whereby the winding of the core is connected via an amplifier to a protective switch.
2. Description of the Prior Art
A current transformer of the above general type is disclosed in PCT Application WO 93/16479. The core of this known sum current transformer can be optionally composed of sintered, ferromagnetic material, or disks stacked on top of one another, or wound bands or wires. All of these core versions have in common the fact that insulator layers are provided by small air gaps in the material or by the division into disks or by winding, these insulator layers reducing eddy currents induced in the material by the alternating field acting thereon. The result is that such cores--especially because of their small dimensions--have low mechanical strength and are therefore sensitive to shock stresses and also have low strength for being wound.
When a sum current transformer is connected to the input of an amplifier, i.e. the power for the switching of a relay is not taken from the core itself, then it requires a relatively low transmission power and can therefore be implemented with small dimensions. The miniaturization of the dimensions is essentially limited by the mechanical weakening of the core of the sum current transformer associated with the dimension reduction and by the unavoidable increase in the ohmic resistance of the winding, since this must then be composed of relatively thin wires. This ohmic resistance of the winding of the core of the sum current transformer, however, is the determining factor for the gain of the following amplifier--among other things. Since the ohmic resistance changes with the temperature, the amplifier will also exhibit a temperature response, so that the precision of the trigger characteristic will suffer therefrom.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a sum current transformer that can have relatively small dimensions and that nonetheless has a mechanically solid core and a low temperature response.
This object is inventively achieved in that a sum current transformer having a core fashioned solid, i.e. without insulating intermediate layers or air gaps that divide the cross section of the core and the material of the core is composed of a metallic alloy having a content of at least 40% nickel which has a positive temperature coefficient for the electrical resistance.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a circuit using a sum current transformer constructed in accordance with the principles of the present invention used in a protective electronic means.
FIG. 2 shows an equivalent circuit diagram of the circuit of FIG. 1 for explaining the functioning thereof.
FIGS. 3-5 show further possible core shapes for a core constructed.
FIG. 6 shows the temperature response of an inventive core.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The sum current transformer 1 in FIG. 1 is composed of a core 2 having a winding 3. Current conductors 5 and 6 are conducted through the core, which connect an alternating voltage source 8 to a user 9 via a protective switch 7. The supply lines of an amplifier 10 are connected to the current conductors 5 and 6, the input lines of the amplifier 10 being connected to the winding 3 of the sum current transformer 1 and the output lines thereof being connected to the cutoff winding 11 of the protective switch 7.
When the aggregate current of the currents flowing through the current conductors 5 and 6 is not zero, for example as a consequence of a short to ground, then an alternating flux is generated in the core 2 of the sum current transformer 1, this alternating flux inducing a voltage in the winding 3 that in turn effects the triggering of the protective switch 7 via the amplifier 10.
An equivalent circuit diagram for the circuit as shown in FIG. 2 is shown given the employment of a solid core composed of a metallic alloy having a high nickel content in accordance with the invention. Metallic nickel-iron alloys having a high nickel content have a magnetic permeability several orders of magnitude higher than required for employment as the core of sum current transformer. The core 2 thus has an extremely high inductance. Since, however, it is implemented solid, a flux in the core 2 causes eddy currents to propagate, since they are not impeded by air gaps or other insulating layers that divide a conventional core cross-section. These eddy currents generate an opposing field to the alternating field in the core 2 caused by the sum current; they are only limited by the electrical resistance of the material of which the core 2 is composed. In the equivalent circuit diagram, the core 2 is therefore illustrated by an ohmic resistor R2 and an inductor L2. In the equivalent circuit diagram of FIG. 2, the winding 3 is divided into an inductance N3 and a resistor R3 that represents the winding resistance of the winding.
It is assumed that the circuit in FIG. 2 is balanced such that a triggering of the protective switch 7 via the amplifier 10 ensues at the desired, maximum value of the sum current. When the ambient temperature then rises, the winding resistance R3 of the winding 3 also increases, so that the input voltage at the amplifier 10 would tend to drop. The resistance R2, however, also increases since the material of the core 2 has a positive temperature coefficient for the electrical resistance. The increase in the resistance R2 the eddy currents in the core 2 to abate and have less than an attenuating effect on the field generated by the sum current. This causes a higher alternating current permeability of the core 2 and leads to an increase of the induced voltage in the winding 3, and thus at the input of the amplifier 10. Temperature compensation of the circuit is possible by employing a solid core and by intentionally accepting significant eddy currents; it has been found in practice that the compensation is optimum when--dependent on the material employed and on the core shape--the wall thickness of the core 2 has a value in the range from 0.01-0.5 in relationship to the average diameter. The especially high static permeability of the inventively employed alloy having high nickel content also allows the core 2 to be formed in various geometrical shapes and/or to be divided into two or more core parts which in combination, compose the core 2.
FIG. 3 shows a divided core in circular form; FIG. 4 shows such a core in rectangular form; and FIG. 5 shows a core of two U-halves that are overlapped when combined. These cores have the advantage that the winding is easier to apply in a known way and that they can be slipped over the core parts completely wound. Although the overlap region in FIG. 5 results in an air gap, however small being present on a part of the core, a significant reduction of the eddy currents does not thereby occur, so that the amplitude of the eddy currents continues to be nearly completely defined by the conductivity of the core material and the temperature-compensating effect is preserved.
The completely solid, undivided core shown in FIG. 1 can be fabricated by cutting a core of appropriate thickness from a tube. The tube from which the core is cut can be manufactured by an extrusion process. The divided cores shown in the embodiments of FIGS. 3-5 can also be cut from a tube as an undivided core, and then divided into the core halves respectively shown in FIGS. 3-5. Alternatively, the core halves can be separately fabricated.
For an exemplary embodiment of an inventive core having 1,000 turns for the winding 3 and a winding resistance of 50 ohms as well as a core cross section of 0.03 cm 2 and an iron length of 4.15 cm, FIG. 6 shows the output voltage of the amplifier 10, i.e. the voltage at the winding 11 of the protective switch 7 dependent on the alternating current permeability that can arise due to different core materials different annealing treatments. The solid curve is thus the output voltage at room temperature; the dashed-line curves are respectively based on temperatures of +70° and -20° C. One can see, first, that an extremely good compensation of the temperature response is achieved and that, second a significant change in the output voltage no longer occurs given an alternating current permeability of more than 15,000 or 20,000, so that the attenuation of the static permeability of the core material employed for the temperature compensation in this application due to the eddy currents which occur in the massive core can be accepted.
The inventor has also recognized that the presence of eddy currents can be accepted under these circumstances because losses due to eddy currents in fact only occur when a fault, i.e. an aggregate current differing from zero, is present, so that a flux is present in the core 2 only briefly from the time of appearance of the fault until the disconnect of the protective switch 7. Heating of the core 2 during normal operation of the sum current transformer thus does not occur. By employing the inventive aggregate current transformer, a transformed is achieved having a core that is mechanically extremely strong and can be practically directly wound and moreover the temperature response caused by the ohmic resistance of the winding of the aggregate current transformer core can be compensated.
Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of their contribution to the art. | A sum current transformer that acts on a protective switch via an amplifier has a core of a solid metallic material composed of an alloy having more than 40% nickel, so that it can be implemented mechanically solid even given small dimensions. The temperature dependency of the arrangement caused by the ohmic resistance of the winding is compensated by the diminishing eddy currents in the core given increasing temperature, so that the smallest dimensions can be realized for the aggregate current transformer. | 7 |
This is a division of application Ser. No. 442,756, filed Nov. 29, 1989, now U.S. Pat. No. 4,968,739.
FIELD OF THE INVENTION
The present invention relates to a composition for producing a metallic sintered body, and a method for producing the metallic sintered body.
The composition for producing a metallic sintered body according to the present invention has excellent properties such as mechanical strength of a green body thereof, and only a short time being necessary for removal or elimination of a binder in comparison with conventional sintering compositions.
The binder in the present composition is substantially composed of a single type of component.
BACKGROUND OF THE INVENTION
For more than about two or three decades, the art for producing a metallic sintered body from powdered metallic materials has been well known in the field of metallurgy.
This art is generally referred to as injection powder metallurgy or metal injection molding (MIM).
The powdered metallic materials are mixed with a binder and then formed into a desired shape by extrusion molding or injection molding, and/or compression molding, to form what is commonly referred to as a green body.
The green body is heated by exposing it to a high temperatures atmosphere to partially remove or eliminate the binder by oxidation or thermal decomposition of the binder, the resultant product being referred to as a brown body.
The brown body is then sintered to provide a fusion of the powdered metallic materials and to completely remove or eliminate the binder, by exposing it to a very high temperature atmosphere, for example, 600° C. to 1,000° C., thereby producing the desired shaped metallic product with desired surface appearance, strength, etc., this being called a silver body, that is, the desired product.
In the production of the green body in the manner described hereinabove, there have heretofore been used thermoplastics such as polyethylene, polypropylene, polystyrene, polyamide, and cellulose and derivatives thereof; thermosetting plastics such as epoxy resins, phenolic resins, polyimide resins, natural waxes such as animal wax, China wax, wool wax, vegetable wax, carnauba wax, Japan wax, etc., synthesis waxes such as montan wax derivatives, paraffin wax derivatives, microcrystalline wax derivatives, higher monohydric alcohols such as cetyl alcohol, higher fatty acids such as capric acid, and glycerides such as tripalmitin, hydrocarbon waxes such as low molecular weight polyethylene, etc., and a mixture thereof as a binder for a powdered metallic material.
Also, an oxygen-containing wax type binder is disclosed in Japanese Unexamined Patent Publication (Kokai) No. 20775/1983 (U.S. Pat. No. 4,649,003).
Also, ethylene-vinyl acetate copolymer, low density polyethylene, methacrylate copolymer, phthalic ester, etc., and a mixture thereof are disclosed in Japanese Unexamined Patent Publication (Kokai) No. 229403/1984.
However, several facts indicate the need for improvements in such sintering compositions, particularly with respect to the binder.
A first fact is that a binder as described hereinabove, for example, thermoplastic or thermosetting plastics, have disadvantages such as that a long time is required for the removal or elimination of them.
A second fact is that a binder cannot be removed or eliminated perfectly in the removal or elimination process therefor.
A third fact is that such waxes typically have disadvantages such as low mechanical strength in a green body.
A fourth fact is that a binder composition is composed of complicated components.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved composition for producing a metallic sintered body, and an improved method for producing a metallic sintered body.
As a result of extensive investigations noting the foregoing background, the inventors of this invention have now found that it is possible to solve the problems and achieve the objects as noted hereinabove by use of a composition consisting essentially of a powdered metallic material and a lactone resin.
The powdered metal to be used has an average particle size of not more than 50 microns, and the lactone resin to be used has a relative viscosity value in the range of from 1.15 to 3.20.
The lactone resin to be used for producing a metallic sintered body can provide excellent mechanical strength in a green body, i.e., a shaped molded body before heating and sintering.
Accordingly, product loss can be reduced in the case of shipment and storage.
Furthermore, with the binder to be used in the present invention substantially composed of single type of resin component, it is only required to adjust the mixing ratio of the lactone resin to the powdered metallic material; accordingly, manufacturing process control can be simplified.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a graph illustrating results obtained in measurement of temperature dependence of flow properties in a melted composition composed of a powdered metal and a lactone resin, in which temperatures are plotted on the abscissa and values measured with a flow-tester are plotted on the ordinate (logarithm scale).
DETAILED DESCRIPTION OF THE INVENTION
The present invention is described hereinafter in more detail.
A lactone resin to be used in the present invention can typically be prepared by subjecting lactone monomers such as ε-caprolactone or trimethyl caprolactone or δ-valerolactone, etc., to ring-opening polymerization in the presence of an appropriate catalyst and an initiating agent having at least one active hydrogen atom.
However, in order to obtain a lactone resin to be used in the present invention, which has a relative viscosity value in a range of from 1.15 to 3.20 a very minor amount (e.g., less than 0.1% by weight, more specifically approximately 0.02% or less) of water normally present in the monomer is utilized as the initiating agent having at least one active hydrogen atom, without addition of any other initiating agents.
As the amount of water in the lactone monomer is lessened, the relative viscosity value of the lactone resin is larger, that is, the molecular weight of the resin is higher.
In preparing the lactone resin, a catalyst is preferably used.
As the catalyst used for the ring-opening polymerization, there can be mentioned an organic titanium compound, and an organic tin compound, and a stannous halide such as stannous chloride.
Preferably the catalyst is used in an amount of from 0.1 to 5,000 ppm by weight based on lactone monomer, more preferably from 10 to 100 ppm.
It is appropriate that the reaction temperature be from 100 to 230° C. and preferably the reaction is carried out under an inert gas atmosphere.
If the reaction temperature is higher than 230° C., such causes thermal decomposition of the lactone polymer, and the molecular weight of the lactone polymer does not increase.
On the other hand, in the case of lower temperatures than 100° C. reaction velocity is slow, and productivity is poor.
Thermoplastic lactone resins haVing Various molecular weight (that is, corresponds to the relative viscosity) are produced and used in many kinds of fields, e.g., because of having a property of low melting temperature of approximately 60 to 80° C.
The relative viscosity value was measured with a capillary viscometer (Ubbelohde's viscometer) according to Japanese Industrial Standard K 6726 in the present invention.
A toluene solution containing 1% by weight of a lactone resin was used to measure.
Measurements of the relative viscosity value were carried out while maintaining a temperature of 25.00°±0.05° C.
Lactone resin having a relative viscosity value in the range of from 1.15 to 3.20 can be used in the present invention.
A preferable relative viscosity value of the lactone resin to be used is a range of from 1.50 to 3.20.
Such resin is rigid and tough at ordinary temperatures (i.e., at about 20° C.).
It is noted that the lactone resins having a relative viscosity value in a range of from 1.15 to 3.20 are commercially available for various kinds of intended uses.
For example, lactone resin is used as a toggle operating body (Japanese Unexamined Patent Publication (Kokai) No. 240492/1985), a composition for a modeling compound (Japanese Unexamined Patent Publication (Kokai) No. 42679/1986), a medical gypsum material (Japanese Unexamined Patent Publication (Kokai) No. 81042/1983), a splint material, a face mask for shielding from radioactive rays, or a modeling material for a periwig (Japanese Unexamined Patent Publication (Kokai) No. 215018/1985).
Specific examples of lactone resin having a relative viscosity value of from 1.15 to 3.20 include caprolactone H-1, H-4, H-5, and H-7, which are manufactured and commercially supplied by Daicel Chemical Industries, Ltd.
Lactone resins H-5 and H-7 are more preferably used, although the other above-described grades on the market can be also used.
Also, it is possible to use either one kind of lactone resin or a mixture composed of two or more kinds thereof.
In the case of using a mixture composed of two grades of the lactone resins, it has an effect of an improved flexural strength in molds (green body) in comparison with a corresponding single grade of resin. Accordingly, it is more suitable for a mold having thin thickness parts in structures which might be easy to break.
The subject matter of the present invention involves the use of a caprolactone resin as a binder for a powdered metallic material in place of thermoplastics such as polypropylene, polyethylene, and the like, and waxes such as carnauba wax, paraffin wax and the like.
One beneficial effect of the present invention is that the time required (dewaxing time and sintering time) to remove or eliminate the binder from shaped molds (green body) can be shortened; thereby, productivity can be promoted.
Also, stearic acid or a metal stearate, which are conventionally used as a lubricant in molding of resin, can be blended optionally.
As a result of blending of a lubricant, the ability of releasing from a molding die can be improved, and flowability of the melted composition can be improved in molding under heating.
Thereby, a shaped molded body having an excellent surface appearance, such as smoothness or glossiness, can be obtained.
The optional stearic acid or a metal stearate is preferably used in an amount of from 0.1 to 5% by weight based on the total weight of the composition, and more preferably from 0.3 to 2% by weight.
In the case that the amount of the stearic acid or metal stearate is less than 0.3%, any lubricating effect is low.
On the other hand, in the case of the mixing amount of more than 5%, the lubricating effect cannot be further improved, and on the contrary, undesired harmful effects tend to occur.
Conditions for producing a metallic sintered body according to the present invention are further described hereinafter.
(a) Mixing amount of lactone resin in a green body:
The mixing amount of the lactone resin is preferably from 5 to 30% by weight, based on the total weight of the composition, and more preferably approximately 10%.
In the case that the amount of the lactone resin is less than 5%, flowability of the melted composition is not only insufficient and difficult to mold, but also the shaped mold (green body) having desired strength can best be obtained.
On the other hand, in case of the mixing amount of more than 30%, the time required to remove the resin is extended, and there further occurs a volume shrinkage in a brown body or a silver body, and still further there occurs an undesired tendency toward brittleness in the brown body or the silver body.
A mixing amount range of from 8 to 10% is most preferable because of a good balance in various properties.
FIG. 1 is a graph illustrating example results obtained in measurement of the temperature dependence of flow properties in the melted composition composed of a powdered SUS 316L stainless steel having an average particle size of 12 μm and a polycaprolactone resin having a relative viscosity value of 2.34, in which a mixing ratio of the caprolactone resin to the powdered metal was 10/90 by weight; in FIG. 1, temperatures are plotted on the abscissa and values measured with a flow-tester (manufactured by Shimazu Mfg. Co., Ltd., a loading weight of 10 kg/cm 2 , a nozzle diameter of 1 mm φ ×a tube length of 10 mm, preheating time of 10 minutes) are plotted on the ordinate (logarithm scale).
(b) Average particle size of a powdered metallic material:
The average particle size is preferably from 1 to 50 μm.
An average particle size smaller than 1 μm is not preferable because of a large specific surface area of the powdered metal.
On the other hand, an average particle size larger than 50 μm is not preferable because of considerable decline of mechanical strength in a green body before heating and in a brown body or a silver body after heating and sintering.
(c) Pressure condition in molding of a green body:
Molding pressures are preferably from 150 to 1,000 kg/cm 2 .
A molding pressure lower than 150 kg/cm 2 is not preferable because of a lack in dimensional precision of a mold.
On the other hand, even though the molding pressures are higher than 1,000 kg/cm 2 , no further advantage is obtained.
(d) Temperature condition in molding of a green body:
Molding temperatures are preferably from 150° to 230° C.
A molding temperature lower than 150° C. is not preferable, because flowability of a melted composition is too low to mold.
On the other hand, a molding temperature higher than 230° C. is not preferable because of decomposition of the lactone resin, though flowability is elevated.
In passing, there is a relationship between temperature conditions and pressure conditions in molding, namely, lower temperatures can be applied in the case of higher pressure conditions.
Flowability, i.e., viscosity of a composition composed of a mixture of a powdered metallic material with a lactone resin, is a significant condition in melting, and it is preferable that a flow condition of being easy to flow is applied in case of a use of a complex shaped mold. Injection molding, extrusion molding, and/or compression molding can be applied.
(e) Dewaxing condition:
(i) Heating speed
The heating speed is preferably from +5° to +100° C./hour. It is not preferable that the speed is more than +100° C./hour, because there occurs small holes or cracks by foaming and then a usable brown body or silver body cannot be obtained.
On the other hand, it is not preferable that the speed is not more than +5° C./hour, because there is poor in actual productivity on account of too slow heating-up speed.
(ii) Heating temperature
The heating temperature is preferably 250° to 800° C. It is not preferable that the heating temperature is less than 250° C., because the lactone resin which is a binder cannot be sufficiently removed or eliminated, and would remain in a sintered metallic mold.
On the other hand, it is not preferable that the heating temperature is more than 800° C., because there tends to occur an imprecision in dimensions of the sintered metallic molded body produced.
(iii) Retention time in heating
The retention time is preferably up to 15 hours. The retention time is not necessarily indispensable in case of manufacturing a mold having thin parts in the structure, because the resin can be sufficiently totally removed during the initial heating process.
On the other hand the lactone resin can be removed from any shaped green body, even having thick parts in the structure, within 15 hours.
(iv) Atmosphere in heating and sintering
It is preferable that air atmosphere is applied in a low temperatures process, and nitrogen gas or a mixture of nitrogen and hydrogen gas atmosphere is applied in a high temperatures process, from the viewpoint of prevention of oxidation in metallic materials. The sintering process (high temperatures) can be also carried out in vacuum.
It is preferable that a green body is buried into inactive alumina or silica and or zirconia powder in heating and sintering when the present invention is put into practice. Thereby not only is an effect of retention of shape of the green body provided, but also exhausting effect of melted lactone resin is promoted owing to capillary phenomenon, whereby heating time can be decreased.
In the following, the present invention is further illustrated by examples and comparative examples more specifically.
EXAMPLE 1
90 parts by weight of a powdered SUS 316L stainless steel having an average particle size of from 5 to 8 μm and 10 parts by weight of a caprolactione resin having a relative viscosity value of 2.34 were mixed by a compression kneader while maintaining a temperature of 135° C. for a period of 1 hour, followed by crushing after cooling to prepare a mixed composition having an average particle size of 2 mm.
Next, an injection pressure of 700 kg/cm 2 and an injection temperature of 180° C. were applied to form a cylindrical mold having tapered thickness of wall, having a height of 45 mm and maximum thickness of 20 mm and minimum thickness of 3 mm and maximum diameter of 45 mm and minimum diameter of 24 mm, followed by dewaxing by burying in alumina powder under the condition of a heating speed of +30° C./hour and a heating temperature of 500° C. and a dewaxing time of 10 hours, followed by sintering in a hydrogen gas atmosphere while maintaining a temperature of 1,200° C. for 4 hours to obtain an excellent metallic sintered body.
EXAMPLE 2
The same procedures as described in Example 1 were repeated, except that 90 parts by weight of Fe-Ni alloy having an average particle size of from 4 to 7 μm was used again in place of the stainless steel component, to obtain an excellent metallic sintered body.
EXAMPLE 3
The same procedures as described in Example 1 were repeated, except that 92 parts by weight of a powdered SUS 316L stainless steel and 8 parts by weight of a polycaprolactone resin were used in place of the component amounts used in Example 1, to obtain an excellent metallic sintered body.
EXAMPLE 4
The same procedures as described in Example 1 were repeated, except that 91 parts by weight of a powdered SUS 316L stainless steel and 9 parts by weight of a polycaprolactone resin were used, to obtain an excellent metallic sintered body.
EXAMPLE 5
The same procedures as described in Example 3 were repeated, except that additionally 0.5 part by weight of stearic acid (supplied by Wako Chemicals Co.) was mixed into the total amount of the lactone resin and the powdered metal, to obtain an excellent metallic sintered body.
Torque (corresponding to melting viscosity) in melting was decreased to 2/3 in comparison with Example 3 in which the conditions were identical except for mixing of stearic acid.
Furthermore, the loading power required to be released from a molding die was decreased to 60%, that is, releasing ability from a molding die was improved.
EXAMPLE 6
The same procedures as described in Example 3 were repeated, except that additionally 1 part by weight of magnesium stearate (supplied by Wako Chemicals Co.) was mixed into a total amount of the lactone resin and the powdered metal to obtain an excellent metallic sintered body.
Torque in melting was not decreased in comparison with Example 3 in which the conditions are identical except for mixing of magnesium stearate; however, the loading power required to be released from a molding die was decreased to the extent of not being capable of measurement, that is, releasing ability from a molding die was considerably improved.
EXAMPLE 7
The same procedures as described in Example 1 were repeated, except that 91 parts by weight of a powdered carbonyl iron having an average particle size of from 5 to 8 μm was used in place of powdered SUS 316L stainless steel, to obtain an excellent metallic sintered body.
EXAMPLE 8
The same procedures as described in Example 1 were repeated, except that 10 parts of polycaprolactone resin having a relative viscosity value of 1.50 were used in place of the polycaprolactone resin used in Example 1, to obtain an excellent metallic sintered body.
EXAMPLE 9
The same procedures as described in Example 1 were repeated, except that 8 parts of polycaprolactone resin having a relative viscosity value of 1.93 were used in place of the polycaprolactone resin used in Example 1, to obtain an excellent metallic sintered body.
EXAMPLE 10
The same procedures as described in Example 6 were repeated, except that 8 parts of polycaprolactone resin having a relative viscosity value of 1.28 were used in place of the polycaprolactone resin used in Example 6, to obtain an excellent metallic sintered body.
EXAMPLE 11
The same procedures as described in Example 6 were repeated, except that 8 parts of polycaprolactone resin having a relative viscosity value of 1.93 were used in place of the polycaprolactone resin used in Example 6, to obtain an excellent metallic sintered body.
COMPARATIVE EXAMPLES
The same procedures as described in the foregoing Examples were repeated, except that the polycaprolactone resins were replaced with a mixture composed of polypropylene resin and paraffin wax, and the compositions were kneaded while maintaining a temperature of 200° C.
A total time of approximately 40 hours was required for conducting a dewaxing process and a sintering process in order to obtain an excellent metallic sintered body.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. | A composition for producing a metallic sintered body consisting essentially of a mixture of a powdered metal having an average particle size of not more than 50 microns with a lactone resin having a relative viscosity value in the range of from 1.15 to 3.20 is disclosed.
The composition has excellent properties such as mechanical strength of a green body thereof, and only a short time being necessary for removal or elimination of binder in comparison with conventional sintering compositions.
Furthermore, the binder in the present composition is substantially composed of a single component; accordingly, manufacturing process control can be simplified by use of the lactone resin.
Furthermore, a method for producing a metallic sintered body using such composition is also disclosed. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Priority of U.S. Provisional Patent Application Ser. No. 60/435,994, filed Dec. 23, 2002, incorporated herein by reference, is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
Not applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to outdoor cooking devices and cooking accessories and more particularly to a gaseous fuel fired outdoor cooker that is supplied with a source of gaseous fuel such as butane or propane from a canister and that includes a stand, pot, and pot liner, the improvement including a special configuration of the burner that protects the underlying support (eg. deck or table) when a user foolishly places the burner on a combustible or heat sensitive surface (for example, wood, paper, or plastic).
2. General Background of the Invention
A number of outdoor cookers have been sold commercially for a number of years and are admitted as “prior art” type burners. These “prior art” burners have traditionally included a metallic frame that supports a burner nozzle, such as a cast iron burner nozzle. Such burner nozzles are commercially available and are often a component part of natural gas fired hot water heaters.
Examples of these prior art type outdoor cooking devices can be seen on the Metal Fusion website (www.KingKooker.com). Patents have issued naming Norman Bourgeois as inventor that relate to burners and related cooking apparatus. Examples include U.S. Pat. No. 5,065,735 for a “Convertible Burner Apparatus” that features different primary burner frames and legs that can elevate the burner frames. Other patents that relate to cooking devices include the aforementioned, and patent numbers 1,335,375; 1,671,677; 1,679,567; 1,859,615; 2,355,948; 2,414,679; 2,485,774; 5,065,735; 5,758,569; 5,813,321; 5,970,852; 6,058,830; 6,314,869; 6,439,107, each of which is hereby incorporated herein by reference.
The burner nozzle can be a cast iron hot water heater type burner nozzle or a jet burner arrangement that uses a single orifice or outlet centered in a cylindrically-shaped, vertically oriented metallic tube. Probably the most common version of the prior art “jet burner” arrangement is seen in Metal Fusion's catalog as Model No. 90 PK. Another version of this type of cooker includes two spaced apart circular rings connected with struts and having a cylindrically-shaped wind guard or shroud. This type of prior art burner can be seen for example as Metal Fusion Model Nos. 82 PK, 83 PK, 85 PK, 86 PK, and 86 PKJ. A prior art portable propane outdoor cooker, various outdoor fryers, and other outdoor cookers and related accessories are shown on the Metal Fusion website (www.KingKooker.com).
One of the problems with outdoor cookers is the unfortunate and foolish user that places the burner on a combustible or heat sensitive surface such as a wooden deck, wooden table, plastic table, plastic deck or on newspaper that is spread on a table, floor, etc. If the burner is operated at a very high intensity for a long period of time over a dry wood surface such as an old deck or table, fire could result.
BRIEF SUMMARY OF THE INVENTION
The present invention includes a burner frame having a base for engaging an underlying support surface, the burner frame having a burner nozzle for generating a high intensity flame for use in cooking. A supply hose can be connected to the nozzle for supplying butane, propane or other gaseous fuel product to the burner nozzle. The burner frame has a support surface for cradling a pot.
The burner frame includes a base portion (e.g. ring) and an upper portion (e.g. ring) with legs connecting the upper and lower portions.
The upper portion supports pot support bars or a grate (e.g. multiple grate members) that can extend horizontally to cradle the bottom of a cooking pot.
A heat shield is supported by the burner frame, at a position below the flame that emits from the nozzle tube. A pair of heat shields can be provided (e.g., welded to the frame). A first shield can be positioned just below the top of the nozzle tube and a second shield can be positioned below the first shield.
One of the shields can be positioned at an elevation next to the burner element.
The burner element can be a vertically oriented tube with a hollow bore. A nozzle is typically placed inside the tube bore so that during cooking the nozzle discharges gaseous fuel upwardly to supply a flame for cooking. Such a vertical tube, bore and nozzle arrangement per se is well known in the art, having been widely sold for decades.
One of the shields can be placed below the burner nozzle. When a vertical tube and nozzle are used, one of the shields can be placed below the vertical tube.
The shields can be of a transverse diameter that is much greater than the transverse diameter of the tube, and can be approaching pot diameter or a greater than pot diameter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
FIG. 1 is a plan view of the preferred embodiment of the apparatus of the present invention;
FIG. 2 is a sectional, elevation view of the preferred embodiment of the preferred embodiment of the apparatus of the present invention taken along lines 2 - 2 of FIG. 1 ;
FIG. 3 is a perspective view of the top view of the preferred embodiment of the apparatus of the present invention;
FIG. 4 is a fragmentary perspective view of the preferred embodiment of the apparatus of the present invention illustrating te vertical tube, nozzle and shield in detail;
FIG. 5 is perspective view of an alternate embodiment of the apparatus of the present invention;
FIG. 6 is a fragmentary view of the alternate embodiment of the apparatus of the present invention;
FIG. 7 is an exploded, partial perspective view of the alternate embodiment of the apparatus of the present invention;
FIG. 8 is an exploded view of the alternate embodiment of the apparatus of the present invention; and
FIG. 9 is a perspective view of the alternate embodiment of the apparatus of the present invention shown in a collapsed, storage or shipping position.
DETAILED DESCRIPTION OF THE INVENTION
Burner apparatus 10 provides burner frame 40 that includes a lower end portion with a base that can be a ring 11 and an upper end portion that can be a ring 15 . A plurality of preferably three legs 12 , 13 , 14 span between base ring 11 and upper end portion ring 15 . The rings 11 , 15 and legs 12 , 13 , 14 can be connected together using welding, for example. The rings 11 , 15 and the legs 12 , 13 , 14 can be of steel or stainless steel as examples.
The upper end portion of frame 40 provides a grate 38 for holding a known pot 39 with known liner or basket 41 . A plurality of preferably three or more pot support bars (e.g., steel) 16 , 17 , 18 can define grate 38 and can be attached to the upper surface of upper ring 15 , for example, being welded thereto. Legs 11 , 12 , 13 can be welded to the combination of ring 15 and pot support bars 16 , 17 , 18 (see FIGS. 1–3 ).
A fuel supply line 19 extends horizontally, being welded to frame 40 at leg 12 as shown in FIG. 2 . Fuel line 19 provides at one of its end portions an inlet fitting 20 to which a commercially available hose 37 , pressure regulator, and fuel (e.g. propane, butane, etc.) tank (or other suitable fuel supply) can be attached.
An end of fuel line 19 opposite fitting 20 provides an elbow 21 that carries a known and a commercially available nozzle jet 42 . Nozzle tube 22 has an open ended bore 35 . Tube 22 extends around the nozzle jet 42 and channels the flame that is generated at the nozzle 42 upwardly toward the cooking pot 39 that is supported by bars 16 , 17 , 18 of grate 38 .
A jet baffle 23 can be rotated to a position above nozzle tube 22 as shown in FIG. 1 or can be mounted to tube 22 so that it can be rotated toward or away from nozzle tube 22 as shown in FIGS. 1 , 3 and 4 to vary heat intensity that is directed to the pot 39 .
Baffle rod 24 is mounted in baffle sleeve 27 . Jet baffle 23 is mounted (for example, welded) to top of baffle rod 24 . A bend 26 in baffle rod 24 provides an offset lower end portion 25 that can be gripped by a user and rotated in order to rotate baffle rod 24 and jet baffle 23 to position it in a desired location before lighting of the burner 10 . Such jet baffles 23 are known prior art.
Upper heat shield 28 is supported by the frame 40 . Shield 28 can be attached to frame 40 at the legs 12 , 13 , 14 , being welded thereto, for example. The upper heat shield 28 can be positioned at an elevation that is next to tube 22 , e.g., in between the upper end 36 and bottom of nozzle tube 22 as shown in FIG. 2 . Shield 28 extends radially from nozzle tube 22 to periphery 33 (See FIGS. 1 , 2 , and 3 ).
Lower heat shield 29 is attached to the frame 40 at legs 12 , 13 , 14 , (for example, being welded thereto). Lower heat shield 29 is at an elevation that is below nozzle tube 22 providing a gap 34 that enables air to enter the bottom of nozzle tube 22 so that air can enter nozzle tube bore 43 and reach the flame that emits from the nozzle jet 42 in tube 22 and ensure combustion.
Periphery 33 can be at the outer edge of lower ring 11 , or at the outer edge of grate 37 , or it can be about equal to or greater than the diameter of pot 39 . Notice in FIG. 1 that the periphery 33 of upper heat shield 28 can extend further from nozzle tube 22 than the periphery 32 of pot support bars 16 , 17 , 18 (and can extend beyond the periphery of any pot 39 placed on bars 16 , 17 , 18 . This configuration ensures that the flame exiting the top 36 of nozzle tube 22 will be reflected upwardly, preventing excessive heat from being transferred to a surface 44 upon which lower ring 11 rests.
The upper and lower heat shield 28 , 29 provide a safety feature for preventing excess heat transfer to surface 44 . The heat shields 29 , 30 thus prevent excessive transfer to surface 44 and, hopefully, prevent fire if a user foolishly places the burner 10 on a combustible or heat sensitive surface such as a wooden deck, wooden table, plastic, or paper articles.
In FIGS. 5–9 , an alternate embodiment of the apparatus of the present invention is shown, designated generally by the numeral 50 . Outdoor cooking apparatus 50 is an alternate embodiment that illustrates a collapsible outdoor cooking apparatus that can more easily be stored in a reduced area. Base ring 51 supports preferably three legs 52 , 53 , 54 . Each leg has an upper end portion 55 that is hollow and provides an internal thread 56 . Each leg 52 , 53 , 54 can removably attach at its upper end portion to a strut 57 , 58 , 59 respectively.
Each strut 57 , 58 , 59 provides a lower end portion 60 that has a bend 61 and hollow sleeve 62 . Sleeve 62 is preferably generally vertically oriented and provides sleeve bore 63 . For assembling the outdoor cooking apparatus 50 in the operating position that is shown in FIG. 5 , bolt 64 passes through bore 63 of sleeve 62 and forms a threaded connection with internal threads 56 at upper end portion 55 of each leg 52 , 53 , 54 .
In order to disassemble the apparatus for storage or shipment, the bolts 64 are removed in the direction of arrows 65 as shown in FIG. 7 so that each strut 57 , 58 , 59 separates from its respective leg 52 , 53 , 54 .
An upper ring 66 is attached to the upper end portion of each of the struts 57 , 58 , 59 with a connection that can be welded, for example. A pot support bar is attached (i.e. welded) to upper ring 66 next to each of the struts 57 , 58 , 59 . As shown, for example, in FIGS. 5 , 8 and 9 , pot support bar 67 attaches to upper ring 66 next to strut 57 . Pot support bar 68 attaches to ring 66 next to strut 58 . Pot support bar 69 attaches to ring 66 next to strut 59 .
A conduit 70 is provided for supplying a selected gas fuel product such as propane, butane or the like to burner element 71 . A flexible hose 77 can be used to supply a selected food product to conduit 70 . Burner element 71 can be provided with a jet baffle 72 . The construction of conduit 70 , burner element 71 and jet baffle 72 can be as shown and described with respect to the preferred embodiment of FIGS. 1–4 , providing a horizontal fuel line, elbow, nozzle, and nozzle tube such as is shown in FIGS. 1 and 2 . The jet baffle 72 can be provided with a rotary connection to the outside of the nozzle tube as shown with respect to FIGS. 1–4 .
Upper baffle plate 73 can be attached (for example, welded) to struts 57 , 58 , 59 as shown in FIGS. 5 , 8 and 9 . Lower baffle plate 74 can be attached (for example, welded) to struts 57 , 58 , 59 . The lower baffle plate 74 is welded to struts 57 , 58 , 59 next to the bend 61 portion thereof as shown in FIGS. 5 , 6 , 8 and 9 . The upper baffle plate 73 can be attached to struts 57 , 58 , 59 , being welded thereto at a position generally in between bend 61 and ring 66 and below the top of burner element 71 .
Upper baffle plate 73 has a periphery 75 provided with a plurality of circumferentially spaced apart opening 76 . In the collapsed storage or transport position of FIG. 9 , bolts 64 can be placed through openings 76 in baffle plate 73 and then connected to the internal threads 56 of upper end portion 55 of struts 52 , 53 , 54 .
Parts List
The following is a list of parts and materials suitable for use in the present invention:
Parts Number
Description
10
outdoor cooking apparatus
11
base ring
12
leg
13
leg
14
leg
15
upper ring
16
pot support bar
17
pot support bar
18
pot support bar
19
fuel line
20
inlet fitting
21
elbow
22
nozzle tube
23
jet baffle
24
baffle rod
25
lower end portion
26
bend
27
baffle sleeve
28
upper heat shield
29
lower heat shield
30
attachment
31
attachment
32
periphery
33
periphery
34
gap
35
tube bore
36
upper end
37
hose
38
grate
39
pot
40
burner frame
41
basket
42
nozzle jet
43
tube bore
44
underlying support surface
50
outdoor cooking apparatus
51
lower ring
52
leg
53
leg
54
leg
55
upper end portion
56
internal thread
57
strut
58
strut
59
strut
60
lower end portion
61
bend
62
sleeve
63
sleeve bore
64
bolt
65
arrow
66
upper ring
67
pot support bar
68
pot support bar
69
pot support bar
70
conduit
71
burner element
72
jet baffle
73
upper baffle plate
74
lower baffle plate
75
periphery
76
opening
77
hose
The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. | A cooking apparatus includes a frame with an upper section for holding a pot and a lower surface for resting upon an underlying support surface. The frame has a burner element that can be a nozzle tube having a commercially available burner nozzle for generating a cooking flame during use. The nozzle can be fueled with propane, butane or the like using a commercially available tank, regulator and supply hose. The frame can include upper and lower rings, the lower ring providing the lower surface and the upper ring having pot support members for holding the bottom of a pot. One or more heat shields positioned below the flame during use lessen heat transfer from the flame to the underlying support surface. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Ser. No. 61/024,397 filed Jan. 29, 2008, the entire contents of which are herein incorporated fully by reference. This application also claims priority from PCT/US2009/032497 filed Jan. 29, 2009, the entire contents of which are herein incorporated fully by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a high concentration functional material gel composition and effective delivery composition thereof. More specifically, the present invention relates to a high concentration functional material gel composition comprising a small organic molecule having at least one of a carbonyl group and at least one of an isolated hydroxyl group from the carbonyl group as a defined mandatory element holding and delivering amounts of functional materials. This is achieved without depending on employing additional incompatible materials in the functional composition, including for example inorganic salts, polymers, absorbents petroleum waxes, and paraffin hydrocarbons.
2. Description of the Related Art
The related art involves a conventional small organic functional material composition, hereinafter referred to broadly as a functional composition, is most likely liquid or oil because the composition contains substantially all small (low weight) organic molecules, which have a molecular weight of less than approximately 500 and which have a lower melting point than an ambient temperature range, namely a melting point lower than about 4 C. Ambient temperatures are suggested to be between about 10 C/50 F to about 38 C/100 F with a normal average of approximately 25° C./77 F as a conventional room temperature.
Conventionally related functional material compositions also comprise single molecules, in other word, monomers.
One popular small molecular functional composition is an aromatic functional composition which has a variety of benefits and functions. For example, an aromatic functional composition may provide a pleasant sensation; enhance mood; cover (or mask) for a bad odor, and organoleptically neutralize (or quench) mal-odor, including urine odors and unpleasant odors like “musty-odors” and “garbage-origin” odor; or to control growth of microorganisms.
Another small molecular functional composition is a cleaning functional composition to remove greasy materials including a variety of oils, glue, gum, paint, and dirt.
There are a few contradictions between an aromatic functional composition and target objects. For example, when applied, an aromatic functional composition to enhance and improve mood quickly disappears from the range of a human organoleptic system because of its volatile characteristics—it can no longer be smelled. For example, sprayed aromatic functional compositions applied over cat litter to control mal-odor from waste is superficial and only a temporary solution to cover the urine odor because the urine odor is continuously generated by and emerging from the litter until removed. A mal-odor from a mold on a wall is persistent until the mold is physically or chemically removed. A mal-odor from deteriorating food in garbage is persistent until the garbage is cleaned. A mal-odor from the water system like toilet or sewage is persistent because of frequent uses and continuously supplied mal-odor-source, i.e. urine, and fills up its proximity. Thus, simple covering odors are ineffective.
No practical functional composition or system is disclosed to control effectively, constantly and on-demand such mal-odors in between a human organoleptic system and a mal-odor source, to deliver easily mood enhancing function on-demand to the user; or to remove easily and clean a variety of both oily and water soluble deposits, dirt and taints without giving adverse and/or harmful effect, including mal-odor, irritation and toxicity.
Although there are systems such as fragrance sprays and scented candles that may provide a short-lived result, none is fully effective and satisfactory, or long lasting to provide neutralizing urinal odor when used because the conventional methods have inherent drawbacks.
One drawback is that the fragrance is dispersed broadly, without considering mal-odor emerging direction. Additionally as a concern a human organoleptic system adapts easily and quickly any odor. In other word, even excessively-used fragrances are useless to control mal-odor after several applications due to loss of organoleptic sensation.
On the other hand, it is well known that fragrance oils may change and/or enhance moods. For example, a lavender scent may provide a relaxed mood and a citrus scent may provide an exciting mood. To receive such affects the closer smelling using portable personal type composition, the more efficient can be obtained and the less fragrance in the environment is needed without wasting aromatic functional materials.
Another mal-odor source is wet and muddy and watery areas filled with such rotten materials, microorganism, garbage, food staffs and waste materials including urine or stool. The mal-odors from these sources are strong and persistent. Nevertheless one of the best temporary methods to cover such mal-odors is to simply apply a quenching substance—the detriment being the need for constant reapplication that has here to for remained unrecognized.
One example used in a water system is sublime chemicals, naphthalene and camphor that have very strong unpleasant odor and are considered toxic and carcinogenic. Another example used in a water system is a solid crystalline toilet-ball generally comprising surfactants and fragrances—unfortunately these types of crystalline balls cannot be left in the water because they dissolve in the water and quickly drain.
A cat litter and a urinal pot that are popular in homes and medical facilities are strong mal-odor sources. One example used in a cat litter is disclosed in US Patent 2007-0181071, the entire contents of which are herein fully incorporated by reference, which uses gypsum and soda ash which is inorganic and incompatible material with organic molecules and fragrance materials. In addition, in-house testing with soda or sodium bicarbonate may worsen urine odor via chemical reaction.
An aromatic functional composition is generally oil or liquid that is the most difficult form to be carried and control in a dispersion rate. Shimizu et. al. JP Laid-Open Patent JP2002065820, the entire contents of which are fully incorporated herein by reference, discloses an oily gelled aromatic composition using 12-hydroxystearic acid, paraffin wax, fatty acid amide or substituted urea compound and volatile hydrocarbon to make a gel aromatic composition or fragrance. Shimizu's composition includes at least biodegradable non-sustainable paraffin waxes and more importantly VOC suspected hydrocarbons.
Mori and Ochi, JP Laid-Open Patent JP61012613, the entire contents of which are fully incorporated herein by reference, discloses a gelatinous aromatic composition including 12-hydroxystearic acid and a relatively volatile paraffinic oily perfume, wherein paraffinic oily perfume comprises lower boiling point paraffin (petroleum hydrocarbon) and aromatic materials.
An all-purpose cleaner is becoming more and more critical to increase quality of life, e.g. hygienic quality of life to prevent a variety of diseases. A traditional way for cleaning dirt, especially oily dirt is to use surfactant. Wherever a large amount of water is available and it is appropriately drained into the sewage, the traditional cleaning method will work to clean the dirt. However, water cannot be applied always or is not practical in a variety of dirty objects, e.g. electric appliances and electronic apparatus.
Traditionally, volatile organic compounds or solvents, including toluene, xylene and limonene, even halogenated compounds in dry cleaning, have been used to remove oily dirt, including exhaust pollutants, wet paint, candle waxes, motor oil and oil base glue. All these solvents are considered neurotoxic (act as a neurotoxin) and/or carcinogenic and environmentally harmful materials under VOC (volatile organic compound) regulation. Accordingly, these are restricted and controlled substances to be used on human. In addition, these solvents have strong intolerable unpleasant odor and/or mal-odor, and cause nausea and headache.
A few fatty acid esters, including non-volatile isopropyl myristate (IPM) and dioctylate, have also solvation ability with resolving organic molecules as described above. DE Patent 4,136,811, the entire contents of which is herein fully incorporated by reference, discloses the formulation of a skin cleanser to remove paint on a hand including IPM and alcohol that is volatile and considered also health hazardous. All these small molecular cleaning functional materials are in liquid form and all are either sprayed or applied with cloth or brush. Any liquid form cleaner application has a few serious common drawbacks. These drawbacks include spreading and quickly and widely over the target object and dripping from the target object to cause secondary taints, while cleaning such an old label on a bottle or a poster glued on the wall. In addition, any liquid form requires a special handling and not considered portable. DE '811 did not provide any gel form.
One commercial gel product having IPM is being sold on line http://www.getspfx.com/IPM-Gel.asp, but does not disclose any detail but non-used gel agents Carbosil and TS100 inorganic silica acid base gel agent and to be applied to mouth and eye to remove chewing gum. Another reference GB Patent 2,400,374, the entire contents of which are incorporated fully by reference, is a liquid chewing gum remover containing 50% of D-limonene considered as VOC.
Another drawback of these organic solvent cleaning composition is that the composition cannot remove water soluble taint, including starch base glue and many residual food staff, including carbohydrates, amino acids, and salts. Accordingly, it is considered not all-purpose cleaner and is among those compositions that are not responsive to the concerns resolved by the present invention.
SUMMARY OF THE INVENTION
Until today, a variety of related disclosures noted the use of 12-hydroxystearic acid or hardened castor oil (include 12-hydroxystearic acid as main) to prepare products. However, any related disclosure has failed to recognize the important property that this composition both molecularly holds and also delivers the functional material effectively and gradually when prepared in the manner and composition suggested herein.
The inventors focused on the structural characteristics of the holding-delivery functional material base materials and discovered that there is common structural characteristics, wherein at least one of a carbonyl group and at least one of an isolated hydroxyl group from the carbonyl group, have common appearances as a solid form like crystal, powder and flake at ambient temperature and an excellent crystalline-forming property, and can provide dual functions in a variety of application environments and purposes including air, water, and material surface.
More specifically, the present invention provides a variety of compositions that are able to hold significant amounts of small aromatic organic functional materials and to delivery these organic functional materials on-demand in a variety of environments with user friendly, sustainable and non-toxic materials.
The present invention provides a gel functional composition and a function delivery composition. Further specifically, the present invention provides a gel aromatic functional composition and an all-purpose cleaning composition with portable, easily applicable, inexpensive, non-toxic, and more importantly user and environmentally friendly properties with utilizing minimum natural resources, and the system applicable easily and portably to almost any mal-odor sources and taints.
Even more specifically, the present invention provides to a high concentration functional material gel composition and an effective delivery composition thereof that is readily formable into commercially desirable shapes, maintains a cost effective formulation, allows the use of sustainable and renewable resources, and usable in a solid gel form, a gel granulated form, a paste form, or a soft gel form without employing additional form-enabling materials. Examples of form-enabling materials include a variety of quarterly ammonium materials, biodegradable surfactants, inorganic salts, polymers, petroleum waxes and suspected VOC (volatile organic compound) materials. The proposed material may be readily employed in conventional consumer quantities and enter the commercial water system without concern (e.g. toilet basin, cat litter, and urinal etc.).
The above, and other aspects, features, and advantages of the present invention will become apparent from the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
There are no drawings for the disclosure.
DETAILED DESCRIPTION OF EMBODIMENTS
Reference will now be made in detail to several optional embodiments of the invention.
In coping with the problems noted above, the present invention provides a system for manufacturing a high concentration functional material composition and effective delivery composition thereof (hereinafter referred to functional composition), the functional compositions that replace conventional functional material delivery composition.
In general, a gel composition, including not only a rigid/firm form but also powder, granules, soft gel and tablet forms but not limited thereto, is more convenient to be transported and be applied in practice. The inventors screened a variety of substances and properties including such as those substances solid at room temperature; highly lipophilic (oil soluble or affinitive to volatile materials) and partially hydrophilic property now recognized as being able to hold a rather large amount of organic small molecules with biodegradable, user friendly, air-phase environmentally friendly property; water-phase environmentally friendly property to avoid side effects and secondary concerns like clotting in water systems; further without compromising olfactory-friendly property which will not decrease pleasantness of aromatic composition, including fragrance and essential oils; an excellent crystalline-forming property; easy and effective delivery of functional materials and outstanding cleaning capability.
According to one aspect of the present invention, a gel and/or solid functional composition comprises a critical and mandatory holding-delivery base material at an ambient temperature comprising at least one molecule, shown in general Formulas (1) or (2) below, which have a carbonyl group and a hydroxyl group, and have at least one carbon atom between the carbon atom with ketone and another carbon atom with hydroxy group which may provide both intra-molecular and inter-molecular hydrogen bonding or either; which is a monomer; which is biodegradable and/or environmentally friendly with oxygen atoms in its molecule, which may hold functional materials at least 5% by weight of the total composition; and which may deliver and release functional materials constantly, adequately and on-demand from the total composition thereof.
Hydrogen boding is well known and studied in pure chemistry and composition chemistry. However, an interaction in outside environments like in air and water is unknown and far from certain. The present invention can provide a means to optimize creation to achieve a desirable holding-delivery property of material compositions, which can satisfy needs without using additional and/or specific device.
In alternatively desirable aspect of the present invention, one or more of the above noted holding-delivery base materials is selected one from the group represented with Formula (1); specifically, wherein (A) R1=OH, X═(CH2)9, Y═C, R2=(CH2)5CH3 and R3=H [as represented by 12-hydroxy-stearic acid shown in Formula (3) below]; (B) R1=OH, X═Y═C, R2=COOH and R3=CH2COOH [as represented by citric acid shown in Formula (4) below]; and wherein (C) R1=CH3, X═CH2, and Y=para-C6H6 (or benzene ring) including R2 and R3 [as represented by a raspberry ketone shown in Formula (5) below], but not limited to the above molecules, if a molecule is represented by Formula (1).
In another alternatively desired aspect of the present invention, one or more of the above noted holding-delivery base materials is selected one from the group represented with Formula (2); specifically, wherein: (A) R4=H and R5=OCH3 [as exemplified in vanillin], (B) R4=H and R5=OCH2CH3 [as exemplified in ethylvanillin], and (C) wherein R4=OCH3 and R5=H (as exemplified in methyl-4-hydroxybenzoate (paraben)].
All selected embodiments as the above have an excellent crystalline-forming property at ambient temperature. It is noted that the phrase ‘gel’ is to be interpreted liberally meaning ‘non liquid’, such that a gel may be a solid, amorphous or non-amorphous (partially or wholly crystalline) or may be a flexible solid like a gel-based composition.
A concentration of one or more of the above noted holding-delivery base materials are in the range of 1% to 95% by weight, and preferably, 2% to 80% and more preferably 3% to 50%.
It will be additionally recognized that the functional material may be selected from a wide group of materials including: an organic molecule; aromatic oil, fragrance; liquid-base remover, liquid-base cleaner, antibacterial, preservative, stabilizer, foaming agent, anti-mollusk, anti-fungous, anti-termite, anti-algae, anti-oxidation, anti-mosquito, and anti-feeding agents; insect repellant; herbicide; fertilizer; soil conditioner and water conditioner, an emollient, a fertilizer, an anti-bacterial material, an insecticide, and isopropyl myristate (IPM) as the ester of isopropanol and myristic acid.
EXPERIMENTAL EMBODIMENTS
A benefit of the present invention is further provided in the following Embodiments.
Embodiment 1
12-Hydroxy-stearic acid is being used to solidify the vegetable oils and to make clear candle, and also used in a variety of cosmetic composition as a firming agent. All compositions were heated and poured to a metal plate. Each weight was measured to calculate a relative ratio for aromatic function delivery composition. Comparison Sample 1, a candle wax (petroleum hydrocarbon wax) and scented candle is being used as an air-freshener. Comparison Sample 2, MC Stearin S (approximately 47% of palmitic acid, 49% of stearic acid and other saturated fatty acid by weight available from Kawaken Fine Chemical Co., Japan and registered as Stearic Acid), have very similar aromatic material delivery property, but the candle wax itself is slightly better than MC Stearin S. Comparison Sample 3 has only 12-hydroxy-stearic acid and Sample 1 is a mixture of 12-hydroxy-stearic acid and MC Stearin S. According to the table 2, it is recognized that addition of 12-hydroxy-stearic acid increases volatile functional material delivery ratio, wherein the chemical structural difference between 12-hydroxy-stearic acid and stearic acid is only if there is an isolated hydroxy group or not, and palmitic acid has no isolated hydroxyl group and two less methylene groups than stearic acid. Additional methylene group is considered generally not significant from chemistry standpoints. Accordingly, it is considered that the hydroxyl group is significant element to increase volatile functional material delivery ratio, also supported by Embodiment 4 of raspberry ketone.
Addition of 12-hydroxy-stearic acid improves appearance of the product and makes a longer lasting aromatic product with higher biodegradability and more affinity property to other ingredients than hydrocarbon petroleum waxes that are not sustainable, a VOC and very hydrophobic and less affinitive to small organic molecules having oxygen and/or nitrogen. Volatile functional material delivery rate can be controlled by changing a ratio between 12-hydroxy-stearic acid and stearic acid.
MC Stearin S sold under Stearic acid, another saturated fatty acid mixture like Triple Pressed Stearic Acid also sold under Stearic Acid containing variable amount of palmitic acid and stearic acid may be used without further concern.
TABLE 1
Volatile
(aromatic)
Candle Wax
HC
12-Hydroxy-
materials
(%), a paraffin
Stearin S
stearic acid
concentration
Samples
wax
(%)
(%)
(%)
Sample 1
50
34
16
Comparison
89
11
Sample 2
Comparison
90
10
Sample 2
Comparison
85
15
Sample 3
(%); By weight; Fragrance: Fragrance name: Green tea fragrance comprising 15% of vertenex, 8% of hexylsalcilate, 8% of hedione, 8% of geraniol, 15% of florol, 2.5% of lemon grass oil and the green tea base.
TABLE 2
Volatile
(aromatic)
materials
delivery
Odor
Odor
(decrease) ratio
Samples
Appearance
strength
quality
(after 17 days)
Sample 1
Smooth homogenous
Strong
Very
21%
with no color
good
irregularity
Comparison
Very smooth but like
Weak
Fair
16%
Sample 1
wet surface
Comparison
Like flour paste with
Very
Very
79%
Sample 2
irregular tone in color
strong
good
and appearance
Comparison
Smooth with small
Very
Fair
11%
Sample 3
irregularity
weak
Embodiment 2
Approximately 1.5 g of each Sample was formed into a plastic plate container, round shape with 40 mm diameter and 13 mm thickness) and a inside plate is turnable, which is called Swing-out available from Qosmedix, N.Y. The base materials were melted by heating and then aromatic materials were added to prepare all Samples by pouring onto the plate having a synthetic glue (organic compound base glue like Glue Dots® and Gorilla Glue®), approximately center of the plastic plate. The glue and each composition became solid without dropping from the plate. The container can be closed and opened at will to deliver conveniently aromatic materials on-demand with high portability. Specifically, there is no dripping and leaking of oily non-gel materials which cause a variety of problems due to oily materials when carried in a pocket or a handbag.
Sample 1 in the container was tested on mal-odor neutralizing effect. The results were evaluated by trained or contract testers.
TABLE 3
Place
Application method
Mal-odor type
Result
Closed-type
Open and placed in
Musty and earthy
Unpleasant musty
closet with a
close proximity to the
odor was not sensed
door
door
when the closet door
is opened.
Toilet room
Open and placed in
Heavy urinal
Sensing clean and
close proximity to the
ammonium note
almost no toilet odor
toilet
when enter.
Taxi with
Get in a taxi and open
Smoky cigarette and
The smoky cigarette
smoky odor
Sample where and when
unpleasant note
odor was gone out of
smoky.
organoleptic
sensation.
Small closed
Open and placed in
Sweaty and sour note
No particular mal-
child room
close proximity to the
odor was sensed
door.
when the door was
opened.
Embodiment 3
Further, another aroma function holding and delivery composition, Sample 2 comprising the materials provided in Table 4 may provide another preferable stable Embodiment 3 with methyl-4-hydroxybenzoate as a preservative and a secondary holding-delivery base material.
Sample 2
Percentage by
Material
weight (%)
MC Stearin S
32.8
12-Hydroxy stearic acid
49.2
Methy-4-hydroxybenzoate
1.6
Fragrance Green tea
16.4
Embodiment 4
Sample 3 is prepared using an insect repellant liquid composition sold in the market. Sample 3 is tested by a contract tester and showed appreciable protective effect from a mosquito.
Sample 3: Solid ball
Percentage by
Material
weight (%)
MC Stearin S
29
12-Hydroxy stearic acid
50
Methy-4-hydroxybenzoate
1
d,d-T-80 Prallethrin mixture*
20
*Commercial insecticidal and insect repellant active composition
Embodiment 5
Raspberry ketone characterizing raspberry odor of the fruit was melted and fragrance Refresh (as an aromatic function material) was added. Completely melted mixed liquid was poured to a mold. Approximately 9.3 g of the solid mixture, Sample 4, comprising 88% of raspberry ketone and 12% of fragrance Refresh by weight was immersed in man's toilet drain.
Each weight of the solid composition was measured and mal-odor neutralizing effect was evaluated. After 9 days the solid mixture completely disappeared into the drain. When the user urinated, the fresh aromatic olfactory sensation neutralized the urinal odor sensation, and in addition, when the toilet was flushed after use, further fresh clean sensation emerged from Sample 3 fills up to provide a fresh clean olfactory sensation when a next user entered the room.
Embodiment 6
Raspberry ketone base Sample 4 with fragrance Refresh and Sample 5 with fragrance Kiku were compared with MC Stearin S base Comparison Sample 4 (MC Stearin S and fragrance Refresh), Comparison Sample 5 (MC Stearin S only), Comparison Sample 6 (sodium bicarbonate only) and Comparison Sample 7 (sodium bicarbonate and fragrance Refresh) in urine. Each approximately 200 mg of Samples were put in the glass jar and 5 g of urine was added to each jar The result indicate that raspberry ketone delivers more aromatic functional materials than stearic acid base in the water system. By the way stearic acid, MC Stearin S and 12-hydroxy-steric acid do not dissolve in water even they were exposed for a few months. After aromatic functional materials were gone from both stearic acid and 12-hydroxy-stearic base, a mold began growing. Accordingly, from user convenient standpoints, it is desirable if the products completely disappeared either into the air, the drain or the water environment. In the soil, since the composition of the present invention is highly biodegradable, it will be quickly decomposed by soil bacteria.
TABLE 4
Urine odor
Terms
strength
Impression
Control (with no chemical)
+++
Very strong urine odor
Sample 4 (Fragrance
−
No urine odor
Refresh)
Sample 5 (Fragrance Kiku)
±
No urine odor and strong
fragrance characteristics
Comparison Sample 4
+++
Very strong urine odor
Comparison Sample 5
+
Weaker but remarkable
urine odor
Comparison Sample 6
+++
Very bad strong urine odor
Comparison Sample 7
±
Weaker but remarkable
urine odor
Fragrance Refresh comprises 15% of galaxolide, 7% of musk T, 23% of linalool, 3% of styralyl acetate, 8% of hedione, 12% of dihydromyrcenol and fresh base. Fragrance Kiku comprise 9% of galaxolide, 4% of triplal, 11% of florol, 22% of hedione, 18% of linalool and kiku base.
Embodiment 7
Sample 4 with the average weight 37.5 g of Embodiment 3 was molded like a cupcake and was tested in practical use for institutional man's rooms. As a commercial toilet cleaning ball from Nissan Chemical, used as a Comparison Sample 8 which is a surfactant base solid product. Sample 4 and Comparison Sample 8 were set in six different men's rooms lactated in different floors of the two premises. Samples and Comparison Samples were set at random inside-bottom of each man's toilet of the same toilet room. All Samples tested were completely disappeared within 5 months. Calculated average daily-decreasing-weights and general user's comments are shown in Table 5. It is obvious that Sample 4 is more acceptably pleasant and credited than the current market leading product.
TABLE 5
Terms
Sample 4
Comparison Sample 8
Daily decreasing
0.30 g-0.95 g
0.76 g-2.0 g
rate range
Preference by
Covered urine odor
Less covered urine odor and
users with
and preferred to
less preferred to Sample
covering mal-odor
Comparison Sample
Embodiment 8
Citric acid is found in citrus fruits and is an important intermediate in the citric acid cycle of human's metabolism. Also it is known to act as an environmentally benign cleaning agent. Citric acid has a rather high melting point at 153° C. Accordingly it is not appropriate to heat the acid with volatile aromatic materials to melt and mold. Thus 45 g of granule citric acid purchased was pulverized and was mixed with 10 g of fragrance Refresh to provide granular Sample 6. The fragrance concentration was 18.2% by weight. Even at this concentration the oil was not apart from the acid in granular form. 2 g of the granular Sample 6 was set at the bottom of a glass jar and approximately 30 g of fresh urine was added. Comparison Sample 9 without any chemical was prepared with the same amount of urine. Both were tested by smelling for a week. Sample 6 was dissolved immediately after the urine was added.
TABLE 6
Term
Sample 6
Comparison Sample 9
Right after
No recognizable urine odor
Strong urine odor
urine was
added
After 1 day
Almost no odor
Strong
After 3 days
No mal-odor, clear yellow-
Very strong ammonium like
brown solution
bad-odor, turbid
After one week
No mal-odor, clear yellow
Very strong mal-odor like
brown solution
typical unclean toilet odor
Embodiment 9
2 g of Sample 6 was dispersed over cat litter sand. After a few weeks, there was no recognizable cat urinal or waste odor and the contract testers were pleased. This application provides further benefits because when the composition dissolved in the urine or even when rain both the fragrance and citric acid were adsorbed on the soil of which most abandoned material is silica gel that is used as adsorbent for most organic molecules. As results, the aromatic functional composition would stay longer on or in proximity of the soil surface.
Embodiment 10
Ethylvanillin is formed into Sample 7 composed of 85% of ethylvanillin by weight and 15% of Fragrance Lavender composed of 18% of Musk T, 8% of Iso Super E, 4% of hedione, 15% of linalool, 20% of linalyl acetate, 20% of lavender oil, 4% of rosemary oil, and 11% of floral fragrance base. Sample 7 provide strong pleasant lavender scent with sweet and weak vanilla scent. Sample 7 has slowly degraded into the water system over a couple of month period.
Embodiment 11
Smooth white gel Sample 8 was prepared by following procedures. 3.05 g of 12-hydroxy-stearic acid and 1.04 g of an Amizol® emulsifier, Amizol CME; an amide ester (Kawaken Fine Chemical, Tokyo Japan), were gently heated to melt and 62 g of IPM and approximately 41 g of water added under continuous rather vigorous agitation until cooled down to give a smooth gel formula. Another smooth white gel Sample 9 was prepared using the same method but different content ratio. The gel formula Sample 8 and 9 are easily applied from a tube applicator. Sample 8 and 9 can be applied on the perpendicular wall without dripping for a while.
Comparison Sample 10, Comparison Sample 11 and Comparison Sample 12 have been prepared by mixing IPM, D-limonene and ethyl adipate with melted 12-hydroxy stearic acid (3) and then reheated to give a homogenous clear hot solution. All are cooled down to provide gels.
TABLE 7 Comparison Comparison Comparison Sample 8 Sample 9 Sample 10 Sample 11 Sample 12 Material (IPM) (IPM) (IPM) (D-Limonene) (Ethyl adipate) Functional 62 g 300 g 5.10 g 5.03 g 5.34 g material 12-Hydroxy 3.05 g 30 g 0.25 g 0.25 g 0.22 g stearic acid (3) Concentration of 2.8% 2.9% 4.7% 4.7% 4.0% acid (3) Water 41 g 700 g 0 0 0 Amizol ™ CME 1.04 g 0 0 0 0 Amizol ™ CDE 0 10 g 0 0 0 Appearance White soft- White soft- Semi-clear Semi-clear Semi-clear gel smooth gel. smooth gel. semi-hard gel. semi-hard gel. Semi-hard gel. Oily on Not oily on Very oily on Remove fat from the skin. the skin. the skin. the skin. Odor Odorless Odorless Odorless Strong odor Odorless
Gel Sample 8 and Sample 9, Comparison Sample 10, Comparison Sample 11, Comparison Sample 12 and water were applied old tin-can labels respectively. The results are shown in Table 8.
TABLE 8
Removal of an old label with
Starch
General
synthetic glue
base glue
observation
Sample 8
Very easy after several
Easily
Very clean easy
minutes and the very small
wiped off.
operation. Little
amount of residual glue was
bit oily but very
easily wiped off.
skin friendly
Sample 9
Very easy after several
Easily
Very clean easy
minutes and the very small
wiped off.
operation and
amount of residual glue was
very skin friendly
easily wiped off.
Comparison
Very easy after several
Not wiped
No odor, no
Sample 10
minutes and the very small
off.
harmful feeling
amount of residual glue was
on the skin and
easily wiped off.
noting is dripped.
Comparison
Easily smoothly peeled off
Not tested.
Strong citrus
Sample 11
the label with recognizable
odor and caused
amount of glue deposition
nausea.
after 5 minutes.
Comparison
The label was not peeled off
Not tested.
No odor.
Sample 12
smoothly and some are
remained.
Water
Almost nothing was peeled
Easily
No odor.
off with loosing color on the
wiped off.
label.
According to the above detail description and Embodiments, the present invention provides a solid fragrance delivery system in both air and water environment with a variety of portable and convenient forms. Those of skill in the art may form other functional elements including but not limited to antibacterial, preservative, stabilizer, foaming agents, anti-mollusk, anti-fungous, anti-termite, anti-algae, anti-oxidation, isopropyl myristate (IPM), anti-mosquito, insect repellant, anti-feeding agents, herbicide, fertilizer, and soil conditioner into a composition of the present invention, but not limited to without departing from the scope and spirit of the present invention.
The novel features that are considered characteristic of the invention are set forth with particularity in the appended claims. The invention itself, however, both as to its structure and its operation together with the additional object and advantages thereof will best be understood from the following description of the preferred embodiment of the present invention when read in conjunction with the accompanying drawings. Unless specifically noted, it is intended that the words and phrases in the specification and claims be given the ordinary and accustomed meaning to those of ordinary skill in the applicable art or arts. If any other meaning is intended, the specification will specifically state that a special meaning is being applied to a word or phrase. Likewise, the use of the words “function” or “means” in the Description of Preferred Embodiments, if employed at all, is not intended to indicate a desire to invoke the special provision of 35 U.S.C. 112, paragraph 6 to define the invention. To the contrary, if the provisions of 35 U.S.C. 112, paragraph 6, are sought to be invoked to define the invention(s), the claims will specifically state the phrases “means for” or “step for” and a function, without also reciting in such phrases any structure, material, or act in support of the function. Even when the claims recite a “means for” or “step for” performing a function, if they also recite any structure, material or acts in support of that means of step, then the intention is not to invoke the provisions of 35 U.S.C. 112, paragraph 6. Moreover, even if the provisions of 35 U.S.C. 112, paragraph 6, are invoked to define the inventions, it is intended that the inventions not be limited only to the specific structure, material or acts that are described in the preferred embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function, along with any and all known or later-developed equivalent structures, materials or acts for performing the claimed function.
Having described at least one of the preferred embodiments of the present invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes, modifications, and adaptations may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims. | The present invention relates to a high concentration functional material gel composition and effective delivery composition thereof. More specifically, the present invention relates to a high concentration functional material gel composition comprising a small organic molecule having at least one of a carbonyl group and at least one of an isolated hydroxyl group from the carbonyl group as a defined mandatory element holding and delivering amounts of functional materials. This is achieved without depending on employing additional incompatible materials in the functional composition, including for example inorganic salts, polymers, absorbents petroleum waxes, and paraffin hydrocarbons. | 2 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to a method for processing electrical parts.
[0002] A method is known in the art for the multiple manufacture of semiconductor chips, i.e. on a semiconductor wafer, which then for further processing is releasably fastened to a carrier, i.e. to a carrier foil (blue foil) clamped in a carrier frame. Afterwards, the wafer is separated into the individual semiconductor chips in such a manner that these chips still adhere to the carrier foil.
[0003] The further processing of the semiconductor chips takes place according to the state of the art, for example in so-called die bonders, in such a manner that these chips are picked up individually from the carrier foil by a pick-up element and then placed on a “second” carrier, which for example is formed by a lead frame or a substrate present in this lead frame. For the pick-up element, movement strokes in at least two axis directions are necessary, namely a transport stroke in horizontal direction between the semiconductor wafer and the second carrier and, both at the beginning and end of this transport stroke respectively, a vertical stroke for grasping and picking up a semiconductor chip from the carrier foil or for placing the respective semiconductor chip on the second carrier.
[0004] The processing of one semiconductor wafer, i.e. the transfer of the semiconductor chips present there in a plurality of rows to the second carrier at a high capacity (the number of transferred semiconductor chips per unit of time) is possible according to the prior art only by means of very fast movements of the pick-up element, particularly also considering the relatively long transport stroke, whereby for reasons of mass acceleration alone there is a limit to the increase in capacity that is possible by increasing the working speed.
[0005] The object of the present invention is to present a method and a device which enables the processing of electrical components held releasably on a carrier foil at a significantly higher capacity.
SUMMARY OF THE INVENTION
[0006] “Electrical components” according to the invention are particularly semiconductor chips, which are held releasably and by separation of a semiconductor wafer on a carrier foil (blue foil) fastened in a carrier frame, hereby forming an array on the carrier foil that corresponds to the array of the chips in the wafer, namely in a plurality of rows that are parallel to each other and extend in one axis direction.
[0007] “Components” according to the invention are furthermore electrical components, particularly also such components that consist of a semiconductor chip with a housing produced by extrusion, for example a plastic housing and, for example, likewise are manufactured multiply using a common semiconductor wafer and are separated into the individual components after being placed on the carrier foil.
[0008] “Processing” according to the invention means in the simplest sense the transfer of the electrical components from the carrier foil to the second carrier in a pick-and-place operation using a pick-up element, which moves between the carrier foil and the second carrier for this purpose.
[0009] “Second carrier” according to the invention is for example the transport surface of a suitable transport element or also any other suitable carrier on which the components are placed.
[0010] “Processing of the first rows” according to the invention means that the electrical components or the groups of components are removed from the individual rows formed on the carrier foil, preferably such that in the following processing steps or strokes, the components of a new, first row are not transferred until the components of preceding rows have already been transferred completely to the second carrier.
[0011] The special feature of the method according to the invention consists in the fact that in each work stroke several components are removed simultaneously as a group directly from the carrier foil, preferably controlled by an electronic control device, so that the components on the second carrier form at least one second row, in which the components then preferably follow each other at regular intervals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention is described below in detail based on exemplary embodiments with reference to the drawings, where:
[0013] FIG. 1 shows a simplified representation in top view of a carrier frame with a carrier foil and with a plurality of components in the form of semiconductor chips arranged on this carrier foil and the semiconductor chips picked up from the carrier foil by means of a pick-up unit and placed in a plurality of rows on a transporter;
[0014] FIG. 2 shows a simplified representation in vertical section of the pick-up unit and the ram unit of a work station for carrying out the method of FIG. 1 , i.e. for picking up a group of a plurality of semiconductor chips from the carrier foil (blue foil) and for placing this group onto the transport element;
[0015] FIG. 3 shows a vertical section of the work station of FIG. 2 in a sectional plane extending perpendicular to FIG. 2 ;
[0016] FIG. 4 shows a component drawing of the pick-up head of the pick-up unit of FIGS. 2 and 3 ;
[0017] FIG. 5 shows a simplified representation similar to FIG. 2 of a further possible embodiment of the invention;
[0018] FIG. 6 and 7 show representations similar to FIGS. 2 and 3 of a further possible embodiment of the invention with a modified ram element as compared with that of FIGS. 2 and 3 ; and
[0019] FIG. 8 shows a simplified perspective functional view of a work station similar to FIGS. 2 and 3 , together with the transport element connected to the work station and a further transporter or transport element connected to the first transport element by means of a flipping station.
DETAILED DESCRIPTION OF THE INVENTION
[0020] In the drawings, 1 designates a semiconductor wafer, which is separated into a plurality of semiconductor chips 2 (integrated circuits or components) and arranged on a carrier foil 3 , which in turn is held in a carrier frame 4 .
[0021] By tensioning the carrier foil 3 at its peripheral area held in the carrier frame 4 , the semiconductor chips 2 are at a distance from each other, but form an array on the carrier foil 3 in which the semiconductor chips 2 are arranged in several rows R 1 -Rn and in several columns, corresponding to the original circular disk form of the wafer 1 so that the rows R 1 -Rn and the columns extending perpendicular to these rows each have different lengths, namely in the manner that the length of the columns and rows increases toward the center of the wafer 1 and the chip array.
[0022] By means of a pick-up unit not depicted in FIG. 1 but generally designated 5 , 5 a , 5 b in the subsequent drawings, the semiconductor chips 2 are picked up from the carrier foil 3 and placed on a transporter generally designated 6 in FIG. 1 , which is suitable for transporting semiconductor chips and can have a wide variety of designs for this purpose, for example on a transporter, which is formed by a self-adhesive belt-like foil or from a transport belt, on which the semiconductor chips 2 are held by a vacuum, etc. The pick-up unit 5 , 5 a or 5 b is part of a work station 7 . By means of the transport element 6 , the semiconductor chips 2 are transported away from this work station or from the carrier frame 4 with the carrier foil 3 and fed to a further application, as indicated by arrow A.
[0023] For the sake of simplification and better clarity, three spatial axes that extend perpendicular to each other are indicated in the drawings, namely the X-axis, the Y-axis and the Z-axis, of which the X-axis and Y-axis are horizontal axes that define the horizontal X-Y plane, while the Z-axis is the vertical axis.
[0024] The carrier foil 3 and thus also the wafer 1 arranged on this carrier foil are located in the horizontal X-Y plane.
[0025] The transport plane of the transport element 6 , on which the semiconductor chips 2 are arranged, is likewise the horizontal X-Y plane. The transport direction A of the transport element 6 extends parallel to the Y-axis in the depicted embodiment.
[0026] The semiconductor chips 2 are placed on the transport element 6 or on the transport plane located there so that they form several—i.e. in the depicted embodiment a total of seven—rows of semiconductor chips 2 extending parallel to the transport direction A and parallel to each other, preferably closed rows, whereby each semiconductor chip 2 in a row perpendicular to the transport direction, i.e. in the X-axis, is next to a semiconductor chip 2 of an adjacent row, i.e. the semiconductor chips 2 are arranged on the transport element 6 in columns extending in the direction of the X-axis with seven semiconductor chips 2 each. The special feature of the work station 7 or of the method carried out by this station consists, firstly, in that the semiconductor chips 2 are transferred from the wafer 1 to the transport element 6 over a short path, and secondly, in that this transfer takes place so that several semiconductor chips 2 are removed from the carrier foil 3 in a row R 1 -Rn as a group and placed on the transport element 6 in one step, for which the pick-up element 5 , 5 a , 5 b executes at least one back-and-forth motion in the direction of the Y-axis (horizontal stroke Hy) and one vertical stroke (Vz) in the Z-axis for removing the group of semiconductor chips 2 from the carrier foil 3 at the one end of the horizontal stroke Hy, and one vertical stroke (V′z) in the Z-axis for placing the group of semiconductor chips 2 on the transport element 6 . The horizontal stroke Hy is thereby parallel to the transport direction A. In the depicted embodiment, six semiconductor chips 2 are picked up from the carrier foil 3 and then placed on the transport element 6 in each working stroke of the pick-up element 5 .
[0027] The work station 7 comprises for example a holder 8 , in which the carrier frame 4 is located and with which this carrier frame is aligned so that the rows R 1 -Rn do not extend in the Y-axis and the corresponding columns in the X-axis, and also that each row R′ 1 -R′n formed on the transport element 6 has a congruent axis with a row R 1 -Rn on the carrier foil 3 . The alignment of the carrier frame 4 and thus of the wafer 1 is effected by means of a camera system and an electronic unit 9 comprising an image processor. The camera system of the electronic unit 9 measures the configuration of the wafer 1 or the array of the semiconductor chips 2 on the carrier foil 3 . The camera system also measures those semiconductor chips or their position, which is saved in the memory of the electronic unit 9 , determined in a preceding test of the wafer 1 to be not usable and marked accordingly with a marking 10 .
[0028] The movement of the pick-up unit 5 is controlled by means of the electronic control unit 9 so that the groups 2 ′ of semiconductor chips 2 placed on the transport element 6 form the respective closed rows R′ 1 -R′n. In the embodiment depicted in FIGS. 1-3 , the pick-up unit 5 is designed so that only semiconductor chips 2 of a particular row R 1 -Rn are picked up from the carrier foil 3 by this pick-up unit. In order to form several rows R′ 1 -R′n on the transport element 6 , which continuously moves by strokes in transport direction A, the pick-up unit 5 is designed so that in addition to the horizontal stroke Hy in transport direction A, it can also execute a horizontal stroke Hx crosswise to the transport direction. The marked, defective semiconductor chips 2 in the depicted method are likewise placed on the transport element 6 and not removed until a later process step, initiated by the electronic control unit 9 , in the memory of which the position of the marked, defective semiconductor chips on the transport element 6 is stored.
[0029] In order to form the rows R′ 1 -R′n on the transport element 6 in which (rows) the semiconductor chips 2 adjoin closely despite the different length of the rows R′ 1 -R′n, at least the horizontal stroke Hy has a different length, controlled by the electronic control unit 9 , i.e. the beginning and the end of this stroke Hy upon picking up the group 2 ′ from the carrier foil 3 and upon placing the respective group 2 ′ on the transport element 6 are controlled by the electronic control unit 9 , taking into account the form of the wafer and the array of the semiconductor chips 2 on the carrier foil 3 , resulting in the continuous rows R′ 1 -R′n. The control program of the electronic control unit 9 is, for example, designed so that upon processing of the individual rows R 1 -Rn, the maximum possible number of semiconductor chips 2 is taken from the carrier foil 3 and placed on the transport element 6 in each stroke, followed in a subsequent stroke by the remaining semiconductor chips of the respective rows R 1 -Rn.
[0030] In the depicted embodiment, the holder 8 can furthermore be moved in the X-axis for processing of the individual rows R 1 -Rn.
[0031] The controlled, different length of the stroke Hy takes into account on the one hand that in the work station 7 for processing the rows R 1 -Rn a forward feed B is provided for the carrier frame 4 only in the X-axis and that the rows R 1 -Rn have differing lengths, so that during both the pick-up and placement of the semiconductor chips or the groups 2 ′, the pick-up element in any case must move to different positions in the Y-axis.
[0032] The work station 7 or the pick-up element 5 located there and a corresponding ram element 11 , which is necessary for releasing the individual semiconductor chips 2 from the carrier foil 3 (self-adhesive foil or blue foil), are depicted in more detail in FIGS. 2 and 3 .
[0033] The pick-up element 5 consists of a pick-up head 12 in which, or in the housing 13 of which, several vacuum holders 14 are present that can move in the direction of the Z-axis, namely with a limited stroke corresponding to the double arrow C.
[0034] The individual vacuum holders 14 have a lamellar design, i.e. they consist of a flat, plate-shaped body 15 with a rectangular form, which is located with its longer sides in the housing 13 parallel to the Z-axis and has a molded-on projection 16 on one lower narrow side, which (projection) with its free end forms a bearing surface 17 located in a plane parallel to the X-Y plane, at which a vacuum channel 18 opens.
[0035] On one long side the body 15 is shaped so that it forms a spring-mounted tongue 19 there, with which the vacuum holder 14 is supported on a surface of the guide 20 formed in the housing 13 for the body 15 of the vacuum holder 14 .
[0036] The vacuum holders 14 are arranged with their bodies 15 adjoined in the form of lamellas in the opening or guide of the housing 13 , namely so that the larger surface sides of the plate-shaped bodies 15 each are located in the X-Z plane. To move the pick-up head 12 , it is fastened on a transport system 21 , which comprises drives not further depicted, for example stepping motors for executing the controlled movements Hx, Hy, Vz, V′z.
[0037] On the pick-up head 12 there is also a vacuum connection, only generally indicated in the drawings as 22 and which is connected with a vacuum source not depicted for supplying the vacuum channels 14 .
[0038] The ram unit 11 consists essentially of a housing 23 , which can move, by means of a motorized drive not depicted and controlled by the electronic control unit 9 , on a frame or base plate 24 of the work station 7 in the direction of the Y-axis by a pre-defined stroke D ( FIG. 3 ). The top of the housing 23 forms a bearing or support surface 25 for the bottom of the carrier foil 3 , namely on a housing section 26 , in which several rams 27 that are tapered to a point at their top end and the axes of which are parallel to the Z-axis, can move axially in the direction of the Z-axis, namely for one movement stroke corresponding to the double arrow E of FIG. 2 . The rams 27 are offset against each other in the direction of the Y-axis. The number of the rams 27 is the same as the number of the vacuum holders 14 , i.e. one ram 27 is allocated to each vacuum holder 14 . By spring means, which in the depicted embodiment are formed by leaf springs 29 , each ram 27 is pre-tensioned in a lower position, in which the free end of the respective tip 28 is located beneath the support surface 25 . On the housing 23 or on a board 30 located there, a shaft 31 can rotate on bearings on an axis parallel to the Y-axis, rotationally driven by a stepping motor and likewise controlled by the electronic control circuit 9 (arrow F of FIG. 2 ). On the shaft there are several cam plates 33 , which are axially offset against each other and each of which forms a control cam 34 . The axis of the shaft 31 is located in a Y-Z plane, in which also the axes of the rams 27 are located. Furthermore, the shaft 31 is located beneath the rams 27 . A cam plate 33 is allocated to each ram 27 , so that with each full revolution of the shaft 31 , the respective ram 27 is moved by the control cam 34 located on the cam plate 33 from its starting position against the force of the spring element 29 upward into an upper stroke position, in which the respective ram 27 protrudes with its tip 28 through the carrier foil 4 clearly above the top of the carrier foil and above the level formed by the top of the wafer 1 .
[0039] In the depicted embodiment, six cam plates 33 are provided for, corresponding to the number of rams 27 . The control cams 34 of the individual cam plates 33 are offset at even angle distances on the axis of the shaft 31 so that when the shaft 31 is rotating, the rams 27 are moved upward from their starting position in temporal succession.
[0040] On the housing section 26 there is a ring groove 35 in the proximity of the bearing surface 25 surrounding the array of the rams 27 , which (ring groove) is open on the bearing surface 25 and can be placed under controlled vacuum.
[0041] The special function of the work station 7 can be described as follows:
[0042] To remove a group 2 ′ of semiconductor chips 2 , the carrier frame with the carrier frame holder is first moved in the forward feed direction B so that the row R 1 -Rn to be processed is located in the middle plane M of the ram 27 . This plane is indicated in FIG. 2 as the middle plane M.
[0043] Afterwards, the pick-up head 12 is moved so that the vacuum holders 14 are located above the semiconductor chips 2 of the respective row R 1 -Rn to be picked up. The ram element 11 also is controlled by the electronic control unit 9 so that one ram 27 is located beneath one chip 2 respectively of the group 2 ′ to be picked up from the carrier foil 3 . Afterwards, the pick-up head 12 is lowered vertically corresponding to the stroke Vz, whereby first each bearing surface 17 of each vacuum holder 14 comes to bear against one semiconductor chip 2 or its top side facing away from the carrier foil 3 . The vacuum holders 14 are located thereby in the lower position of their stroke or sliding movement C relative to the housing 13 . By means of the cam plates 33 located on the rotating shaft 31 , the rams 27 are then moved upward and lowered again in succession. In each upward movement of a ram 27 , the ram penetrates the carrier foil 3 with its tip 28 , releases the corresponding semiconductor chip 2 from the carrier foil 3 and moves this semiconductor chip 2 , which already bears against the bearing surface 17 and is held there by means of vacuum (vacuum channel 18 ), upward, whereby also the vacuum holder 14 in the guide 20 is pressed upward by means of the corresponding ram 27 . By means of the spring-mounted tongue 19 , the respective position of the vacuum holder 14 in the guide 20 is maintained, so that then during the subsequent downward movement of the respective ram 27 , i.e. when the corresponding control cam 34 again releases the lower end of the ram 27 , the corresponding semiconductor chip 2 is held on the bearing surface 17 of the vacuum holder 14 which has been pushed upward. In this way, all semiconductor chips 2 of the group 2 ′ to be removed are released in succession from the carrier foil 3 and moved together with the corresponding vacuum holder 14 into a position above the carrier foil 3 . By means of the pick-up head 12 , the semiconductor chips 2 held on the vacuum holders 14 are then moved as a group 2 ′ to the transport element 6 and then placed there after being lowered (vertical stroke V′z), corresponding to the rows R′ 1 -R′n to be formed, as described above. During the return stroke of the pick-up head 12 for picking up a new group of semiconductor chips 2 , i.e. before the initiation of the next work stroke, the vacuum holders 14 are moved back to their starting position by means of a slide 36 indicated in FIGS. 2 and 3 by a broken line. Due to the ring groove 35 that can be placed under vacuum, the carrier foil 3 is fixed to the bearing surface 25 during removal of the semiconductor chip 2 , which significantly improves the removal of the semiconductor chip 2 .
[0044] The fact that the raising of the rams 27 takes place in succession enables the efficient removal of each chip 2 from the self-adhesive carrier foil 3 , namely due to the fact that the carrier foil 3 is deformed by the respective tip 28 before being penetrated, so that the carrier foil 3 hereby is completely released from the bottom of the respective semiconductor chip 2 and adheres to the latter only at the point of contact between the tip 28 and the bottom of the semiconductor chip 2 .
[0045] FIG. 5 shows in a depiction similar to FIG. 2 as a further possible embodiment a work station 7 a , which differs from the work station 7 essentially only in that in each work stroke, semiconductor chips 2 of two adjacent rows R 1 -Rn are picked up as a group 2 ′ from the carrier foil 3 . For this purpose, two rows of vacuum holders 14 are provided for on the pick-up head 12 a of the pick-up element 5 a , which corresponds in its function to the pick-up element 5 , on both sides of the middle plane M, each of which can be movably guided in a housing 13 a ′ and 13 a ″ in the direction of the Z-axis. Each ram 27 a corresponding to a ram 27 forms two tips 28 . The distance between the axes of the vacuum holders 14 and their bearing surfaces 17 in the direction of the X-axis is the same as the distance between the axes of the two tips 28 in this X-axis and in the depicted embodiment is the same as the distance between the axes of two rows R 1 -Rn. The tips 28 are arranged in two rows extending in the direction of the Y-axis, namely such that upon removing the semiconductor chips 2 from the carrier foil 3 , the axis of one tip 28 is congruent with each vacuum holder 4 . The function of the work station 7 a corresponds to the function of the work station 7 , only with the difference that the semiconductor chips 2 of two adjacent rows R 1 -Rn are released in temporal succession from the carrier foil 3 and are lifted above the plane of the wafer 1 with the respective ram 27 a held on the respective vacuum holder 2 , i.e. the two adjacent semiconductor chips 2 of the two adjacent rows R 1 -Rn in the direction of the X-axis.
[0046] FIG. 6 shows as a further possible embodiment a work station 7 b , which differs from the work station 7 only in that instead of the ram element 11 , a ram element 11 b is provided for. The latter likewise comprises a plurality of rams 27 b on the housing 23 b corresponding to the housing 23 , which (rams) each form a tip 28 and can be moved axially, i.e. in the direction of the Z-axis, by the stroke E. The movement of the rams 27 b is achieved by a control slide 37 , which, mounted on bearings, can be moved back and forth in the housing 23 b , in the direction of the Y-axis (double arrow I of FIG. 7 ), controlled by the electronic control unit 9 . The slide 37 is provided with a control curve 38 of a groove 39 , which extends over the majority of its length in the direction of the Y-axis and forms a section 39 ′, in which the control curve 38 rises diagonally in the direction of the Z-axis and then falls off again. A pusher 40 engages with each ram 27 b in the control groove 39 . With each full movement stroke of the control slide 37 in the one direction or the other direction, all rams 27 b are moved in temporal succession one time from their starting position, in which the tips 28 are located below the plane of the carrier foil 3 , into a raised position, in which the tips 28 have penetrated the carrier foil 3 and are located above the plane of the wafer 1 , and then moved back into their starting position. In this embodiment, the control slide 37 with the control curve 38 replaces the cam plate 33 with the control cam 34 . Otherwise, the function of the work station 7 b corresponds to the function of the work station 7 .
[0047] FIG. 8 shows in a simplified perspective representation a work station 7 c , which is designed similar to the work station 7 a , but in the depicted embodiment is used to process electrical components 40 , which consist of a semiconductor chip enclosed in a plastic housing and are arranged on the carrier foil 3 in the carrier frame 4 in the same manner as the semiconductor chips 2 , namely in a rectangular array with several rows and columns. By means of the work station 7 c or the pick-up element 5 c located there, in one work stroke, two rows of components 40 are picked up from the carrier foil 3 and placed in rows R′ 1 , R′ 2 on a transport element 6 , which is formed by a rotating transport belt. For this purpose, the pick-up head 12 c of the pick-up element 5 c comprises one row of vacuum holders 14 on each of two housings 13 c ′ and 13 c ″, which (vacuum holders) adjoin each other in each housing in the direction of the Y-axis. The two housings 13 ′ and 13 ″ can furthermore be moved relative to each other in the direction of the X-axis, namely by a pre-defined stroke, as indicated by the double arrow G. This not only makes it possible to pick up two rows of components 40 from the carrier foil 3 and place them on the transport element 6 c in one work step, but also enables a distance between the rows R′ 1 and R′ 2 on the transport element 6 c that is greater than the distance between the rows of components 40 on the carrier foil 3 .
[0048] By means of a flipping station 41 , which comprises groups of two vacuum holders each offset by 90° on a housing 42 that is driven rotationally in a pulsed cycle on the X-axis, the components 40 of the two rows R′ 1 and R′ 2 are transferred in succession to vacuum holders 44 of a transporter 45 . For this purpose, the vacuum holders 43 can be controlled to move radially to the rotational axis of the housing 41 (X-axis), namely for the removal of the components 40 on the transport element 6 c and for the transfer of two components respectively to the vacuum holders 44 of the transport element 45 .
[0049] In FIG. 1 , BL designates a reference line extending in the direction of the X-axis and thus perpendicular to the rows R 1 -Rn. The ends of the rows have differing distances from this reference line.
[0050] The invention was described above based on exemplary embodiments. It goes without saying that numerous modifications and variations are possible. It is possible, for example, to eliminate a vertical stroke Vz and/or V′z for the respective pick-up head 12 , 12 a , 12 b for the pick-up elements 5 , 5 a , 5 b and to achieve the corresponding vertical movement for the advance of the vacuum holders 14 to the chips 2 on the carrier foil 3 and for placing the chips 2 on the transport element 6 solely by moving the vacuum holders 14 within the respective pick-up head 12 , 12 a or 12 b.
[0051] Furthermore, it is of course also possible to use the work stations 7 , 7 a and 7 b for processing components 40 or, conversely, to use the work station 7 c for processing semiconductor chips 2 .
REFERENCE SYMBOLS
[0000]
1 wafer
2 semiconductor chip
2 ′ group of semiconductor chips
3 carrier foil
4 carrier frame
5 , 5 a , 5 b , 5 c pick-up element
6 , 6 c transport element
7 , 7 a , 7 b , 7 c work station
8 holder
9 electronic control unit
10 marking
11 , 11 a , 11 b ram elements
12 , 12 a , 12 b , 12 c pick-up head
13 , 13 a ′, 13 a ″, 13 c ′, 13 c ″ housing
14 vacuum holder
15 body
16 projection
17 bearing surface
18 vacuum channel
19 spring-mounted tongue
20 guide
21 transport or movement system
22 vacuum connection
23 , 23 b housing
24 frame
25 bearing surface
26 housing section
27 , 27 a , 27 b ram
28 ram tip
29 spring
30 board
31 shaft
32 motor
33 cam plate
34 control cam
35 ring groove
36 reset slide
37 control slide
38 control curve
39 control groove
39 ′ control groove section
40 component
41 flipping station
42 housing
43 vacuum holder
44 vacuum holder
45 transport element
X, Y, Z spatial axis
A transport direction
B forward feed
C, D, E movement stroke
F direction of rotation
G movement stroke
Hx, Hy horizontal stroke
Vz, V′z vertical stroke
I movement stroke
K direction of rotation
R 1 , Rn row
R′ 1 , R′n row
M middle plane | The invention relates to a novel method for processing electrical parts, particularly for processing semiconductor chips and electrical components, and a device for carrying out the inventive method. | 7 |
RELATED APPLICATIONS
This application is a Continuation of and claims the priority benefit of U.S. application Ser. No. 14/168,782 filed Jan. 30, 2014, which claims priority under 35 U.S.C. §119 from Taiwan Patent Application 102103699, filed on Jan. 31, 2013, which is incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
The present inventive subject matter generally relates to task scheduling in a multi-processor computer system.
Unlike a uniprocessor computer system, a multi-processor computer system follows different rules to meet specific needs when performing task scheduling. For example, to achieve equilibrium of loads between processors, Completely Fair Scheduler is in use under Linux. For more details, read “Inside the Linux 2.6 Completely Fair Scheduler: Providing fair access to CPUs since 2.6.23.”, written by M. Tim Jones.
SUMMARY OF THE INVENTION
Embodiments of the inventive subject matter include a method of prioritizing processing units in a system for task scheduling, the method comprising, for each processing unit of a plurality of processing units in the system, determining a value that represents a thermal condition of a location of the processing unit. It is determined which of the plurality of processing units is not fully loaded and is in a location with a most favorable thermal condition based on the value of the processing unit that represents thermal conditions of the location of the processing unit. A task is scheduled to the processing unit determined to be not fully loaded and in a location with a most favorable thermal condition based on the value of the processing unit that represents thermal conditions of the location of the processing unit
In an aspect, the present invention provides a method of task scheduling based on thermal conditions at locations of processors. In a multi-processor computer system, thermal conditions at the locations of the processors are not necessarily identical because of system layout constraint. For example, in the multi-processor computer system, some processors are positioned proximate to a cooling fan or a heat-generating device and thus have an advantage or disadvantage over the other processors in terms of the working environment. The aforesaid issue is not addressed by the conventional task scheduling techniques put forth according to the prior art.
In view of this, the present invention includes considerations given to thermal conditions (also known as cooling conditions) at the locations of processors when performing task scheduling on the processors. According to some embodiments of the present invention, a task which has a scheduling-related priority is scheduled to processors because of favorable thermal conditions at the locations of the processors. Hence, a task is scheduled to processors with favorable thermal conditions at the locations thereof rather than processors with unfavorable thermal conditions at the locations thereof to thereby reduce heat accumulated in the system, enhance overall system performance, and reduce power consumption incurred in heat dissipation.
The concept about “thermal conditions at the locations of processors” refers to ambient conditions at the locations (such as processor slots) of the processors, for example, thermal contribution or cooling contribution of a heating source (such as another processor, memory module, or power supply) outside the processor or a cooling source (such as a fan or heat dissipation module) to the locations of the processors, or the fact that the processors are upstream or downstream from a heat-dissipating path (such as a cooling air current) in the system.
For an illustrative purpose, “thermal conditions at locations of processors” as disclosed in the present invention in another aspect refer to ambient conditions which are considered at a system design stage and serve as default parameters. For example, they come in the form of a lookup table accessible by an operating system, thus dispensing the need to consider situations in which the processors at the locations are operating (for example, temperature and consumed power while operation is underway).
In another embodiment of the present invention, a task scheduling method applies to a computer system and comprises:
prioritizing the first processor and the second processor based on thermal conditions of the first zone and the second zone, respectively; and scheduling one of a plurality of tasks to the first processor and the second processor according to the prioritization performed in the aforesaid step.
Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment.
Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention will be readily understood, amore particular description of the invention briefly described above will be rendered by reference to embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings.
FIG. 1 is a schematic view of a computer system according to a specific embodiment of the present invention;
FIG. 2 is a schematic view of an operating system in the computer system according to a specific embodiment of the present invention;
FIG. 3 is a schematic view of the layout in the computer system according to a specific embodiment of the present invention;
FIG. 4 is a flow chart of a method according to a specific embodiment of the present invention; and
FIG. 5 is a flow chart of the method according to another specific embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language 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,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
As will be appreciated by one skilled in the art, the present invention may be embodied as an apparatus, a computer system, a method or a computer program product. Accordingly, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, the present invention may take the form of a computer program product embodied in any tangible medium of expression having computer-usable program code embodied in the medium.
Any combination of one or more computer usable or computer readable medium(s) may be utilized. The computer-usable or computer-readable medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. More specific examples (a non-exhaustive list) of the computer-readable medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a transmission media such as those supporting the Internet or an intranet, or a magnetic storage device. Note that the computer-usable or computer-readable medium could even be paper or another suitable medium upon which the program is printed, as the program can be electronically captured, via, for instance, optical scanning of the paper or other medium, then compiled, interpreted, or otherwise processed in a suitable manner, if necessary, and then stored in a computer memory. In the context of this document, a computer-usable or computer-readable medium may be any medium that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device. The computer-usable medium may include a propagated data signal with the computer-usable program code embodied therewith, either in baseband or as part of a carrier wave. The computer usable program code may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc.
Computer program code for carrying out operations of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirety on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer or server may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an internet Service Provider).
The present invention is described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable medium that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable medium produce an article of manufacture including instruction means which implement the function/act specified in the flowchart and/or block diagram block or blocks.
The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
FIG. 1 shows the hardware framework of a computer system 100 in an embodiment. The computer system 100 comprises a power supply 102 , a central processing unit (CPU) 104 , a memory 106 , a hard disk drive 108 , a fan 110 , and an interface firmware module 112 . For information about the other fundamental framework and components of the computer system 100 , make reference to a typical personal computer or server, such as IBM's System X, Blade Center or eServer. Details not relevant to the present invention are not described herein for the sake of brevity.
When the computer system 100 is operating, the power supply 102 supplies DC power to the central processing unit 104 , memory 106 , hard disk drive 108 , and fan 110 . The power supply 102 , central processing unit 104 , memory 106 , and hard disk drive 108 generate high heat while operating, and are cooled down by the fan 110 .
The computer system 100 is a multi-processor system and has a plurality of central processing units 104 . One or more central processing units 104 execute an operating system OS (such as Linux). Referring to FIG. 2 , the operating system OS comprises a prioritizing unit PR and a scheduling unit TS. More related details are described later.
Although FIG. 1 depicts two central processing units 104 , the present invention is not limited thereto. For details of the computer system 100 , make reference to IBM System x3755 M3 equipped with four AMD Opteron 6200 series processors each having 16 cores (maximum 2.5 GHz), 12 cores (maximum 2.6 GHz), or 8 cores (maximum 3.0 GHz). For more information about IBM System x3755 M3, read IBM System x 3755 M3:IBM Redbooks Product Guide, which is incorporated herein by reference.
The interface firmware module 112 may be for example, but not limited to, a read only memory (ROM) with Extensible Firmware Interface (EFI), Universal Extensible Firmware interface (UEFI), Basic Input/Output System (BIOS) or other interface. However, the present invention is not limited hereto.
In this embodiment, interface firmware module 112 maintains hardware data, such as ACPI table, in the computer system 100 , such that the hardware data are accessible by the operating system OS (shown in FIG. 2 ) of the computer system 100 . Details of ACPI table are described in ACPI Table Storage Specification (v091) published by Intel and are not reiterated herein for the sake of brevity.
FIG. 3 further shows system layout in the computer system 100 . For an illustrative purpose, FIG. 3 is simplified in showing the power supply 102 , two central processing units (CPU) 104 a , 104 b , and the fan 110 . Referring to FIG. 3 , the two central processing units 104 a , 104 b are mounted on processor slots 105 a , 105 b , respectively. The actual details of the system layout are described in the aforesaid technical document, that is, IBM System x 3755 M3:IBM Redbooks Product Guide. The operating system of the computer system 100 is executed either by the central processing unit 104 a and/or central processing unit 104 b , or by any central processing unit (not shown in FIG. 3 ) other than the central processing units 104 a , 104 b.
In the embodiment illustrated with FIG. 3 , thermal conditions of the processor slot 105 a are more favorable than that of the processor slot 105 b for reasons as follows: the processor slot 105 a is positioned proximate to the cooling fan 110 and thus receives the cooling air current to a great extent; and, with the power supply 102 generating high heat, the processor slot 105 b positioned proximate to the power supply 102 is subjected to relatively great thermal effect from the power supply 102 . At the system design stage, a system designer uses the distance to the cooling/heating sources or sophisticated heat flow simulation in analyzing the thermal conditions of processor slots 105 a , 105 b , assigning different effective values to different factors in thermal conditions, as shown in Table 1 below, and pre-storing the assigned effective values in interface firmware module 112 (such as ACPI DSTD table), such that the stored effective values can be accessed by the operating system OS (see FIG. 2 ).
TABLE 1
factor in thermal conditions
slot 105a
slot 105b
power supply 102
1
2
fan 110
2
3
total
3
5
Effective values arising from a single factor (such as power supply) in thermal conditions mainly reflect the relative difference in the effects on thermal conditions of processor slot 105 a and processor slot 105 b . Hence, when considering the difference in the overall thermal conditions between processor slot 105 a and processor slot 105 b , it is feasible to add together the effective values of different factors in thermal conditions. However, a system designer can assign different weights to different factors in thermal conditions, though the present invention is not limited thereto.
In another embodiment, processor slots 105 a , 105 b are usually adjacent to each other, and processors 104 a , 104 b mounted thereon generate plenty of heat while operating and thus affect each other. As a result, if specific data (such as nominal consumed power) pertaining to processors 104 a , 104 b are known during the system design state, it will be feasible to give considerations to the effect of operation of processors fixed to adjacent slots on the slot thermal conditions as illustrated with Table 2 below. For example, it is feasible to consider the effect on slot 105 a of operation of central processing unit 104 b fixed to slot 105 b . Processors 104 a , 104 b are not necessarily identical, and thus processors 104 a , 104 b are likely to have different effects on slot thermal conditions, as illustrated with Table 2 below.
TABLE 2
factor in thermal condition
slot 105a
slot 105b
power supply 102
1
2
fan 110
2
3
central processing unit 104a
0
2
central processing unit 104b
5
0
total
8
7
Hence, all the thermal conditions of slot 105 a and slot 105 b can be quantized and thereby be subjected to subsequent automated judgment or applied to data processing. Not only is it feasible, as described before, to simulate and specify all the thermal conditions of slot 105 a and slot 105 b during the system design stage, but factors in thermal conditions can also be measured and identified while the system is operating.
The task scheduling method in an embodiment of the present invention is illustrated with the flow chart shown in FIG. 4 and comprises the steps as follows:
Step 400 : a system designer determines respective thermal conditions of processor slots 105 a , 105 b and specifies corresponding values to be written to or updated in the interface firmware module 112 . Alternatively, the system designer specifies corresponding values for the respective thermal conditions of slots 105 a , 105 b according to the model numbers of various hardware components (such as fans of different powers), such that the operating system OS selects one of the values as needed. Preferably, interface firmware module 112 has ACPI DSTD table for storing thermal condition values of slots 105 a , 105 b , and the stored thermal condition values are accessible by the operating system OS through UEFI. Step 402 : computer system 100 boots, wherein operating system OS undergoes initialization, accesses interface firmware module 112 through and selects appropriate thermal condition values of processor slots 105 a , 105 b (see Table 1 or Table 2). Step 404 : the prioritizing unit PR in operating system OS prioritizes processors 104 a , 104 b mounted on processor slots 105 a , 105 b according to thermal condition values attributed to processor slots 105 a , 105 b and obtained in step 402 . In this embodiment, the prioritizing unit PR gives priority to the processor mounted on the processor slot with favorable thermal conditions (i.e., with the least total of thermal condition values, as shown in Table 1 or Table 2). Take the thermal condition values in Table 2 as an example, the processor 104 b mounted on processor slot 105 b has priority over the processor 104 a mounted on processor slot 105 a . Although FIG. 3 shows only two processors 104 a , 104 b and two processor slots 105 a , 105 b corresponding thereto for an illustrative purpose, in an embodiment where computer system 100 has at least three processors (and corresponding processor slots), the prioritizing unit PR prioritizes all the processors according to the thermal conditions of the processor slots, respectively. Step 406 : the scheduling unit TS in operating system OS determines whether processor 104 b is fully loaded according to the priority provided by the prioritizing unit PR in step 404 , for example, processor 104 b has priority over processor 104 a . If processor 104 b is not fully loaded, the task will be scheduled to processor 104 b (step 408 ). If processor 104 b is fully loaded, the task will be scheduled to the processor with the second priority (i.e., processor 104 a ) in the prioritization performed by the prioritizing unit PR (step 410 ).
The implementation of the task scheduling method performed with the scheduling unit TS in operating system OS, illustrated with the flow chart shown in FIG. 5 , and disclosed in another embodiment of the present invention, can continue from step 404 of FIG. 4 , when compared with step 406 .
Step 506 : the scheduling unit TS in operating system OS schedules a task to processor 104 a according to a predetermined rule (such as round-robin algorithm). In this step, it is feasible for the scheduling unit TS to first ignore the prioritization performed by the prioritizing unit PR. Step 508 : in an embodiment, the scheduling unit TS determines whether processor 104 a has first priority in the prioritization performed by the prioritizing unit PR in step 404 . In another embodiment, the scheduling unit TS determines whether processor 104 a has not yet been fully loaded and whether processor 104 a has first priority in the prioritization performed by the prioritizing unit PR in step 404 . In the two aforesaid embodiments, keep the task schedule of step 506 (step 510 ) if the determination is affirmative, and a negative determination indicates either that processor 104 a has been fully loaded or that processor 104 a has not yet been fully loaded but does not have first priority, thereby returning the task to the scheduling unit TS (step 512 ) and going back to step 506 for rescheduling the task to another processor until the process flow of the method goes to step 510 .
In the aforesaid embodiments, task scheduling is based on the thermal conditions (or ambient conditions) of the slots. According to the present invention, no consideration is given to the heat generated from processors mounted on the slots, as far as the thermal conditions of the slots are concerned. In Table 2, considerations are given to the processors mounted on adjacent slots. For example, for the thermal condition of the slot 105 A, no consideration is given to the heat generated from the processor 104 A but to the processor 104 B which is mounted on the adjacent slot 105 b . However, the teaching (i.e., the thermal conditions of the slots) of the present invention can also be integrated into the prior art in terms of task scheduling based on the temperature (i.e., the present thermal conditions) of the processors mounted on the slots, and the present invention is not limited thereto.
The foregoing preferred embodiments are provided to illustrate and disclose the technical features of the present invention, and are not intended to be restrictive of the scope of the present invention. Hence, all equivalent variations or modifications made to the foregoing embodiments without departing from the spirit embodied in the disclosure of the present invention should fall within the scope of the present invention as set forth in the appended claims. | A method of prioritizing processing units in a system for task scheduling includes, for each processing unit of a plurality of processing units in the system, determining a value that represents a thermal condition of a location of the processing unit. It is determined which of the plurality of processing units is not fully loaded and is in a location with a most favorable thermal condition based on the value of the processing unit that represents thermal conditions of the location of the processing unit. A task is scheduled to the processing unit determined to be not fully loaded and in a location with a most favorable thermal condition based on the value of the processing unit that represents thermal conditions of the location of the processing unit. | 8 |
FIELD OF THE INVENTION
The present invention relates to a method and apparatus for signal processing in scintillation cameras employed for nuclear medicine. Such scintillation cameras are also known as gamma cameras or Anger cameras and are more generally referred to as position and energy sensitive radiation detectors.
BACKGROUND ART
A common type of camera is shown in FIG. 1. An area (2) of a body (4) of a patient containing a radioactive pharmaceutical, emits gamma rays indicated as at (6). The camera (8) includes a collimator comprising an apertured lead sheet (10) so that only gamma rays within a predetermined narrow angle from the patient can pass through the collimator to a scintillation block (12) of Nal(T1). Single gamma rays entering block (12) give rise to a large number of secondary photons which radiate outwards through a glass light guide and support block (14) to an array of photomultipliers (16). Photomultipliers (16) are usually arranged in a rectangular or hexagonal grid. Each photomultiplier tube is arranged to detect individual photons or groups of photons to produce a significant electrical signal which is conducted to a signal processing unit (18). Unit (18) assesses all the signals received from the individual photomultiplier tubes to carry out an analysis of the signals received at consecutive time instants in order to determine approximately where each gamma ray impinges on scintillation block (12).
Position reconstruction in a gamma camera is usually performed by taking a linear weighted mean of the signals of the photomultiplier array, see for example US-A-4228315. Problems arise with signals from photomultipliers far from a gamma ray event where only a very small number of photons are detected. Since the statistical noise fluctuations are proportional to the square root of number of photons detected, the fluctuation in small signals is comparable to the signal itself. Because of this relatively large statistical noise fluctuation some form of limiting has to be applied to the smallest signals to exclude noise in order to obtain better spatial resolution. This may be done with a thresholding device, for example a diode, which provides a fixed thresholding level and which therefore only passes signals from a photomultiplier tube having a voltage level greater than the junction voltage of the diode. Whilst this provides a simple way of excluding low value signals which have a large amount of noise associated therewith, some useful information is also discarded. Now each gamma ray incident will create a distinctive energy dependent distribution curve of detected photons. Therefore, if a fixed threshold level is subtracted from each photomultiplier tube signal, the resulting distribution curve is effectively distorted during measurement and position reconstruction becomes inaccurate.
Referring now to FIG. 3, this shows a hexagonal array of close-packed photomultiplier tubes; this is a preferred configuration from the point of view of signal processing since the nearest neighbors of each tube are spaced the same distance R from the center of the tube as indicated in FIG. 3. This simplifies analog processing of the signals. However a problem arises with the hexagonal array in that at the edges of the array there are gaps as indicated in FIG. 3 in the region (30), which give rise to a reduced field of view indicated by the dotted line (32). This is a particular problem with arrangements such as shown in FIG. 4 wherein two cameras (40) are arranged at right-angles, contacting one another at their edges in order to get an improved view of a side region (42) of a patient's torso (44), for example the head. The result of the reduced field of view in the corner area is to create a dead region (46) for detection, with the result that the two cameras have to be positioned relatively far from the patient, resulting in a loss of resolution.
A preferred configuration which avoids the reduced field of view is to employ square photomultiplier tubes (20) arranged in a rectangular grid as shown in FIG. 2. In this arrangement the array extends right up to the edge of the camera. However, a disadvantage is that the nearest neighbors of each tube are spaced at various distances from the center of the tube as indicated by the dimensions R1 and R2 in FIG. 2. This places greater demands on analog signal processing required to identify the spatial location of a gamma ray incident. With a rectangular array therefore the noise effects and threshold effects are likely to be more pronounced. These effects will be exacerbated when large aperture photomultiplier tubes are employed for low cost. Clearly smaller photomultiplier tubes increase the overall resolution of the array, but larger tubes are preferred from the point of view of expense.
SUMMARY OF THE INVENTION
It is an object of the invention to reduce the above described problems of noise.
The present invention is based on the realization that there are two different types of noise encountered with scintillation cameras and that it is possible to discriminate between the two. The first type of noise is random noise, generated by photomultiplier dark current, amplifier noise, scintillator afterglow, etc. It is often referred to as thermal noise and contains no useful information. The second type of noise is small signal noise associated with the detection of a small number of photons far from the source; due to the statistical nature of the scintillation, the magnitude of these small signals will vary by an amount comparable to the magnitude of these signals, giving rise to apparent noise; however these signals do have a useful information content.
In accordance with the invention, signals from a row or column of a photodetector, e.g., photomultiplier array in a scintillation camera are summed or combined in some way before thresholding. This as will be shown will average out thermal or random noise, but will amplify small value photon signals which will occur coincident in time and can therefore be summed arithmetically to reduce the statistical fluctuation thereof.
The present invention thus provides a method of signal processing in a scintillation camera, the camera comprising a collimator adjacent a scintillation block which is optically coupled to an array of photodetectors, the array being distributed relative to two different axes to form rows and columns relative to the two axes, wherein the method comprises, for each row and for each column, summing or otherwise combining the output signals of the photodetectors of the respective row or column as a first step in the processing of the signals.
In a further aspect the invention provides a scintillation camera including a collimator adjacent a scintillation block which is optically coupled to an array of photodetectors, the array being distributed relative to two different axes to form rows and columns relative to the two axes, each photodetector having output port means providing an output signal, the output signals of each respective row or column being connected to a respective means for summing or otherwise combining the output signals whereby the output signals from each row and column are combined as a first step in signal processing.
The photodetectors may be of any well-known type, for example photomultiplier tubes or solid state detectors such as avalanche diodes or silicon diodes. The detectors may be used to detect single gamma ray events or more than one simultaneous event, as with position emission tomography.
The detectors may be arranged in any convenient array which is defined relative to two axes. Hexagonal and rectangular arrays have been descried above but others arrays may be envisaged, for example, a rectangular array where detectors in one row are staggered relative to detectors in adjacent rows.
In the camera according to the invention, the scintillation block will commonly be optically coupled to the array of photodetectors by a light guide, e.g., a glass block. However, with, for example, positron emission tomography, the light guide may be dispensed with.
The photodetectors will not normally have any signal processing elements contained within them and the output signal will be delivered in an unprocessed state at the output port. However each detecting element may include some linear processing, e.g., pre-amplification, integration or pulse shaping. In any event, the summing of the output signals will be in accordance with the invention the first signal processing step external to the photodetectors.
Each photodetector may include more than one output port. Thus where two dimensional position information is required a second output port will be provided providing a second output signal. In addition, for deriving a total energy signal from all of the detectors as is commonly required in signal processing, each detector may provide a third output signal at a third output port. Each output port is a separate source of signal energy and is adapted to provide a sufficient amount of energy for the desired purpose of summing a number of such signals at a common node. For example in the case of a photomultiplier tube, the tube includes a preamplifier providing an output voltage signal. A plurality of resistors are coupled to receive the output voltage and each provides a desired output current to a respective output port.
A second step in the processing of the output signals subsequent to summing, will normally be some type of thresholding or weighting. It is preferred in accordance with the invention to subject the summed output signals to a predetermined transfer function which linearizes the photon energy distribution curve. This will be described in more detail below.
In one arrangement the transfer function may comprise an attenuation value which is directly dependent on the total energy of the signals from all tubes and the individual signal. Thus the transfer function weights an input signal according to the degree of confidence one has in the input signal. Various other arrangements may be employed for weighting the summed input signals with a predetermined transfer function including digital arrangements.
The present invention lends itself to the application of digital electronics. Although digital electronics have been employed in prior arrangements, it has previously been necessary to provide a separate analog-to-digital converter for each photodetector. In accordance with the invention, however, in a digital implementation the number of ADCs may be drastically reduced since it is only necessary to have one ADC for each summed output signal of a respective row or column. Thus for example for a 6×8 array of photodetectors, it is only necessary to have 14 ADCs as opposed to prior arrangements of 48 ADCs. In addition, if very high speed ADCs are employed, it may be possible to sample the outputs of two or more rows or columns with a single multiplexing ADC.
Where ADCs are employed, conversion will take place subsequent to summing of the output signals and prior to thresholding or weighting of the output signals. A digital weighting transfer function may be implemented simply with a look-up table or through mathematical description.
Subsequent to weighting of the output signals, it is necessary to process the output signals to ascertain the position of an event. This is preferably done by linear weighting in predetermined manner of the row signals, summing the weighted signals and performing arithmetic computations as described below. A similar procedure is carried out for the column signals.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the invention will now be described with reference to the drawings wherein:
FIG. 1 is a schematic view of a known type of scintillation camera.
FIGS. 2 and 3 are schematic elevational views of rectangular and hexagonal arrays of photomultiplier tubes, respectively.
FIG. 4 is a schematic view of two cameras, each of a type shown in FIG. 1, arranged at right-angles for viewing a region, for example the heart, in a side region of a torso.
FIG. 5 is a schematic illustration of the concept which the present invention incorporates for reducing noise problems.
FIG. 6 is a scale diagram of the intensity distribution curve for photons detected from a gamma ray incident as measured in a direction across the camera.
FIG. 7 is a schematic circuit diagram of an array of photomultipliers of a scintillation camera in accordance with a first embodiment of the invention including analog signal processing circuitry.
FIG. 8A is a schematic view of a circuit for generating a predetermined weighting transfer function to be applied to the sum output signals, and FIG. 8B is a graph showing the transfer function generated.
FIG. 9 is a schematic circuit diagram of a scintillation camera in accordance with a second embodiment of the invention including digital processing circuitry.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 5, this illustrates the concept referred to above which is incorporated in the present invention for reducing noise problems.
It is important to distinguish between two different types of noise which thresholding attempts to deal with. Type 1 noise is random noise, generated by photomultiplier dark current, amplifier noise, or scintillator afterglow. This contains no useful information, and should always be discarded. Type 2 noise is small signal noise, associated with the detection of a small number of photons far from the source. Due to the statistical nature of the scintillation, the magnitude of these small signals will vary a lot, giving rise to apparent "noise." However, these signals do have a useful information content.
In the prior art the requirement for thresholding out noise of type 1 did not allow individual small signals to make any contribution to the position signal, as the individual small signals are insufficient to exceed the threshold. However, in accordance with the invention combining a number of these signals along a direction with equal information content (along a row or column) prior to thresholding gives a distinct advantage; where the signals contain position information, the fact that this will be highly correlated "noise" (type 2) which will be approximately coincident in time means the combined signal can exceed a threshold whereas uncorrelated noise (type 1) will not. Thus the rounding error associated with the assumption that all small signals are equal to zero (which is implied by thresholding them out completely) is removed (see FIGS. 1 and 2).
Referring now to FIG. 6 this shows to scale, a photon energy distribution curve for a single gamma ray event as detected by a single photomultiplier (line with diamonds) or row or column of photomultipliers (line with squares). In this figure the ordinate axis represents lateral displacement across camera width of the source of radiation with respect to the center of the photomultiplier row or column, in millimeters. It may be seen that at a source displacement of 76 mm (the edge of a photomultiplier tube) the total unthresholded signal detected in a row of photomultipliers is approximately 1.8 times greater than the signal on an individual tube.
Referring now to FIG. 7 a rectangular array of photomultipliers (50) is shown, each photomultiplier being of rectangular cross-section. The array shown is a 4×4 array although in a practical camera the array will be much larger, for example 6×8. Each photomultiplier has first, second and third output ports (52,54,56) respectively.
Each row of photomultipliers (R1,R2,R3 . . . etc.) have their first output ports (52) connected in common to a summing amplifier (58). Each column of photomultipliers (C1,C2,C3 . . . etc.) have their second output ports (54) connected in common to a summing amplifier (60). The output from each summing amplifier (58) is applied to a weighting transfer function device (62R), and the outputs from summing amplifiers (60) are applied to weighting transfer function devices (62C), described hereinafter in connection with FIG. 8. The output signals from devices (62R,C) are respectively applied to linear weighting networks (64R,64C) (described hereinafter) where the signals are combined in a predetermined manner and then processed in normalization units (66R,66C) (likewise described hereinafter).
The third output port (56) of each photomultiplier tube is summed in a summing amplifier (68) to provide a total energy signal E for a gamma ray event detected in the tubes. The output detected energy signal is applied to normalization units (66R,66C). In an alternative embodiment, this energy signal may be applied only to the transfer function devices (62R,C).
Referring now to FIG. 8A, a weighting transfer function device (62,R,C) is shown in more detail as comprising a variable gain amplifier (80) whose gain is determined by the total energy signal E applied via a buffer amplifier (82) and a unit (84) to the variable gain input of amplifier (80). It may be seen from FIG. 7 that the other input to amplifier (80) in the output of a summary amplifier (58) or (60). Unit (84) is a translating unit, that is, a device that translates upward or downward the signal input to amplifier 80. In addition a non-linear element (86) is provided in the output signal path of amplifier (80) whose impedance is determined by the total energy signal. The nonlinear element (86) may for example comprise a transistor.
As indicated in FIG. 8B the characteristics of amplifier (80) and non-linear element (86) are so determined as to provide the transfer function illustrated. The transfer function actually provided by the device (62,R,C) is depicted by a solid line comprising an initial state representing a variable threshold level followed by a straight line curve, the slope of the curve depending on the total energy, followed by a straight line of smaller slope for high value input signals. The two straight line slopes are provided by unit (84). It may be seen this transfer function is an approximation to an ideal energy distribution curve, which is indicated in dotted lines, and thus provides a weighting to the output signal which takes due account of the statistical noise value in the signal.
The output signals from the thresholding devices (62R) are applied to a resistive network (64R) where the signals are linearly weighted in the ratios indicated by impedances 72 and then added in two sets R + and R - . For the four resistors of each set, the ratios between respective resistances are designated by the numerals 1-4 shown in FIG. 7. A similar network (64C) is provided for the output column signals where the signals are weighted and added in two sets C + , C - . It will be noted that the conductance value of the impedances (72) in the two sets change linearly and stepwise from one side of the array of tubes to the other. This represents a position dependent weighting and enables the position of the gamma ray event within the row or column to be computed in normalization units (66,R,C) from the following equation: ##EQU1## where Si represents the total energy of the output signals from the devices (62R,C) for a row or column, and Xi represents the position of the tube in the row or column. The units 66R and 66C thus comprise any computational device available for making the above normalization calculation.
Thus at this point the position of a gamma ray event detected by the camera is known in terms of its position and its total energy. This essentially fully characterizes the signal for further processing in a digital signal processing unit (70).
Referring now to FIG. 9 a second embodiment of the invention is shown wherein the same reference numeral is employed for that shown in FIG. 7. The principal difference is that following summation of the rows and column signals the signals are digitized in ADC units (90) and are then applied to digital versions of weighting transfer function devices (92). Following weighting, the signals are normalized by a microprocessor unit (94) in order to provide the above normalization equation. | In order to average out thermal noise but to magnify small value photon signals resulting from a gamma ray event in a scintillation camera having an array of photodetectors arranged in rows and column, the photon signals are summed for each row and summed for each column as a first step in the processing of the signals. As a second step the summed signals are weighted in accordance with an approximation to an energy distribution curve, and the weighted signals are then further weighted and summed for determining the position of the gamma ray event. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to an ornament capable of being completely illuminated about its surface, comprising an enclosed water-proof battery capsule within the ornament's hollow shell enclosing a battery pack, that is capable of being displayed outside for long periods of time in various adverse weather conditions, wherein the ornament has a plurality of lighting modes which can include full-on, blinking-on, and timer.
BACKGROUND OF THE INVENTION
[0002] Illuminated decorations have long been used to celebrate the holiday season. In particular, the presence and display of light strings, ornaments, and other illuminated decorations is an indicator that the holiday season has arrived, and creates a feeling of nostalgia. Christmas is most well known for being the time when lighted decorations are used, although lights are also traditionally used during other holidays such as Halloween and New Years. Lights and illuminated ornaments are used by themselves but are also presented together with other non-illuminated decorative elements.
[0003] Holidays are not the only time people use lighted strings and ornaments for decorative effect. For example, light strings are often placed on or near trees, buildings, lampposts, sidewalks of major thoroughfares, store windows, and other general places of assembly such as ice skating rinks Thus, lights and illuminated ornaments are used for decoration purposes all year round, both indoors and outdoors.
[0004] There are various kinds of illuminated decorations. The lights can be assembled on a string with each light a fixed distance apart from the next light. Alternatively, the decoration can be a lighted ornament. An ornament can itself be any number of things, including spheres or cubes, animals or animal-like characters (e.g., Santa Claus, elves, reindeer, snowmen, etc.) or any number of objects (e.g., sleds, trees, candy canes, etc.).
[0005] Traditionally, the lights and lighted decorations can have different lighting modes. For instance, instead of the lights being continuously illuminated, they can also be blinking on and off at set time increments. Additionally, the lights can be configured using a timer, such that they are on continuously or blinking but then set to turn off after a fixed number of minutes or hours. This way the lights can be used as decoration during the evening, but then are set to turn off after several hours to conserve energy.
[0006] Several configurations of ornament displays are possible. The ornaments themselves can be illuminated by being comprised of several lights or by just one light. Ornaments can have different sizes. If spherical, the ornaments can range from about the size of a golf ball (1.7 inches in diameter) to as large as a cage ball (72 inches in diameter) and everywhere in between (baseball, volleyball, basketball) although they can be larger or smaller and can be any shape. The corresponding triangular or rectangular ornaments can be of that approximate size as well.
[0007] The source of power for these lights, if not plugged into an electrical outlet, is typically a battery or battery pack comprising one or more batteries. Ornaments with exterior battery packs are known, but they have a form factor that can be difficult to handle, and are not aesthetically pleasing.
[0008] U.S. Pat. No. 5,772,312 describes an ornament containing a hollow shell such that lights are placed inside of the ornament in order to illuminate the ornament. The ornament is powered using conventional AC power from a wall outlet. U.S. Pat. No. 6,053,620 describes an improvement of a water-draining passage structure of a lamp set for an ornament. While '620 describes a water-draining passage structure, it does not describe a water proof ornament containing a water-proof battery capsule comprising a battery pack whose configuration enables a plurality of lighting modes. U.S. Pat. No. 6,547,414 describes an underwater flashlight comprising a water-proof battery pack which can be removably changed underwater. While '414 describes a flashlight containing a water-proof battery pack, it does not describe an illuminated decorative ornament comprising a water-proof battery capsule comprising a battery pack which enables various lighting configurations including full-on, blinking-on, and timer.
SUMMARY OF THE INVENTION
[0009] The present invention relates to a unique illuminated ornament that houses a water-proof battery capsule containing a battery pack which enables a plurality of lighting modes. The battery pack consists of one or more batteries. The ornament is adorned with a plurality of light bulbs which may be secured to the shell through light bulb apertures on an exterior surface. The light bulbs can be any number of colors. The ornament can be further adorned with a plurality of translucent member decorations corresponding to each light bulb. The translucent member decorations may be secured to the exterior surface of the shell to permit light generated by the light bulbs to shine with an embellished appearance from the ornament. The ornament can be displayed indoors or outdoors using the battery pack as a source of power, the battery pack being housed within a water-proof battery capsule. The water-proof battery capsule protects the battery pack from rain, snow and extreme temperatures. Further, the battery pack's associated circuitry enables a multitude of lighting modes, including but not limited to full-on, blinking-on, and timer. Full-on mode illuminates the ornament continuously, blinking-on illuminates the ornament on and off after set time increments, and timer illuminates the ornament either full-on or blinking-on for a set number of minutes or hours, after which the ornament ceases being illuminated. Preferably, the present invention concerns an ornament that contains a water-proof battery capsule comprising a battery pack enabling a plurality of lighting modes, and is to be used together with similarly structured ornaments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a side view of an example spherical ornament in a closed arrangement containing an enclosed water-proof battery capsule.
[0011] FIG. 2 is a side view of the example spherical ornament in a partially open arrangement shown with the water-proof battery capsule inside.
[0012] FIG. 3 is a top view of the example spherical ornament in a partially open arrangement shown with the water-proof battery capsule inside.
[0013] FIG. 4 is a side view of the example spherical ornament in a fully open arrangement shown with its contents.
[0014] FIG. 5 is a close-up side view of the spherical ornament in an open arrangement.
[0015] FIG. 6 is a side view of an example water-proof battery capsule.
[0016] FIG. 7 is a side view of the example water-proof battery capsule.
[0017] FIG. 8 is a top view of the water-proof battery capsule in an open arrangement.
[0018] FIG. 9 is a top view of the example spherical ornament in a partially open arrangement showing all of its components.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] The present invention is directed to an ornament which employs a hollow shell to house a water-proof battery capsule containing a battery pack used as a power source to illuminate the light bulbs and to enable a plurality of lighting modes including full-on, blinking-on and timer.
[0020] As is shown in FIG. 1 , one preferred spherical ornament 100 consistent with the present invention is embellished with a plurality of decorated light bulbs 170 . The light bulbs are typically either incandescent or light emitting diodes. In this embodiment, the spherical ornament 100 is comprised of one hundred two such light bulbs 170 , and the light bulbs 170 are each themselves decorated with a translucent member decoration 150 . The translucent member decorations 150 serve as aesthetic enhancement but also enhance the illuminative effect of the light bulbs 170 . The spherical ornament 100 is shown in a closed arrangement with the water-proof battery capsule 110 enclosed inside, although the removable battery capsule lid 130 is optionally visible. The water-proof battery capsule 110 can be designed to complement the shape of the ornament, although this is not required. For example, if the battery pack comprises cylindrical batteries, and the ornament is cube-shaped, then the battery capsule tube 135 may be cylindrical while the capsule lid 130 rectangular so as to complement visually and structurally the cube-shaped ornament. In the present example, the battery capsule 110 is cylindrically shaped with a circular battery capsule lid 130 such that the top of the lid 130 visually and structurally complements the shape of the example spherical ornament 100 . The type (e.g., size) of battery pack used will depend on the size of the ornament. As such, the battery pack's life can vary anywhere between two weeks to six months. The battery capsule 110 can accommodate a battery pack comprising one or more batteries.
[0021] In this example, the water-proof battery capsule 110 is made out of the same water proof plastic material as the ornament surface 160 , and lid 130 makes a water-impregnible seal when engaged (e.g., as a screw top). However, this material is not limited to plastic material, and may be any water proof material allowing the spherical ornament 100 to be displayed outdoors in a variety of weather conditions. Other examples of such water-resistant material include rubber and resin impregnated fiber. The ornament surface 160 is thick enough (greater than 0.1 mm) so that the ornament is both water-proof and durable. The ornament surface 160 may be in festive colors such as red and green for Christmas or orange and black for Halloween. The spherical ornament 100 also comprises a fastening wire 180 , which serves to fasten the ornament in a closed arrangement. The fastening wire 180 can also be used to hang the ornament from a suspended structure and/or to attach the ornament to other like ornaments. Lid 130 may alternatively use a quick-release construction, such as a spring-engaged button, for greater ease of consumer access and battery replacement. Pushing the button may pop out the battery compartment, which may then be popped back in against the spring tension, resetting the button.
[0022] FIG. 2 shows the example spherical ornament 100 in a partially open arrangement. The example spherical ornament 100 contains several ornament connectors 190 that permit the example spherical ornament 100 to be fastened together. The ornament is typically comprised of two halves. Thus, the example spherical ornament 100 contains an ornament half indicator 165 that protrudes slightly (approximately 0.5 mm) from the ornament surface 160 . When in a closed arrangement, the two halves of the ornament are fastened via the ornament connectors 190 using either an ornament tie 177 or a fastening wire 180 , either of which will run through the ornament connector apertures 195 , which are shown in more detail in FIG. 5 . FIG. 2 further shows electrical wire 179 which connects to and serves to illuminate the plurality of light bulbs 170 . An optional gasket may be used at the seam between the halves.
[0023] FIG. 3 shows a top view of the example spherical ornament 100 . The battery capsule 110 is housed in the hollow shell 101 of the ornament 100 . The light bulbs 170 are placed in the light bulb apertures 185 while the ornament is being displayed. Several such light bulb apertures 185 are located on the ornament surface 160 typically at equally spaced distances apart from each other. In the example spherical ornament 100 shown in FIG. 3 , there are one hundred two such apertures 185 , one for each light bulb 170 . A light bulb 170 protrudes through each such light bulb aperture 185 . In the example spherical ornament 100 , they are separated, approximately, by 1 inch. The light bulbs 170 , when lit, illuminate the entire ornament. Further in this example, a translucent member decoration 150 is placed around every light bulb 170 at every light bulb aperture 185 . FIG. 3 further shows a capsule accommodation 120 of approximately the same radius as the water-proof battery capsule 110 , allowing the capsule 110 to fit inside the ornament while the battery capsule lid 130 is exposed while still complementing visually and structurally the ornament surface 160 . Also shown in FIG. 3 is a fastening wire 180 tied through the ornament connector apertures 195 . The fastening wire 180 is long enough to pass through the ornament connector apertures 195 and still has enough length to suspend the ornament from a ceiling or connect to other ornaments. A button activator 136 exists on the capsule lid 130 for a user to toggle between different lighting modes.
[0024] FIG. 4 shows the ornament in an open arrangement. A circuit board 200 is used in the conventional manner to route electrical current from the battery to the plurality of light bulbs 170 via the electrical wire 179 . The circuit board is approximately 4 inches lengthwise by 2 inches, or small enough to fit into the hollow shell 101 of the ornament 100 . The entirety of the electrical wire 179 is housed in the hollow shell 101 of the water-proof spherical ornament 100 . When the example spherical ornament 100 is in an open arrangement, the water-proof battery capsule tube 135 is visible. The battery capsule's 110 size will vary proportionately to the size of the ornament. In this example, the capsule 110 is about 7 inches long with a ¾ inch radius. The battery capsule lock clasps 115 join the halves of the battery capsule 110 together. FIG. 4 also shows the light bulb interior casing 171 and light bulb exterior casing 172 . Typically four of the electrical wires will route through the underside of the interior casing 171 through the interior casing apertures 175 (shown in FIG. 5 ), two through each interior casing aperture 175 .
[0025] The ornament connectors 190 can bee seen in more detail in FIG. 5 . In addition to having an ornament connector aperture 195 , some of them can have ornament connector pegs 197 and corresponding peg apertures 198 . The pegs 197 are inserted into the peg apertures 198 when the ornament is closed. In this way, the pegs 197 and corresponding peg apertures 198 fasten the halves of the ornament together and ensure that the two halves are perfectly aligned when the ornament is in a closed arrangement. The ornament connectors 190 themselves can vary in size as some can be slightly smaller than the others, the smaller ornament connectors 190 typically being the ones that contain the pegs 197 and peg apertures 198 .
[0026] FIG. 5 shows the electrical wire 179 being routed into the light bulb interior casing 171 via the interior casing apertures 175 through the light bulb exterior casing 172 and ultimately to the light bulbs 170 . An interior casing ring 173 separates the interior 171 and exterior 172 casing. Importantly, the ring 173 serves to secure both interior 171 and exterior 172 casings against the bottom of the ornament surface 160 . Other manners of retaining the light bulbs in the shell may include rubber gaskets, clips, or any other mechanisms which would allow the light bulbs to be secured on the ornament surface.
[0027] The exterior casing furrows 174 secure the translucent member decorations 150 to the light bulbs 170 .
[0028] FIGS. 6 and 7 show the water-proof battery capsule 110 by itself. In this example, it is cylindrically shaped because the ornament is spherical, although the capsule 110 can be any number of shapes. Its shape will conform to the shape of the ornament within which it is housed. Generally, the same water resistant material used for the ornament surface 160 is used for the battery capsule 110 , although this need not be the case as they each merely need to be made of a suitable water resistant material. Screws are typically used in the battery capsule lock clasps 115 to join the two halves of the capsule together. The capsule tube half indicator 137 protrudes slightly from the capsule surface. The electrical wire 179 accesses the battery pack features within the capsule 110 through the capsule wire apertures 140 . Each capsule generally has two such capsule wire apertures 140 , one for each battery pack charge.
[0029] FIG. 8 shows the capsule 110 with its lid 130 open. In one embodiment, the lid 130 is secured onto the capsule tube 135 by twisting the lid 130 in a clockwise direction such that the lid lock 132 fits into the lid lock aperture 131 . The electrical wire 179 is routed from the circuit board 200 through the capsule wire aperture 140 and finally to the positive battery pack terminal 133 . The positive battery pack terminal 133 receives from the battery pack a positive charge and sends this charge to the circuit board 200 and then to the plurality of light bulbs 170 . Likewise, a negative battery charge is received from the battery pack via the negative battery pack terminal 134 and then sent via the electrical wire 179 to the light bulbs 170 . FIG. 9 shows all of the components of the invention together. The mode functionality is provided by a suitable electronic circuit inside the unit.
[0030] Although the description here highlights a spherical embodiment of the invention, generally the present invention can employ any number of decorative ornament shapes and sizes. In each instance, a water-proof battery capsule, comprising a battery pack enabling multitude of lighting mode configurations, is enclosed within the hollow shell of the ornament where the size of the capsule is such that it fits within the ornament and such that its lid (or whichever portion is exterior to the ornament) visually complements and conforms to the ornament's shape.
[0031] While the above specification and example provide a description of the invention, many embodiments of the invention can be made without departing from the spirit and scope of the invention. It is to be understood that the foregoing embodiment is provided as illustrative only, and does not limit or define the scope of the invention. Various other embodiments are also within the scope of the claims. | A decorative ornament capable of being completely illuminated about its surface including a hollow shell comprising a water-proof battery capsule is described. When the ornament is on display, the battery capsule is stored in a hollow shell of the ornament, in a manner such that only the removable lid of the battery capsule is visibly exposed. A battery pack, comprising one or more batteries, provides the power to illuminate the ornament and is enclosed within the battery capsule. The ornament surface is made using a water-resistant material. The battery capsule is made of a similar water-proof material and is sealed so as to prevent the battery pack from malfunctioning during various weather conditions. The battery pack's configuration enables the ornament to comprise a plurality of lighting modes, including full-on, blinking-on, and timer. The ornament can be displayed indoors or outdoors, and may be used year after year. | 5 |
BACKGROUND OF THE INVENTION
Related Application
This application is a continuation in part of application Ser. No. 08/440,780, filed May 15, 1995 U.S. Pat. No. 5,747,017.
FIELD OF THE INVENTION
The present invention relates to a kits, methods, and compositions for enhancing the appearance of the lips. The invention contemplates cosmetic compositions for applying the color to the lips, compositions for enhancing the finish the finish of the cosmetic, color enhancing powders, and formulations for removing the color. Kits containing the above compositions are also contemplated. The present invention also relates to methods of using the preceding compositions.
Description of the Prior Art
For many years, lipstick has been utilized as a cosmetic preparation for heightening or altering the color of the lips. Conventional lipstick is formed by a cosmetic coloring in a wax carrier. Although lipstick has many disadvantages, there has thus far been no suitable alternative.
The lipsticks which have heretofore been available have the marked disadvantage of being readily transferrable from a person's lips to other objects. Lipstick smears and rubs off while swimming, smoking, kissing, or by any other contact of the lips with articles such as coffee cups, tea cups, napkins and clothing. This leads to the loss of the lipstick application when drinking beverages, when swimming, and even when in engaging in none of these activities due simply to licking the lips. Thus, while lipstick is normally initially applied in a relatively even application across the externally exposed areas of the lips, the application of lipstick will readily dissipate and assumes a nonuniform coverage. The greatest loss of the lipstick application is typically near the portions of the lips closest to a person's mouth. As a consequence, it is necessary to frequently reapply layers of lipstick in order to maintain a uniform coverage of a lipstick application on a person's lips. This frequent necessity for reapplication aggravates a further disadvantage of conventional lipstick.
Lipstick has the additional disadvantage of being susceptible to cracking and caking. This disadvantage is particularly pronounced when several layers of lipstick have been applied to attempt to replenish a lipstick application that has been lost due to transfer to other articles. As a consequence, the frequent reapplication of lipstick results in perceptible cracking and caking of the lipstick covering a person's lips. Caking and cracking of a lipstick application detracts from the natural appearance of the lips and is aesthetically undesirable.
Attempts have been made over the years to provide alternative cosmetic which do not entail the disadvantages of lipstick. For example, U.S. Pat. No. 2,230,063 describes a liquid lip rouge preparation which employs a combination of ethyl cellulose and wax-free shellac as film-forming materials. However, shellac does tend to crack. Heretofore, no suitable alternative to lipstick has been found.
SUMMARY OF THE INVENTION
The present invention is an innovative new alternative to lipstick. The cosmetic of the present invention does not take the form of a gooey stick, but rather is a unique, smear-proof and waterproof liquid that dries quickly to an extremely sheer, soft finish that feels remarkably like bare skin.
The cosmetic of the present invention is both smear-proof and waterproof. It will not streak, smear, or rub off while swimming, smoking, or kissing. Use of the cosmetic of the present invention avoids the disadvantages of stains on coffee cups, cheeks and collars. The cosmetic of the present invention has twice the staying power of lipsticks which purport to be waterproof or kiss-proof.
The cosmetic of the present invention has further advantages in that it won't stick to dental work or braces. It can also be used on hair or eyebrows, as well as to cover any bald areas on the head. It can be used to cover scars or tatoos anywhere on the body.
The present invention provides a perfect cosmetic for busy professional women. It is highly advantageous for wear at weddings, parties, for use at the beach, for use while skiing and for wear during all active sports. The cosmetic of the invention is extremely attractive and can be worn at important dinner dates, as well as informal events. The wearer can even sleep or shower while wearing the cosmetic, since it will not fade or smear under such circumstances. The user may apply several layers of the cosmetic to achieve the desired appearance.
The present invention also relates to compositions for enhancing the finish of the cosmetic. Such compositions, when applied over the cosmetic, transform the finish of the cosmetic from a matte to a high-gloss finish. The finish enhancing compositions also keep the lips soft and moist and may be massaged lightly into the lips prior to application of the cosmetic to condition and moisturize the lips. The finish enhancing compositions may be applied with an applicator wand. The user can apply the finish enhancing composition multiple times, whenever it is desired to moisturize the lips or to enhance the finish of the cosmetic.
The appearance of the lips can be further enhanced using color enhancing compositions comprising a colorant powder, which may be supplied in pressed or loose form. The colorant powder may be supplied in a compact and can be gently pressed onto the cosmetic using a brush. The colorant powders may also be used as a foundation base or may be applied between the second and third layers of the cosmetic. The visual effect of the colorant powders may be moderated by applying the finish enhancing composition over the colorant powder.
The present invention also relates to compositions for removing the cosmetic, finish enhancer, and color enhancers. These compositions may be dabbed on a tissue and applied to the lips when the user desires to remove the preceding compositions from the lips.
The present invention also relates to kits comprising the preceding compositions and to methods of using the preceding compositions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In one broad aspect, the invention may be considered to be a cosmetic comprising between about 0.1 and about 20 parts of an alcohol soluble and water insoluble resin, between about 0.1 and about 15 parts ethyl cellulose, between about 0.1 and about 15 parts of a cosmetic pigment, and between about 50 and about 99 parts of an organic solvent. All parts used herein are percent by weight.
Preferentially, the solvent is denatured alcohol. In a preferred version the alcohol soluble and water insoluble resin is present in between about one and about 10 parts. In a further preferred embodiment, the ethylcellulose is present in between about 1 and about 10 parts. In a further preferred embodiment, the cosmetic pigment is present in between about 2 and about 10 parts.
In another broad aspect, the invention may be considered to be an improvement in a cosmetic employing a coloring agent and a plasticizer in a volatile solvent. The improvement is comprised of at least one film-forming agent present in an amount of at least about one percent wherein the film-forming agent is selected from the group consisting of: Amphomer, Lovocryl, Carboset, Joncryl, Quadamer, Gantrez and polyvinyl acetate copolymers.
In yet another broad aspect, the invention may be considered to be an improvement in a cosmetic employing a pigment and a film-forming agent in an organic solvent carrier. According to the improvement of the invention, the film-forming agent includes an alcohol soluble and a water insoluble substance present in an amount of at least about one percent and selected from the group consisting of Amphomer, Lovocryl, Carboset, Joncryl, Quadamer, Gantrez and polyvinyl acetate copolymers.
The critical component of the invention is the alcohol soluble and water insoluble resin. A number of different resins of the type may be employed in formulating the cosmetic of the invention. The alcohol soluble, water insoluble resin may be selected from the group consisting of octylacrylamides, acrylates, butylaminoethyl methacrylate copolymers and polyvinyl acetate copolymers. The alcohol soluble, water insoluble resin or mixture of resins serves as a vital component of the film-forming agent. This film-forming agent may be selected from the group consisting of: Amphomer, Lovocryl, Carboset, Joncryl, Quadamer, Gantrez and polyvinyl acetate copolymers. Five performance tests were conducted on a variety of resins to determine their suitability for use in the present cosmetics. The suspension test was employed to assess the ability of the test compound to be solubilized in a solution of 4.4% test resin, 3.5% ethyl cellulose, 0.5% castor oil, 0.8% D&C Red #7 Calcium Lake pigment, and 90.7% ethyl alcohol.
The rub test was designed to determine the test resin's ability to be retained on the skin. The composition used for the suspension test was painted on the skin and allowed to dry. Thereafter, the skin was rubbed under cool tap water until the composition began to fall apart. A composition received a score of "Good" if it was able to withstand five minutes or more of rubbing. A compound received a score of fair or poor if it withstood less than one minute of rubbing.
In the color test, the color of the resin containing compositions used in the suspension test was applied to the lips and the quality of the color obtained was compared to that produced using a composition lacking the test resin.
In the "feel on lips" test, the compositions used in the suspension test the compounds were evaluated to determine whether they produced a tight shrinking feeling, cracked, dried the lips, or caked on the lips. Compounds performing favorably in this test produced none of the preceding effects and were not noticeable to the wearer.
In the drying time test, the compositions used in the suspension test were applied to the lips and the length of time the composition took to dry was evaluated. Preferentially, the compositions take about 20 seconds to dry.
The above tests were performed on the following resins:
(1) Resin 28-2930 (VA/crotonates/vinyl neodecanoate copolymer) available from National Starch, Bridgewater, N.J.
(2) Amphomer LV-71 (octylacrylamide/acrylates/butylaminoethyl methacrylate copolymer) available from National Starch.
(3) Water Lock G40-A180-D242 (corn starch/acrylamide/sodium acrylate copolymer) available from Grain Processing Corp., Muscatine, Iowa 52761.
(4) Daihold (amp/acrylate copolymer) available from Sandoz Chemical Corp., Charlotte, N.C.
(5) Eastman AQ-385 and AQ-555 (Diglycol/cyclo hexanedimethanol/isophthalates/sulfylisophthates copolymer) available from Eastman Kodak, Rochester, N.Y.
(6) Ultra Hold 8 (acrylates/acrylamide copolymer) available from Base Corp., Clifton, N.J.
(7) Omnirez 2000 (2 butenedioic acid 2-monoethyl ester polymer with methoxyethene available from ISP, Sherman Oaks, Calif.
(8) Gantarez compounds such as A-425, ES 425, and ES-435 (which are butyl esters of PVM/MA copolymers), ES-335 (isopropyl ester of PVM/MA copolymer), or ES-225 and SP-215 (ethylesters of PVM/MA copolymer), all of which are available from ISP, Sherman Oaks, Calif.
(9) H2old EP-1 Terpolymer (Vinyl caprolactam/PVP/dimthylaminoethyl/methylacrylate copolymer) available from ISP, Sherman Oaks, Calif.
(10) Amphomer Lovocryl-47 (octylacrylamide/acrylates/butylaniinoethyl methacrylate copolymer) available form National Starch, Bridgewater, N.J.
(11) Amphomer 28-4910 (octylacrylamide/acrylates/butylaminoethyl methacrylate copolymer) available form National Starch, Bridgewater, N.J.
(12) Advantage Plus terpolymer (VA/butylmaleate/isobornyl acrylate copolymer) available from ISP, Sherman Oaks, Calif.
(13) Copolymer 958 (PVP dimethylaminoethylmethacrylate copolymer) available from ISP, Sherman Oaks, Calif.
(14) Joncryl (styrene/acrylates copolymer available form SC Johnson Polymer, Racine, Wis.
(15) Sentry Polyvinyl acetate-12 (polyvinyl acetate) available from Union Carbide Corp,. Houston, Tex.
(16) Carboset-525 (acrylates copolymer) available from B. F. Goodrich, Brecksville, Ohio.
Table I summarizes the results of the performance tests.
Resin 28-2930, Amphomer LV-71, Amphomer Lovlocryl-47, and Amphomer 28-4910 received an overall performance rating of "good" in the above performance tests. While any of the substances tested in the performance tests could be utilized in the formulation of the cosmetic of the invention, the alcohol soluble, water insoluble resin that serves as the film-forming agent preferably includes an Amphomer component. The most highly preferred Amphomer is Amphomer LV-71. In the preferred formulation the film-forming agent is preferably comprised of an Amphomer and ethyl cellulose.
Amphomer is a trademark under which copolymers of N-tert-octylacrylamide, methyl methacrylate, hydroxypropyl methacrylate, acrylic acid and t-butyl aminoethyl methacrylate are sold. Gantrez is a trademark under which copolymers of vinyl methyl ether and mono-alkyl esters of maleic anhydride are sold by GAF. Quadamer is a trademark under which terpolymers of alkyl acrylamide, acrylamide or methacrylamide, N-vinyl pyrrolidone and acrylic or methacrylic acid are sold by American Cyanamid. The most preferred film-forming agent is the commercially available Amphomer sold as LV-71 by National Starch and Chemical Company, Specialty Polymers, having an address of 10 Finderne Avenue, P.O. Box 6500, Bridgewater, N.J. 08007-3300.
The amphoteric acrylic resin forming the chemicals sold in the trade as Amphomer has previously been utilized as a fixture in hair spray as described, for example, in U.S. Pat. Nos. 4,192,861 and 4,315,910. However, Applicant has discovered that this substance can also serve as the preferred form of the critical ingredient of a cosmetic which forms a clear, colorless film on the lips and which has a staying power far greater than that of conventional lipsticks.
The Amphomer utilized in the cosmetic of the invention functions as a transparent sealer. It binds and seals the cosmetic to the lips in a clear, sheer film which does not crack or cake. The film-forming agent in the cosmetic composition is what makes the product so long lasting.
The Amphomer is an amphoteric acrylic resin. Its official Cosmetic Toiletries and Fragrances Association (CTFA) product designation is Octylacrylamide/Acrylates/Butylaminoethyl Methacrylate Copolymer. Amphomer is carboxylated at regular intervals along its molecular chain. In its undissolved form it is a fine white free-flowing powder. It has an intrinsic viscosity of 0.40 in ethanol at 25 degrees Centigrade. It contains about three percent volatiles and has an acidity of 2.05 me/gram.
The cosmetic of the invention contains no waxes or petroleum products. Waxes can smear while petroleum products can burn or dry the lips. The cosmetic of the invention is so sheer that a wearer can layer on at least three different layers without any danger of the product caking up on the lips. Indeed, the different layers of the cosmetic of the invention can be applied in different colors to achieve a unique, aesthetic effect.
Also, a different number of layers of the cosmetic can be applied to produce different aesthetic appearances. A single layer of the preferred embodiment of the cosmetic of the invention dries to a shear finish. If a second layer of the cosmetic is applied over the first, a medium matte finish is achieved. By applying a third layer, a wearer achieves a full cover matte finish. Even with use of multiple layers, however, the cosmetic of the invention will not cake, cake or smear.
The cosmetic of the invention can be formulated in any number of different colors by varying the color of the pigment employed. The cosmetic of the invention is in a liquid form when applied and the colors can be used individually or mixed by layering to create an unlimited array of custom, personalized colors. Each layer takes about twenty seconds to dry from the time of application.
In addition to its basic components, the cosmetic of the invention may include other substances to achieve certain effects. For example, the cosmetic may be formulated with at least about one part of a dimethicone component to achieve a gloss or satin effect. Although the cosmetic formulated in this manner looks and feels viscid or sticky, it will not come off, but will stay on the lips despite extended wear and exposure to moisture.
The cosmetic may also be formulated as a lip liner by utilizing a higher concentration of cosmetic dyes or pigments in the formulation. When formulated in this manner, the cosmetic may be utilized to outline the lips in the same or a different color as the basic application.
The cosmetic of the invention provides natural sun protection and keeps the lips from chapping, indoors or outdoors, in both cold and hot weather. It will not stick to teeth or dental braces. Unlike a user wearing lipstick, an individual wearing the cosmetic of the present invention can actually brush and floss after means without smearing the cosmetic or reducing the thickness of its lip coating, and without having to reapply the lip covering.
The cosmetic of the invention is organic and hypoallergenic. Unless a flavor or fragrance is added, it is also odor free and contains no petroleum products.
The cosmetic of the invention enhances the beauty of the wearer without surgery by filling in the inner lips where conventional lipstick will not stay. The cosmetic of the invention is extremely sheer and is not gooey like conventional lipstick. Even after three or more layers of the cosmetic of the invention are applied, the lips still fee bare and have a perfect matte finish.
The cosmetic of the invention is not at all viscous, and can even be poured from a container. Its sheer consistency allows it to be applied with a fine tip applicator so that it can be applied with the precision of a makeup artist.
The Amphomer utilized in the cosmetic of the invention functions as a transparent sealer. It binds and seals the cosmetic to the lips in a clear, sheer film which does not crack or cake. The film-forming agent in the cosmetic composition is what makes the product so long lasting.
The cosmetic of the invention will not come off with petroleum jelly or cleansing cream. Due to its permanence, care must be taken not to spill the cosmetic of the invention in liquid form onto clothing or other fabrics. However, if the cosmetic is accidentally spilled onto carpeting or clothing, it can be readily removed by applying water and then applying isopropyl alcohol or the cosmetic removing formulations described below, provided that cleanup is undertaken promptly.
To use the cosmetic of the invention, it is recommended that the lip area be cleaned thoroughly with with the cosmetic removing compositions described below. A bottle of the cosmetic containing small mixing balls should be shaken for four or five times until the mixing balls move freely within the bottle.
The cosmetic of the invention is then applied generously in liquid form to dry, clean lips. It is recommended that three consecutive layers be applied at a time for full day-time coverage. The cosmetic can be applied with a soft doefoot applicator or brush applicator and should be applied across the lips in a single direction only. When applying the cosmetic, the wearer should keep in mind the freedom of creating fuller lips by filing in the inner lips where regular lipstick does not stay. Approximately 20 seconds should be allowed to elapse between consecutive coats in order to allow the immediately preceding coat to dry. During this time, the lips should be kept apart and not blotted. For best results after the application of the cosmetic of the invention, the wearer should refrain from eating, drinking or smoking for at least one minute.
With the application of the cosmetic, the wearer's lips will tingle at first. This tingling sensation diminishes or goes away entirely with repeated use, because the sealing effect of the product actually helps to eliminate the mild, but ever present chapping common to most lips.
The tingling sensation which is sometimes present may be avoided by applying at first a thin layer of the cosmetic containing dimethicone. Subsequent layers of the same or a different formulation of the cosmetic may be applied to achieve the desired degree of sheer or matte finish.
The bottle containing the cosmetic of the invention should be kept closed after each use. With daily use, a one quarter ounce bottle should last approximately two months.
As previously noted, the organic solvent or carrier employed is preferably denatured alcohol, sometimes termed ethyl alcohol or ethanol. Other organic solvents which may be employed instead of or in addition to denatured alcohol include stearyl alcohol, cetyl alcohol, cetearyl-cetostearyl alcohol, SDA alcohol, methyl alcohol, isopropyl alcohol, isostearyl alcohol, laurel alcohol, myristyl alcohol, behenyl alcohol, synthetic alcohol and C18-40 alcohol. Other organic solvents which may be employed include higher fatty-acids which are immiscible in water. These include lauric acid, myristic acid, stearic acid, palmitic acid, behenic acid, and lanolin fatty acid. Lanolin and triterpene may also be employed in the organic solvent.
Depending upon the concentration of the other components, the organic solvent, which is preferably SDA 40B 190 denatured alcohol, is preferably present to the extent of between about 30 to 95 percent. Within this range, a concentration of 80 to 95 percent organic solvent will normally be utilized.
The pigments which are employed to provide the coloring to the cosmetic are normally provided as dispersions in castor oil. The pigment and castor oil are preferably present in the cosmetic of the invention in an aggregate amount of between about 0.1 percent and about ten percent. Pigments of this type are standardized in the cosmetic industry and are identified in that industry by FD&C designations, D&C designations, and natural color designations that are compatible with alcohol solutions. The preferred pigments that are employed include D&C Red No. 6, Barium Lake, D&C Red No. 7 Calcium Lake, D&C Orange No. 5, D&C Red No. 27, FD&C Yellow No. 5, FD&C Blue No. 1, iron oxide and others. The D&C lake colors are all made with iron, aluminum, calcium, barium, potassium, strontium or zirconium.
Other pigments which may be employed include those of dye or coal tar origin and chemical compounds used as pigments. Inorganic colors such as iron oxides may be utilized. White pigments may be formed of titanium dioxide, zinc oxide, mica or pearls. Pigments formed of nitro dyes may be utilized if desired. These dyes contain one atom of nitrogen and two of oxygen. However, only a few nitro dyes are certified by the FD&C or D&C because nitro dyes can be absorbed through the skin and some are toxic. However, D&C Yellow No. 5 is one acceptable nitro dye which can be used as a component of the pigment of the invention.
Azo pigments may also be utilized. These pigments are characterized by the presence of the azo bond, and monoazo pigments include the greatest number of pigments within this group.
Another group of suitable pigments is the triphenylmethane group. FD&C Blue No. 1 is the most popular dye of the group and is widely used in the cosmetic industry. Xanthene pigments may also be utilized. This group of pigments includes Berry brilliant, which is widely used in lipstick colors, as well as D&C orange.
Certain of the quinoline dyes are also suitable for use as pigments. There are only two certified cosmetic colors in this category, namely D&C Yellow Nos. 10 and 11. These are bright greenish yellow colors.
The anthraquinone dyes are also suitable for use in formulating the pigment required by the compositions of the invention. These dyes are widely used in cosmetics because they are not affected by light. D&C Violet No. 2 is one example of such a dye suitable for use in the invention. The anthraquinone dyes should not be used in the lip area, but may be used in other applications, such as on the nails.
Indigo dyes are also suitable for use and have been used in cosmetics for many years. D&C Blue No. 6 is one example of a suitable indigo dye.
Pigments of vegetable, animal, or mineral origin may also be utilized according to the invention. One suitable pigment of animal origin is cochineal extract. Natural colors and vegetable compound pigments which may be utilized include alkanet, annatto, carotene, chlorophyll, saffron and tumeric, beet juice powder, carmine, alkanet root, carmel, grape skin extract, and beta carotene. Hydroxyascetone and indelible dyes may also be utilized in formulating the pigment in the cosmetic of the invention.
The preferred embodiments of the cosmetic of the invention employ pigments of coloring dispersed in castor oil. This dispersion is present to the extent of between one percent and ten percent of the formulation. The degree of concentration of the pigments in caster oil determines the shade of the coloring. Normally a concentration of between 25-65 percent pigments in caster oil, in the aggregate, is employed in formulating the cosmetic. The castor oil acts like a plasticizer and also makes the film formed more flexible.
Alternatively, the pigments may be alcohol soluble pigments, such as D&C Red 28 Lake, in which case a castor oil dispersion is not necessary to solubilize the pigments in the present cosmetics.
The pigments may contain 0.1 to 5% stain. Preferably the pigment contains 0.65%-1.5% stain.
The alcohol soluble, water insoluble resin which is employed is the critical component that provides the cosmetic of the invention with its numerous advantages over lipstick. While Amphomer is preferably utilized as the requisite alcohol soluble, water insoluble resin, other may be used not only to add a white component of color, but also to serve as a sunscreen.
The cosmetic of the invention may also employ vitamins, minerals, antioxidants, drugs, organic compounds, herbs, proteins, currant extracts, root extracts, enzymes, sorbitol, pectin and PCA to take advantage of their known coloring, flavoring, moistening and adhering properties.
The invention may be further illustrated by way of the following examples.
EXAMPLE 1
The first step in formulating the cosmetic of the preferred embodiment of the invention is to create the sealer. The sealer is formed by mixing the film-forming agent in the organic solvent. Specifically, 4.4 parts of Amphomer LV-71, obtained from National Starch and Chemical Company, and 1.9 parts Ethocel N-22, obtained from Aqualon Corporation, are mixed at room temperature in 93.7 parts 190-proof specially denatured alcohol, sold as SDA 38B-190. The Ethocel N-22 provides ethyl cellulose which functions as an adjunct film former in the sealant. The sealer is then momentarily set aside.
Five parts by weight of a dispersion of D&C Red No. 7 Calcium Lake in castor oil and 0.5 parts by weight of a dispersion of D&C Orange No. 5 in castor oil are then selected for use as the pigment or coloring agent. Both the D&C Red No. 7 Calcium Lake and the D&C Orange No. 5 each comprise about 50 percent of the total weight of their respective dispersions. The remaining weight of the dispersions is attributable to the castor oil. The pigments should be obtained in as finely ground a form as possible. The pigment dispersions are mixed together along with another 0.5 parts by weight castor oil.
The pigment and castor oil mixture is then mixed in with the sealer, also at room temperature. The Amphomer, the Ethocel and the pigment ingredients are all readily soluble in the denatured alcohol. When mixed, the formulation forms a somewhat turbid solution. Pigment grinds can be stirred into the sealer in any convenient manner. The resultant liquid mixture is one preferred embodiment of a cosmetic according to the invention.
EXAMPLE 2
The formulation of Example 1 is repeated, but with the addition of two parts methyl silicone to the sealer prior to adding the pigments to the sealer. The use of a dimethicone such as methyl silicone increases the shininess of the cosmetic.
EXAMPLE 3
The formulation of Example 1 is repeated, but with the addition of two parts by weight of glycerin as a humectant in producing the sealer. The use of a humectant aids in moisturizing the lips.
EXAMPLE 4
A sealer is first prepared by mixing 4.3 parts by weight of Amphomer LV-71 along with 3.2 parts by weight Ethocell N-4 into 92.5 parts specially denatured alcohol SDA 40B-190. 8.25 parts of D&C Red No. 7 pigment dispersion in caster oil along with 0.25 parts D&C Orange No. 5 pigment dispersion in castor oil are then mixed with an additional 0.5 parts castor oil and introduced into the quantity of sealer previously prepared. The sealer, therefore, constitutes 90.75 parts by weight of the total composition. The pigment grinds and additional castor oil are stirred into the sealer to produce the finished liquid cosmetic composition according to the invention.
All of the formulations of the cosmetic of the foregoing examples will dry in a thin film, when applied to the lips. The cosmetic will not crack or cake even with repeated applications. When any of the foregoing formulations are applied to a wearer's lips in a least three layers, the cosmetic covering provided will last a wearer engaged in virtually any normal activity throughout an entire day without fading or rubbing off.
The above formulations may also be used to apply color to skin, nails, hair, or to cover bald spots. In addition, the above compositions can be used as liners to provide definition. For use as a liner, darker pigments are preferred, although any pigment will work. Additionally, if used as a liner, the composition should be applied to the lips with a fine tip brush.
Furthermore, with slight modifications, the above formulations may be used to apply color around the eyes. For application around the eyes, an aqueous solvent is used, the ethylcellulose is omitted, and Aminonathyl amino methyl propanol is added. A preferred composition for use around the eyes comprises between about 0.1 and about 20 parts of a water soluble resin, between about 0.1 and about 15 parts of a cosmetic pigment, between about 0.5 and about 4 parts Aminonathyl amino methyl propanol.
The present invention also contemplates compositions for enhancing the finish of the cosmetic. The composition can be applied over the cosmetic to enhance the matte finish of the cosmetic alone into a high-gloss finish. In addition, the lips remain soft and silky while leaving the waterproof and smearproof cosmetic in place. The finish enhancing compositions may also be massaged lightly into the lips prior to application of the cosmetic to condition and moisturize the lips.
The finish enhancing composition comprises a silicone. Preferentially, the silicone is a silicone copolymer. In one version of this composition, the composition comprises about 100% silicone. The silicones function to provide a water barrier, gloss, and spreading and wetting activity. They may also include moisturizing abilities and may function as a carrier for other active ingredients such as sunscreens or vitamins. Mixtures of different silicones may also be used to achieve the desired moisturizing, carrier, or other beneficial effects. Virtually any of the silicones offered by GE Silicones will work in the present invention, including Cyclomethicone, Dimethicone, mixtures of the Cyclomethicone and Dimethicone, Dimethicone and Laureth-4 and Laureth-23, Dimethicone Copolyol, Cycomethicone and Dimethicone Copolyol, Trimethylsilylamodimethicone, and other silicones provided by GE Silicones for use in personal products. Preferentially, the silicone is a silicone copolymer. Preferred silicones are the Dimethicones available from GE Silicone and dimethylsiloxane methyl(polyoxytheylene)siloxane copolymer, such as the Dimethicone and Trimethylsiloxysilicate available from GE Silicones. Representative dimethicones include a polydimethylsiloxane having a viscosity of 5 centistokes at 25° C. such as SF96® (5), a polydimethylsiloxane having a viscosity of 20 centistokes at 25° C. such as SF96® (20), a polydimethylsiloxane having a viscosity between 50 and 1000 centistokes at 25° C. such as SF96° (50-1000), a polydimethylsiloxane having a viscosity of 60,000 centistokes at 25° C. such as Viscasil® 60M, a blend of 15% of a high molecular weight methyl terminated polydimethylsiloxane fluid gum having a penetration between 500 and 1500. mm and 85% of a polydimethylsiloxane which has a viscosity of 5 centistokes at 25° C. at a concentration of 85% such as SF1236, and a high molecular weight methyl terminated polydimethylsiloxane fluid gum having a penetration between 500 and 1500 mm such as SE30 all of which are available from GE Silicones.
In another version of this embodiment, the finish enhancing composition comprises a silicone, a lipophilic gelling agent and a preservative. The silicones suitable for use in this embodiment are the same as those for the composition above. The lipophilic gelling agent acts as a carrier for introducing additional components into the composition. Desirable additional components are discussed below. In a highly preferred embodiment, the lipophilic gelling agent is a cyclomethicone pentamer and aluminum magnesium hydroxide stearate such as Gilugel SIL 5 (produced by Giulini Chemie, Germany and available from Morse Chemical, Inc., San Gabriel, Calif.). A preferred preservative is phenoxyethanol. In a highly preferred version of the present invention, the finish enhancing composition comprises about 1 to about 99% silicone, about 0.1 to about 50% lipophilic gelling agent, and about 0.1 to about 10% preservative. In a highly preferred version the dimethylsioxane methyl (polyoxyethylene)siloxane copolymer is present at a concentration of 88.40%. In a highly preferred version, the cyclomethicone pentamer and aluminum magnesium hydroxide stearate such as Gilugel SIL 5 is present at 10%. Preferentially, the preservative is phenoxyethanol or BHT (butylated hydroxytoluene). In a preferred version, the phenoxyethanol is present at 1.6%. In another preferred embodiment, the BHT is present at 1.6%.
Additional components may be added to the above composition, including flavoring agents, skin conditioning agents, emollients, skin protectants, sunscreens, UV light absorbers, anti-oxidants, humectants, essential oils, minerals, PABA, hetrocyclic compounds, oils, fats, and fatty acids.
Representative flavoring agents which may be used in the present compositions include cinnamon, peppermint extract, saccharin, Acesulfame K and other flavoring agents such as those listed in the CTFA Cosmetic Ingredient Handbook 2d. ed., published by the cosmetic, Toiletry, and Fragrance Association, 1101 17th St. N.W., Suite 3000, Washington, D.C. 20036 (1992). The amounts and identities of such flavoring agents may be adjusted to provide a desirable flavor to the composition.
Numerous skin conditioning agents may be selected for use in the present compositions, provided they are oil soluble. These include the emollients, humectants, miscellaneous, and occlusive skin conditioning agents listed in the CTFA Cosmetic Ingredient Handbook. The amounts and identities of such skin conditioning agents can be adjusted to provide the desired results. A highly preferred humectant is glycerin. Many UV absorbing compounds are known to those skilled in the art, including those listed in the CTFA Cosmetic Ingredient Handbook. However, the preferred UV absorber is octylcrylene.
Numerous sunscreen agents are known to those skilled in the art, including those listed in the CTFA Cosmetic Ingredient Handbook. However, a preferred sunscreen is octyl methoxycinnamate. In a preferred version of this aspect, the antioxidant is a vitamin E linoleate mixture available from Seltzer Chemicals, Carlsbad, Calif.
Many skin protectants are known to those skilled in the art, including those listed in the CTFA Cosmetic Ingredient Handbook.
Many essential oils, minerals, PABA, heterocyclic compounds, oils, fats, and fatty acids suitable for use in the present compositions are known to those skilled in the art. Representative compounds in each of these categories are listed in the CTFA Cosmetic Ingredients Handbook. Effective amounts of such compounds may be included in the present compositions to achieve the desired effect.
Preferred finish enhancing compositions are listed in Examples 5-8.
EXAMPLE 5
______________________________________AMOUNT (BY WEIGHT) COMPOUND______________________________________88.40 Dimethylsiloxane methyl (polyoxyethylene) siloxane copolymer 10.00 Gilugel SIL5 1.60 Phenoxyethanol______________________________________
To formulate the above composition, the Gilugel SIL 5 is heated until it melts. The phenoxyethanol is then added thereto, and the resulting mixture is added to the the Dimethylsiloxane methyl(polyoxyethylene)siloxane copolymer.
EXAMPLE 6
______________________________________AMOUNT (BY WEIGHT) COMPOUND______________________________________7.00 Dimethylsiloxane methyl (polyoxyethylene) siloxane copolymer 5.50 Gilugel SIL5 0.30 BHT (butylated hydroxytoluene) 1.00 Phenoxyethanol 84.10 Dimethicone 1.00 Octylcrylene 1.00 Octyl methoxycinnamate .10 Vitamin E linoleate mixture______________________________________
The composition is prepared by heating the Gilugel to the melting point and adding the octylcrylene, octyl methoxycinnamate, vitamin E, phenoxyethanol and BHT. The two silicones are separately mixed and the Gilugel mixture is then added thereto.
EXAMPLE 7
______________________________________AMOUNT (BY WEIGHT) COMPOUND______________________________________100.00 Dimethicone______________________________________
EXAMPLE 8
______________________________________AMOUNT (BY WEIGHT) COMPOUND______________________________________100.00 Dimethylsiloxane methyl (polyoxyethylene) siloxane______________________________________
The present invention also contemplates compositions for removing the cosmetic. One version of the cosmetic remover is a solution comprising a mild detergent plus a preservative. Preferentially, the mild detergent is present from between about 0.5 parts and about 10 parts and the preservative is present between about 0.1 and about 3 parts. A preferred mild detergent is sodium lauryl sulfate and a preferred preservative is Quaternium 15 (Dowicil 200 available from Dow Chemical) In a highly preferred embodiment of this composition, the sodium lauryl sulfate is present at 0.5 parts and the preservative is quaternium 15 (Dowicil 200 available from Dow Chemical) at 0.1 parts, with the remainder of the composition being water.
Alternatively, the lip removing composition may comprise a solution of alcohol and a chelating agent. In a preferred version of this embodiment, the alcohol is ethyl alcohol and the chelating agent is trisodium phosphate. Preferentially, the trisodium phosphate is present at about 0.1-5 parts by weight.
In yet another embodiment, the cosmetic removing composition comprises an aqueous solution of a chelating agent, one or more mild detergents, and a preservative. Preferentially, the water is distilled. Preferentially, the chelating agent is trisodium phosphate. Preferred mild detergents are Empigen CDR 30 (cocoampho acetate) available from Albright & Wilson, Cumbria, United Kingdom) and the nonionic surfactant polyoxyethylene poloxypropylene glycol (Pluronic® F127, Poloxamer 407). Preferred preservatives are phenoxyethanol, sodium benzoate, and Quaternium 15 (Dowacil 200 available from Dow Chemicals). In further aspects of this embodiment, one or more thickeners are added. A preferred thickener is xanthan gum. The xanthan gum also functions to maintain the solubility of sodium lauryl sulfate and trisodium phosphate in alcohol based formulations. In yet further embodiments of the cosmetic removing composition a flavoring may be added. Preferred flavorings are Acesulfame K (a sweetener Sunnett Brand Sweetener available from Hoechst Celanes, 3340 W. Norfolk Rd, Portsmouth, Va. 23703), and sodium saccharin.
Preferentially, the chelating agent is present between about 0.5 and about 5 parts. It is preferred that the detergents be present from about 5.05 to about 20.5 parts. Preferentially the preservative is present between 0.1 and 5 parts. Preferentially, the thickener is present between about 0.05 and 10 parts. Preferentially the sweetener is present between about 0.05 and 5 parts.
Mild alkali solutions may also be used to remove the cosmetic. A preferred aspect of this embodiment is 0.5-5 parts sodium borate, with the remainder being water. In a highly preferred embodiment, the sodium borate comprises 1.78 parts of the aqueous solution.
Examples 9-15 describe highly preferred embodiments of the cosmetic removing formulations.
EXAMPLE 9
______________________________________AMOUNT (BY WEIGHT) COMPOUND______________________________________90.29 DI water 1.78 Trisodium phosphate .20 Polyoxyethylene polyoxypropylene glycol (Poloxamer 407) .13 Acesulfame K 1.60 Phenoxyethanol 6.00 Cocoampho acetate (Empigen CDR 30)______________________________________
To formulate the above composition, trisodium phosphate, Poloxamer, Acesulfame K are first added to warm water. The cocoampho acetate is then added to this aqueous composition, followed by the addition of the phenoxyethanol.
The above formulation may also be used to remove coloring applied around the eyes.
EXAMPLE 10
______________________________________AMOUNT (BY WEIGHT) COMPOUND______________________________________80.67 DI water 16.25 Ethanol (denatured with flavor) 190 proof 1.25 Trisodium phosphate .25 Xanthan gum .20 Polyoxyethylene polyoxypropylene glycol (Poloxamer 407) .15 Sodium lauryl sulfate .13 Sodium saccharin 1.0 Sodium benzoate______________________________________
To prepare the above formulation, trisodium phosphate, Poloxamer, sodium saccharine, sodium lauryl sulfate, and sodium benzoate are added to warm water. The xanthan gum is added separately to the alcohol. Next the alcohol mixture is added to the aqueous mixture. Finally, the glycerin is added to the above mixture.
Alternatively, the xanthan gum may be added to half of the water at room temperature. The trisodium phosphate, Poloxamer, sodium saccharin, sodium lauryl sulfate, and sodium benzoate may be added to warm water. The two aqueous mixtures may then be combined with the alcohol.
EXAMPLE 11
______________________________________AMOUNT (BY WEIGHT) COMPOUND______________________________________80.02 DI water 16.25 Ethanol (denatured with flavor) 190 proof 1.25 Trisodium phosphate .25 Xanthan gum .20 Polyoxyethylene polyoxypropylene glycol (Poloxamer 407) .30 Glycerin .13 Sodium saccharin 1.60 Phenoxyethanol______________________________________
To formulate the above composition, the trisodium phosphate, sodium saccharine, phenoxyethanol, and Poloxamer are added to warm water. The xantham gum is separately mixed with the alcohol. The alcohol mixture is then combined with the aqueous mixture and the glycerin is added thereto.
Alternatively, the xanthan gum may be added to half of the water at room temperature. The trisodium phosphate, sodium saccharine, phenoxyethanol, and Poloxamer are added to warm water may be added to warm water. The two aqueous mixtures may then be combined with the alcohol.
EXAMPLE 12
______________________________________AMOUNT (BY WEIGHT) COMPOUND______________________________________90.30 DI water 1.78 Trisodium phosphate .20 Polyoxyethylene polyoxypropylene glycol (Poloxamer 407) 6.00 Cocoampho acetate (Empigen CDR 30) .12 Sodium saccharin 1.60 Phenoxyethanol______________________________________
To formulate the above composition, the trisodium phosphate, sodium saccharine, phenoxyethanol, and Poloxamer are added to warm water. The xantham gum is separately mixed with the alcohol. The alcohol mixture is then combined with the aqueous mixture and the glycerin is added thereto. Finally, the cocoampho acetate is added thereto.
The above formulation may also be used to remove color applied around the eyes.
EXAMPLE 13
______________________________________AMOUNT (BY WEIGHT) COMPOUND______________________________________91.69 DI water 1.78 Trisodium phosphate .20 Polyoxyethylene polyoxypropylene glycol (Poloxamer 407) 6.00 Cocoampho acetate (Empigen CDR 30) .13 Acesulfame K .20 Quaternium 15______________________________________
To formulate the above composition, the Quaternium 15 is first added to the water. The Poloxamer, trisodium phosphate, and Acesulfame K are then added thereto. Finally, the cocoampho acetate is added thereto.
EXAMPLE 14
______________________________________AMOUNT (BY WEIGHT) COMPOUND______________________________________0.5 Sodium lauryl sulfate 90.3 Distilled water 0.2 Quaternium 15______________________________________
EXAMPLE 15
______________________________________AMOUNT (BY WEIGHT) COMPOUND______________________________________1.78 Trisodium phosphate 98.22 Ethyl alcohol______________________________________
The compositions of Examples 12 and 13 are highly preferred.
The present invention also relates to compositions for further enhancing the color of the cosmetic. These color enhancing compositions comprise colorants such as mica, bismuth oxychloride, iron oxides, D&C Lake colorants, FD&C Lake colorants, D&C colorants, and FD&C colorants. The color enhancing compositions are provided in pressed or loose form. If provided in pressed form, the colorants are mixed with preservatives. Preferred preservatives are ethyl paraben, methyl paraben, or polyparaben. Additionally if provided in the pressed form, a the color enhancing composition also comprises a wax such as corn glutin protein or a synthetic wax and as C12-C15 alkyl benzoate.
A preferred formulation for enhancing the color of the cosmetic is described in Example 16.
EXAMPLE 16
______________________________________AMOUNT (BY WEIGHT) COMPOUND______________________________________4.24 Zinc Stearate 3.74 Bismuth oxychloride 66.03 Colored mica powder 14.95 C12-C15 alkyl benzoate 8.72 Synthetic wax/ corn glutin protein mixture from Presperse, Inc., 601 Hadley Rd., South Plainfield, NJ 07080 1.3 Ethylparaben 0.65 Methylparaben 0.15 Propylparaben______________________________________
To press the above composition, the loose powder is first blended in an industrial blender. The resulting composition is therafter placed in a press.
Undoubtedly, numerous variations and modifications of the invention will become readily apparent to those familiar with cosmetic products. Accordingly, the scope of the invention should not be construed as limited to the specific examples described, as those examples are presented herein only as being illustrative of the many formulations possible according to the invention. | An improved cosmetic employing a coloring agent and a plasticizer in a volatile solvent includes a film-forming agent which preferably has as components an Amphomer and ethyl cellulose, as well as a cosmetic pigment. The resultant cosmetic is water insoluble and has a staying power far greater than that of conventional lipstick. The novel cosmetic will not smear and come off on beverage receptacles, fabrics or the human skin once it drys. The finish is so sheer that the cosmetic can be applied in at least three successive layers without caking up or cracking. Once applied in this fashion, while allowing each layer to dry between each successive application, a person can shower, swim, smoke, kiss and imbibe beverages without leaving stains from the cosmetic on coffee cups, cheeks or collars. Compositions for enhancing the finish of the cosmetic are also provided. Such compositions transform the finish of the cosmetic from a matte to a high-gloss finish. The finish enhancing compositions also moisturize and condition the lips, and may also include protective compounds. Compositions for enhancing the color of the cosmetic are also provided. The present invention also relates to compositions for removing the above compositions from the lips. Kits including the above compositions and methods for using the above compositions are also provided. | 0 |
BACKGROUND OF THE INVENTION
(a) Field of the Invention
The present invention relates to a method of producing a cast coated paper. More particularly, the invention relates to a method of effectively obtaining a cast coated paper which is superior in gloss, printability, abrasion resistance and water resistance to conventional cast coated papers.
(b) Description of the Prior Art
Conventional methods of producing a printing paper having a high gloss called a cast coated paper include a wet casting method, a rewet casting method and a gel-casting method. Said wet casting method comprises a base paper being coated with a cast coating composition, the main components of which are pigments and adhesives, then said base paper being pressed against the highly polished surface of a heated drum when the coating layer is still wet so that the paper is dried and glossed. Said rewet casting method comprises a coating composition in a wet state being dried once, rewetted and plasticized by means of a rewet liquid, and then pressed against the highly polished surface of a heated drum. Said gel-casting method comprises a coating composition in a wet state being gelled and pressed against the highly polished surface of a heated drum so that the paper is dried and glossed.
All of said casting methods are the same in that the coating layer in a wet, plasticized state is pressed against the highly polished surface of a heated drum, dried thereby and removed from said heated drum so that said coating layer copies the highly polished surface of said drum. Cast coated papers thus obtained have a high gloss and surface smoothness as compared with conventional super-calendered coated papers, and ensure a superior printing effect. Therefore, said cast coated papers are used particularly as high-grade printing papers and materials of high-grade paper ware, etc.
With the improvements of the grade of printed matters, book covers, paper ware, etc., it has been demanded that the gloss should be further improved over the conventional cast papers and the water resistance and abrasion resistance should be made higher. Methods used at present as means for satisfying such quality demands include a method of making a conventional coated paper, cast coated paper, etc. into a varnished paper or a press coat by coating said coated paper, cast coated paper, etc. with a transparent resin by a printing means and a method of making said papers into a paper laminated with a plastic film of polyethylene, vinyl chloride, etc. In all of these methods, said conventional coated paper and cast coated paper are subjected to secondary treatment.
Since it is impossible to print said varnished paper, press coat or laminated paper directly with a printing ink, these papers are varnished or laminated after being printed. It is inconvenient to do so. Particularly, said laminated paper widely used is very difficult to recycle because the laminated film thereof hinders defiberization and furthermore there is an excessive burden in the recycling process. Thus the laminated paper has many disadvantages in terms of the environmental problem, etc. over the conventional coated paper and cast coated paper.
It is an object of the present invention to obtain a cast coated paper good enough to be used in place of said varnished paper, press coat and laminated paper.
It is another object of the invention to obtain a cast coated paper having a gloss, ink gloss, abrasion resistance, water resistance etc. much better than those of said varnished paper.
Discussion will now be made as to what improvements can be made on the present technical level in an attempt to obtain a cast coated paper having high qualities comparable to those of said varnished paper, etc.
The composition of a conventional cast coating layer comprises a coating pigment and an adhesive generally used in the field of coated papers for printing, said pigment normally being used in an amount of 100 parts by weight per 5 to 50 parts by weight of said adhesive. Since the main component of said coating layer is the coating pigment, the cast coated paper obtained is superior in the absorption and retention of printing ink but much inferior in gloss, ink gloss, abrasion resistance and water resistance to said varnished paper, press coat and laminated paper.
It is possible to improve the gloss and ink gloss of a cast coated paper to some extent by increasing the amount of the adhesive in the cast coating composition. If the amount of the adhesive is increased, however, the porosity of the coating layer is lost, and the vapor permeability of said layer and the releasability from the polished drum is reduced. This will make the production speed mu(:h lower and extremely deteriorate the high printability, particularly ink set and ink drying, which is a characteristic feature of the cast coated paper.
It may seem possible to add a known release agent to the coating composition or increase the amount of the pigment in order to improve said releasability. However, the addition of the release agent alone cannot improve the releasability to a satisfactory level. If the pigment is added to such an extent as that said releasability is improved, the gloss will be reduced.
Also, it may seem possible to add a lubricant such as a polyethylene wax and a natural wax to the coating composition in order to improve the abrasion resistance of the cast coated paper. However, to obtain abrasion resistance comparable to that of said varnished paper, press coat or laminated paper, it is necessary to add said lubricant in large quantities and as a result printability such as ink set and surface strength may by reduced.
The water resistance of the cast coated paper can be improved by adding a water resisting agent which has been used in the field of paper coating. However, it is difficult to obtain water resistance equal to that of said varnished paper, press coat or laminated paper.
As apparent from the above, it is very difficult to find in the present technical level a means for satisfying all of said qualities, printability and releasability of the cast coated paper . In other words, even if an improvement is made on the basis of the conventional method of producing the cast coated paper, it is very difficult to obtain gloss, ink gloss, abrasion resistance and water resistance comparable to those of said varnished paper, press coat or laminated paper.
A case is known in which an attempt was made to improve the qualities of a cast coated paper by means of a rewetting method by improving a rewet liquid used in a reset casting method. For example, Japanese Patent Publication No. Sho 48-38005 discloses cast finishing by a rewet casting method by means of a rewet liquid containing a film forming substance in an amount of 0.1 to 20% immediately before a coating layer comprising a pigment and an adhesive is pressed against the highly polished surface of a heated drum. In this method, said coating layer comprising a pigment and an adhesive is in charge of printability such as the absorption and retention of ink, and an attempt is made to improve gloss by forming a thin layer of said film forming substance on the surface of said coating layer. However, the film forming substance can be added only to such an extent that the porosity of the coating layer is not lost and it is impossible to obtain sufficient gloss.
It is possible to improve gloss by increasing the amount of said film forming substance within said rewet liquid. Since in this case a thick layer of said film forming substance is formed on the surface of the pigment in the coating layer, the absorption of ink by the pigment is hindered and ink set is reduced. Since vapor permeability is reduced, releasability is also deteriorated. To obtain satisfactory printability and releasability on these conditions, the film forming substance itself must be excellent in the absorption, retention, etc. of ink and releasability. However, the film forming substance shown in said publication does not satisfy these requirements.
SUMMARY OF THE INVENTION
The present invention obtains a cast coated paper having gloss comparable to that of said varnished paper, press coat or laminated paper, as well as excellent printability, abrasion resistance, water resistance and releasability. The present invention obtains a novel cast coated paper by a method which is rather close to the rewet casting method among the methods of producing cast coated paper.
The method of producing a cast coated paper according to the present invention comprises a pigment coating composition for casting being applied onto a base paper and dried, said coating composition being a normal mixture, the coating layer preferably being adapted to have a smoothness of above 50 seconds in accordance with JIS P8119, the surface of the pigment coating layer being plasticized by means of a rewet liquid having a component as in the following, then said coating layer being pressed against a cast drum surface for specular finish (cast finish). Said rewet liquid is an aqueous dispersion, the main component of which is a complex resin comprising a copolymer resin and a colloidal silica, said copolymer resin being obtained by copolymerizing a styrene monomer and/or an unsaturated carboxylic ester monomer, said colloidal silica having a mean particle diameter of 0.005 to 0.1 μm, preferably 0.01 to 0.05 μm.
In the present invention as mentioned above, said rewet liquid is used, the main component thereof being a complex resin comprising a copolymerized resin and a colloidal silica having a specific mean particle diameter, said rewet liquid being applied onto the surface of the dried coating layer for casting to plasticize said coating layer, then said coating layer being adapted to have a high gloss I)y being pressed against the highly polished surface of a heated drum. This method makes it possible to obtain a gloss comparable to that of the conventional varnished paper, press coat or laminated paper, and also to remarkably increase the efficiency of producing the cast coated paper.
The technical reason why said desired effects are obtained by the above-mentioned means is not necessarily clear, but the reason is assumed to be as follows: Generally speaking, to obtain an excellent appearance of a cast coated paper, it is important that two requirements contradictory to each other are satisfied when a coating layer in a wet plasticized state is pressed against the highly polished surface of a heated drum, one being that said wet coating layer closely contacts the drum surface with a suitable adhesion so that said coating layer faithfully copies the drum surface, the other being that said coating layer after being dried easily separates from the drum surface. Said complex resin used in the present invention forms a uniform coating film on the cast coating layer, the copolymer component within said complex resin in a wet state giving a suitable adhesion between the coating layer and the highly polished surface of the heated drum. In course of the drying process, the adhesion between the coating layer and the drum surface is rapidly reduced and the coating layer is easily separated from the drum surface because the hydroxyl group of the colloidal silica is strongly combined mutually with the colloidal silica or with an adhesive ingredient within said cast coating layer through dehydration and condensation. The above would give the cast coated paper an excellent appearance with respect to gloss, pin holes, uneven gloss, etc. as well as excellent releasability. The cast coated paper would have excellent abrasion resistance and water resistance because said complex resin comprising said monomer resin and colloidal silica forms a strong film on the surface of the cast coated paper.
Since said complex resin has a high affinity for ink, ink set would be improved. Also, since the amount of vehicle within ink permeating into the cast coating layer is small, the cast coated paper would have (excellent ink gloss.
Said resin obtained by copolymerizing a styrene monomer and/or an unsaturated carboxylic ester monomer and said monomers as well as said colloidal silica will be explained in detail below.
Said unsaturated carboxylic ester monomer which is an indispensable component of the present invention may be acrylic ester or methacrylic ester in which the alkyl group has 1 to 18 carbons. To be concrete, said unsaturated carboxylic ester monomer may be any of the following: acrylic ester monomers such as methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethyl hexyl acrylate, lauryl acrylate, 2-hydroxyethyl acrylate and glycidyl acrylate, and methacrylic ester monomers such as methyl methacrylate, ethyl methacrylate, 2-hydroxyethyl methacrylate, 2-hydroxy propyl methacrylate and glycidyl methacrylate. These monomers are used in an amount of 100 to 30% by weight of the total resin content.
In addition to the unsaturated carboxylic monomer copolymer, a copolymer comprising a styrene monomer and an unsaturated carboxylic monomer is also used in the present invention. Said styrene monomer used in the present invention may be, for example, any of styrene, α-methyl styrene and vinyl toluene. Among them, styrene is often used. It is desirable that these monomers are used in an amount of 0 to 70% by weight, preferably 0 to 40% by weight of the total resin content.
It is also possible to use the following copolymers with these monomers: vinyl cyanide monomers such as acrylonitrile and methacrylonitrile; ethylene unsaturated carboxylic amides such as acrylic amide, methacrylic amide, N-methylol acrylic amide and N-methylol methacrylic amide; or monomers such as vinyl chloride, vinylidene chloride, vinyl acetate, vinyl propionate, ethyrene and butadiene.
The copolymer component used in the present invention may be obtained by copolymerizing said monomers or may be a substitution derivative of the copolymer. The substitution derivative may be carboxylated or made alkali active.
The resin component of the copolymer resin forming a complex with the colloidal silica may be, for example, any of the following: styrene-acrylic ester copolymer resin, styrene-methacrylic ester-acrylic ester, copolymer resin and methacrylic ester-acrylic ester copolymer resin. These acrylic resins give excellent printability. In view of releasability, it is desirable that these copolymers have a glass transition temperature (Tg) of above -30° C., preferably above -20° C. Monomers forming said copolymers may be optionally selected according to the glass transition temperature (Tg) of the copolymers obtained and the desired printability.
As a result of experiments, the inventors have found that said resins alone can not gi.,e desired effects and it is very important that the resin obtained by polymerizing said monomers under the existence of the colloidal silica by a conventional emulsion polymerization method forms a complex such as Si-O-R (R: resin) with the colloidal silica. Only when a complex resin obtained by combining said specific copolymer resin and colloidal silica is used, it is possible to obtain excellent gloss, ink set, abrasion resistance, water resistance, etc. it is impossible to obtain them where said copolymer resin and aqueous colloidal silica dispersed in water are simply dispersed and mixed together.
The particle diameter of the colloidal silica should be taken into consideration because the quality of a cast coated paper obtained depends upon the particle diameter of the colloidal silica used. If the mean particle diameter of the colloidal silica is below 0.005 μm, printability such as ink set may be reduced. If the mean particle diameter of the colloidal silica is above 0.1 μm, gloss may be much reduced and surface strength may be reduced.
It is desirable that the resin and colloidal silica forming said complex resin are in a ratio of 100:30 to 100:300, preferably 100:40 to 100:200. If the amount of the colloidal silica is below 30 parts by weight or above 300 parts by weight per 100 parts by weight of the resin, this is not desirable because releasability may be reduced.
In the present invention as mentioned above, a rewet liquid mainly comprising a complex of said copolymer and colloidal silica is applied onto the surface of a pigment coating layer once dried to plasticize and cast said coating layer, thereby said desired effects being obtained.
The percentage of the resin mainly comprising a complex of said copolymer and colloidal silica to the rewet liquid is adjusted to be in a range of 0.1 to 45% by weight, preferably 0.5 to 25% be weight.
It is desirable that the composition of the rewet liquid in the present invention contains, besides said complex resin, an aqueous colloidal silica having a mean particle diameter of 0.005 to 0.1 μm as a pigment component. In this case, printability such as ink set and releasability are remarkably improved. If the mean particle diameter of the aqueous colloidal silica dispersible in water is below 0.005 μm, releasability is not improved very much. If the mean particle diameter of the aqueous colloidal silica is above 0.1 μm, gloss and ink gloss are reduced. If the mean particle diameter of the aqueous colloidal silica is below 0.005 μm or above 0.1 μm, there is a further disadvantage that printability, abrasion resistance, water resistance, etc. are reduced.
It is desirable that the aqueous colloidal silica dispersed in water is added in a ratio of 10 to 200 parts by weight, preferably 30 to 150 parts by weight per 100 parts by weight of said complex resin. If the ratio of the aqueous colloidal silica is below 10 parts by weight, it is difficult to obtain the desired effects. If the ratio of the aqueous colloidal silica is above 200 parts by weight, gloss is liable to be reduced.
To ensure the releasability at the time of casting, it is possible in the method of the present invention to use a release agent along with said complex which is the main component of the rewet liquid. The release agent may be, for example, any of the following: fatty acids such as stearic acid, oleic acid and palmitic acid; salts thereof such as calcium, zinc, sodium and ammonium: amides such as stearic acid amide, ethylene bis stearic acid amide and methylene bis stearic acid amide; hydrocarbons such as microcrystalline wax, paraffin wax and polyethylene emulsion; higher alcohols such as cetyl alcohol and stearyl alcohol; fats and fatty oils such as red oil and lecithin; surface active agents such as surface active agent containing fluorine; fluorine polymers such as poly-tetrafluoro ethylene and ethylene-tetrafluoro copolymer. The release agent is added in a ratio of 0.5 to 100 parts by weight, preferably 5 to 50 parts by weight per 100 parts by weight of said complex resin.
As a result of further study, the inventors have found that the rewet liquid may be obtained simply by mixing said various ingredients but a cast coated paper having better appearance with respect to gloss, uneven gloss and pin holes can be obtained if said rewet liquid is adapted to have a viscosity of 50 to 5000 cps, preferably 70 to 3000 cps as measured by means of a Brookfield viscometer (measured on conditions of a room temperature/60 rpm).
It is not necessarily clear why such better effects are obtained by adjusting the viscosity of the rewet liquid as mentioned above. It is assumed that when the viscosity of the rewet liquid is in said range the uneven gloss and pin holes are effectively eliminated because the surface of the cast coating layer is more uniformly plasticized.
The viscosity of the rewet liquid may be adjusted to said range by any method, for example by increasing the consistency of said complex of said copolymer and colloidal silica and the consistency of said release agent, or by mixing the rewet liquid with the following additives in a range of 0.05 to 50 parts by weight, preferably 0.1 to 25 parts by weight per 100 parts by weight of said complex resin: proteins such as casein, soybean protein and synthetic protein; starches such as starch and oxidized starch; polyvinyl alcohol, cellulose derivatives such as carboxymethyl cellulose and methyl cellulose; thickners or viscosity modifiers such as polycarboxylic acid, polyacrylic acid, acrylic emulsion, polyamide, polyester, alkaline thickner and non-ionic surface active agent; ammonium salts or metallic salts of inorganic acids or organic acids such as sodium chloride, ammonium chloride, zinc chloride, magnesium chloride, sodium sulfate, potassium sulfate, ammonium sulfate, zinc sulfate, magnesium sulfate, ferrous sulfate, sodium nitrate, ammonium nitrate, sodium phosphate, ammonium phosphate, calcium phosphate, sodium polyphosphate, sodium hexametaphosphate, sodium formate, ammonium formate, sodium acetate, potassium acetate, sodium monochloroacetate, sodium malonate, sodium tartrate, potassium tartrate, sodium citrate, potassium citrate, sodium lactate, sodium gluconate, sodium adipate and sodium dioctyl sulfosccinate; amines such as methyl amine, diethanolamine, diethylene triamine, diisopropylamine, triethanolamine and ethanolamine; or aqueous ammonia, etc.
It is possible to add the following as required to the rewet liquid: synthetic resin latexes such as styrene-butadiene latex, methylmethacrylate-butadiene latex, styrene-acrylate resin and acrylic emulsion; polyfunctional epoxy compounds for improving the water resistance and blocking resistance of the coating composition such as diglycerol polyglycidyl ether, glycerol polyglycidyl ether, polyethylene glycol diglycidyl ether, polypropylene glycol diglycidyl ether and adipic acid diglycidyl ester; zirconium compounds such as zirconium ammonium carbonate and zirconium acetate; water-resisting agents and printability improving agents such as urea-formaldehyde, melamine-formaldehyde, polyamide urea-formaldehyde, polyamideepichlorhydrine and glyoxal.
It is also possible to add pigments to the rewet liquid in such a range that the characteristics of the complex resin component of the present invention are not lost. The pigments added may be for example as follows: clay, kaolin, calcined clay, amorphous silica, aluminium hydroxide, titan oxide, barium sulfate, zinc oxide, satin white, calcium sulfate, talc, plastic pigments, and cubic, pillar-shaped, rice-shaped, spindle-shaped, ball-shaped, or amorphous precipitated calcium carbonate or ground calcium carbonate. These pigments may be added preferably in a range of 0 to 200 parts by weight per 100 parts of said resin component.
Auxiliary agents such as a dispersing agent, anti-foaming agent, coloring agent, fluorescent dye, antistatic agent and antiseptic may be added to the rewet liquid.
The pigment coating composition for casting used in the present invention is not limited and mainly comprises one or more coating pigments and one or more adhesives generally used in the production of cast coated papers. The pigments may be for example as follows: kaolin, aluminium hydroxide, satin white, barium sulfate, ground calcium carbonate, precipitated calcium carbonate, talc, plastic pigment, calcined clay, titan dioxide, etc. One or more of these pigments may be used. The adhesives may be for example as follows: proteins such as casein and soybean protein; conjugate diene polymer latexes such as styrene-butadiene copolymer and methyl methacrylate-butadiene copolymer; acrylic polymer latexes such as a polymer or copolymer of acrylic ester and/or methacrylic ester; vinyl polymer latexes such as ethylene-vinyl acetate copolymer; alkali soluble or alkali non-soluble copolymer latexes comprising said polymers being subjected to functional group denaturization by means of a monomer containing a functional group such as carboxyl group; synthetic resin adhesives such as polyvinyl alcohol, olefinmaleic acid anhydride resin and melamine resin; starches such as positive starch, oxidized starch and esterified starch: and cellulose derivatives such as carboxymethyl cellulose and hydroxyethyl cellulose. These adhesives are generally used for coated papers. One or more of these adhesives may be used in the present invention. The adhesives are used in a range of 5 to 50 parts by weight, generally 10 to 30 parts by weight per 100 parts by weight of pigments. In addition to said pigments and adhesives, auxiliary agents such as an anti-foaming agent, coloring agent, release agent, viscosity modifier, water-resisting agent and antiseptic are used as required.
The pigment coating composition for casting comprising the above-mentioned materials is adapted to have a solid matter consistency of 45 to 65% by weight, said cast coating composition being applied onto a base paper having a basis weight of about 35 to 400 g/m 2 and a porous film by means of a conventional coater so that the dry weight is about 5 to 50 g/m 2 , then the coating layer being cast.
The coater may be, for example, any of the following conventional ones: blade coater, air knife coater, roll coater, brush coater, Champflex coater, bar coater, gravure coater, etc. After coating, the coated layer in a dried or half dried state is supplied with said rewet liquid and finished by are wet casting method.
When the pigment coating composition for casting has been applied onto a base paper and dried, the rewet liquid may be immediately applied thereon for plasticization. However, it is desirable to smooth the surface of the coated layer before the rewet liquid is applied so that the surface of the coated layer has a Bekk smoothness by JIS P8119 of above 50 seconds, preferably above 100 seconds. If the Bekk smoothness is below 50 seconds, the surface of the coating layer is slightly rugged and therefore the surface of the finished cast coated paper may have some pin holes and uneven gloss. The desired smoothness may be obtained by calendering the paper as required by means of a calender, super calender or brush calender. It is of course possible in the present invention to use a cast coated paper, already cast finished, as a base paper with a pigment coating composition.
The base paper used in the present invention is not limited and may be an acidic paper or a neutralized paper generally used in the field of cast coated papers. The base paper may be preliminarily coated in advance on one surface or two surfaces thereof with a usual pigment coating composition as required. The amount of coating thereof is preferably 5 to 30 g/m 2 (dry weight) per surface. The preliminarily coated paper may be smoothed in advance by super calendering, brushing, cast finishing, etc. as required.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows an apparatus used in the method of the present invention. In the apparatus, a pigment coating layer for casting is applied onto a base paper, dried, coated with a rewet liquid by means of a roll coater and pressed against the surface of a cast drum, thereby a cast coated paper being obtained.
FIG. 2 schematically shows an apparatus in which said pigment coating layer is sprayed with a rewet liquid through a nozzle for plasticization, then said pigment coating layer being pressed against the surface of a cast drum, thereby a cast coated paper being obtained.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in detail with reference to examples. It is to be noted that the present invention is not limited to the examples. In the examples, "parts" or "%" (percent) means "parts" or "%" by weight, unless otherwise stated.
EXAMPLE 1
A pigment coating composition for casting comprising 70 parts kaolin, 30 parts precipitated calcium carbonate, 0.5 part sodium polyacrylate, 6 parts oxidized starch, 15 parts (solid matter) styrene-butadiene copolymer latex and 0.5 part calcium stearate was adapted to have a solid matter consistency of 64%, said pigment coating composition being applied onto a base paper having a basis weight of 100 g/m 2 by means of a blade coater so that the dry weight was 25 g/m 2 . After being dried, the paper coated with said pigment coating composition was smoothed by means of a super calender so as to have a Bekk smoothness of 150 seconds.
A coated paper for rewet casting thus obtained was coated with a rewet liquid comprising 100 parts of a resin component A shown in Table 1, 10 parts of polyethylene wax and 2 parts of sodium polyacrylate, said rewet liquid having a solid matter consistency of 25% and a Brookfield viscosity (measured by means of a Brookfield viscometer at 60 rpm, room temperature) of 200 cps. Then, said coated paper was subjected to rewet cast finish by means of a cast coating apparatus shown in FIG. 1.
To be concrete, said paper was coated with said rewet liquid by means of a roll coater 2, immediately after that said paper being pressed against a highly polished cast drum 4 having a surface temperature of 75° C. and a diameter of 3000 mm, after being dried said paper being separated from said cast drum. Thus a cast coated paper 5 was obtained.
Table 1 shows the particle diameter of the colloidal silica in resin components (complex resins) used in Examples, the weight ratio between the copolymer and the colloidal silica, the glass transient temperature (Tg/°C.) of the copolymer and the mean particle diameter and number of parts of the aqueous colloidal silica dispersed in water added as a pigment component.
EXAMPLE 2
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a resin component B shown in Table 1.
EXAMPLE 3
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a resin component C shown in Table 1.
EXAMPLE 4
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a resin component D shown in Table 1.
EXAMPLE 5
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a resin component E shown in Table 1.
EXAMPLE 6
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a resin component F shown in Table 1.
EXAMPLE 7
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a resin component G shown in Table 1.
EXAMPLE 8
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a resin component H shown in Table 1.
EXAMPLE 9
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by x resin component I shown in Table 1.
EXAMPLE 10
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a resin component J shown in Table 1.
EXAMPLE 11
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a resin component K shown in Table 1.
EXAMPLE 12
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a resin component L shown in Table 1.
EXAMPLE 13
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by t resin component M shown in Table 1.
EXAMPLE 14
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a mixture B1 shown in Table 1, said mixture B1 comprising 100 parts resin component B and 200 parts aqueous colloidal silica dispersed in water having a mean particle diameter of 0.02 μm.
EXAMPLE 15
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a mixture B 2 shown in Table 1, said mixture B 2 comprising 100 parts resin component B and 150 parts aqueous colloidal silica dispersed in water having a mean particle diameter of 0.02 μm.
EXAMPLE 16
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a mixture B3 shown in Table 1, said mixture B3 comprising 100 parts resin component B and 100 parts aqueous colloidal silica dispersed in water having a mean particle diameter of 0.004 μm.
EXAMPLE 17
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a mixture B4 shown in Table 1, said mixture B4 comprising 100 parts resin component B and 100 parts aqueous colloidal silica dispersed in water having a mean particle diameter of 0.15 μm.
EXAMPLE 18
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a mixture B5 shown in Table 1, said mixture B5 comprising 100 parts resin component B and 250 parts aqueous colloidal silica dispersed in water having a mean particle diameter of 0.02 μm.
EXAMPLE 19
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by i mixture B 6 shown in Table 1, said mixture B 6 comprising 100 parts resin component B and 5 parts aqueous colloidal silica dispersed in water having a mean particle diameter of 0.02 μm.
EXAMPLE 20
A pigment coating composition for casting comprising 40 parts kaolin, 60 parts ground calcium carbonate, 0.5 part sodium polyacrylate, 7 parts oxidized starch, 10 parts styrene-butadiene copolymer latex and 0.5 part zirconium ammonium carbonate was adapted to have a solid matter consistency of 64% said pigment coating composition being applied onto a base paper having a basis weight of 100 g/m 2 by means of a blade coater so that the dry weight was 10 g/m 2 , then said pigment coating composition being dried. A coated paper for rewet casting thus obtained had a Bekk smoothness of 40 seconds.
A cast coated paper was obtained by applying said rewet liquid used in Example 2 onto he coated paper prepared above by the same method as in Example 1.
EXAMPLE 21
A pigment coating composition for casting comprising 60 parts kaolin, 40 parts precipitated calcium carbonate, 5 parts casein, 15 parts styrene-butadiene copolymer latex and 0.5 part epoxy water resisting agent was adapted to have a solid matter consistency of 45% said pigment coating composition being applied onto a base paper having a basis weight of 100 g/m 2 by means of an air knife coater so that the dry weight was 25 g/m 2 . After being dried, the paper coated with said pigment coating composition was smoothed by means of a super calender so as to have a Bekk smoothness of 250 seconds. Thus a coated paper for rewet casting was obtained.
A cast coated paper was obtained by applying said rewet liquid used in Example 2 onto the coated paper prepared above by the same method as in Example 1.
COMPARATIVE EXAMPLE 1
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a resin component N shown in Table 1.
COMPARATIVE EXAMPLE 2
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a resin component O shown in Table 1.
COMPARATIVE EXAMPLE 3
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a resin component P shown in Table 1.
COMPARATIVE EXAMPLE 4
A cast coated paper was obtained in the same way as in Example 1 except that said resin component A in said rewet liquid of Example 1 was replaced by a mixture N1 shown in Table 1, said mixture N1 comprising 100 parts resin component N and 100 parts aqueous colloidal silica dispersed in water having a mean particle diameter of 0.02 μm.
The gloss, uneven gloss, pin holes, ink gloss, ink mottling, ink set, abrasion resistance and water resistance of the cast coated papers thus obtained in Examples 1 to 21 and Comparative Examples 1 to 4 were evaluated as shown in Table 2. Also the speed of cast coating of each of said papers is shown in Table 2.
EXAMPLES 22 to 29 and COMPARATIVE EXAMPLES 5 to 8
A pigment coating composition for casting comprising 70 parts kaolin, 30 parts precipitated calcium carbonate, 0.5 part sodium polyacrylate, 1.0 part calcium stearate, 10 parts (solid matter) casein dissolved with ammonia and 16 parts (solid matter) styrene-butadiene copolymer latex was adapted to have a solid matter consistency of 45%. said pigment coating composition being applied onto a base paper having a basis weight of 100 g/m 2 by means of an air knife coater so that the dry weight was 25 g/m 2 , then said pigment coaling composition being dried. A coated paper for rewet casting thus obtained was subjected to rewet cast finish by means oil an apparatus shown in FIG. 2 as follows:
Said coated paper 6 was passed through a press nip 9 formed by a press roll 7 and a cast drum 8. At the nip 9, the surface of the coated layer of the coated paper 6 was rewetted with a rewet liquid having components shown in Table 3, said rewet liquid being supplied from a nozzle 10. Then the coated paper 6 was pressed against the cast drum 8 having a temperature of 95° C. at a linear pressure of 150 kg/cm and dried thereby. Now the paper 6 was removed from the cast drum 8 by a take-off roll 11. Thus a rewet cast coated paper 12 was obtained.
EXAMPLES 30 to 36 and COMPARATIVE EXAMPLE 9
A pigment coating composition for casting comprising 70 parts kaolin, 30 parts precipitated calcium carbonate, 0.5 part sodium polyacrylate, 6 parts (oxidized starch, 15 parts styrene-butadiene copolymer latex and 1.0 part calcium stearate was adapted to have a solid matter consistency of 64%, said pigment coating composition being applied onto a base paper having a basis weight of 100 g/m 2 by means of a blade coater so that the dry weight was 25 g/m 2 , then said pigment coating composition being dried. A coated paper for rewet casting thus obtained was rewetted with a rewet liquid having components shown in Table 4 by the same method as in Examples 22 to 29 and then subjected to rewet cast finish.
The gloss, uneven gloss, pin holes, ink gloss, ink mottling, ink set, abrasion resistance and water resistance of the cast coated papers thus obtained in Examples 22 to 36 and Comparative Examples 5 to 9 were evaluated as shown in Table 5. Also the speed of cast coating of each of said papers is shown in Table 5.
The quality evaluations of said cast coated papers were made as in the following:
Gloss
Gloss was measured in accordance with JIS-P-8142.
Uneven Gloss
Uneven gloss on the surface of each cast coated paper was visually measured. The results of the visual measurements are represented in Tables 2 and 5 by the following relative valuations:
______________________________________⊚: No uneven gloss was found.◯: Slight uneven gloss was found but there was no problem in practice.Δ: Uneven gloss was found.X: Much uneven gloss was found.______________________________________
Pin Holes
The surface of each cast coated paper was observed by means of a microscope. The existence of pin holes is represented in Tables 2 and 5 by following relative valuations:
______________________________________◯: Less than 10 pin holes were found per 1 cm.sup.2.Δ: 10 to 50 pin holes were found per 1 cm.sup.2.X: More than 50 pin holes were found per 1 cm.sup.2.______________________________________
Ink Gloss
The surface of each cast coated paper was printed with 0.3 ml of a sheet offset ink ("F-Gloss" made by Dainippon Ink And Chemicals, Incorporated) by means of a printing tester ("RI-1" made by Akira Seisakusho Co., Ltd.), and the paper was let alone at a room temperature for a whole day and night. Then, the gloss at 60° of the printed surface was measured by means of a gloss meter made by Murakami Color Research Laboratory.
Ink Mottling
The surface of each cast coated paper was printed with 0.1 ml of said sheet offset printing ink ("F-Gloss" made by Dainippon Ink And Chemicals, Incorporated) by means of a printing tester ("RI-1" made by Akira Soisakusho Co., Ltd.), and the paper was let alone at a room temperature for a whole day and night. The ink mottling on the printed surface was visually measured. The results of the visual measurements are represented in Tables 2 and 5 by the following relative valuations:
______________________________________◯: No ink mottling was found.Δ: Ink mottling was found.X: Serious ink mottling was found.______________________________________
Ink Set
The surface of each cast coated paper was printed with 0.6 ml of said sheet offset printing ink ("F-Gloss" made by Dainippon Ink And Chemicals, Incorporated) by means of a printing tester ("RI-1" made by Akira Seisakusho Co., Ltd.). Immediately after printing and 10 minutes after printing, a wood free paper was placed upon each cast coated paper, and these papers were pressed together with a certain pressure. The density of ink transferred to the surface of the wood free paper was visually measured. The results of the visual measurements are represented in Tables 2 and 5 by the following relative valuations:
______________________________________⊚: 10 minutes after printing, almost no ink was transferred.◯: The density of ink transferred 10 minutes after printing was about half of the density of ink transferred immediately after printing. There was no problem in practice.Δ: The density of ink transferred 10 minutes after printing was a little lower than the density of ink transferred immediately after printing.X: There was almost no difference between the density of ink transferred immediately after printing and the density of ink transferred 10 minutes after printing.______________________________________
Abrasion Resistance
The surface of each cast coated paper was printed with 0.3 ml of said sheet offset printing ink ("F-Gloss" made by Dainippon Ink And Chemicals, Incorporated) by means of a printing tester ("RI-1" made by Akira Seisakusho Co., Ltd.) and the paper was let alone at a room temperature for a whole day and night. The printed surface and the non-printed surface were rubbed together 20 times under a load of 1.8 kg by means of a Sutherland Tester. Scratches and stains on the printed surface and the non-printed surface were visually measured. The results of the visual measurements are represented in Tables 2 and 5 by the following relative valuations:
______________________________________◯: Almost no scratches or stains were found.Δ: Scratches and stains were found. There was no problem in practice.X: Serious scratches and stains were found.______________________________________
Water Resistance
Two pieces of each cast coated paper were place one upon the other so that the coated surface thereof is in contact with each other. These pieces of paper were let alone for 24 hours at 40° C. and 90% RH under a load of 500 g/cm 2 . The state of the coated surface of each cast coated paper was inspected. The results of the inspection are represented in Tables 2 and by the following relative valuations:
______________________________________◯: The coated surfaces of the paper did not stick to each other at all.Δ: The coated surfaces of the paper slightly stuck to each other.X: The coated surfaces of the paper seriously stuck to each other.______________________________________
Maximum Production Speed
Tables 2 and 5 further show a maximum production speed (meter/minute) of each cast coated paper produced by the method described above, which speed ensures stable production free from the sticking of the cast coated paper to the cast drum as well as from drum pick and drum blistering.
TABLE 1__________________________________________________________________________Resin Component Celloidal silica Weight ratio be- Tg of copolymer Aqueous colloidal silica(See notes Average particle tween copolymer resin resin Mean particlebelow.) diameter (μm) and colloidal silica (°C.) diameter Number of__________________________________________________________________________ partsA 0.02 100:100 -15B 0.02 100:100 -20C 0.02 100:100 -15D 0.02 100:100 -5E 0.02 100:40 -20F 0.02 100:250 -20G 0.01 100:100 -15H 0.05 100:100 -15I 0.02 100:350 -20J 0.02 100:20 -20K 0.004 100:100 -15L 0.15 100:100 -15M 0.02 100:150 -20B1 0.02 100:100 -20 0.02 20B2 0.02 100:100 -20 0.02 150B3 0.02 100:100 -20 0.004 100B4 0.02 100:100 -20 0.15 100B5 0.02 100:100 -20 0.02 250B6 0.02 100:100 -20 0.02 5N -- 100:0 -15 -- --O -- 100:0 38 -- --P -- 100:0 -- -- --N1 -- 100:0 -15 0.02 100__________________________________________________________________________
Notes to Table 1
A Complex of styrene-butyl acrylate copolymer and colloidal silica
B. Complex of styrene-methyl methacrylate-2-ethyl hexyl acrylate copolymer and colloidal silica
C: Complex of styrene-2-ethyl hexly acrylate copolymer and colloidal silica
D: Complex of methyl methacrylate-2-ethyl hexyl acrylate copolymer and colloidal silica
E: Complex of styrene-methyl methacrylate-2-ethyl hexyl acrylate copolymer and colloidal silica
F: Complex of styrene-methyl methacrylate-2-ethyl hexyl acrylate copolymer and colloidal silica
G: Complex of styrene-butyl acrylate copolymer and colloidal silica
H: Complex of styrene-butyl acrylate copolymer and colloidal silica
I: Complex of styrene-methyl methacrylate-2-ethyl hexyl acrylate copolymer and colloidal silica
J: Complex of styrene-methyl methacrylate-2-ethyl hexyl acrylate copolymer and colloidal silica
K: Complex of styrene-butyl acrylate copolymer and colloidal silica
L: Complex of styrene-butyl acrylate copolymer and colloidal silica
M: Complex of styrene-methylmethacrylate-2-ethyl hexyl acrylate copolymer and colloidal silica
B1: Complex of styrene-methyl methacrylate-2-ethyl hexyl acrylate copolymer and colloidal silica
B2: Complex of styrene-methyl methacrylate-2-ethyl hexyl acrylate copolymer and colloidal silica
B3: Complex of styrene-methyl methacrylate-2-ethyl hexyl acrylate copolymer and colloidal silica
B4: Complex of styrene-methyl methacrylate-2-ethyl hexyl acrylate copolymer and colloidal silica
B5: Complex of styrene-methyl methacrylate-2-ethyl hexyl acrylate copolymer and colloidal silica
B6: Complex of styrene-methyl methacrylate-2-ethyl hexyl acrylate copolymer and colloidal silica
N: Styrene-butyl acrylate copolymer
O: Methyl methacrylate-2-ethyl hexyl acrylate copolymer
P: Casein
N1: Styrene-butyl acrylate copolymer
TABLE 2__________________________________________________________________________ Maximum Uneven Ink Abrasion Water productionGloss gloss Pin holes Ink gloss mottling Ink set resistance resistance speed__________________________________________________________________________Example 1 95 ⊚ ◯ 97 ◯ ◯ ◯ ◯ 302 96 ⊚ ◯ 92 ◯ ◯ ◯ ◯ 303 96 ⊚ ◯ 90 ◯ ◯ ◯ ◯ 304 95 ⊚ ◯ 92 ◯ ◯ ◯ ◯ 305 96 ⊚ ◯ 93 ◯ ◯ ◯ ◯ 256 95 ⊚ ◯ 94 ◯ ◯ ◯ ◯ 307 95 ⊚ ◯ 97 ◯ ◯ ◯ ◯ 308 94 ⊚ ◯ 98 ◯ ◯ ◯ ◯ 309 93 ⊚ ◯ 85 ◯ ⊚ ◯ ◯ 2010 95 ⊚ ◯ 91 ◯ ◯ Δ ◯ 1011 96 ⊚ ◯ 95 ◯ Δ Δ Δ 2012 92 ⊚ ◯ 87 ◯ Δ Δ Δ 2013 96 ⊚ ◯ 94 ◯ ◯ ◯ ◯ 3014 96 ⊚ ◯ 93 ◯ ⊚ ◯ ◯ 3515 94 ⊚ ◯ 90 ◯ ⊚ ◯ ◯ 4016 95 ⊚ ◯ 88 ◯ ⊚ ◯ ◯ 3017 90 ⊚ ◯ 80 ◯ ⊚ Δ Δ 3518 90 ⊚ ◯ 83 ◯ ⊚ Δ Δ 4019 96 ⊚ ◯ 92 ◯ ◯ ◯ ◯ 3020 80 Δ Δ 87 ◯ ◯ ◯ ◯ 3021 96 ⊚ ◯ 92 ◯ ◯ ◯ ◯ 30Comp. 1 89 ⊚ ◯ 95 Δ X X X 5example 2 93 ⊚ ◯ 98 Δ X Δ Δ 53 97 ⊚ ◯ 100 X X X X 304 95 ⊚ ◯ 92 Δ X X X 5__________________________________________________________________________
TABLE 3__________________________________________________________________________Composition of rewet liquid ViscosityResin component Release agent and other component (cps)__________________________________________________________________________Example 22 A 10% Calcium stearate 2% 1023 G 10% Calcium stearate 2%, casein 5% 70024 H 10% Calcium stearate 2%, casein 5% 70025 D 10% Ammonium stearate 2%, acrylic emulsion 3% 100026 M 25% Zink stearate 5%, sodium hexametaphosphate 1% 300027 A 10% Calcium stearate 2%, sodium hexametaphosphate 1% 50028 K 10% Calcium stearate 2%, sodium hexametaphosphate 1% 50029 L 10% Calcium stearate 2%, sodium hexametaphosphate 1% 500Comp. 5 N 10% Calcium stearate 2%, sodium hexametaphosphate 1% 500Example 6 O 10% Calcium stearate 2%, sodium hexametaphosphate 1% 5007 P 10% Ammonium stearate 2% 308 -- Polyethylene emulsion 2% 10__________________________________________________________________________
TABLE 4__________________________________________________________________________Composition of rewet liquid ViscosityResin component Release agent and other component (cps)__________________________________________________________________________Example 30 M 15% Polyethylene emulsion 2%, carboxymethyl cellulose 1% 50031 E 15% Zink stearate 2%, polyvinyl alcohol 2% 60032 F 15% Zink stearate 2%, polyvinyl alcohol 2% 60033 C 20% Ammonium oleate 2%, sodium polyacrylate 3% 400034 I 15% Ammonium oleate 2%, sodium polyacrylate 2% 150035 E 15% Ammonium oleate 2%, sodium polyacrylate 2% 150036 C 25% Zink stearate 5%, ammonium sulfate 1% 7000Comp. 9 -- Polyethylene emulsion 2% 10Example__________________________________________________________________________
TABLE 5__________________________________________________________________________ Maximum Uneven Printing Ink Abrasion Water productionGloss gloss Pin holes gloss Ink gloss mottling resistance resistance speed__________________________________________________________________________Example 22 94 ◯ Δ 95 ◯ ◯ ◯ ◯ 6523 97 ⊚ ◯ 97 ◯ ◯ ◯ ◯ 7024 96 ⊚ ◯ 98 ◯ ◯ ◯ ◯ 7025 96 ⊚ ◯ 93 ◯ ⊚ ◯ ◯ 6526 95 ⊚ ◯ 95 ◯ ⊚ ◯ ◯ 7027 97 ⊚ ◯ 94 ◯ ◯ ◯ ◯ 6528 96 ⊚ ◯ 95 ◯ Δ Δ Δ 6529 90 ◯ ◯ 85 ◯ ◯ Δ Δ 70Comp. 5 88 Δ X 85 Δ Δ X X 45Example 6 95 X X 97 Δ X Δ Δ 207 94 ◯ ◯ 98 X X X X 658 92 Δ Δ 85 ◯ ⊚ X X 70Example 30 96 ⊚ ◯ 93 ◯ ⊚ ◯ ◯ 6031 98 ⊚ ◯ 92 ◯ ◯ ◯ ◯ 5532 97 ⊚ ◯ 93 ◯ ⊚ ◯ ◯ 6033 98 ⊚ ◯ 91 ◯ ⊚ ◯ ◯ 5534 91 ⊚ ◯ 87 ◯ ⊚ ◯ ◯ 4535 97 ⊚ ◯ 90 ◯ Δ ◯ ◯ 4036 93 ◯ Δ 90 ◯ ⊚ ◯ ◯ 50Comp. 9 70 X X 75 X ⊚ X X 60Example__________________________________________________________________________ | The present invention provides a method of producing a cast coated paper including the steps of providing a pigment coating layer for casting on a base paper, plasticizing the coating layer by means of a rewet liquid, and drying the coating layer by pressing the coating layer against a heated metal drum having a highly polished surface such that the dried coating layer has a high gloss. The rewet liquid is an aqueous dispersion having a complex resin. The complex resin includes a copolymer resin and a colloidal silica, the copolymer resin being obtained by copolymerizing a styrene monomer and an unsaturated carboxylic ester monomer, and the colloidal silica having a mean particle diameter ranging from 0.005 μm to 0.01 μm. | 3 |
BACKGROUND
[0001] The present invention relates to storage retrieval machines (SRMs), and more specifically to drive mechanisms for such systems.
[0002] SRMs are used to automatically store and retrieve items, such as in a warehouse. The storage area typically includes an array of storage locations that are each specifically identified. Each location is capable of storing a single unit, which can be stored or retrieved on command. Such systems commonly have a product input area, a product storage area, and a mechanism for moving products into and out of storage.
[0003] Storage areas in SRMs are commonly arranged into rows and columns. As a result, mechanisms that move the products must be capable of both vertical and horizontal movement. Such mechanisms can include, for example, a robotic arm mounted on a platform with both vertical and horizontal actuators. Vertical movement is commonly provided by hydraulic lifts or rack and pinions (e.g., with a driven pinion). Horizontal motion is commonly provided by a driven wheel on a surface, such as a wheel on a rail, which is typically used with overhead cranes in manufacturing environments.
[0004] Because precise placement into storage locations is important, the mechanisms that move the product must have a means to determine location. When using positive-position mechanisms, such as a rack and pinion, precise location can be determined by sensing the position of the drive wheel (e.g., counting rotations and detecting angular orientation of a drive pinion on a rack and pinion arrangement). When using other mechanisms where slippage can occur, such as a wheel on rail, the system must use other sensing systems, such as limit switches, to determine position.
SUMMARY
[0005] The present invention provides an SRM drive system that can be used in conjunction with other systems in order to provide an economical means to move products, while at the same time providing positive positioning. In particular, the present invention provides a storage retrieval machine comprising an input area, an array of storage locations, an output area, a carriage assembly adapted to hold a product when being transferred to and from the storage locations, and a drive mechanism positioned to move the carriage assembly. The drive mechanism includes a flexible element (e.g., a chain) tensioned between two points and having a plurality of spaced recesses, and a toothed element mounted to the carriage assembly and engaging the flexible element.
[0006] Preferably, the flexible element is pre-tensioned to a certain percentage of the rated load of the flexible element (e.g., 10%, 20%, 30%, or 40% of the rated load). It is also preferred that the pre-tensioned load on the flexible element is greater than the service load that is anticipated to be applied to the chain during normal operation.
[0007] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of an SRM embodying features of the invention.
[0009] FIG. 2 is a perspective view of a first guide of the SRM of FIG. 1 .
[0010] FIG. 3 is a perspective view of a second guide of the SRM of FIG. 1 .
[0011] FIG. 4 is a perspective view of a third guide of the SRM of FIG. 1 .
[0012] FIG. 5 is a partial perspective view of the SRM of FIG. 1 .
[0013] FIG. 6 is a partial perspective view of the SRM of FIG. 1 .
[0014] FIG. 7 is a perspective view of an anchor of the SRM of FIG. 1 .
[0015] FIG. 8 is a perspective view of a horizontal drive system for another SRM embodying features of the invention.
DETAILED DESCRIPTION
[0016] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
[0017] FIG. 1 shows a storage facility 10 including a loading space 14 , an array of storage locations 22 , and a storage retrieval machine (SRM 26 ). The loading space 14 is positioned such that a product 30 may access the loading space 14 from a holding area 34 . In other embodiments, the storage facility 10 could be different, such as a warehouse, stocking area, car park, or another storage facility as desired. Correspondingly, the array of storage locations 22 could be arranged differently. For example, the array 22 could include any number of columns, any number of rows, or may include a three-dimensional matrix of storage locations. The storage locations could be sized and arranged to hold any product 30 , as desired. Additionally, the product 30 could be anything that is advantageously stored, such as cars, boats, produce, toys, or any other appropriate product 30 , as desired.
[0018] The illustrated storage facility 10 includes four rows and four columns of storage locations 22 . The four rows extend along an X-axis and are referred to throughout this application as the first level 38 (i.e., closest to the base), the second level 42 , the third level 46 , and the fourth level 50 (i.e., farthest from the base). The four columns extend along a Y-axis and are referred to as the first position 54 (i.e., farthest to the right), the second position 58 , the third position 62 , and the fourth position 66 (i.e., the farthest to the left). A Z-axis is defined perpendicular to the X-axis and the Y-axis (i.e., extending out of the page of FIG. 1 and indicated in the lower left).
[0019] A support structure is built into the storage facility 10 and includes rails 70 that support the SRM 26 for movement from the first through fourth positions 54 , 58 , 62 , 66 and from the first through fourth levels 38 , 42 , 46 , 50 . In the illustrated embodiment, the support structure is a part of the storage facility 10 , and the rails 70 project from the walls of the storage facility 10 to support the SRM 26 . In other embodiments, the support structure may be free standing within the storage facility 10 or arranged differently, as desired.
[0020] The SRM 26 further includes a SRM frame 74 , a carriage assembly 86 , an upper drive assembly 78 , and a lower drive assembly 82 . The SRM frame 74 includes vertical columns 87 that extend from the first level 38 to the fourth level 50 , an upper cage 88 , and a lower cage 89 . The vertical columns 87 connect the upper cage 88 and the lower cage 89 and are further reinforced by struts 90 . The upper cage 88 connects the SRM frame 74 to the upper drive assembly 78 such that the upper drive assembly 78 supports the SRM frame 74 for movement on the rails 70 , and the lower cage 89 provides a frame work that supports the lower drive assembly 82 . The upper and lower cages 88 , 89 include additional frame work such that the SRM frame 74 is a rigid structure.
[0021] Three of the four vertical columns 87 include guide rails. A first guide rail 91 is attached to one of the vertical columns 87 (lower right in FIG. 1 ), a second guide rail 92 is attached to another vertical column 87 (lower left in FIG. 1 ), and a third guide rail 93 is attached to another vertical column 87 . The first, second, and third guide rails 91 , 92 , 93 are formed separately from and are attached to the vertical columns 87 . In other embodiments, the first, second, and third guide rails 91 , 92 , 93 could be formed integrally with the vertical columns 87 .
[0022] The SRM frame 74 also includes four bumpers in the form of shock absorbers or barriers 98 that cushion and stop the SRM 26 if it moves past the desired location. For example, if the SRM 26 is moving to the fourth position 66 but overshoots the location slightly, the barriers 98 will slow the SRM 26 movement and inhibit damage to the SRM 26 and/or the storage facility 10 . In other embodiments, the bumpers may be air bladders, hydraulic cylinders, compressible bumpers, or another type, as desired.
[0023] The carriage assembly 86 includes a carriage frame 102 that is supported by the SRM frame 74 and is positioned between the vertical columns 87 . The carriage frame 102 includes a first guide member 110 that engages the first guide rail 91 , a second guide member 114 that engages the second guide rail 92 , and a third guide member 118 that engages the third guide rail 93 . The first, second, and third guide members 110 , 114 , 118 are positioned at three corners of the carriage frame 102 corresponding with the first, second, and third guide rails 91 , 92 , 93 of the SRM frame 74 , and engage the guide rails 91 , 92 , 93 to guide the carriage assembly 86 during vertical movement of the carriage assembly 86 (i.e., along the Y-axis). FIGS. 3-5 include more details about the interaction between the guide rails 91 , 92 , 93 and guide members 110 , 114 , 118 and will be discussed in detail below. The fourth corner of the illustrated carriage frame 102 (upper left in FIG. 2 ) does not include a guide member such that alignment of the carriage assembly 86 is maintained by the first, second, and third guide members 110 , 114 , 118 . This arrangement allows the carriage assembly 86 to move freely along the Y-axis while inhibiting binding.
[0024] FIG. 2 shows the first guide member 110 engaged with the first guide rail 91 . The first guide member 110 is fixed to the carriage frame 102 with a rod 122 with bearings (not shown) such that the first guide member 110 can rotate with respect to the carriage frame 102 . The first guide member 110 engages the first guide rail 91 that has a T section and constrains the movement of the carriage assembly 86 with respect to the SRM frame 74 in the X-axis and the Z-axis such that the carriage assembly 86 can move in the Y-axis along the guide rail 90 .
[0025] FIG. 3 shows the second guide member 114 engaged with the second guide rail 92 . The second guide member 114 includes a first portion 126 and a second portion 130 . The first portion 126 is fixed to the carriage frame 102 with a rod 122 with bearings (not shown), similar to the first guide member 110 , such that the second guide member 114 can rotate with respect to the carriage frame 102 . The first portion 126 also includes a T-shaped slot 135 . The second portion 130 engages the second guide rail 92 that has a T section such that the second portion 130 is constrained in the X-axis and the Z-axis and moves freely along the Y-axis. The second portion 130 also includes a T-shaped protrusion 136 that engages the corresponding T-shaped slot 135 formed in the first portion 126 . The first portion 126 can slide along the X-axis relative to the second portion 130 via the T-shaped slot and protrusion 135 , 136 such that the second guide member 114 constrains the movement of the carriage assembly 86 with respect to the SRM frame 74 in the Z-axis but allows movement along the X-axis.
[0026] FIG. 4 shows the third guide member 118 engaged with the third guide rail 93 . The third guide member 118 is fixed to the carriage frame 102 with a rod 122 with bearings (not shown) such that the third guide member 118 can rotate with respect to the carriage frame 102 . The third guide member 118 engages the third guide rail 93 and constrains the movement of the carriage assembly 86 with respect to the SRM frame 74 in the X-axis such that the carriage assembly 86 can move in the Y-axis along the third guide rail 93 . The third guide member 118 allows the carriage assembly 86 to translate slightly relative the third guide rail 93 along the Z-axis.
[0027] Referring to FIG. 1 , the upper drive assembly 78 includes a vertical drive system 138 that moves the carriage assembly 86 relative to the SRM frame 74 along the Y-axis between the first level 38 and the fourth level 50 , and a horizontal drive system 142 that moves the SRM 26 along the X-axis between the first position 54 and the fourth position 66 .
[0028] With reference to FIG. 5 , the illustrated vertical drive system 138 includes a motor 146 , a gear box 150 , a drive shaft 154 , and counterweights 158 . FIG. 5 shows one side of the vertical drive system 138 , and the opposite side of the upper drive assembly 78 includes an identical arrangement and the two motors 146 are coupled together with a synchronizer shaft 162 . The synchronizer shaft 162 provides for the motors 146 to run synchronously and to move the carriage assembly 86 along the Y-axis smoothly. The illustrated motor 146 is an electric motor that drives the drive shaft 154 via the gear box 150 . In other embodiments, the motor 146 may be a servo-motor and the synchronizer shaft 162 may be removed. The motor 146 may be any drive unit that moves the carriage assembly 86 along the Y-axis. For example, hydraulic cylinders are contemplated.
[0029] The drive shaft 154 is rotated by the motor 146 via the gear box 150 and includes four sprockets 166 , two positioned on each end of the SRM frame 74 , respectively. The drive shaft 154 is mounted to the SRM frame 74 with mounts 170 that allow the drive shaft 154 to rotate freely.
[0030] The illustrated counterweights 158 slide along the corresponding vertical columns 87 (along the Y-axis) of the SRM frame 74 . Two chains 174 connect each weight 158 to the SRM frame 74 . One end of each chain 174 attaches to a connecting portion 178 of the weight 158 , loops over the sprocket 166 , and attaches at the opposite end of the chain 174 to the carriage assembly 86 at connecting portions 182 (see FIGS. 2-4 ). Each corner of the carriage assembly 86 is lifted by two chains 174 (i.e., two chains 174 are attached to each weight 158 and each corner of the carriage assembly 86 ).
[0031] With reference to FIGS. 5 and 6 , the illustrated horizontal drive system 142 includes a motor 186 , a gear box 190 (see FIG. 5 ), a toothed element in the form of a drive sprocket 194 , two idler sprockets 198 , a flexible element in the form of a chain 202 , two anchor points 206 (see FIGS. 1 and 7 ), and two wheels 210 that ride on the rails 70 of the support structure to support the SRM 26 . FIG. 6 shows one side of the horizontal drive system 142 , and the opposite side of the upper drive assembly 78 includes an identical arrangement. The illustrated motor 186 is an electric motor that drives the drive sprocket 194 via the gear box 190 . The motor 186 may be any drive unit that moves the carriage assembly 86 along the X-axis. For example, hydraulic cylinders are contemplated.
[0032] The chain 202 includes a number of spaced recesses that the teeth of the sprockets 194 , 198 engage. The chain 202 is stretched along the X-axis and mounted at the anchor points 206 (see FIG. 7 ) on opposite ends of the storage facility 10 . The SRM 26 exerts a service load on the chain 202 while in operation and, in the illustrated embodiment, the chain 202 is pre-tensioned to a force greater than the service load to reduce the effects of the chain's 202 elasticity. For example, when the illustrated SRM 26 is accelerating along the X-axis, a force of about three thousand pounds is exerted on the chain 202 . The illustrated chain 202 is pre-tensioned to about five thousand pounds. This pre-tension inhibits slack in the chain 202 during acceleration and stopping of the SRM 26 and reduces elastic elongation by at least about fifty percent.
[0033] The chain 202 also has a rated load that is a physical characteristic of the chain 202 and is set by the chain manufacturer. In the preferred embodiment, the chain 202 is pre-tensioned to at least forty percent of the rated load. In other embodiments, the chain 202 may be pre-tensioned differently, as desired. This pre-tension provides accurate positioning of the SRM 26 and at least partially avoids exaggerated chain 202 flexing.
[0034] The drive sprocket 194 and two idler sprockets 198 are arranged such that the chain 202 serpentines through the sprockets 194 , 198 and maintains a desired angle of engagement with the sprockets 194 , 198 during movement of the SRM 26 . The drive sprocket 194 is driven by the motor 186 via the gear box 190 such that the SRM 26 is translated along the X-axis between the first position 54 and the fourth position 66 . The idler sprockets 198 are mounted to the SRM frame 74 with bearings (not shown) such that they rotate freely and maintain the chain 202 in engagement with the drive sprocket 194 .
[0035] With reference to FIG. 7 , the anchor points 206 are fixed relative to the rail 70 and include a tensioning system to pre-tension the chain 202 . The tensioning system includes a threaded rod 214 , washers 218 , and fasteners 222 . The fasteners 222 are rotated on the threaded rod 214 to move the threaded rod 214 relative to the anchor point 206 such that the chain 202 is tensioned along the X-axis.
[0036] Referring to FIG. 1 , the lower drive assembly 82 is mounted to the lower cage 89 and is similar to the horizontal drive system 142 of the upper drive assembly 78 . The horizontal drive system of the lower drive assembly includes a motor, a gear box, a toothed element in the form of a drive sprocket, two idler sprockets, a flexible element in the form of a chain, and two anchor points. The lower drive assembly 82 operates in a manner similar to the horizontal drive system 142 of the upper drive assembly 78 to move the SRM 26 along the chain in the X-axis.
[0037] A control system 94 is coupled to the SRM 26 adjacent the upper drive assembly 78 and controls the movement of the SRM 26 in response to user input. The control system 94 may control the synchronization of the system to provide smooth operation. In other embodiments, the control system 94 may be located remotely or on another part of the SRM 26 , as desired.
[0038] The invention provides several advantages over prior art SRMs. The chains 202 provide a built in shock absorber due to the chain 202 elasticity while minimizing the negative effects associated with chain elasticity by pre-tensioning the chain 202 above the maximum operational force. In other words, during normal operation, the chain 202 will not stretch an unreasonable amount because the pre-tension is above the normal service load. However, if the SRM 26 stops suddenly or experiences another abnormality, the chain 202 can absorb some of the shock by stretching beyond the pre-tension.
[0039] The chains 202 also avoid the alignment problems of many prior art designs. The chain 202 and sprocket 194 , 198 arrangement does not require the tight tolerances required when using other systems (e.g., a rigid rack and pinion). As such, minor skewing of the SRM 26 will not cause substantial service damage. Additionally, previous systems required installation across the entire length of the SRM's 26 movement, whereas the chain 202 need only be fixed at two points at the ends of the rails 70 . The anchor points 206 fix the chain 202 to the support structure (not shown) and pre-tension the chain 202 . The chain 202 may be designed with self lubricating materials and/or materials that are highly resistant to corrosion such that prior art lubrication and corrosion problems may be avoided.
[0040] The operation of the illustrated embodiment will be described with respect to FIGS. 1 . To initiate a storing operation, the product 30 is placed in the loading space 14 . The control system 94 determines which storage location 22 the product 30 will be stored in and actuates the SRM 26 . The product 30 is placed on the carriage assembly 86 and the SRM 26 is then ready to move to the appropriate level and position.
[0041] The horizontal drive systems 142 of the upper and lower drive assemblies 78 , 82 then move the SRM 26 to the appropriate position (e.g., the third position 62 ). The motors 186 turn the drive sprockets 194 such that the SRM 26 is pulled along the chains 202 and rolled on the wheels 210 along the rails 70 .
[0042] Once in the desired position (e.g., the third position 62 ), the SRM 26 moves the carriage assembly 86 to the desired level (e.g., the second level 42 ). The motors 146 turn the drive shaft 154 such that the sprockets 166 are turned and pull the carriage assembly 86 between the first level 38 and the fourth level 50 on the chains 174 . As the carriage assembly 86 is raised the counterweights 158 are lowered to maintain contact between the chains 174 and the sprockets 166 . The motors 146 continue to raise the carriage assembly 86 until the carriage assembly 86 is at the desired level (e.g., the second level 42 ).
[0043] Once located at the desired storage location 22 , the product 30 is unloaded into the storage location 22 , and the SRM 26 returns the carriage assembly 86 to the first level 38 and translates back to the loading space 14 .
[0044] When it is desired to remove the product 30 from the storage facility 10 , the control system 94 initiates a retrieval operation. The control system 94 will take an input from a user to determine which product 30 must be retrieved and where in the array that product 30 is located. Once the correct storage location 22 is determined, the SRM 26 translates along the X-axis to the appropriate position (e.g., the third position 62 ). The vertical drive system 138 then lifts the carriage assembly 86 to the appropriate level (e.g., the second level 42 ). Then the product 30 is loaded onto the carriage assembly 86 , the vertical drive system 138 lowers the carriage assembly 86 to the first level 38 , and the horizontal drive system 142 translates the SRM 26 to the loading space 14 . Once the product 30 is placed in the loading space 14 , the product 30 is removed to the holding area 34 .
[0045] FIG. 8 shows an alternate horizontal drive system 230 that includes a motor 234 , a gear box 238 , a toothed element in the form of a drive sprocket 242 , an idler shoe 246 , a flexible element in the form of a chain 202 , two anchor points 206 (same as shown in FIGS. 1 and 7 ), and two wheels 250 that ride on the rails 70 of the support structure to support the SRM 26 . In operation, the idler shoe 246 moves with the horizontal drive system 230 to maintain the chain 202 in contact with the drive sprocket 242 . The operation of the horizontal drive system 230 is similar to the operation of the horizontal drive system 142 described above.
[0046] Various features and advantages of the invention are set forth in the following claims. | A storage retrieval machine comprising an input area, an array of storage locations, an output area, a carriage assembly adapted to hold a product when being transferred to and from the storage locations, and a drive mechanism positioned to move the carriage assembly. The drive mechanism includes a flexible element (e.g., a chain) tensioned between two points and having a plurality of spaced recesses, and a toothed element mounted to the carriage assembly and engaging the flexible element. Preferably, the flexible element is pre-tensioned to a certain percentage of the rated load of the flexible element (e.g., 10%, 20%, 30%, or 40% of the rated load). It is also preferred that the pre-tensioned load on the flexible element is greater than the service load that is anticipated to be applied to the chain during normal operation. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to well casing handling equipment, and in particular to well casing elevator and spiders.
2. Description of the Prior Art
In a typical derrick arrangement, a traveling block is suspended from the derrick crown block by a series of cables, which are driven by the derrick drawworks to raise and lower the traveling block along the vertical axis of the derrick. The traveling block supports a derrick hook, a pair of links, and an elevator. When handling casing, sliptype elevators are used. Such elevators have a tapered interior bowl and a set of gripping slips, which are moved pivotally up and down within the bowl to grip the exterior surface of the casing.
A casing spider rests on the derrick floor and supports the casing string in the well bore with a set of slips, which are set to grip the casing exterior. A new joint of casing is raised into position over the well bore by the casing elevator, and the lower end of the casing joint is connected to the upper end of the casing string in the well bore. The elevator is then used to lift the casing string, releasing the slips of the lower spider, and then the casing string is lowered into the well bore. The slips of the spider are then set to support the casing string in the well bore, and the elevator is disengaged and stripped upward and off of the casing to allow another casing joint to be moved into position. This cycle is repeated until all of the casing has been run into the well bore.
Elevator/spiders are powerful, double-duty tools designed to handle long, heavy casing strings. These tools are convertible and can be used either as casing spiders or as elevators. Often, when handling casing strings, elevator/spiders will be used in tandem, utilizing one tool as a casing spider and the other tool as an elevator.
Elevator/spiders generally have slips which are pivotally operable between an upper, retracted position and a lower, gripping position. The slips are moved between the upper and lower positions by a yoke, which is connected to the slips by suitable linkages. The yoke pivots about a pivot axis in the approximate center of the yoke, when fluid pressure is applied to the fluid cylinders connected to the other end of the yoke.
The slips may also be raised and lowered manually by an operator using a handle inserted into a socket on the yoke. Whether the slips are raised and lowered manually or hydraulically, the weight of the slips should be counterbalanced. Counterbalancing the slips makes it easier for the operator to raise the slips, and lessens the chances of damage to the elevator/spider, the slips, and the casing, when the slips are lowered. U.S. Pat. No. 3,149,391 (Boster), issued on Sept. 22, 1964, shows one method of counterbalancing the weight of the slips. A compression spring is attached to the yoke to urge the yoke in a direction which applies an upward force on the slips. Another type of counterbalance is a torsional spring mounted on the pivot point of the yoke. All of the prior art counterbalances have been rather large, and somewhat difficult to install and to remove from the elevator/spider, partly because the spring must be preloaded prior to installment.
SUMMARY OF THE INVENTION
This invention provides a safe, easy to install counterbalance for the slips of an elevator/spider. The counterbalance mechanism is a torsional spring, mounted on the body of the elevator/spider below the yoke. A wire rope extends from a connection on the yoke down to a sheave which is attached to the free end of the torsional spring.
In operation, when the slips are in their upper, retracted position, there is no force on the torsional spring. As the slips are lowered, either manually or hydraulically, the spring end of the yoke rises and pulls the wire rope upward. The wire rope turns the sheave, winding the torsional spring. The force of the torsional spring counterbalances the weight of the falling slips. The counterbalance of the torsional spring also makes it easier to raise the slips. As the slips approach their upper, retracted position, the moment arm between the pivot point and the slips becomes shorter, and the moment arm between the pivot point and the spring end of the yoke becomes longer. Thus, as the slips are raised, and the force of the torsional spring lessens, the effect of the torsional spring on the slips is increased by the changing moment arms. The overall result is that the effect of the torsional spring on the weight of the slips remains generally constant.
The above, as well as additional objects, features, and advantages of the invention, will become apparent in the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a top view of the improved elevator/spider.
FIG. 2 is a back view of the elevator/spider, with the cover removed.
FIG. 3 is a sectional view of the elevator/spider, taken along lines 3--3 of FIG. 2, with the slips in the lower, gripping position.
FIG. 4 is a sectional view of the elevator/spider, taken along lines 3--3 of FIG. 2, with the slips in the upper, retracted position.
FIG. 5 is a perspective view of the counterbalance mechanism.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates an elevator/spider, designated generally as 11, having a cylindrical body 13 with a tapered interior bowl 15. A pair of ears 17 are provided on the sides of the body 13, so that the elevator 11 may be suspended from a derrick hook with links. A central bore 19 through the body 13 receives a section of pipe, casing, or tubing. A side gate 21, which pivots about a point 23 on one side of a gate opening 25, provides radial access to the bore 19. The side gate 21 is secured to the body 13 by a latch mechanism 27 on the opposite side of opening 25. A set of three slips 29 are seated in the tapered bowl 15. Each slip 29 has gripping teeth 31, on the interior face, which are equally spaced about the vertical axis passing through the center of bore 19.
Each of the slips 29 is connected for pivotal movement by pins 33 and linkages 35 to a yoke 37. FIG. 2 shows the elevator/spider 11 with the rear cover 39 removed. A pair of fluid cylinders 41 are mounted on the body 13 and have output shafts 43 connected to the yoke 37. When fluid pressure is applied through fluid conduits 45 to the lower ends of the fluid cylinders 41, the output shafts 43 extend upward, raising the yoke 37 When fluid pressure is applied through fluid conduits 47 to the upper ends of the fluid cylinders 41, the output shafts 43 retract downward, lowering the yoke 37. A socket 49 is provided on the yoke 37, so that a lever can be inserted and the yoke 37 can be raised and lowered manually.
A lock rod 51 is attached to the yoke 37 by means of a clevis 53 and a pin 55. The lock rod 51 extends downward into a locking mechanism 57, which is attached to the body 13. A counterbalance mechanism 59 is mounted to the body 13 below the locking mechanism 57. A wire rope 61 is the connector means for connecting the counterbalance mechanism 59 to the yoke 37. The wire rope 61 is connected to the spring end of the yoke 37 with a clevis 63 and a pin 65.
FIGS. 3 & 4 are sectional views of the elevator/spider 11. The output shafts 43 are connected to the spring end 67 of the yoke 37 by a pin 68. The slips 29 have a pin 71, which fits within an oval slot 73 in the slip end 69 of the yoke 37. As the output shaft 43 moves upward, the yoke 37 rotates about a pivot point 75 and lowers the slip 29. When the output shaft 43 moves downward, the yoke 37 pivots in the opposite direction, and raises the slips 29. When the slips 29 are raised, the slips 29 move upward and outward in the bowl 15. Thus, as the slips 29 are moved upward, the slips 29 are also retracted. When the slips 29 are moved downward, the slips 29 are also moved inward to a gripping position. The moment arm, indicated by numeral 77, between the pivot point 75 and the slip 29 becomes shorter as the slips are raised. Conversely, the moment arm, indicated by numeral 79, between the pivot point 75 and the pin 68 becomes longer as the slips are raised.
The counterbalance mechanism 59 is illustrated in detail in FIG. 5. The counterbalance mechanism 59 is housed in a metal frame 81. The wire rope 61 enters the mechanism 59 from above, and extends 270 degrees around a sheave 83. The dead end of the wire rope 61 is connected to the sheave 83 with a swage button 85. This swage button 85 is placed into a sheave swage pocket to retain the dead end of the wire rope 61. The swage button 85 is further retained by a swage button cap 84, to keep the wire rope 61 in the sheave groove 83. The swage button cap 84 is held in place by a capscrew and lockwasher 86. A sheave spring stop 87 is connected to the sheave 83 near the point where the wire rope 61 is attached. The sheave 83 rotates around a shaft 89, which is mounted in the frame 81.
A torsional spring 91 is mounted on the frame 81 with a dead end block 93. The dead end block 93 is attached to the frame 81 with a cap screw 95. The frame 81 has a plurality of holes 97, so that tension on the torsional spring 91 may be adjusted. A barrier block 99 is attached to the bottom of the frame 81 to limit the travel of the sheave 83.
In operation, there is no force on the torsional spring 91 when the slips 29 are in the upper, retracted position, and the slip end 69 of the yoke 37 is in the lower position. As the slips 29 are lowered, either hydraulically or manually, the spring end 67 of the yoke 37 is raised. The wire rope 61 is pulled upward, and the sheave 83 is rotated. As the sheave 83 rotates, the torsional spring 91 is wound, and counterbalances the weight of the slips 29. Normal travel of the sheave 83 is 149 degrees, but if for some reason the sheave 83 is further rotated, the barrier block 99 limits sheave 83 travel to a maximum of 180 degrees. The barrier block 99 thus prevents overloading of the torsional spring 91, and also prevents the wire rope 61 from being pulled completely out of the sheave 83.
When the slips 29 are in the lower, gripping position, the torsional spring 91 is wound and counterbalances the weight of the slips 29. Thus, the force of the torsional spring 91 helps to break out the slips 29 and to raise the slips 29. As the slips 29 approach the upper, retracted position, the torsional spring 91 begins to weaken. However, the moment arm 79 between the pivot point 75 and the spring end 67 of the yoke 37 becomes longer, and the moment arm 77 between the pivot point 75 and the slip end 69 of the yoke 37 becomes shorter. The effect of this change in moment arms 77, 79 is to increase the effect of the torsional spring 91 as the slips 29 are raised. As a result, the overall effect of the torsional spring 91 on the slips 29 remains generally constant.
The improved counterbalance mechanism 59 provides several advantages over the prior art. The modular construction of the counterbalance mechanism 59 makes it easy to install and to remove the mechanism 59 from the body 13 of the elevator/spider 11. Also, there is no need to preload the spring 91 prior to installation, because there is no force on the spring 91 when the slips are in the upper, retracted position. Thirdly, because of the force multipling effect of the moment arms 77, 79, a smaller spring 91 may be used to counterbalance the weight of the slips 29. The plurality of holes 97 in the easily accessible counterbalance mechanism 59 makes it easy to adjust the tension on the counterbalance spring 91.
While the invention has been shown in only one of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes and modifications without departing from the spirit thereof. | An elevator/spider having a series of slips in a tapered bowl and a yoke for pivotally setting slips, a torsion spring is mounted on the body of the elevator/spider. A wire rope connects the torsional spring to the yoke, so that the weight of the slips is counterbalanced by the force of the torsional spring. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority as a national stage application of International Application No. PCT/CN2008/072205 filed on Aug. 29, 2008, the entire contents of which are incorporated herein by reference in its entirety.
FIELD OF INVENTION
Disclosed herein is a surface functionalized poly(dimethylsiloxane) (PDMS) and methods for making the same. The surface functionalized poly(dimethylsiloxane) (PDMS) disclosed herein is applicable in the general field of microfluidics, bioMEMS (bio-microelectromechanical systems), soft lithography, and other related biotechnology fields.
BACKGROUND OF THE INVENTION
Poly(dimethylsiloxane) (PDMS) is the choice of material for a wide range of applications (Whitesides, G. M. Nature 2006, 442, 368-3731; Psaltis, D.; et al. Nature 2006, 442, 381-386; El-Ali, J.; et al. Nature 2006, 442, 403-411) due to its many advantageous properties. These properties include chemical inertness, non-toxicity, ease of handling, and commercial availability. Strategies for PDMS surface modification have been developed, such as physisorption and chemical coupling. Physisorption of materials to a PDMS surface, such as surfactants (Huang, B.; et al. Science 2007, 315, 81-84) and polyelectrolytes (Liu, Y.; et al. Anal. Chem. 2000, 72, 5939-5944) are driven by hydrophobic and electrostatic forces, respectively. Chemical coupling is stable but generally involves high-energy bombardment (i.e., plasma) to PDMS surface (Donzel, C.; et al. Adv. Mater. 2001, 13, 1164). A number of issues are associated with chemical coupling: (1) plasma treatment is easy, but not sustainable (Olah, A.; et al. Appl. Surf. Sci. 2005, 239, 410-423), (2) high-energy bombardment has the tendency to damage PDMS and is only applicable to planar surfaces because of its limited penetration depth, and (3) the concentration gradient in “grafting to” strategy prevents the preparation of thick and dense films (Ma, H.; et al. Adv. Funct. Mater. 2005, 16, 640-648).
SUMMARY OF THE INVENTION
An alternative to the development of new materials is modifying the surface of PDMS. However, a condition of such methods is that the surface modified PDMS would ideally retain the desired bulk properties of unmodified PDMS. Recently, Ma et al., reported a facile method for permanent and functional surface modification of PDMS based on a commercial material (Wu, Y.; et al. J. Am. Chem. Soc. 2007, 129, 7226-7227). Further study of surface initiated polymerization from iPDMS confirmed that permanent and functional surface coating was successfully immobilized. However, this method does not provide a way to selectively (spatially) modify/functionalize the surface of iPDMS, which is the key for iPDMS to be useful in many applications in the field of microfluidics, bioMEMS, soft lithography and other related biotechnology fields. Disclosed herein is a surface functionalized poly(dimethylsiloxane) (PDMS) and methods for making the same. The surface functionalized poly(dimethylsiloxane) (PDMS) disclosed herein is applicable in the general field of microfluidics, bioMEMS (bio-microelectromechanical systems), soft lithography and other related biotechnology fields.
Disclosed herein is a compound of Formula I:
wherein:
R 1 is hydrogen or methyl;
R 2 is selected from the group consisting of alkyl optionally substituted with 1-3 R 4 groups, haloalkyl optionally substituted with 1-3 R 4 groups, aryl optionally substituted with 1-4 R 4 groups, cycloalkyl optionally substituted with 1-4 R 4 groups, heterocycloalkyl optionally substituted with 1-4 R 4 groups, and heteroaryl optionally substituted with 1-4 R 4 groups;
X is selected from the group consisting of nitro, —N(R 3 ) 3 + , trifluoromethyl, cyano, —C(O)OR 3 , —C(O)R 3 , where R 3 is hydrogen or alkyl; and
L 1 and L 2 are independently selected from the group consisting of a direct bond, methylene optionally substituted with 1-2 R 4 groups, (C 2 -C 12 )alkylene optionally substituted with 1-4 R 4 groups, (C 6 -C 12 )arylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )cycloalkylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )heterocycloalkylene optionally substituted with 1-4 R 4 groups, and (C 6 -C 12 )heteroarylene optionally substituted with 1-4 R 4 groups; and
R 4 is selected from the group consisting of halo, nitro, cyano, oxo, aminoacyl, aminoacyloxy, carboxyl, carboxyl ester, carbonate ester, aminosulfonyl, (C 1 -C 10 )alkyl, (C 1 -C 10 )haloalkyl, (C 1 -C 10 )alkoxy, (C 6 -C 12 )aryl, (C 5 -C 12 )heteroaryl, (C 6 -C 12 )aryloxy, (C 3 -C 12 )cycloalkyl and (C 3 -C 12 )heterocycloalkyl.
In one embodiment, the compound is of Formula II.
Also disclosed herein is a surface functionalized poly(dimethylsiloxane) (PDMS), comprising a polydimethyl siloxane (PDMS) substrate having a compound of Formula III incorporated therein:
wherein:
R 1 is hydrogen or methyl;
R 2 is selected from the group consisting of alkyl optionally substituted with 1-3 R 4 groups, haloalkyl optionally substituted with 1-3 R 4 groups, aryl optionally substituted with 1-4 R 4 groups, cycloalkyl optionally substituted with 1-4 R 4 groups, heterocycloalkyl optionally substituted with 1-4 R 4 groups, and heteroaryl optionally substituted with 1-4 R 4 groups;
X is selected from the group consisting of nitro, —N(R 3 ) 3 + , trifluoromethyl, cyano, —C(O)OR 3 , —C(O)R 3 , where R 3 is hydrogen or alkyl; and
L 1 and L 2 are independently selected from the group consisting of a direct bond, methylene optionally substituted with 1-2 R 4 groups, (C 2 -C 12 )alkylene optionally substituted with 1-4 R 4 groups, (C 6 -C 12 )arylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )cycloalkylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )heterocycloalkylene optionally substituted with 1-4 R 4 groups, and (C 6 -C 12 )heteroarylene optionally substituted with 1-4 R 4 groups; and
R 4 is selected from the group consisting of halo, nitro, cyano, oxo, aminoacyl, aminoacyloxy, carboxyl, carboxyl ester, carbonate ester, aminosulfonyl, (C 1 -C 10 )alkyl, (C 1 -C 10 )haloalkyl, (C 1 -C 10 )alkoxy, (C 6 -C 12 )aryl, (C 5 -C 12 )heteroaryl, (C 6 -C 12 )aryloxy, (C 3 -C 12 )cycloalkyl and (C 3 -C 12 )heterocycloalkyl.
In some embodiments, the surface functionalized poly(dimethylsiloxane) (PDMS) has the compound incorporated therein at a ratio of from about 11:0.5 to about 11:10 −3 . The concentration of the compound can be varied depending on the application, provided that the surface functionalized poly(dimethylsiloxane) (PDMS) possesses similar physical properties to that of unfunctionalized poly(dimethylsiloxane) (PDMS). In one embodiment, the contact angle is from about 0 to about 155 degrees.
Disclosed herein is a method of preparing a surface functionalized poly(dimethylsiloxane) (PDMS) substrate, comprising contacting a monomer mixture with a compound of Formula I under polymerization conditions:
wherein:
R 1 is hydrogen or methyl;
R 2 is selected from the group consisting of alkyl optionally substituted with 1-3 R 4 groups, haloalkyl optionally substituted with 1-3 R 4 groups, aryl optionally substituted with 1-4 R 4 groups, cycloalkyl optionally substituted with 1-4 R 4 groups, heterocycloalkyl optionally substituted with 1-4 R 4 groups, and heteroaryl optionally substituted with 1-4 R 4 groups;
X is selected from the group consisting of nitro, —N(R 3 ) 3 + , trifluoromethyl, cyano, —C(O)OR 3 , —C(O)R 3 , where R 3 is hydrogen or alkyl; and
L 1 and L 2 are independently selected from the group consisting of a direct bond, methylene optionally substituted with 1-2 R 4 groups, (C 2 -C 12 )alkylene optionally substituted with 1-4 R 4 groups, (C 6 -C 12 )arylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )cycloalkylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )heterocycloalkylene optionally substituted with 1-4 R 4 groups, and (C 6 -C 12 )heteroarylene optionally substituted with 1-4 R 4 groups; and
R 4 is selected from the group consisting of halo, nitro, cyano, oxo, aminoacyl, aminoacyloxy, carboxyl, carboxyl ester, carbonate ester, aminosulfonyl, (C 1 -C 10 )alkyl, (C 1 -C 10 )haloalkyl, (C 1 -C 10 )alkoxy, (C 6 -C 12 )aryl, (C 5 -C 12 )heteroaryl, (C 6 -C 12 )aryloxy, (C 3 -C 12 )cycloalkyl and (C 3 -C 12 )heterocycloalkyl;
to provide a functionalized poly(dimethylsiloxane) (PDMS) substrate.
Also disclosed herein is a method of preparing a surface functionalized poly(dimethylsiloxane) (PDMS) substrate, comprising contacting a monomer mixture with a compound of Formula II under polymerization conditions.
In some embodiments, the surface functionalized poly(dimethylsiloxane) (PDMS) further comprises at least one indentation on the surface. This can be accomplished using a number of known methods, such as standard soft lithography or with the use of a mold. It is contemplated that the surface functionalized poly(dimethylsiloxane) (PDMS) can be produced in any theoretical size or shape so long as the bulk properties of the poly(dimethylsiloxane) (PDMS) are not substantially effected. In one embodiment, the surface functionalized poly(dimethylsiloxane) (PDMS) is a microfluidic device.
Disclosed herein is a method for producing a microfluidic device, comprising:
1) providing a poly(dimethylsiloxane) (PDMS) polymer substrate having a compound of Formula III incorporated therein:
wherein:
R 1 is hydrogen or methyl;
R 2 is selected from the group consisting of alkyl optionally substituted with 1-3 R 4 groups, haloalkyl optionally substituted with 1-3 R 4 groups, aryl optionally substituted with 1-4 R 4 groups, cycloalkyl optionally substituted with 1-4 R 4 groups, heterocycloalkyl optionally substituted with 1-4 R 4 groups, and heteroaryl optionally substituted with 1-4 R 4 groups;
X is selected from the group consisting of nitro, —N(R 3 ) 3 + , trifluoromethyl, cyano, —C(O)OR 3 , —C(O)R 3 , where R 3 is hydrogen or alkyl; and
L 1 and L 2 are independently selected from the group consisting of a direct bond, methylene optionally substituted with 1-2 R 4 groups, (C 2 -C 12 )alkylene optionally substituted with 1-4 R 4 groups, (C 6 -C 12 )arylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )cycloalkylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )heterocycloalkylene optionally substituted with 1-4 R 4 groups, and (C 6 -C 12 )heteroarylene optionally substituted with 1-4 R 4 groups; and
R 4 is selected from the group consisting of halo, nitro, cyano, oxo, aminoacyl, aminoacyloxy, carboxyl, carboxyl ester, carbonate ester, aminosulfonyl, (C 1 -C 10 )alkyl, (C 1 -C 10 )haloalkyl, (C 1 -C 10 )alkoxy, (C 6 -C 12 )aryl, (C 5 -C 12 )heteroaryl, (C 6 -C 12 )aryloxy, (C 3 -C 12 )cycloalkyl and (C 3 -C 12 )heterocycloalkyl; and
2) applying a photomask to a surface of the functionalized poly(dimethylsiloxane) (PDMS) substrate; and
3) irradiating at a wavelength of from about 150 nm to about 400 nm, to produce the microfluidic device.
It is contemplated that the surface functionalized poly(dimethylsiloxane) (PDMS) disclosed herein can be used in all of the applications where standard PDMS is used. For example, these include but are not limited to, the fabrication of microfluidic devices, bioMEMS, microelectronics, biotechnology, microreactors, microsensors, microanalyzers, microoptics, and in research.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of an illustrative embodiment of the formation of a pattern on the surface of the surface functionalized PDMS via photolithography.
FIG. 2 is a schematic of an illustrative embodiment of the formation of a functionalized polymer on the surface of the surface functionalized PDMS using a functionalized monomer.
FIG. 3 shows the shift in the nitrogen signal from before (the peak on the left) and after (the peak on the right) exposure to UV irradiation confirming the decomposition of compound II.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here.
ABBREVIATIONS AND DEFINITIONS
Unless otherwise stated all temperatures are in degrees Celsius (° C.). Also, in these examples and elsewhere, abbreviations have the following meanings:
TABLE 1
Abbreviations
Abbreviation
Term
MPa
megaPascal
PDMS
polydimethyl siloxane
M
molar
mg
milligram
mmol
millimole
mL
milliliter
ppm
parts per million
TMS
trimethylsilane
δ
chemical shift
NMR
nuclear magnetic resonance
v/v
volume/volume
N
normal
UV
Ultraviolet
HMPA
hexamethylphosphoramide
XPS
x-ray photoelectron spectroscopy
DMAP
4-dimethylaminopyridine
DCC
dicyclohexylcarbodiimide
eV
electron volts
nm
nanometer
bioMEMS
biomicroelectromechanical systems
As used herein, certain terms may have the following defined meanings.
As used herein, the term “comprising” means that the compositions and methods include the recited elements, but do not exclude others. “Consisting essentially of” when used to define compositions and methods, shall mean excluding other elements of any essential significance to the combination when used for the intended purpose. Thus, a composition consisting essentially of the elements as defined herein would not exclude trace contaminants or inert carriers. “Consisting of” shall mean excluding more than trace elements of other ingredients and substantial method steps for preparing the microfluidic device. Embodiments defined by each of these transition terms are within the scope of the present technology.
As used herein, the term “polydimethyl siloxane (PDMS) substrate” refers to a solid polydimethyl siloxane (PDMS) polymer composed of at least one dimethylsiloxane monomer. In some instances, at least two dimethylsiloxane monomers are used to make the polydimethyl siloxane (PDMS) substrate. In some cases, monomers comprise a poly(dimethylsiloxane) having a sufficient number of vinyl groups and a silicon hydride containing monomer having a sufficient number of Si—H groups, such that the silicon hydride containing monomer forms more than one covalent bond with at least one vinyl group on the poly(dimethylsiloxane) and the resulting polymer substrate has a density of about 1 g mL −1 . The monomer mixtures may comprise additional components, such as other monomers or a catalyst, such as platinum. Various monomer mixtures are commercially available and include, for example, Sylgard® 184 (Dow Corning Corporation, Midland, Mich., United States), RTV 615 (Sil-Mid limited, Coleshill, West Midlands, United Kingdom) and ELASTOSiL® RT 601 (Wacker Chemie AG, San Jose, Calif., United States). The size of the polymer substrate is easily determined by one of skill in the art. It is contemplated that the size of the polymer substrate is not limited by any of the physical characteristics of the polymer. In addition, the shape of the polymer substrate can be dictated by the use of a mold. Such molds are well known to those of skill in the art.
The term “prepolymer” refers to a reactive low-molecular-weight macromolecule or an oligomer, capable of further polymerization. Examples of prepolymers include, but are not limited to, e.g., poly(dimethyl-methylvinylsiloxane) prepolymer and poly(dimethyl-methylhydrogensiloxane) precursors. The term “poly(dimethyl-methylhydrogensiloxane) precursors” refers to a reactive low-molecular-weight macromolecule or an oligomer of dimethylmethylhydrogensiloxane, capable of further polymerization. Polymerization of these prepolymers or monomers can be accomplished by, as an example, free radical polymerization, metal catalyzed polymerization, heat, or combination thereof. In some embodiments, polymerization is accomplished using both metal catalyzed polymerization and heat.
The term “monomer” has the meaning understood by those skilled in the chemical art. That is, a monomer is a chemical compound that is capable of forming a macromolecule of repeating units of itself, i.e., a polymer. The term “monomer” is also intended to include “oligomers” which consists of more than one monomer unit, capable of further polymerization. A “monomer mixture” refers to a mixture of two or more different monomers capable of being polymerized under polymerization conditions. In some embodiments, the monomer mixture comprises poly(dimethyl-methylvinylsiloxane) prepolymer and poly(dimethyl-methylhydrogensiloxane) precursors.
As used herein, the term “contact angle” refers to the angle at which a liquid interface meets a solid surface. On many hydrophilic surfaces, water droplets will exhibit contact angles of 0 degrees to 30 degrees. If the solid surface is hydrophobic, the contact angle will be larger than 90 degrees. In some embodiments, the contact angle of the surface functionalized poly(dimethylsiloxane) (PDMS) is from about 0 to about 155 degrees. In one embodiment the contact angle is from about 10 to about 145 degrees, or alternatively, from about 20 to about 135 degrees, or alternatively, from about 30 to about 135 degrees, or alternatively, from about 50 to about 135 degrees, or alternatively, from about 60 to about 135 degrees, or alternatively, from about 70 to about 135 degrees, or alternatively, from about 80 to about 135 degrees, or alternatively, from about 90 to about 120 degrees, or alternatively, from about 100 to about 120 degrees. In one embodiment, the contact angle is about 114 degrees.
The term “bonded” refers to a chemical bond. Various types of chemical bonds can be employed in the methods disclosed herein, either alone or in combination. Examples of bonds include a covalent bond, a polar covalent bond, an ionic bond and a hydrogen bond.
The term “reaction conditions” refers to conditions which comprise solvent (if required), time, temperature, pressure, concentration, and the like. It is well known to those skilled in the art that the reaction conditions may vary depending on the components which are being reacted.
The term “indentation” refers to a concave depression or cut on a surface. The indentations as disclosed herein can be of any possible shape, size or design. In some embodiments, the indentation is a microfluidic channel. In one embodiment, the indentation is a well. The indentations can be provided using a number of known methods, such as photolithography, soft lithography, isotropic or anisotropic etching, or with the use of a mold. Such technologies are well known in the art (Xia, et al., Angew. Chem. Int. Ed, 1998, 37, 550-575).
As used herein, the term “alkyl” refers to saturated monovalent hydrocarbyl groups having from 1 to 10 carbon atoms. This term is exemplified by groups such as methyl, ethyl, n-propyl, iso-propyl, n-butyl, t-butyl, n-pentyl, and the like.
As used herein, the term “alkenyl” refers to an hydrocarbyl group preferably having from 2 to 8 carbon atoms and having from 1 to 2 sites of alkenyl unsaturation. The term “terminal alkenyl” refers to an alkenyl group wherein a site of alkenyl unsaturation is at the end of the carbon chain.
As used herein, the term “haloalkyl” refers to an alkyl group as defined herein above, wherein one or more hydrogen has been replaced with a halo group. This term is exemplified by groups such as bromomethyl, trifluoromethyl, and the like.
As used herein, the term “cycloalkyl” refers to a saturated or an unsaturated but nonaromatic cyclic alkyl groups of from 3 to 10 carbon atoms having single or multiple cyclic rings including, by way of example, adamantyl, cyclopropyl, cyclobutyl, cyclopentyl, cyclooctyl, cyclohexenyl, and the like.
As used herein, the term “aryl” refers to a monovalent aromatic carbocyclic group of from 6 to 14 carbon atoms having a single ring (e.g., phenyl) or multiple condensed rings (e.g., naphthyl or anthryl) which condensed rings may or may not be aromatic (e.g., 2 benzoxazolinone, 2H-1,4-benzoxazin-3(4H)-one-7-yl, and the like) provided that the point of attachment is the aryl group.
As used herein, the term “heterocycloalkyl” and “heterocyclic” refers to a saturated or unsaturated (but not aromatic) group having a single ring or multiple condensed rings, from 1 to 10 carbon atoms, and from 1 to 4 hetero atoms selected from the group consisting of nitrogen, sulfur or oxygen within the ring wherein, in fused ring systems, one or more of the rings can be aryl or heteroaryl provided that the point of attachment is at the heterocycle.
As used herein, the term “heteroaryl” refers to an aromatic ring of from 1 to 15 carbon atoms, preferably from 1 to 10 carbon atoms, and 1 to 4 heteroatoms within the ring selected from the group consisting of oxygen, nitrogen, and sulfur. Such heteroaryl groups can have a single ring (e.g., pyridinyl, furyl, triazole or thienyl) or multiple condensed rings (e.g., indolizinyl or benzothienyl) provided the point of attachment is through a ring containing the heteroatom and that ring is aromatic. The nitrogen and/or sulfur ring atoms can optionally be oxidized to provide for the N-oxide or the sulfoxide, and sulfone derivatives. Examples of heteroaryls include but are not limited to, pyridinyl, pyrrolyl, indolyl, thiophenyl, thienyl, triazole, tetrazole, and furyl.
Examples of heterocycles and heteroaryls include, but are not limited to, azetidine, pyrrole, imidazole, pyrazole, pyridine, pyrazine, pyrimidine, pyridazine, indolizine, isoindole, indole, dihydroindole, indazole, purine, quinolizine, isoquinoline, quinoline, phthalazine, naphthylpyridine, quinoxaline, quinazoline, cinnoline, pteridine, carbazole, carboline, phenanthridine, acridine, phenanthroline, isothiazole, phenazine, isoxazole, phenoxazine, phenothiazine, imidazolidine, imidazoline, piperidine, piperazine, indoline, phthalimide, 1,2,3,4-tetrahydroisoquinoline, 4,5,6,7-tetrahydrobenzo[b]thiophene, thiazole, thiazolidine, thiophene, benzo[b]thiophene, morpholinyl, thiomorpholinyl (also referred to as thiamorpholinyl), triazole, tetrazole, piperidinyl, pyrrolidine, tetrahydrofuranyl, and the like.
As used herein, the term “alkylene” refers to divalent saturated aliphatic hydrocarbyl groups preferably having from 1 to 5 and more preferably 1 to 3 carbon atoms which are either straight-chained or branched. This term is exemplified by groups such as methylene (—CH 2 —), ethylene (—CH 2 CH 2 —), n-propylene (—CH 2 CH 2 CH 2 —), iso-propylene (—CH 2 CH(CH 3 )—) and the like. “(C u-v )alkylene” refers to alkylene groups having from u to v carbon atoms. The alkylidene or alkylene groups include branched and straight chain hydrocarbyl groups. For example “(C 1-6 )alkylene” is meant to include methylene, ethylene, propylene, 2-methylpropylene, pentylene, and the like.
As used herein, the term “arylene” refers to divalent aryl groups as defined above.
As used herein, the term “cycloalkylene” refers to divalent cycloalkyl groups as defined above.
As used herein, the term “heterocycloalkylene” refers to divalent heterocycloalkyl groups as defined above.
As used herein, the term “heteroarylene” refers to divalent heteroaryl groups as defined above.
As used herein, the term “halo” or “halogen” refers to fluoro, chloro, bromo, and iodo.
As used herein, the term “nitro” refers to the group —NO 2 .
As used herein, the term “cyano” refers to the group —CN.
As used herein, the term “hydroxyl” refers to the group —OH.
As used herein, the term “amino” refers to the group —NH 2 .
As used herein, the term “thio” refers to the group —SH.
As used herein, the term “oxo” refers to the atom (═O) or (—O − ).
As used herein, the term “aminoacyl” refers to the group —C(═O)NRR where each R is independently selected from the group consisting of hydrogen, alkyl, aryl, cycloalkyl, heteroaryl, and heterocycloalkyl, and where R 23 and R 24 are optionally joined together with the nitrogen bound thereto to form a heterocyclic group, and wherein alkyl, cycloalkyl, aryl, heteroaryl, and heterocycloalkyl, are as defined herein.
As used herein, the term “aminoacyloxy” refers to the group —O—C(═O)NRR where each R is independently selected from the group consisting of hydrogen, alkyl, aryl, cycloalkyl, heteroaryl, and heterocycloalkyl, and where R 23 and R 24 are optionally joined together with the nitrogen bound thereto to form a heterocyclic group, and wherein alkyl, cycloalkyl, aryl, heteroaryl, and heterocycloalkyl, are as defined herein.
The term “amido” refers to the groups —C(═O)—NR-alkyl, —C(═O)—NR-cycloalkyl, —C(═O)—NR-aryl, —C(═O)—NR-heteroaryl, —C(═O)—NR-heterocyclic, wherein R is hydrogen or alkyl.
The term “alpha-haloester” refers to the group —O—C(═O)-haloalkyl, wherein at least one halogen is at the alpha-position.
As used herein, the term “carboxyl” refers to —COOH or salts thereof.
As used herein, the term “carboxyl ester” refers to the groups —C(═O)—O-alkyl, —C(═O)—O-cycloalkyl, —C(═O)—O-aryl, —C(═O)—O-heteroaryl, —C(═O)—O-heterocyclic.
As used herein, the term “carbonate ester” refers to the groups —O—C(═O)—O-alkyl, —O—C(═O)—O-cycloalkyl, —O—C(═O)—O-aryl, —O—C(═O)—O-heteroaryl, —O—C(═O)—O-heterocyclic.
As used herein, the term “aminosulfonyl” refers to the group SO 2 NRR wherein each R is independently selected from the group consisting of hydrogen, alkyl, aryl, cycloalkyl, heteroaryl, and heterocycloalkyl, and where R 23 and R 24 are optionally joined together with the nitrogen bound thereto to form a heterocyclic group, and wherein alkyl, cycloalkyl, aryl, heteroaryl, and heterocycloalkyl, are as defined herein.
As used herein, the term “alkoxy” refers to the group “alkyl-O—” which includes, by way of example, methoxy, ethoxy, n-propoxy, iso-propoxy, n-butoxy, t-butoxy, sec-butoxy, n-pentoxy, and the like.
As used herein, the term “aryloxy” refers to the group aryl-O— that includes, by way of example, phenoxy, naphthoxy, and the like.
Compounds
Disclosed herein is a compound of Formula I:
wherein:
R 1 is hydrogen or methyl;
R 2 is selected from the group consisting of alkyl optionally substituted with 1-3 R 4 groups, haloalkyl optionally substituted with 1-3 R 4 groups, aryl optionally substituted with 1-4 R 4 groups, cycloalkyl optionally substituted with 1-4 R 4 groups, heterocycloalkyl optionally substituted with 1-4 R 4 groups, and heteroaryl optionally substituted with 1-4 R 4 groups;
X is selected from the group consisting of nitro, —N(R 3 ) 3 + , trifluoromethyl, cyano, —C(O)OR 3 , —C(O)R 3 , where R 3 is hydrogen or alkyl; and
L 1 and L 2 are independently selected from the group consisting of a direct bond, methylene optionally substituted with 1-2 R 4 groups, (C 2 -C 12 )alkylene optionally substituted with 1-4 R 4 groups, (C 6 -C 12 )arylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )cycloalkylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )heterocycloalkylene optionally substituted with 1-4 R 4 groups, and (C 6 -C 12 )heteroarylene optionally substituted with 1-4 R 4 groups; and
R 4 is selected from the group consisting of halo, nitro, cyano, oxo, aminoacyl, aminoacyloxy, carboxyl, carboxyl ester, carbonate ester, aminosulfonyl, (C 1 -C 10 )alkyl, (C 1 -C 10 )haloalkyl, (C 1 -C 10 )alkoxy, (C 6 -C 12 )aryl, (C 5 -C 12 )heteroaryl, (C 6 -C 12 )aryloxy, (C 3 -C 12 )cycloalkyl and (C 3 -C 12 )heterocycloalkyl.
In one embodiment, R 1 is hydrogen.
In one embodiment, R 2 is alkyl substituted with an oxo and halo group.
In one embodiment, X is nitro.
In one embodiment, L 1 and L 2 are (C 1 -C 12 )alkylene.
In one embodiment, R 1 is hydrogen; R 2 is alkyl substituted with an oxo and halo group; X is nitro; and L 1 and L 2 are (C 1 -C 12 )alkylene.
Also disclosed herein is a compound of Formula II.
Synthesis of the Compounds
The compounds described herein can be prepared from readily available starting materials using, for example, the following general methods, and procedures. It will be appreciated that where reaction conditions (i.e., reaction temperatures, times, mole ratios of reactants, solvents, pressures, etc.) are given, other process conditions can also be used unless otherwise stated. Optimum reaction conditions may vary with the particular reactants or solvent used, but such conditions can be determined by one skilled in the art by routine optimization procedures.
Additionally, as will be apparent to those skilled in the art, conventional protecting groups may be necessary to prevent certain functional groups from undergoing undesired reactions. Suitable protecting groups for various functional groups as well as suitable conditions for protecting and deprotecting particular functional groups are well known in the art. For example, numerous protecting groups are described in T. W. Greene and G. M. Wuts (1999) Protecting Groups in Organic Synthesis, 3rd Edition, Wiley, New York, and references cited therein.
The starting materials for the following reactions are generally known compounds or can be prepared by known procedures or obvious modifications thereof. For example, many of the starting materials are available from commercial suppliers such as Aldrich Chemical Co. (Milwaukee, Wis., USA), Bachem (Torrance, Calif., USA), Emka-Chemce or Sigma (St. Louis, Mo., USA). Others may be prepared by procedures, or obvious modifications thereof, described in standard reference texts such as Fieser and Fieser's Reagents for Organic Synthesis, Volumes 1-15 (John Wiley, and Sons, 1991), Rodd's Chemistry of Carbon Compounds, Volumes 1-5, and Supplementals (Elsevier Science Publishers, 1989), Organic Reactions, Volumes 1-40 (John Wiley, and Sons, 1991), March's Advanced Organic Chemistry, (John Wiley, and Sons, 5th Edition, 2001), and Larock's Comprehensive Organic Transformations (VCH Publishers Inc., 1989).
The compounds disclosed herein can be prepared by, but are not limited to, the synthetic protocols illustrated in Scheme 1. In Scheme 1, the substituents X, R 1 , R 2 , R 10 , L 1 and L 2 are as defined herein.
Compounds of Formula I can be prepared from compounds Ic and Id, wherein R 10 is a leaving group such as a mesylate or halogen. Compounds Ic and Id are reacted under standard substitution reaction conditions to provide Formula I. In some embodiments, additional reagents may be required to enhance the reactivity of certain starting materials, such as coupling agents like dicyclohexylcarbodiimide (DCC), and the like. Such reagents are commonly known to those of skill in the art and are generally acids, bases, oxidizing agents, reducing agents, or a solvent such as a polar solvent.
Compound Ic can be prepared from reacting compounds Ia and Ib under standard coupling conditions. Compound Ia is first activated with at least a stoichiometric amount and preferably a slight excess thereof of a coupling agent, such as a carbodiimide, in the presence of a base, such as dimethylaminopyridine.
Compounds Ib and Id can either be purchased from commercial sources or synthesized using methods known to those skilled in the art.
Surface Functionalized Poly(dimethylsiloxane) (PDMS)
Disclosed herein is a surface functionalized poly(dimethylsiloxane) (PDMS), comprising a polydimethyl siloxane (PDMS) substrate having a compound of Formula III incorporated therein:
wherein:
R 1 is hydrogen or methyl;
R 2 is selected from the group consisting of alkyl optionally substituted with 1-3 R 4 groups, haloalkyl optionally substituted with 1-3 R 4 groups, aryl optionally substituted with 1-4 R 4 groups, cycloalkyl optionally substituted with 1-4 R 4 groups, heterocycloalkyl optionally substituted with 1-4 R 4 groups, and heteroaryl optionally substituted with 1-4 R 4 groups;
X is selected from the group consisting of nitro, —N(R 3 ) 3 + , trifluoromethyl, cyano, —C(O)OR 3 , —C(O)R 3 , where R 3 is hydrogen or alkyl; and
L 1 and L 2 are independently selected from the group consisting of a direct bond, methylene optionally substituted with 1-2 R 4 groups, (C 2 -C 12 )alkylene optionally substituted with 1-4 R 4 groups, (C 6 -C 12 )arylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )cycloalkylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )heterocycloalkylene optionally substituted with 1-4 R 4 groups, and (C 6 -C 12 )heteroarylene optionally substituted with 1-4 R 4 groups; and
R 4 is selected from the group consisting of halo, nitro, cyano, oxo, aminoacyl, aminoacyloxy, carboxyl, carboxyl ester, carbonate ester, aminosulfonyl, (C 1 -C 10 )alkyl, (C 1 -C 10 )haloalkyl, (C 1 -C 10 )alkoxy, (C 6 -C 12 )aryl, (C 5 -C 12 )heteroaryl, (C 6 -C 12 )aryloxy, (C 3 -C 12 )cycloalkyl and (C 3 -C 12 )heterocycloalkyl.
In one embodiment, R 1 is hydrogen.
In one embodiment, R 2 is alkyl substituted with an oxo and halo group.
In one embodiment, X is nitro.
In one embodiment, L 1 and L 2 are (C 1 -C 12 )alkylene.
In one embodiment, R 1 is hydrogen; R 2 is alkyl substituted with an oxo and halo group; X is nitro; and L 1 and L 2 are (C 1 -C 12 )alkylene.
Also disclosed herein is a surface functionalized poly(dimethylsiloxane) (PDMS), comprising a polydimethyl siloxane (PDMS) substrate having a compound of Formula IV incorporated therein:
In one embodiment, the surface functionalized poly(dimethylsiloxane) (PDMS) has the compound incorporated therein at a ratio of from about 11:0.5 to about 11:10 −3 . The concentration of initiator can be varied depending on the application, provided that the surface functionalized poly(dimethylsiloxane) (PDMS) possesses similar physical properties to that of unfunctionalized poly(dimethylsiloxane) (PDMS). In one embodiment, the contact angle of unfunctionalized poly(dimethylsiloxane) (PDMS) is from about 0 to about 155 degrees. In one embodiment the contact angle is from about 0 to about 149 degrees, or alternatively, from about 10 to about 145 degrees, or alternatively, from about 20 to about 135 degrees, or alternatively, from about 30 to about 135 degrees, or alternatively, from about 50 to about 135 degrees, or alternatively, from about 60 to about 135 degrees, or alternatively, from about 70 to about 135 degrees, or alternatively, from about 80 to about 135 degrees, or alternatively, from about 90 to about 120 degrees, or alternatively, from about 100 to about 120 degrees. In one embodiment, the contact angle is about 114 degrees.
The surface functionalized poly(dimethylsiloxane) (PDMS) can be patterned using irradiation with UV light with a photomask, as is depicted in FIG. 1 .
Methods of Preparing a Surface Functionalized Poly(dimethylsiloxane) (PDMS)
Disclosed herein is a method of preparing a surface functionalized poly(dimethylsiloxane) (PDMS) substrate, comprising contacting a monomer mixture with a compound of Formula I under polymerization conditions:
wherein:
R 1 is hydrogen or methyl;
R 2 is selected from the group consisting of alkyl optionally substituted with 1-3 R 4 groups, haloalkyl optionally substituted with 1-3 R 4 groups, aryl optionally substituted with 1-4 R 4 groups, cycloalkyl optionally substituted with 1-4 R 4 groups, heterocycloalkyl optionally substituted with 1-4 R 4 groups, and heteroaryl optionally substituted with 1-4 R 4 groups;
X is selected from the group consisting of nitro, —N(R 3 ) 3 + , trifluoromethyl, cyano, —C(O)OR 3 , —C(O)R 3 , where R 3 is hydrogen or alkyl; and
L 1 and L 2 are independently selected from the group consisting of a direct bond, methylene optionally substituted with 1-2 R 4 groups, (C 2 -C 12 )alkylene optionally substituted with 1-4 R 4 groups, (C 6 -C 12 )arylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )cycloalkylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )heterocycloalkylene optionally substituted with 1-4 R 4 groups, and (C 6 -C 12 )heteroarylene optionally substituted with 1-4 R 4 groups; and
R 4 is selected from the group consisting of halo, nitro, cyano, oxo, aminoacyl, aminoacyloxy, carboxyl, carboxyl ester, carbonate ester, aminosulfonyl, (C 1 -C 10 )alkyl, (C 1 -C 10 )haloalkyl, (C 1 -C 10 )alkoxy, (C 6 -C 12 )aryl, (C 5 -C 12 )heteroaryl, (C 6 -C 12 )aryloxy, (C 3 -C 12 )cycloalkyl and (C 3 -C 12 )heterocycloalkyl
In one embodiment, the polymerization conditions comprise heat. In some cases the polymer substrate is cured at about 80° C. for about 2 hours. Higher temperatures such as this can be used to decrease the polymerization or curing time although the monomer mixture can be polymerized at room temperature (about 25° C.) for about one day. As would be obvious to one of skill in the art, the exact polymerization conditions used can vary greatly based on the requirements for a given monomer mixture. Determination of the polymerization conditions is within the skill of one in the art.
In one embodiment, R 1 is hydrogen.
In one embodiment, R 2 is alkyl substituted with an oxo and halo group.
In one embodiment, X is nitro.
In one embodiment, L 1 and L 2 are (C 1 -C 12 )alkylene.
In one embodiment, R 1 is hydrogen; R 2 is alkyl substituted with an oxo and halo group; X is nitro; and L 1 and L 2 are (C 1 -C 12 )alkylene.
Also disclosed herein is a method of preparing a surface functionalized poly(dimethylsiloxane) (PDMS) substrate, comprising contacting a monomer mixture with a compound of Formula II under polymerization conditions.
In one embodiment, the monomer mixture comprises a poly(dimethylmethylvinylsiloxane) prepolymer. In another embodiment, the monomer mixture further comprises a poly(dimethylmethylhydrogensiloxane) precursor. In the case where the monomer mixture comprises a poly(dimethyl-methylvinylsiloxane) prepolymer and a poly(dimethylmethylhydrogensiloxane) precursor, the compound is incorporated therein at a ratio of from about 10:1:0.5 to about 10:1:10 −3 . In one embodiment, the ration of poly(dimethylmethylvinylsiloxane) prepolymer and poly(dimethylmethylhydrogensiloxane) precursor to the compound is about 10:1:0.5, or alternatively, about 10:1:0.1, or alternatively, about 10:1:0.05, or alternatively, about 10:1:10 −2 , or alternatively, or alternatively, about 10:1:10 −3 .
Surface Initiated Atom Transfer Radical Polymerization (SI-ATRP) to Add a Functionalized Polymer Layer
Once the surface functionalized poly(dimethylsiloxane) (PDMS) is provided as disclosed herein, a functionalized polymer layer can be deposited on the surface thereof. In one embodiment, the surface functionalized poly(dimethylsiloxane) (PDMS) disclosed herein further comprises a functionalized polymer layer bonded to the compound of Formula III. This can be accomplished by contacting a functionalized monomer with the surface functionalized poly(dimethylsiloxane) (PDMS) under polymerizing conditions thus providing the functionalized polymer layer. In some embodiments, the functionalized polymer layer is the outermost layer. Various functionalized monomers can be used in the methods disclosed herein and are known to those of skill in the art. In some embodiments, the functionalized polymer layer comprises oligo(ethylene glycol).
In some embodiments, the polymerizing conditions comprise heating the monomers to about 80° C. In some embodiments, the reaction conditions comprise first forming a monomer mixture comprising a catalyst prior to contacting the surface functionalized poly(dimethylsiloxane) (PDMS). In some embodiments, the second polymerizing conditions comprise heating the monomer and linker to a temperature of from about 25° C. to about 90° C. Alternatively, in some embodiments, the second polymerizing conditions comprise allowing the monomer to react with the polymer substrate for about two days at room temperature (about 25° C.). The height of the functionalized polymer layer is largely dependent on the polymerization reaction time. In some embodiments, the polymerizing conditions comprise a deoxygenating step.
Also disclosed herein is a method for making a surface functionalized poly(dimethylsiloxane) (PDMS) having a functionalized polymer layer, said method comprising:
1) polymerizing a mixture comprising a poly(dimethyl-methylvinylsiloxane) prepolymer, poly(dimethyl-methylhydrogensiloxane) precursors and a compound of Formula Ito provide a surface functionalized poly(dimethylsiloxane) (PDMS):
wherein:
R 1 is hydrogen or methyl;
R 2 is selected from the group consisting of alkyl optionally substituted with 1-3 R 4 groups, haloalkyl optionally substituted with 1-3 R 4 groups, aryl optionally substituted with 1-4 R 4 groups, cycloalkyl optionally substituted with 1-4 R 4 groups, heterocycloalkyl optionally substituted with 1-4 R 4 groups, and heteroaryl optionally substituted with 1-4 R 4 groups;
X is selected from the group consisting of nitro, —N(R 3 ) 3 + , trifluoromethyl, cyano, —C(O)OR 3 , —C(O)R 3 , where R 3 is hydrogen or alkyl; and
L 1 and L 2 are independently selected from the group consisting of a direct bond, methylene optionally substituted with 1-2 R 4 groups, (C 2 -C 12 )alkylene optionally substituted with 1-4 R 4 groups, (C 6 -C 12 )arylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )cycloalkylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )heterocycloalkylene optionally substituted with 1-4 R 4 groups, and (C 6 -C 12 )heteroarylene optionally substituted with 1-4 R 4 groups; and
R 4 is selected from the group consisting of halo, nitro, cyano, oxo, aminoacyl, aminoacyloxy, carboxyl, carboxyl ester, carbonate ester, aminosulfonyl, (C 1 -C 10 )alkyl, (C 1 -C 10 )haloalkyl, (C 1 -C 10 )alkoxy, (C 6 -C 12 )aryl, (C 5 -C 12 )heteroaryl, (C 6 -C 12 )aryloxy, (C 3 -C 12 )cycloalkyl and (C 3 -C 12 )heterocycloalkyl; and
2) contacting a functionalized monomer with the surface functionalized poly(dimethylsiloxane) (PDMS) under polymerization conditions to provide the surface functionalized poly(dimethylsiloxane) (PDMS) having a functionalized polymer layer.
In some embodiments, the functionalized monomer comprises a terminal alkenyl group and a functional group. This embodiment in depicted in FIG. 2 . In principal, the terminal functional group can be any functional group provided that it does not react with the compound of Formula I. In some embodiments, the terminal functional group is selected from the group consisting of a hydroxyl, amino, thio, carboxyl, carboxyl ester, amino, alpha-haloester and haloalkyl. In one embodiment, the terminal functional group is a hydroxyl. In one embodiment, the functionalized monomer is oligo(ethylene glycol) methacrylate.
In some embodiments, the polymerization conditions can result in various polymerization mechanisms. Various types of polymerizations can be used such as, for example, cationic, anionic, free radical and living polymerizations. Such polymerizations can be metal catalyzed polymerization reactions. In some embodiments, the polymerization conditions comprise a metal catalyst. Various metals can be used as a catalyst herein, such as, platinum, copper, iron, manganese, cobalt, molybdenum, tin, zinc, ruthenium, rhodium, and the like. In some embodiments, the metal comprises copper.
Further embodiments of the present disclosure can be found in PCT application No. PCT/CN2008/071944, filed Aug. 11, 2008 and entitled “Superhydrophobic Poly(dimethylsiloxane) and Methods for Making the Same”, which is herein incorporated by reference in its entirety.
Methods for Using the Surface Functionalized Poly(dimethylsiloxane) (PDMS)
In some embodiments, the surface functionalized poly(dimethylsiloxane) (PDMS) further comprises at least one indentation on the surface. This can be accomplished using a number of known methods, such as photolithography, soft lithography, isotropic or anisotropic etching, or with the use of a mold. Such technologies are well known in the art (Xia, et al., Angew Chem. Int. Ed, 1998, 37, 550-575). For example, the formation of channels on the surface of the functionalized via photolithography is depicted in FIG. 1 .
It is contemplated that the surface functionalized poly(dimethylsiloxane) (PDMS) can be produced in any theoretical size or shape so long as the bulk properties of the poly(dimethylsiloxane) (PDMS) are not effected. In some embodiments, the surface functionalized poly(dimethylsiloxane) (PDMS) is a microfluidic device.
Also disclosed herein is a method for producing a microfluidic device, comprising:
1) providing a poly(dimethylsiloxane) (PDMS) polymer substrate having a compound of Formula III incorporated therein:
wherein:
R 1 is hydrogen or methyl;
R 2 is selected from the group consisting of alkyl optionally substituted with 1-3 R 4 groups, haloalkyl optionally substituted with 1-3 R 4 groups, aryl optionally substituted with 1-4 R 4 groups, cycloalkyl optionally substituted with 1-4 R 4 groups, heterocycloalkyl optionally substituted with 1-4 R 4 groups, and heteroaryl optionally substituted with 1-4 R 4 groups;
X is selected from the group consisting of nitro, —N(R 3 ) 3 + , trifluoromethyl, cyano, —C(O)OR 3 , —C(O)R 3 , where R 3 is hydrogen or alkyl; and
L 1 and L 2 are independently selected from the group consisting of a direct bond, methylene optionally substituted with 1-2 R 4 groups, (C 2 -C 12 )alkylene optionally substituted with 1-4 R 4 groups, (C 6 -C 12 )arylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )cycloalkylene optionally substituted with 1-4 R 4 groups, (C 3 -C 12 )heterocycloalkylene optionally substituted with 1-4 R 4 groups, and (C 6 -C 12 )heteroarylene optionally substituted with 1-4 R 4 groups; and
R 4 is selected from the group consisting of halo, nitro, cyano, oxo, aminoacyl, aminoacyloxy, carboxyl, carboxyl ester, carbonate ester, aminosulfonyl, (C 1 -C 10 )haloalkyl, (C 1 -C 10 )alkoxy, (C 6 -C 12 )aryl, (C 5 -C 12 )heteroaryl, (C 6 -C 12 )aryloxy, (C 3 -C 12 )cycloalkyl and (C 3 -C 12 )heterocycloalkyl; and
2) applying a photomask to a surface of the functionalized poly(dimethylsiloxane) (PDMS) substrate; and
3) irradiating at a wavelength of from about 150 nm to about 400 nm,
to produce the microfluidic device.
In some embodiments, R 1 is hydrogen.
In some embodiments, wherein R 2 is alkyl substituted with an oxo and halo group.
In some embodiments, X is nitro.
In some embodiments, L 1 and L 2 are (C 1 -C 12 )alkylene.
In some embodiments, R 1 is hydrogen; R 2 is alkyl substituted with an oxo and halo group; X is nitro; and L 1 and L 2 are (C 1 -C 12 )alkylene.
Also disclosed herein is a method for producing a microfluidic device, comprising:
1) providing a poly(dimethylsiloxane) (PDMS) polymer substrate having a compound of Formula II incorporated therein:
2) applying a photomask to a surface of the functionalized poly(dimethylsiloxane) (PDMS) substrate; and
3) irradiating at a wavelength of from about 150 nm to about 400 nm,
to provide the microfluidic device.
In some embodiments, the method further comprises the addition of a functionalized polymer layer bonded to the compound of Formula III. In one embodiment, the functionalized polymer layer comprises oligo(ethylene glycol).
It is contemplated that the surface functionalized poly(dimethylsiloxane) (PDMS) disclosed herein can be used in all of the applications where standard PDMS is used. For example, for the fabrication of microfluidic devices, bioMEMS, microelectronics, biotechnology, microreactors, microsensors, microanalyzers, microoptics, and in research.
All publications, patent applications, issued patents, and other documents referred to in this specification are herein incorporated by reference as if each individual publication, patent application, issued patent, or other document was specifically and individually indicated to be incorporated by reference in its entirety. Definitions that are contained in text incorporated by reference are excluded to the extent that they contradict definitions in this disclosure.
EXAMPLES
The present technology is further illustrated by the following examples, which should not be construed as limiting in any way. All numerical designations, e.g., pH, temperature, time, concentration, and molecular weight, including ranges, are approximations which are varied (+) or (−) by increments of 10%. It is to be understood, although not always explicitly stated that all numerical designations are preceded by the term “about”. It also is to be understood, although not always explicitly stated, that the reagents described herein are merely exemplary and that equivalents of such are known in the art.
These and other embodiments of the present technology will readily occur to those of ordinary skill in the art in view of the disclosure herein and are specifically contemplated.
The present technology is further understood by reference to the following examples, which are intended to be purely exemplary of the present technology. The present technology is not limited in scope by the exemplified embodiments, which are intended as illustrations of single aspects of the present technology only. Any methods that are functionally equivalent are within the scope of the present technology. Various modifications of the present technology in addition to those described herein will become apparent to those skilled in the art from the foregoing description and accompanying figures. Such modifications fall within the scope of the appended claims.
Example 1
Synthesis of Compound II
Compound 2 (38.8 mmol) was added into a flask containing compound 1 (40.0 mmol), dry tetrahydrofuran (40 mL), and 4-dimethylaminopyridine (DMAP, 47.7 mmol) in a dropwise fashion. The mixture was stirred at room temperature for 5 h, diluted with tetrahydrofuran, and filtered. A 2N HCl aqueous solution was used to neutralize the filtrate and ethyl ether was used to extract the organic phase four times. The organic extracts were combined and dried over anhydrous sodium sulfate. After the removal of solvents by a rotavapor, the crude product was purified by column chromatography (CH 2 Cl 2 /hexanes, 1:1, v/v) to give compound 3 (84.0%).
To a flask with dry tetrahydrofuran (40 mL) under N 2 atmosphere, compound 3 (1.9 mmol) and compound 4 (1.9 mmol) were mixed along with NaOH and hexamethylphosphoramide (HMPA). The mixture was stirred at room temperature overnight, diluted with tetrahydrofuran, and filtered. A 2N HCl aqueous solution was used to neutralize the filtrate and ethyl ether was used to extract the organic phase four times. The organic extracts were combined and dried over anhydrous sodium sulfate. After the removal of solvents by a rotavapor, the crude product was purified by column chromatography (CH 2 Cl 2 /hexanes, 10:1, v/v) to give compound II (54.0%). Putative 13 C-NMR calculated using ChemDraw Ultra® version 10.0, in ppm relative to TMS: δ 211.3, 173.1, 165.9, 147.3, 139.1, 138.5, 136.2, 128.4, 127.9, 123.7, 115.7, 64.8, 63.6, 58.9, 36.0, 33.9, 33.9, 32.1, 32.1, 31.7, 29.7, 29.7, 29.6, 29.3, 29.3, 29.3, 29.1, 29.0, 25.8, 25.0, 23.1.
Example 2
Preparation of a Surface Functionalized Poly(dimethylsiloxane) (PDMS)
According to the method shown in FIG. 1 , prepolymer A (polydimethyl-methylvinylsiloxane), cross-linker B (vinyl-endcapped polydimethyl-methylvinylsiloxane) and compound II (from example 1) were mixed at a ratio of 10:1:0.2 and cured at 80° C. to form the surface functionalized poly(dimethylsiloxane) (PDMS). X-ray photoelectron spectroscopy (XPS) was applied to characterize the surface composition of the PDMS. FIG. 3 shows the shift in the nitrogen signal from before (the peak on the left) and after (the peak on the right) exposure to UV irradiation confirming the decomposition of compound II. Compared with regular PDMS, compound II referred (a unique Br 3d peak at 71 eV) were presented at the surface of the PDMS and accomplished the surface modification of PDMS.
The surface functionalized poly(dimethylsiloxane) was then exposed to UV light (360-370 nm) through a photomask (see FIG. 1 ) to form surface patterns of compound II.
Example 3
1. Surface Initiated Atom Transfer Radical Polymerization (SI-ATRP) to Add a Functionalized Polymer Layer
Surface initiated atom transfer radical polymerization (SI-ATRP) of oligo(ethylene glycol) methacrylate was performed on the surface functionalized poly(dimethylsiloxane) for permanent and functional surface coating. The surface functionalized poly(dimethylsiloxane) was placed in a 100 ml bottle and processed anaerobic treatment. The functionalized polymer layer was obtained by mixing well with water (5 mL), methanol (10 mL), and the monomer oligo(ethylene glycol) methacrylate (8 mmol, 0.35 M), CuBr (36 mg, 0.25 mmol) and bipyridine (78 mg, 0.5 mmol) resulting in a dark-red solution. The solution was deoxygenated just before use. The mixture was transferred into the bottle with the surface functionalized poly(dimethylsiloxane) under inert gas protection. The reaction was continued for 24 hours at 20° C. The surface functionalized poly(dimethylsiloxane) was rinsed with methanol and Milli-Q® water, and dried under flowing nitrogen. XPS characterization confirmed the success of polymerization and film deposition on the surface of the surface functionalized poly(dimethylsiloxane).
2. Equivalents
The present disclosure is not to be limited in terms of the particular embodiments described in this application, which are intended as single illustrations of individual aspects of. Many modifications and variations can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and apparatuses within the scope of the disclosure, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. It is to be understood that this disclosure is not limited to particular methods, reagents, compounds compositions or biological systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.
As will be understood by one skilled in the art, for any and all purposes, such as in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art all language such as “up to,” “at least,” “greater than,” “less than,” and the like include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member. Thus, for example, a group having 1-3 cells refers to groups having 1, 2, or 3 cells. Similarly, a group having 1-5 cells refers to groups having 1, 2, 3, 4, or 5 cells, and so forth.
While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims. | Disclosed herein is a surface functionalized poly(dimethylsiloxane) (PDMS) and methods for making the same. The surface functionalized poly(dimethylsiloxane) (PDMS) disclosed herein is applicable in the general field of microfluidics, bioMEMS (bio-microelectromechanical systems), soft lithography and other related biotechnology fields. | 2 |
BOTANICAL CLASSIFICATION
[0001] Doritaenopsis sp.
VARIETY DENOMINATION
[0002] ‘Sunrise Beautiful Girl’.
[0003] The present invention relates to botanical classification/cultivar designation: Doritaenopsis Orchid cultivar Sunrise Beautiful Girl.
BACKGROUND OF THE INVENTION
[0004] The present invention comprises a new and distinct cultivar of Doritaenopsis Orchid, hereinafter referred to by the cultivar name, Sunrise Beautiful Girl.
[0005] The new cultivar is a product of a planned breeding program conducted by the inventor in Taiwan. The objective of the breeding program is to create new uniform pot-type Doritaenopsis Orchid cultivars having attractive flower coloration.
[0006] The new cultivar breeder was Hou-Chih Lin. The new cultivar was discovered by the inventor from within the progeny of a cross-pollination of two identified proprietary selections of Doritaenopsis Orchid, not patented, on Mar. 3, 1994, in a controlled environment in Taiwan. Later, it was verified and registered in Royal Horticulture Society (R.H.S.) and had its variety name “Dtps. Sunrise Beautiful Girl” on January, 2003.
[0007] Asexual propagation by tissue culture in a laboratory in Taiwan has been used to increase the number of plants for evaluation and has demonstrated that the unique combination of characteristics as herein disclosed for the new Doritaenopsis Orchid are firmly fixed and are retained through successive generations of asexual reproduction.
SUMMARY OF THE INVENTION
[0008] The following traits have been repeatedly observed and are determined to be basic characteristics of new cultivar which, in combination, distinguish this Doritaenopsis Orchid as a new and distinct cultivar:
[0009] 1. Petal main color: purple; Petal color pattern: white edge.
[0010] 2. Purple-colored flowers with a very clear white edge and greyed purple-colored labellum.
[0011] 3. Freely flowering habit.
[0012] 4. Upright, sturdy flowering stems.
[0013] 5. Excellent postproduction longevity.
[0014] Plants of the new cultivar differ primarily from plants of the parent cultivars in flower color.
[0015] Plants of the new Doritaenopsis Orchid can be compared to plants of the cultivar Dtps. Ruey Lih Beauty, differing from plants of the cultivar Dtps. Ruey Lih Beauty the following characteristics:
[0016] 1. Plants of the new Doritaenopsis Orchid are larger than plants of the cultivar Dtps. Ruey Lih Beauty.
[0017] 2. Plants of the new Doritaenopsis Orchid are more freely flowering than plants of the cultivar Dtps. Ruey Lih Beauty.
[0018] 3. Plants of the new Doritaenopsis Orchid have more flowers per inflorescence than plants of the cultivar Dtps. Ruey Lih Beauty.
[0019] 4. Plants of the new Doritaenopsis Orchid have larger flowers than plants of the cultivar Dtps. Ruey Lih Beauty.
[0020] 5. Plants of the new Doritaenopsis Orchid and the cultivar Dtps. Ruey Lih Beauty differ in flower color. The color of petal and sepal are purple and bright with a very clear white edge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Colors in the photographs may appear different from the color values that appear in the detailed botanical description which more accurately describe the new cultivar.
[0022] FIG. 1 is a side view of a plant of ‘Sunrise Beautiful Girl’ flowering in a 12 cm pot.
[0023] FIG. 2 is a close-up view showing the characteristics of the flower.
[0024] FIG. 3 is a close-up view showing the characteristics of the leaf.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Plants of the new cultivar have not been observed under all possible environmental conditions. The phenotype may vary significantly with variations in environment such as temperature and light intensity, without however, any change in genotype. In the following description, color references are made to The Royal Horticultural Society Colour Chart, 1995 Edition, except where general terms of ordinary dictionary significance are used.
[0026] Plants used for the aforementioned photographs and following detailed botanical description were 14 months old and grown in 12 cm containers in Taiwan, in a greenhouse with day temperatures about 25 to 28° C., night temperatures about 18 to 20° C., and light levels about 15,000 to 25,000 lux. The photographs and the detailed botanical description were taken during the winter.
Parentage:
Seed.— Dtps. Formosa Rose, not patented. Pollen.— P. Hsinton Rose, not patented. Propagation.— Asexual propagation by tissue culture. Root description.— Very thick, fleshy, and greenish white in color. Plant shape.— Two-ranked leaves affixed to a short central stem (monopodial growth). Single flowers arranged on upright and sturdy flowering compound racemes. Plant height, soil level to top of foliar plane.— About 14 to 17 cm. Plant height, soil level to top of inflorescences.— About 60 to 70 cm. Plant diameter.— About 35 to 45 cm. Flowers per stem.— Approximately 10 to 15.
Foliage description:
Leaves.— Simple, opposite, sessile. Quantity per plant.— About 5 to 6. Length.— About 20 to 25 cm. Width.— About 8 to 10 cm. Shape.— Oblong. Apex.— Obtuse. Base.— Cuneate. Margin.— Entire. Aspect.— Mostly flat and folded upward from the midrib. Texture, upper and lower surfaces.— Leathery, thick, glabrous. Venation.— Parallel. Color ( upper surface ).—RHS 146A. Color ( lower surface ).—RHS 146A.
Flower description:
Flower type.— Single zygomorphic flowers, orbicula in shape. Flower arrangement.— Compound racemes. Flowering stems.— Upright, freely branching and sturdy. Flowering habit.— Plants freely flowering; plants typically produce one to two branched flowering stems with at least 10 to 15 flowers each. Fragrance.— Flowers not fragrant. Self cleaning or persistent.— Flowers persistent. Flower aspect.— Flowers facing mostly outward. Natural flowering season.— From January to April in Taiwan. Plants begin flowering about 14 th months after planting. Post - production longevity.— Plants of the new Doritaenopsis Orchid maintain good leaf and flower substance for about three to six months on the plant under interior environmental conditions. Cut flowers of the new Doritaenopsis Orchid maintain good substance for about three to four weeks. Inflorescence length.— About 50 to 60 cm. Inflorescence diameter.— About 25 to 30 cm. Flower bud ( just before anthesis ).— Flower bud shape.— bullet-like. Flower bud length.— About 2.8 cm. Flower bud diameter.— About 2.5 cm. Flower bud color.— About RHS N77B. Flower diameter.— About 8 to 10 cm. Flower depth.— About 1.6 to 1.9 cm. Number of petals.— Two per flower. Petal size.— Lateral petals similar in size and shape; the lowermost petal, the labellum, is deeply three-lobed. Length.— About 4 cm. Diameter.— About 4 cm. Shape.— Semicircular. Apex.— Rounded. Base.— Attenuate; fused with the column. Margin.— Entire. Texture.— upper and lower surfaces: Velvety, silky; smooth. Color.— When blossoming, the main color of the adaxial surface of petal is purple (RHS 78A). The main color of the abaxial surface of petal is purple (RHS N74B).
Labellum:
Length, not flattened.— About 3.4 cm. Diameter, not flattened.— About 1.8 cm. Shape.— Deeply three-lobed with two prominent callosities on the upper surface at the central junction of the lateral lobes and base of the midlobe. The lateral lobes fold upward about the column, the extends extend forward and is are terminated by two twisted filiform appendages (about 14 mm in length) at the apex. Base color of the abaxial surface of the apical lobe.— Purple (RHS N79C). Tip color of the adaxial surface of the apical lobe.— Purple (RHS N79C).
Sepals:
Quantity.— Three per flower. Dorsal sepal length.— About 4.9 cm. Lateral sepal length.— About 3.6 cm. Dorsal sepal diameter.— About 3.6 cm. Lateral sepal diameter.— About 3.1 cm. Shape.— Elliptical. Apex.— Rounded acute to retuse. Base.— Attenuate; fused with the petals and column. Margin.— Entire. Texture, upper and lower surfaces.— Velvety; smooth. Dorsal sepal main color.— RHS78A. Dorsal sepal pattern color.— RHS 78A. Lateral sepal main color.— RHS78A to the base. Lateral sepal pattern color.— spotted RHS 78A and shaded RHS 155C.
Peduncles:
Length.— About 45 to 60 cm. Diameter.— About 7 mm. Aspect.— Upright. Strength.— Strong, sturdy. Texture.— Smooth, glabrous. Color.— RHS 147A.
Pedicels:
Length.— About 20 to 25 cm. Diameter.— About 4 to 5 mm. Aspect.— About 45° from vertical. Strength.— Strong. Texture.— Smooth, glabrous. Color.— RHS 147A. Color towards the base.— RHS 147A.
Reproductive organs: The stamens, style and stigmas are fused into a single, short structure called the column, possessing one terminal anther with pollen grains united into a pollinia, which are covered by an anther cap. The stigma is located under the column behind the pollinia. The ovary is inferior with three carpels presented. The plant has not produced seed. Column:
Length.— About 1 cm. Diameter.— About 6 mm. Color.— RHS 78A. Color towards to apex.— RHS 78A.
Pollinia:
Quantity of pollen masses.— Two pollen masses. Diameter.— About 1 mm. Color.— RHS 23A.
Ovary:
Length.— About 4.9 to 5.3 mm. Diameter.— About 3 to 6 mm. Color.— RHS 15C.
Root: In tissue culture plantlets, the first root emerged 30 days after being deflasked.
Diameter.— About 5 mm. Color.— RHS 144B.
Disease/pest resistance: Resistance to known pathogens and pests common to Doritaenopsis Orchids has not been observed on plants of the new cultivar grown under commercial greenhouse conditions. Temperature tolerance: Plants of the new Doritaenopsis Orchid have been observed to be tolerant to temperatures from about 14 to 32° C. | A new and distinct Doritaenopsis orchid plant named ‘Sunrise Beautiful Girl’ having attractive and unique purple-colored flowers with a very clear white edge and economical propagation via tissue culture. ‘Surnise Beautiful Girl’ has upright, sturdy flowering stems and excellent postproduction longevity. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/857,674, filed Aug. 17, 2010, which is hereby incorporated by reference for all purposes.
TECHNICAL FIELD
[0002] The invention relates generally to analog-to-digital converters (ADCs) and, more particularly, to time-interleaved (TI) ADCs.
BACKGROUND
[0003] Referring to FIG. 1 of the drawings, the reference numeral 100 generally designates a conventional ADC. ADC 100 generally comprises a track-and-hold (T/H) circuit 102 and a sub-ADC 104 so that, in operation, the ADC 100 can sample an analog input signal X(t) at a plurality of sampling instants and convert the sampled signal into a digital signal Y[n]. As is shown in FIG. 1 , though, the T/H circuit 104 generally comprises switches and capacitors. The switch has a non-zero resistance, which causes the T/H circuit 102 to function as a filter (typically a single pole low pass filter).
[0004] Turning to FIG. 2 , a model 200 of the ADC 100 is shown. In model 200 , the filter aspects of the ADC 100 are represented by filter 202 , while the remainder of the functionality of the ADC 100 is represented by ideal ADC 204 . Filter 202 has a transfer function in the time-domain of h a (t), which can, in turn, be represented in the frequency-domain as:
[0000]
H
a
(
ω
)
=
g
a
ωΔ
t
1
+
(
ω
ω
a
)
,
(
1
)
[0000] where g a is the gain of ADC 100 , Δt a is the time delay relative to a reference, and ω a is the cutoff frequency (bandwidth). This model 200 can be useful when determining mismatches for TI ADCs.
[0005] In FIG. 3A , an example of a TI ADC 300 can be seen. TI ADC 300 generally comprises ADCs 100 - 1 to 100 -M (where each of ADCs 100 - 1 to 100 -M generally has the same structure as ADC 100 from FIG. 1 ) that are clocked by divider 302 so that the outputs from ADCs 100 - 1 to 100 -M can be multiplexed by multiplexer 304 to produce digital signal Y[n]. Yet, when building TI ADC 300 , ADCs 100 - 1 to 100 -M are not identical to each other; there are slight structural and operational variations. These slight variations result in Direct Current (DC) offset mismatches, timing skew, gain mismatches, and bandwidth mismatches between ADCs 100 - 1 to 100 -M.
[0006] Of the different types of mismatches listed, the performance impact, as the result of bandwidth mismatches, are the weakest, and, to date, have largely been ignored, but, in order to build a high accuracy (generally greater than 6 bits), high speed (generally greater than 1 GS/s) TI ADCs, bandwidth mismatches between interleaved ADC branches need to be corrected. Looking to TI ADC 300 , the output spectrum when the input signal is a tone with frequency ω * can be represented as follows:
[0000]
Y
(
ω
)
=
∑
k
=
0
M
-
1
(
1
M
∑
a
=
0
M
-
1
H
a
(
ω
*
)
-
2
π
k
M
a
)
δ
(
ω
-
ω
*
-
2
π
k
M
)
.
(
2
)
[0000] Assuming a 2-way TI ADC (M=2), which generally represents the upper-bound or worst-case for bandwidth mismatch, equation (2) can be reduced to:
[0000]
Y
(
ω
)
=
(
H
0
(
ω
0
)
+
H
1
(
ω
0
)
2
)
X
(
ω
)
+
(
H
0
(
ω
0
)
+
H
1
(
ω
0
)
2
)
X
(
(
ω
-
π
)
)
(
3
)
[0000] with a Spurious-Free Dynamic Range (SFDR) of
[0000]
SFDR
=
20
log
10
(
H
0
(
ω
0
)
+
H
1
(
ω
0
)
H
0
(
ω
0
)
-
H
1
(
ω
0
)
)
(
4
)
[0000] The SFDR for an M-way interleaved TI ADC, therefore, can then be determined to be:
[0000]
SFDR
=
max
k
(
20
log
10
(
A
[
0
]
A
[
k
]
)
)
where
(
5
)
A
[
k
]
=
∑
a
=
0
M
-
1
H
a
(
ω
0
)
-
2
π
k
M
a
(
6
)
[0000] Now, equation (1) can be applied to TI ADC 300 for the purposes of simulation so
[0000]
H
a
(
ω
0
)
=
1
1
+
τ
a
ω
0
,
for
T
S
>
τ
a
=
1
ω
a
,
(
7
)
[0000] where T S is the period of clock signal CLK. Such a simulation yields that variations in bandwidth mismatches are dependent on gain mismatches and timing skews and that (with high accuracy, high speed TI ADCs) bandwidth mismatch can significantly affect performance. An example of a simulation of the effect bandwidth mismatch can be seen in FIG. 3B for different gain and skew compensations. Thus, to achieve the desired SFDR (i.e., greater than 70 dB) for a TI ADC, the bandwidths of ADCs within the TI ADC should be matched to be within 0.1% to 0.25%.
[0007] To date, however, no estimation algorithm or circuit exists to blindly determine bandwidth mismatches. The two most relevant conventional circuits, though, are described in the following: Satarzadeh et al., “Bandwidth Mismatch Correction for a Two-Channel Time-Interleaved A/D Converter,” Proceedings of 2007 IEEE International Symposium on Circuits and Systems, 2007; and Tsai et al., “Bandwidth Mismatch and Its Correction in Time-Interleaved Analog-to-Digital Converters,” IEEE Transactions on Circuits and Systems II: Express Briefs, Vol. 53, No. 10, pp. 1133-1137, Oct. 23, 2006. Neither of these circuits, though, adequately addresses blind bandwidth mismatch estimation.
[0008] Assuming, however, that one is able to adequately perform blind bandwidth mismatch estimation, adjustment of bandwidths of the T/H circuits (like T/H circuit 102 ) in TI ADC 300 can be difficult due at least in part to the precision of the bandwidth matching. A switched capacitor arrangement included within the T/H circuit 102 would be undesirable because it would be difficult to implement, and capacitive tuning (such as with a varactor and a tuning voltage) would also be undesirable because of signal dependencies. Thus, there is a need for a bandwidth adjustment circuit that can be adjusted from a blind bandwidth mismatch estimation.
[0009] Some other conventional circuits are: U.S. Pat. No. 5,500,612; U.S. Pat. No. 6,232,804; U.S. Pat. No. 6,255,865; U.S. Patent Pre-Grant Publ. No. 2004/0070439; U.S. Patent Pre-Grant Publ. No. 2004/0239545; U.S. Patent Pre-Grant Publ. No. 2009/0009219; and Abo et al. “A 1.5-V, 10-bit, 14.3-MS/s CMOS Pipeline Analog-to-Digital Converter,” IEEE J. of Solid State Circuits, Vol. 34, No. 5, pp. 599-606, May 1999;
SUMMARY
[0010] A preferred embodiment of the present invention, accordingly, provides an apparatus. The apparatus comprises a clock divider that receives a clock signal; a plurality analog-to-digital converter (ADC) branches that each receive an analog input signal, wherein each ADC branch includes: a delay circuit that is coupled to the clock divider; an ADC having: a bootstrap circuit that is coupled to the delay circuit; a sampling switch that is coupled to the bootstrap circuit; and a controller that is coupled to the bootstrap circuit to provide a control voltage to the bootstrap circuit so as to control a gate voltage of the sampling switch to adjust the impedance of the sampling switch when the sampling switch is actuated; a sampling capacitor that is coupled to the sampling switch; and a correction circuit that is coupled to the ADC; and a mismatch estimation circuit that is coupled to each delay circuit, each correction circuit, and each controller, wherein the mismatch estimation circuit provides a control signal to each controller to adjust for relative bandwidth mismatches between the ADC branches.
[0011] In accordance with a preferred embodiment of the present invention, the apparatus further comprises a multiplexer that is coupled to each ADC branch.
[0012] In accordance with a preferred embodiment of the present invention, the correction circuit adjusts the output of its ADC to correct for DC offset and gain mismatch.
[0013] In accordance with a preferred embodiment of the present invention, the bootstrap circuit further comprises: a boost capacitor that is charged during a hold phase of the ADC; a transistor having first passive electrode, a second passive electrode, and a control electrode, wherein the first passive electrode of the transistor is coupled to the boost capacitor, and wherein the second passive electrode of the transistor is coupled to the sampling switch; a passgate circuit that is coupled to the delay circuit, that is coupled to the control electrode of the transistor, and that receives the control voltage; and a skew circuit that is coupled to sampling switch and that is controlled by the control voltage.
[0014] In accordance with a preferred embodiment of the present invention, the transistor further comprises a first transistor, and wherein the passgate circuit further comprises: a second transistor having a first passive electrode, a second passive electrode, and a control electrode, wherein the first passive electrode of the second transistor is coupled to the controller so as to receive the control voltage, and wherein the control electrode of the second transistor is coupled to the delay circuit, and wherein the second passive electrode of the second transistor is coupled to the control electrode of the first transistor; a third transistor having a first passive electrode, a second passive electrode, and a control electrode, wherein the first passive electrode of the third transistor is coupled to the second passive electrode of second transistor, and wherein the control electrode of the third transistor is coupled to the delay circuit; and a fourth transistor having a first passive electrode, a second passive electrode, and a control electrode, wherein the first passive electrode of the fourth transistor is coupled to the control electrode of the first transistor, and wherein the control electrode of the fourth transistor is coupled to the sampling switch, and wherein the second passive electrode of the fourth transistor is coupled to the second passive electrode of the third transistor.
[0015] In accordance with a preferred embodiment of the present invention, the skew circuit further comprises a fifth transistor having a first passive electrode, a second passive electrode, and a control electrode, wherein the first passive electrode of the fifth transistor is coupled to the sampling switch, and wherein the control electrode of the fifth transistor is coupled to the controller so as to receive the control voltage.
[0016] In accordance with a preferred embodiment of the present invention, the controller is a digital-to-analog converter (DAC).
[0017] In accordance with a preferred embodiment of the present invention, the controller is a charge pump.
[0018] In accordance with a preferred embodiment of the present invention, an apparatus comprising a clock divider that receives a clock signal; a plurality ADC branches that each receive an analog input signal, wherein each ADC branch includes: a delay circuit that is coupled to the clock divider; an ADC having: a bootstrap circuit that is coupled to the delay circuit; a sampling switch that is coupled to the bootstrap circuit; a controller that is coupled to the bootstrap circuit to provide a control voltage to the bootstrap circuit so as to control a gate voltage of the sampling switch to adjust the impedance of the sampling switch when the sampling switch is actuated; a sampling capacitor that is coupled to the sampling switch; an output circuit that is coupled to the sampling capacitor; and a sub-ADC that is coupled to the output circuit; and an correction circuit that is coupled to the ADC; a mismatch estimation circuit that is coupled to each delay circuit, each correction circuit, and each controller, wherein the mismatch estimation circuit provides a control signal to each controller to adjust for relative bandwidth mismatches between the ADC branches; and a multiplexer that is coupled to each ADC branch.
[0019] In accordance with a preferred embodiment of the present invention, an apparatus is provided. The apparatus comprises a clock divider that receives a clock signal; a plurality ADC branches that each receive an analog input signal, wherein each ADC branch includes: a delay circuit that is coupled to the clock divider; an ADC having: a bootstrap circuit that is coupled to the delay circuit; a PMOS transistor that is coupled to the bootstrap circuit; a controller that is coupled to the bootstrap circuit to provide a control voltage to the bootstrap circuit so as to control a gate voltage of the sampling switch to adjust the impedance of the sampling switch when the sampling switch is actuated; a sampling capacitor that is coupled to the PMOS transistor at its drain; an output circuit that is coupled to the sampling capacitor; and a sub-ADC that is coupled to the output circuit; and an correction circuit that is coupled to the ADC, wherein the correction circuit adjusts the output of its ADC to correct for DC offset and gain mismatch; a mismatch estimation circuit that is coupled to each delay circuit, each correction circuit, and each controller, wherein the mismatch estimation circuit provides a control signal to each controller to adjust for relative bandwidth mismatches between the ADC branches; and a multiplexer that is coupled to each ADC branch.
[0020] In accordance with a preferred embodiment of the present invention, the PMOS transistor further comprises a first PMOS transistor, and wherein the bootstrap circuit further comprises: a boost capacitor that is charged during a hold phase of the ADC; a second PMOS transistor that is coupled to the boost capacitor at its source and the gate of the first PMOS switch at its drain; a passgate circuit that is coupled to the delay circuit, that is coupled to the gate of the second PMOS transistor, and that receives the control voltage; and a skew circuit that is coupled to sampling switch and that is controlled by the control voltage.
[0021] In accordance with a preferred embodiment of the present invention, the passgate circuit further comprises: a third PMOS transistor that is coupled to the controller at its source, the delay circuit at its gate, and the gate of the second PMOS transistor at its drain; a first NMOS transistor that is coupled to the drain of the third PMOS transistor at its drain and the delay circuit at its gate; and a second NMOS transistor that is coupled to the drain of the third PMOS transistor at its drain, the source of the first NMOS transistor at its source, and the gate of the first PMOS transistor at its gate.
[0022] In accordance with a preferred embodiment of the present invention, the skew circuit further comprises a third NMOS transistor that is coupled to the gate of the first PMOS transistor at its drain and the controller at its gate.
[0023] In accordance with a preferred embodiment of the present invention, the controller is a DAC or a charge pump.
[0024] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
[0026] FIG. 1 is a circuit diagram of a conventional ADC;
[0027] FIG. 2 is a block diagram of a model of the ADC of FIG. 1 ;
[0028] FIG. 3A is a circuit diagram of a convention TI ADC using the ADC of FIG. 1 ;
[0029] FIG. 3B is an example of a simulation showing the effect of bandwidth mismatch on the Spurious-Free Dynamic Range (SFDR) of a TI ADC;
[0030] FIG. 4 is a circuit diagram of a TI ADC in accordance with a preferred embodiment of the present invention;
[0031] FIG. 5 is a circuit diagram of the T/H circuit of FIG. 4 ;
[0032] FIG. 6 is a circuit diagram of the bootstrap circuit of 5 ; and
[0033] FIG. 7 is a graph depicting the bandwidth for the T/H circuit of FIG. 5 versus “on” resistance of the sampling switch of the T/H circuit of FIG. 5 .
DETAILED DESCRIPTION
[0034] Refer now to the drawings wherein depicted elements are, for the sake of clarity, not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views.
[0035] Referring to FIG. 4 of the drawings, the reference numeral 400 generally designates a TI ADC in accordance with a preferred embodiment of the present invention. ADC 400 generally comprises ADC branches 402 - 1 to 402 -M, divider 404 , multiplexer or mux 408 , and a mismatch estimation circuit 410 . Each ADC branch 402 - 1 to 402 -M also generally comprises (respectively) ADC 410 - 1 to 410 -M, correction circuit 416 - 1 to 416 -M, and adjustable delay element or circuit 418 - 1 to 418 -M. Additionally, each ADC 410 - 1 to 410 -M generally comprises (respectively) a T/H circuit 410 - 1 to 410 -M and a sub-ADC 414 - 1 to 414 -M.
[0036] In operation, TI ADC 400 converts analog input signal X(t) to a digital signal Y[n]. To accomplish this, divider 402 divides a clock signal CLK (with a frequency of F S or period of T S ) into M clock signals (each with a frequency of F S /M) that are staggered by delay circuits 418 - 1 to 418 -M and provided to ADCs 410 - 1 to 410 -M. This allows each of ADCs 410 - 1 to 410 -M to convert the analog signal X(t) to digital signals X 1 (k) to X M (k). The gain and DC offset adjustments are applied to digital signals X 1 (k) to X M (k) by correction circuits 416 - 1 to 416 -M to generate digital signals Y[1] to Y[M], which can then be multiplexed by mux 408 to generate a digital signal Y[N].
[0037] To generally ensure that signals Y[ 0 ] to Y[M−1] are matched, mismatch estimation circuit 410 calculates and compensates for gain mismatches, DC offset mismatches, timing skews, and bandwidth mismatches. The mismatch estimation circuit 410 is generally a digital signals processor (DSP) or dedicated hardware, which determines the gain mismatches, DC offset mismatches, timing skews, and bandwidth mismatches and which can provide adjustments for gain, DC offset, timing skew, and bandwidth to correction circuits 416 - 1 to 416 -M and T/H circuits 412 - 1 to 412 -M. A more complete explanation of the mismatch estimation circuit 410 can be found in co-pending U.S. patent application Ser. No. 12/572,717, which is entitled “BANDWIDTH MISMATCH ESTIMATION IN TIME-INTERLEAVED ANALOG-TO-DIGITAL CONVERTERS,” and which is incorporated by reference for all purposes.
[0038] Turning now to FIG. 5 , T/H circuits 412 - 1 to 412 -M (hereinafter referred to as 412 for the sake of simplicity) can be seen in greater detail. T/H circuit 412 generally comprises a bootstrap circuit 502 , a controller 504 , a sampling switch S 1 (which is typically an NMOS transistor or NMOS switch), a sampling capacitor CSAMPLE, and an output circuit 506 . In operation, the bootstrap circuit 502 controls the actuation and de-actuation of the sampling switch S 1 based at least in part on a clock signal CLKIN (which is received from a respective delay circuit 418 - 1 to 418 -M) and a control voltage VCNTL from controller 504 . Generally, the mismatch estimation circuit 406 provides a control signal to the controller 504 (which may be a digital-to-analog converter (DAC) or charge pump) to generate the control voltage VCNTL. The control voltage VCNTL, through the bootstrap circuit 502 , is able to control the gate voltage of the sampling switch S 1 to adjust the impedance or “on” resistance of the sampling switch S 1 when the sampling switch S 1 is actuated.
[0039] Looking to FIG. 6 , the bootstrap circuit 502 can be seen in greater detail. When the clock signal CLKIN is logic low (such as during a hold phase), inverter 508 turns transistor Q 1 (which is typically an NMOS transistor) “on,” while passgate circuit (which generally comprises transistors Q 2 , Q 3 , and Q 5 ) maintains transistor Q 4 (which is generally a PMOS transistor) in an “off” state. Assuming that signal CLKZ is logic high so that transistors Q 8 and Q 9 (which are typically NMOS transistors) are in an “on” state and during this logic low period of clock signal CLKIN, supply voltage VDD charges the boost capacitor CBOOST. When clock signal CLKIN transitions to logic high, passgate circuit turns transistor Q 4 “on,” while transistors Q 1 is turned “off.” At this point, a voltage is applied to the gate of sampling switch S 1 to turn it “on.” This gate voltage for sampling switch S 1 is generated at least in part from the discharge of capacitor CBOOST, the input signal IN (which is applied through transistor Q 6 ), and the control voltage VCNTL (which is applied through the passgate circuit and the skew circuit (which generally comprises transistors Q 7 and Q 8 )). Generally, this control voltage VCNTL is applied to the source of transistor Q 2 (which is generally a PMOS transistor) and the gate of transistor Q 7 (which is generally an NMOS transistor) so as to adjust the gate voltage of sample switch S 1 . Thus, the gate voltage of the sampling switch S 1 can be easily controlled by varying control voltage VCNTL. Additionally, because the sampling switch S 1 is generally a NMOS switch operating in a linear region, variation of this gate voltage varies the “on” resistance of the sampling switch S 1 , which adjusts the filter characteristics (and bandwidth) of the filter created by the sampling switch S 1 , resistor R 1 , and sampling capacitor CSAMPLE.
[0040] To illustrate the operation to bootstrap circuit 502 and sampling switch S 1 , a graph depicting bandwidth of T/H circuit 412 versus “on” resistance for the sampling switch S 1 can be seen in FIG. 7 . As can be seen, the bandwidth for T/H circuit 502 varies between about 2.956 GHz at for a VCNTL DAC code of zero to about 3.051 GHz for a VCNTL DAC code of 1023Ω. Thus, the bandwidths for multiple T/H circuits 412 (such as 412 - 1 to 412 -M) with nominal bandwidths of 3 GHz can be adjusted to match one another to between about 0.25% and about 0.1%.
[0041] Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | To date, bandwidth mismatch within time-interleaved (TI) analog-to-digital converters (ADCs) has been largely ignored because compensation for bandwidth mismatch is performed by digital post-processing, namely finite impulse response filters. However, the lag from digital post-processing is prohibitive in high speed systems, indicating a need for blind mismatch compensation. Even with blind bandwidth mismatch estimation, though, adjustment of the filter characteristics of track-and-hold (T/H) circuits within the TI ADCs can be difficult. Here, a T/H circuit architecture is provided that uses variations of the gate voltage of a sampling switch (which varies the “on” resistance of the sampling switch) to change the bandwidth of the T/H circuits so as to precisely match the bandwidths. | 7 |
BACKGROUND OF THE INVENTION
The field of the invention is generally that of office equipment of the type adapted to be placed on a desk for the purpose of facilitating the temporary segregation and storage of paper items, such as memos, bills, urgent letters, and the like, which require some action on the part of the recipient and which, after receipt, will usually be at least partially segregated and placed in such equipment so as to be available for use when a subsequent action or response thereto is to be effected by the recipient thereof. For example, in many offices a series of several vertically-spaced, stacked trays sometimes marked "Outgoing" and "Incoming" or sometimes marked "Bills" or "Urgent," or bearing other similar designations, may be employed for the purpose of temporarily storing segregated bills, leters, and other received paper items so that the recipient will be aware of where they can be found when he wants to respond thereto and also will know that the more urgent ones are in a correspondingly indicated portion of the storage unit. However, such prior art desk-top paper item organizers or collectors are not very efficient since once an item is placed therein and stacked upon another item, the item upon which is has been stacked cannot readily be seen and the old expression of "out of sight, out of mind" comes into play. In fact, it can be said that the last item placed in such a desk-top storage tray will be the only one which is acutally visible to a user of the desk, while the other paper items stacked lower down may be forgotten or ignored until such time as each paper item is individually removed from the stack thereof and is again individually examined. It is obvious that it would be extremely desirable to segregate, collect, and temporarily store multiple receive paper items in an order-of-importance category or priority, fashion, or manner and in a manner where all such temporarily stored paper items are virtually equally visible and equally accessible to a user of the device sitting at a desk upon which it is mounted. It is precisely for the purpose of providing an improved multiple-paper-item-holder having the advantages mentioned immediately above that the present invention has been developed, since it provides an equal visibility, equal access, multiple-paper-item-holder having the above-mentioned novel advantages, all of which flow from, and occur by reason of, the specific features of the invention pointed out hereinafter.
SUMMARY OF THE INVENTION
Generally speaking, the multiple-item-holder for paper items and the like of the present invention comprises a substantially non-tippable base member adapted to rest on a substantially horizontal, auxiliary underlying supporting surface (such as a desk top or the like, although not specifically so limited in all forms of the invention) which is provided (usually removably) with upstanding supporting framework means carrying a plurality of vertically spaced, transversely directed supporting arms and also including a plurality of clamp devices adapted to be mounted at virtually any desired location relative to any of the transverse supporting arms to temporarily support and position a paper item therebelow (and, in a preferred form, behind the next lower adjacent transverse supporting arm), and with a preferred form of the invention also including title or designation marking means adapted to be mounted at any desired location with respect to any of the transverse supporting arms for indicating the adjacent area as being suitable for the temporary positioning of a certain segregated class of paper items or the like, thus making it possible to effectively classify, segregate, and mount in a selected area any paper item which it is desired to temporarily classify and store until it is responded to or acted upon. In a preferred form, the framework means carrying the transverse supporting arms and the base supporting the framework means may be arranged to removably carry one or more object-supporting trays or shelves and/or a cup-shaped receptacle for long objects such as pens, pencils, and the like, to enhance the overall utility of the device. In one preferred form, the framework means is provided with means for visibly mounting any selected type of visible display means, such as the person's initials, an emblem associated with some organization, group, company, or the like, with which the person is associated, or it may display virtually any selected type of display means or emblem. In a preferred form, the base member, the framework means, the shelf or tray means, and the cup-shaped receptacle means (when employed) may all be of effectively disassembled or knocked-down construction to facilitate small-space-volume storage and shipping requirements of the device when stored or shipped and prior to assembly for operative use.
OBJECTS OF THE INVENTION
With the above points in mind, it is an object of the present invention to provide a novel multiple-item-holder for paper items, such as memos, or the like, and which is of a character such as is referred to herein generically and/or specifically, and which may include any or all of the features referred to herein (or functional equivalents), either individually or in combination, and which is of extremely easy-to-mount-and-assemble and easy-to-use construction suitable for use by relatively inexperienced persons, and which is of relatively simple, inexpensive, easy-to-manufacture and easy-to-store-and-ship construction suitable for ready mass production and distribution thereof in any of its various forms at relatively low cost, both as to the initial capital cost (including production set-up cost) and as to the subsequent per-unit manufacturing cost, whereby to be conducive to widespread production, distribution, and sale of the novel multiple-item-collector and segregated or classified holder of the present invention as a disassembled, knocked-down, easy-to-ship and easy-to-store unit adapted for easy assembly after delivery, or as an initially completely assembled unit, intended for the purposes outlined herein or for any substantially equivalent or similar purposes.
Further objects are implicit in the detailed description which follows hereinafter (which is to be considered as exemplary of, but not specifically limiting, the present invention), and said objects will be apparent to persons skilled in the art after a careful study of the detailed description which follows. For the purpose of clarifying the nature of the present invention, several exemplary embodiments of the invention are illustrated in the hereinbelow-described figures of the accompanying single drawing sheet and are described in detail hereinafter.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a reduced-size, front elevational view of one exemplary representative form of the invention in fully assembled, upstanding, operative use supported by an auxiliary, horizontal supporting surface, such as a desk top surface indicated fragmentarily in phantom lines only.
FIG. 2 is a right-side elevational view of the exemplary representative first form of the invention shown in FIG. 1.
FIG. 3 is a somewhat-enlarged, fragmentary, vertical-plane, cross-sectional view taken along the plane and in the direction indicated by the arrows 3--3 of FIG. 1 (in cross-section with respect to all portions of the device except the fragmentarily-shown paper item held by the device, which is shown fragmentarily in side elevation).
FIG. 4 is a fragmentary, enlarged view substantially comprising a sectional view (with certain fragmentary portions shown in side elevation, however) taken substantially along the plane and in the direction indicated by the arrows 4--4 of FIG. 1 and clearly illustrates an exemplary representative one of the coupling means which facilitate the initial storage and shipment of the entire device in disassembled, small-space-volume configuration, but adapted to be readily assembled into the operative condition shown in FIGS. 1-9 inclusive.
FIG. 5 is a top view taken substantially along the plane and in the direction indicated by the arrows 5--5 of FIG. 1.
FIG. 6 is an enlarged, fragmentary, sectional view taken substantially along the plane and in the direction indicated by the arrows 6--6 of FIG. 2 and shows one representative, exemplary, base-attaching engaging or engagement means to facilitate the assembly and disassembly of the device for convenience in shipping and storing the entire device in a small-space-volume configuration.
FIG. 7 is a somewhat enlarged, fragmentary, cross-sectional view taken substantially along the plane and in the direction indicated by the arrows 7--7 of FIG. 1 and illustrates the structure and mounting of one representative exemplary form of title or designation marking means for indicating the kinds of paper items to be temporarily stored in an adjacent (usually underlying) region.
FIG. 8 is an enlarged, fragmentary view taken substantially along the plane and in the direction indicated by the arrows 8--8 of FIG. 1 and illustrates a portion of one exemplary form of visible display supporting means and visible display means supported thereby.
FIG. 9 is en enlarged, fragmentary view, taken substantially along the plane and in the direction indicated by the arrows 9--9 of FIG. 1 and illustrates another optional portion of the representative visible display supporting means and the representative visible display means supported thereby as best shown in FIG. 1.
FIG. 10 is a view similar in many respects to FIG. 3, although it is in end or side elevation rather than in section, and further illustrates a slight modification of the invention wherein the upstanding framework means is not provided with a plurality of progressively rearwardly displaced, stepped portions in the manner of the first form of the invention as best shown in FIG. 2.
FIG. 11 is another fragmentary, side elevational view generally similar to FIGS. 3 and 10, but illustrates a slightly modified form of paper-item-holding clamp device.
FIG. 12 is an exploded isometric view of a modified form of the title or designation marking means shown in front elevation in FIG. 1 at three different locations, and shown in side section in FIG. 7, in a representative first form thereof. The FIG. 12 exploded, isometric showing illustrates a very slight variation thereof.
FIG. 13 is a fragmentary, partially broken-away, side elevational view similar to FIG. 3 with the exception that FIG. 3 is sectional in nature, and illustrates a different type of mounting portion for the paper-item-holding clamp means which is not of a magnetically attachable or engageable nature in contrast to the mounting portion of the first form of the invention.
FIG. 14 is a very fragmentary view illustrating an auxiliary base-member-stabilizing clamp for use in firmly attaching the base member of any of the various forms of the invention to an auxiliary underlying supporting member (such as a desk top, or the like), and merely illustrates one of many possible representative exemplary types of such base-member-stabilizing clamps, for illustrative purposes only.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An exemplary representative first form of the invention is illustrated in FIGS. 1-9 inclusive wherein the multiple-item holder includes a base member, such as is generally designated by the reference numeral 20, which is of a substantially non-tippable nature by reason of its longitudinal and lateral dimensions and/or its weight, which factors may be relatively varied as long as the combined effect thereof is such as to substantially prevent tipping of the entire device when in use. It may be said that the base member 20 is effectively weighted, which may be accomplished by having it made of a relatively medium-weight or light-weight material supplemented by auxiliary weight means, or it may be accomplished by using a relatively heavy material of which to form the base member 20. The latter election is the preferred arrangement and the base member 20 may be made of metal so as to provide a substantially non-tippable base having a substantially flat bottom-contact surface 22 adapted to rest upon and be supported by a substantially horizontal auxiliary underlying supporting surface, such as that shown in phantom lines at 24 in FIGS. 1 and 2, for example, which may comprise the top surface of a desk or the like where the multiple item holder of the present invention is primarily adapted for use, although not specifically so limited.
In the example illustrated, the base member 20 is of substantially rectangular configuration, as seen in top plan view in FIG. 5, and extends in two different mutually perpendicular (but both still horizontal) directions which may be said to comprise an effective length direction and an effective width direction, the length direction extending between opposite side edges of the drawing sheet as shown in FIG. 5 and the so-called width direction extending at right angles thereto between top and bottom edges of the drawing sheet as shown in FIG. 5. It should be clearly understood, however, that the exact plan view configuration and, indeed, the entire shape of the base member 20, are not limited to the showings of the exemplary representative first form of the invention illustrated in FIGS. 1-9, which are for illustrative purposes only.
The exemplary first form of the invention also includes upstanding supporting framework means, one exemplary representative form of which is designated by the reference numeral 26, which is provided at the bottom with base-engaging or attaching means for attaching engagement with respect to the base member 20, whereby to be firmly supported thereby in a substantially centrally symmetrically positioned location with respect to central portion of the base member 20 so as to provide firm non-tipping support to the upstanding framework means 26 in virtually all directions. In the example illustrated, the central or center portion of the base member may be said generally to be that portion surrounding the geometrical center thereof, which is indicated in broken lines in FIG. 1 and by a dot in FIG. 5 designated by the reference numeral 28.
It will be noted that the upstanding supporting framework means 26, in said exemplary first form of the invention, comprises a pair of substantially rigid upstanding rod-shaped members, such as indicated at 30, which are of substantially similar configuration but are longitudinally spaced apart in the previously mentioned length direction of the base member in a manner providing longitudinal symmetrical spacing thereof on each side of the previously mentioned center portion of the base member surrounding the center point 28 thereof so as to extend upwardly therefrom on each side of the vertical center line of said center portion, also indicated by the reference numeral 28; although, in the exemplary first form of the invention as best shown in FIG. 2, being intermittently and regularly displaced in a stepped manner in a direction which corresponds to the previously mentioned width direction of the base member 20 and which is transverse to the longitudinal direction thereof and to the longitudinal plane carrying said pair of supporting members at their bottom attachment point to the base member 20 so as to provide a series of vertically spaced and progressively similarly displaced steps in the complete pair of upstanding rod-shaped members 30 of the framwork means 26. This is best shown in FIG. 2 where each of the displacement portions is indicated by the reference numeral 32, the lowermost one of which is shown in somewhat enlarged form in FIG. 4 also. It will be noted that each of the rearwardly displaced stepped portions 32 causes the next immediately upwardly adjacent part of the rod member 30 to lie in a different longitudinal plane from the next upwardly adjacent rod portion 30 positioned immediately above the next upwardly adjacent rear displacement step 32. The purpose of this series of multiple progressively rearwardly displaced planes for each of the vertically adjacent rod portions 30 will be explained in greater detail hereinafter.
In the example illustrated, the two rod-shaped upstanding members 30 of the supporting framework means 26 are provided with top terminal ends, indicated by the reference numeral 34 in each of the two instances thereof, and in the exemplary representative first form of the invention, said upper terminal end 34 of the upstanding supporting framework means 26 are formed inwardly so as to extend in a substantially horizontal line toward each other and to terminate in a manner providing a central, open display member region or space therebetween, such as is generally designated by the reference numeral 36.
In the example illustrated, the lower ends of the framework means 26 are provided with base engaging means, as indicated at 38 and which, in the example illustrated, as best shown in FIGS. 5 and 6, are of a removable type which includes male insert members 38 carried at the bottom of each of the two rod-shaped members 30 adapted to be removably inserted downwardly into corresponding female recess attaching and engaing means, indicated by the reference numeral 40 in FIG. 6 and provided in the upper surface 42 of the base member 20.
In the example illustrated, the two attaching engaging means, comprising the two insert portions 38 and the two female receiving socket portions 40 may be optionally effectively keyed by being of non-round shape or by the provision of any other type of well-known key means to properly position each of the upstanding rod members 30 and to prevent rotative displacement thereof.
It should be noted that, for ease of assembly and disassembly whereby to make it possible to store and ship the entire device in a relatively small-space-volume configuration when in disassembled relationship, the upstanding framework means 26 may be provided with quick connect and disconnect coupling means at one or more convenient assembly and disassembly locations, such as indicated generally at 44 in the exemplary first form of the invention illustrated. Said coupling means 44 may comprise a sleeve 46 adapted to receive the bottom insert member 48 carried by each of the two rod member 30 and also to similarly receive another lower insert member 50 carried by a lower portion of the rod-shaped member 30 of the framwork means 26 so that they can be effectively joined together in assembled relationship or can be effectively separated into disassembled relationship. They may be non-rotatively keyed, also, if desired, in a manner similar to the base engagement and attaching elements 38 and 40 previously described.
In the exemplary first form of the invention illustrated, lower portions of the upstanding framework means 26 are provided with laterally directed shelf-mounting recess means, such as indicated 52 and 54 (best shown in FIG. 2), for receiving and mounting therein object-supporting shelf means such as the representative lower shelf 56 and upper shelf 58 shown in FIGS. 1, 2, and 5. In the exemplary form illustrated, the two recess means 52 and 54 are formed by bending the corresponding lower rod-shaped member so as to form said two recesses 52 and 54 which, in the exemplay form illustrated are open at the front and closed at the rear and are vertically spaced apart by a vertical spacing portion indicated at 60. In the example illustrated, the lower shelf has a back wall and two side walls, but no front wall, thus forming an open-fronted shelf convenient for the purpose of placing thereon various writing instruments, memo pads, rubber stamps, stamp pads, and other small office equipment. The upper shelf 58, in the example illustrated, has two walls, a rear wall, and a front wall and, thus, comprises an open-topped but otherwise closed receptacle well adapted to contain similar small items such as paper clips, erasers, and the like, which might tend to become accidentally displaced from the open fronted lower shelf 56. However, in the example illustrated, the back wall and the two end walls of the upper shelf of 58 are of greater vertical height than the front wall thereof. This facilitates the placing of small memo pads in an inclined and at least partially upstanding relationship against the high rear wall of the upper shelf 58 so they will be in plain view for use. It will be noted that the reason that the higher rear wall is provided on the upper shelf 58 rather than on the lower shelf 56 is because there is substantial clearance space above the upper shelf 58 which facilitates the provision of such an upwardly extended rear wall. In the example illustrated, in order to facilitate the mounting of the upper shelf 58 in the upper recess 54, despite the provision of the upwardly extended rear wall, which is deeper than the recess 54, said rear wall is slotted at the locations of the two upper rearwardly extending portions of the two rod-shaped members forming the upper boundary of the upper recess 54. However, various other means providing for appropriate mounting of the upper shelf 58 irrespective of whether or not it has an upwardly extending rear wall, may be employed in lieu of the exemplary arrangement illustrated and described in the drawing. The extended upper rear wall may be eliminated entirely or the extended portion of the end walls may be eliminated entirely, or either may be provided on the lower shelf 56 if desired. Also, in the preferred arrangement illustrated, the upper shelf 58 is of slightly smaller size than the lower shelf 56 so as to facilitate the stacking of one within the other for reducing the space volume required for stacking and storing the entire device when in disassembled storage and shipping form. In this connection, it should be clearly understood that this invention does not lie in the exact construction and arrangement of the shelves or in the question of whether or not they are open or closed at the top, or in the number of such shelves or in the positioning of such shelves. All of these convenient structural arrangements are subject to substantial variation and the invention is certainly not to be specifically so limited. In the example illustrated, the shelves 56 and 58 are preferably made of light-weight, molded plastic construction and, in certain forms thereof, may preferably be also of a translucent or transparent type to facilitate visibility. However, the invention is not specifically so limited in all forms thereof. It should also be noted that in the exemplary form illustrated the two shelves 56 and 58 are provided with vertical, through-passing vertical apeture means, such as indicated at 62 and 64, at a central location so as to be capable of receiving upwardly therethrough the circular side wall portion 66 of a centrally positioned, upwardly open, object reciver, indicated generally at 68, and, in the example illustrated, taking the form of a cylindrically-shaped, open-topped cup in which relatively lengthy objects, such as pencils, pens and the like, may preferably be positioned for convenient access.
The previously mentioned upper terminal end 34 of the upstanding framework means 26 are adapted to be provided with visible display means, and visible display supporting means, one exemplary form of which is indicated generally at 70 in the case of one representative type of visible display means and such as indicated generally at 72 and 74 in the case of one representative form of visible display play supporting means. In the exemplary form illustrated, the representative visible display meanas 70 comprises a ring-shaped member 76 carrying a particular display structure 78 therein and which, in the example illustrated, comprises an initial. However, it could just as well comprise an emblem representing a lodge, an organization, or any group, sect, creed, or other type of organization with which one perhaps is affiliated or is a member of and, therefore, wishes to display same, or perhaps it is of an honorary character or indictes one's qualifications, prefession, or activities. In other words, the display means 70 may assume virtually any form which is desired. In the example illustrated, the display supporting means 72 and 74 comprise a pair of laterally positioned, controllably manually fastenable and unfastenable fastening means of a slip-over spring-clamp type, such as indicated at 80 in FIG. 8, for example, adapted to slip over the terminal end 34 of the corresponding upper part of the rod-shaped member 30 in an easily fastenable and unfastenable manner. Also, in the exemplary first form illustrated, the remaining display supporting means, indicated generally at 74, comprises a bottom receiver 82 carried at the bottom of the ring member 76 adapted to be slipped over an upwardly directed projecting pin 84 carried at the center of an upper transverse member 86 which will be described hereinafter. It should be clearly understood that, in certain instances, it may be possible to eliminate either the supporting means 74 or the supporting means 72 rather than to employ both of same simultaneously. This is optical, as is the substitution in lieu thereof of various other types of display supporting means, all of which are intended to be included and comprehended within the broad scope of the present invention.
The upstanding rod-shaped memers 30 of the framework means 26 carry a plurality of substantially horizontally directed, vertically spaced, transverse supporting arms, each of which is designated by the reference numeral 86 and each of which is attached in any suitable or appropriate manner to corresponding portions of the pair of rod-shaped members 30 of the framework means 26, in each case being attached to a different one of the progressively rearwardly displaced stepped portions of the rod-shaped members 30 most clearly shown in FIG. 2 so that each one of the vertically adjacent, transverse supporting arms 86 lies in a plane slightly behind the next lower adjacent one of the transverse supporting arms 86, as is best shown in FIG. 2. In the example illustrated, the attachment of each of the transverse supporting arms 86 to corresponding portions of the rod-shaped members 30 is by welding or other mechanical attachment, as is best shown at 88 in FIG. 4. However, the attachment may be by various adhesive means, cohesive means, mechanical fasteners, or any other suitable type of attachment means and is not specifically limited to welding, such as shown at 88 in FIG. 4.
It should be noted that the transverse supporting arms 86 have ferromagnetic frontal surfaces whereby to comprise magnetically attractable paper-holding clamp means mounting surfaces, as is best indicated at 90 in FIG. 3. These may be provided on an otherwise non-ferromagnetic, transverse supporting arm 86. However, in the exemplary preferred form illustrated, each entire transverse supporting arm 86 is made of such ferromagnetic material so that all surfaces thereof effectively comprise such ferromagnetic, magnetically attracable mounting surfaces.
The invention also includes one or more (usually a substantial plurality of) magnetically mountable clamp means, such as the representative one shown at 92 in FIGS. 1 and 3, which can be magnetically mounted on any of the ferromagnetic surfaces 90 of any of the transverse supporting arms 86 at any desired location. This is made possible by reason of the fact that each such magnetically mountable clamp means 92 includes a magnetic mounting portion 94 cooperable and controllably selectively placeable, in magnetically-held mounting attachment with respect to any selected ferromagnetic surface portion 90 of any of the transverse supporting arms 86, and with each such magnetically mountable clamp means 92 also including a controllably operable paper-engaging- and disengaging clamp portion, such as is indicated at 96, which includes a pair of opposed jaws 98 and a clamp-operating portion comprising two upper operating arms or members 100 effectively pivotally interconnected in effective fulcrum manner at a pivot location such as is indicated at 102 and effectively spring-biased in a direction such as to cause the jaws 98 to be biased toward closed relationship with respect to each other. It will be noted that it is the rear side of one of the operating arms 100 which mounts the magnetic mounting portion 94 which, in the example illustrated comprises an elastomeric magnet 104 of the type having an elastomeric or rubber-like matrix material carrying disseminated therethrough ferromagnetic particles which are permanetly magnetized so as to together comprise a resilient compressible permanent magnet 104 which will be magnetically attracted to any of the ferromagnetic surfaces 90 of any of the transverse supporting arms 86 and be magnetically held in engagement therewith until manually disengaged and removed therefrom when desired.
Thus, it will be understood that it is possible to place any small sheet of paper within the opposed jaws 98 comprising a clamp portion of the magnetically mountable clamp means 92 and to magnetically mount the magnetic portion 94 on any part of any of the multiple ferromagnetic surfaces 90 of any of the transverse supporting arms 86 so as to mount, hold, and display the particular small sheet of paper in a desired location with respect to the entire multiple item holder.
In the exemplary stepped arrangement of the framework means 26 shown in the first form of the invention, the rearward displacement stepped portions 32 may be of sufficient magnitude to readily allow such a mounted sheet of paper, indicated by the reference numeral 106, to lie behind the next lowermost transverse arm 86 so as to not obscure it from the front, or the magnetically mountable clamp means 92 may be of effectively rearwardly displaced configuration, as best shown in FIG. 3, wherein the upper operating arms 100 are forwardly displaced from the lower paper grasping jaw means 98 so that the paper item 106 can readily be positioned behind the next lower adjacent transverse supporting arm 86 in the manner shown in both FIGS. 1 and 2. Both of these two arrangements are intended to be included and comprehended within the broad scope of the disclosure of the present invention.
The rearwardly progressively vertically stepped relationship of the upstanding rod-shaped members 30 of the supporting framework means 26, in certain forms of the invention, where the rear positioning of a paper item 106 is not thought to be important or necessary, may be of a substantially non-displaced configuration extending directly upwardly, and such an arrangement is fragmentarily illustrated in FIG. 10 and will be briefly referred to hereinafter.
FIG. 7 illustrates one exemplary, representative form of title or designation marking holding and mounting apparatus, which is generally indicated by the reference numeral 105. In the representative exemplary form illustrated, it comprises a thin attachment plate 107, which comprises a permanent magnet, which may be made of metallic ferromagnetic material 107', or may be made of such a plate 107 provided at its rear with a compressible, elastomeric, ferromagnetic material of a type similar to that employed in the magnetic mounting portion 94 of the mounting clamp means 92. Of course, the ferromagnetic material of which the attachment plate 107 (and 107' in the form shown) is made is permanently magnetized so as to be magnetically attracted to the ferromagnetic surface 90 of any of the transverse arms 86 so that the title mounting member 105 may be mounted at any desired location.
It should be understood that the mounting of the title mounting means 105 on any particular surface portion 90 of any of the transverse arms 86 will not prevent the mounting at the same location of any one of the previously described mounting clamps 92 since its magnetic mounting portion 94 may merely be placed on the front side of the mounting magnetic plate 107 (and 107') which will cause both to be magnetically attracted to the corresponding ferromagnetic surface 90 of the arm 86. Thus, it will be understood that the title mounting member 105 can be mounted separately from any of the paper-holding mounting clamps 92, as shown at the upper left corner of the apparatus in FIG. 1 for example, or they may be effectively super-imposed in the manner shown at the center portion of the apparatus of FIG. 1, or the title mounting apparatus 105 may be completely independently mounted in the manner shown at the upper right hand corner of the apparatus as in FIG. 1. In the exemplary form of the title mounting apparatus illustrated in FIGS. 1 and 7, the magnetic plate 107 is provided with display plate 108 having a title or designation display surface 110 upon which writing or printing can be produced so as to visibly display the desired title, such as the exemplary title shown at 112 in FIG. 1, for example. The title 112 may be produced by adhesively affixing a label, or the like, onto the display surface 110, with said label having been previously provided with a desired title, such as by typing, writing, or hand-lettering same thereon, or otherwise producing the title on the label surface either before or after affixing same to the display surface 110.
Alternatively the title 112 may be produced on the display surface 110 by actually writing or hand-lettering same directly, thereon, by using an appropriate lettering or writing tool, such as a grease pencil, a ball point pen, a felt pen, or other equivalent writing instrument. In certain forms of the invention, the display surface 110 may be of a nature such as to facilitate such hand-writing or hand-lettering of the title directly thereon. For example, when the display surface 110 is made of plastic material, it may be of a type having a very slight surface roughness so as to facilitate writing thereon as opposed to the usual rather glossy plastic surface upon which writing is relatively difficult. Also, various other means for producing a visibly observable title, such as the representative one shown at 112, may be employed in lieu of the specific arrangement described, and all such are intended to be included and comprehended within the broad scope of the present invention.
The purpose of the title mounting apparatus 105 is to make it possible to effectively designate certain portions of the entire device for the mounting of certain particular kinds of corresponding paper items so that they can be quickly found by a user of the device. Also, in such title mounting apparatus, the title may make it possible to indicate the urgency or the order of priority of handling of the paper items mounted in different portions of the complete device so that it will be possible to handle the more urgent items on a proper priority basis and without the necessity of again examining all of the paper items to determine the propr priority orer each time such item handling is to be done.
FIG. 10 illustrates a very slight modification of the first form of the invention as illustrated in FIGS. 1-9 inclusive. In this modification all parts which are similar, structurally or functionally, to corresponding parts of the first form of the invention are designated by similar reference numerals followed by the letter "a", however. In this modification the major change from the first form of the invention, is the fact that each of the rod-shaped members 30a is substantially straight and does not include the series of rearwardly directed steps, such as those shown at 32 in the first form of the invention. This means that if the paper holding clamp 92a is of the effectively bent type shown in FIG. 3 illustrating the first form of the invention, it will, of necessity, require a greater bend, or displacement, of the lower jaw clamping portion 96a than is required in the first form of the invention, as illustrated in FIG. 3, if each sheet of paper held by the clamp portion 96a is intended to lie behind the next lower transverse arm 86a in a manner generally similar to the rear positioning of the paper items as shown in the first form of the invention. On the other hand, if a straight clamp is employed, a sheet of paper held thereby will lie in front of the next lowermost transverse arm, and either arrangement may be desirable under some circumstances. The bent clamp arrangement is clearly shown in FIG. 10 while the straight clamp arrangement is clearly shown in FIG. 11, wherein similar parts are designated by similar reference numerals always followed by the letter "b", however. It should be clearly understood that the straight clamp arrangement shown in FIG. 11 can also cause each sheet of held paper to lie behind the next lower transverse arm by merely providing a series of rearwardly directed displacement step portions similar to the steps shown at 32 in FIG. 2 in the first form of the invention, only of greater magnitude, and the showing of FIG. 11, taken in conjunction with the description, is intended to provide a full disclosure of such an arrangement.
FIG. 12 illustrates a slight modification of the title or designation marking mounting and holding apparatus from the first form thereof best shown in FIGS. 1 and 7. It will be noted that it consists primarily of a substantially identical structure with corresponding parts bearing similar reference numerals followed by the letter "c", however. A magnetically mountable permanent magnet attachment plate 107c (and 107'c) is adapted to be attached to the front surface of any of the transverse arms, such as shown at 86 of the first form, at any desired location, and it has the upwardly extending title bearing portion 108c which is provided with a title display space 110c. However, in this modification the title or designation 112c is not borne directly by the title display space 110c, but instead is carried on the display face of a title sheet or card 114 which is adapted to be removably mounted in front of the title display space 110c. In the example illustrated, this is done by slidably inserting same behind the upper and lower retaining lips 116, although not specifically so limited in all forms of the invention. This arrangement allows the inter-changeable title card 114 to be prepared and easily inserted and removed, as desired, and it is clear that other substantially effectively equivalent arrangements are entirely within the broad scope of the present invention.
FIG. 13 is a view of similar aspect to FIGS. 3, 10, and 11, but illustrates a modification of the mounting portion of any of the clamp means of any of the various forms of the invention previously described and/or illustrated in any of the figures of the drawing. Therefore, parts which are similar functionally or structurally to corresponding parts of previously described forms of the invention are designated by similar reference numerals, followed by the letter "d", however. It will be noted that, in this modification, any particular transverse arm 86d to which a paper-item-holding clamp means, such as is shown fragmentarily at 92d in FIG. 13, is to be attached need not comprise a ferromagnetic surface as designated at 90 of the first form of the invention. In the FIG. 13 modification, it may be of ferromagnetic or non-ferromagnetic material and may even be made of plastic material if it has sufficient structural strength for the purposes of the invention. The attachment of the paper-item-holding clamp member 92d in this modification is accomplished by a somewhat different type of mounting portion, which is inidicated by the reference numeral 94d and which comprises an effective hook attached to, or formed out of, the end of the ear one of the two operating arms 100d of the paper-item-holding clamp 92d. This makes it possible to merely slip on the hook 94d at any desired location with respect to any of the transverse arms 86d, with the emainder of the device being adapted to be any of the various types illustrated in the other figures of the drawings and/or previously described or referred to elsewhere in this specification. Therefore, in view of the full descriptions of the remainder of the device in any and all of its various forms, which have been set forth hereinbefore, it is believed that any further detailed description of corresponding portions of the FIG. 13 variation would be entirely redundant and, thus, are not repeated at this point.
FIG. 14 discloses an additional base-member-stabilizing structure which may be used with any of the base members of any of the various forms of the invention in the event that it is of inadequate weight and/or size to properly and fully stabilize the entire device. Whenever it is thought that the upper portions of the device will, perhaps, be top-heavy and may tend to cause the entire device to fall over, and that it would be necessary to greatly enlarge the base member in order to preven this (and such a corrective step is not thought desirable), an auxiliary base-member-stabilizing structure may be employed, one exemplary representative form of which is shown (entirely for illustrative purposes) in FIG. 14. Despite the fact that the auxiliary base-member-stabilizing structure, which is generally designated by the reference numeral 118 in FIG. 14, may be employed with any of the different base members of any of the different forms of the invention, nevertheless, in the interest of consistency, and in keeping with the part designation procedure followed in other views involving slight modificatons, the representative base member shown in FIG. 14 is designated by a reference numeral corresponding to that employed in the first form of the invention, but followed by the letter "e", however. The phantom-line representation at 24e in FIG. 1 of the top surface of the so-called auxiliary underlying horizontal supporting surface, in the example shown in FIG. 14, takes the form of the top surface of a cross-sectionally shown portion of a desk top, which is generally designated by reference numeral 120. It will be noted that the base-member-stabilizing structure 118 is illustrated in a form which might be termed a modification of a C-clamp which has an upper, downwardly facing, contact member 122, an intermediate, substantially C-shaped connecting member 124, and a lower, threadedly upwardly advanceable and upwardly facing bottom-surface contact member 126. The arrangement is such that the downwardly facing, upper contact member 122 can be placed adjacent to the top surface 42e of any desired portion of the base member 20e of the entire device (the rest of which is not shown in FIG. 14 for reasons of drawing simplification and clarity), and the lower, upwardly facing, contact member 126 can be threadedly upwardly advanced into firm contact with the bottom surface 128 of the portion of the desk top or table top which is illustrated fragmentarily at 120 in FIG. 14. This will rigidly and firmly clamp the base member 20e to the top surface 24e of the desk top or table top 120 in a manner which will absolutely and positively prevent tipping of the entire device irrespective of how tall it may be and irrespective of how heavily it may be loaded in a manner which would otherwise make it top-heavy and make it subject to tipping. It should be clearly understood that the showing of FIG. 14 is representative and exemplary only, and that it is intended to include and comprehend the provision of a variety of types of base-member-stabilizing structures other than the specific arrangement illustrated for exemplary purposes, and it should be understood that, where the base is of sufficient size and/or sufficient weight, the auxiliary clamp structure may be entirely eliminated.
It should be understood that the figures and the specific description thereof set forth in this application are for the purpose of illustrating the present invention and are not to be construed as limiting the present invention to the precise and detailed specific structure shown in the figures and specifically described hereinbefore. Rather, the real invention is intended to include substantially equivalent constructions embodying the basic teachings and inventive concept of the present invention. | A multiple-item holder for paper items, such as memos, and the like, intended to be supported on a substantially horizontal auxiliary underlying supporting surface (such as that of a desk, for example) and adapted to support in any of a plurality of selected positions from one to a large number of small paper items such as bills, memos, and the like, and in a conveniently arranged, segregated manner such as to facilitate the subsequent handling of the more important ones of said items on what might be termed a priority basis. The multiple-item holder consists of an upstanding portion and a plurality of spaced laterally directed arms, thus providing a very substantial measure of visibility and not obscuring a person's view and making it possible to magnetically (or otherwise) attach or engage any desired number of small clamping devices to any portion of the device and to clampingly engage corresponding paper items which will be supported at the selected locations. In a preferred arrangement, the device is so arranged that the lower portions of supported paper items will lie behind lower adjacent transverse arms of the device so as to avoid obscuring the top portion of each paper item and a title or designation marking which may be removably carried by any of the transverse arms at any desired location to indicate the nature of adjacent supported paper items and possibly the order of priority of the handling of same. In a preferred form, the paper-item-holding clamp means may be magnetically mountable on any ferromagnetic surface portion of the transverse arms, and the clamping jaws thereof provide for the easy clamping and unclamping of the paper items. Also, in a preferred form, the title or designation markings may be magnetically attached to the transverse arms at any desired location and in a manner which does not in any way interfere with the attachment at the same location of one or more of the paper-holding clamp devices. In one preferred form, the device is provided with a substantially non-tippable base member and means for supporting at least one tray or shelf (preferably more than one such tray or shelf) and also an open-topped cup-shaped receptacle to facilitate the storage of the numerous small desk top items customarily found on a desk, including writing instruments, erasers, paper clips, stapler, and the like. Also, in one preferred form, the device may be optionally provided with means for mounting a controllably removable and interchangeable visible display means, usually at the top thereof. | 0 |
BACKGROUND OF INVENTION
This invention related to hydraulic water hammer suppressors such as are usually associated with water distribution systems in domestic homes and other buildings.
Generally the construction of such hydraulic suppressors is regulated by governmental codes and these are normally used at each water supply outlet and are frequently located within a wall where they are not readily accessible.
A typical approved suppressor consists of a tube about fourteen inches long having an internal diameter of one inch over the major portion of its length and is adopted for vertical installation in a piping system. The upper end of the tube is closed by a generally conical portion and the lower end is reducd to a one-half inch internal diameter portion about an inch in length through a generally frusto-conical portion about one-half inch in length. The one-half diameter portion is connected into the one-half inch diameter piping system in fluid flow relation. This suppressor construction results from the governmental code which requires a one-half inch piping system. A suppressor consisting of a one-half inch in diameter tube would be of undue length for effective performance and efficient installation. The above-described one inch diameter suppressor reduced to a one-half inch outlet appears to be a satisfactory compromise and my invention is primarily concerned with a suppressor of this construction.
When installed in a piping or distribution system, the air chamber in the suppressor is initially filled with air. When water is caused to flow in the water line, and an outlet is opened, the water flows into the air chamer in accordance with the pressure in the line, compressing the air in the chamber until the compressed air balances in the line pressure. When the outlet is suddenly closed as for example by a quick-closing valve, there is a sudden increase in the line pressure. The shock of this increase in pressure is cushioned by the somewhat compressed air in the suppressor chamber, thus suppressing water hammer. After the initial shock the line pressure stabilizes at the normal line pressure of, for example, 50 psi and the compressed air in the suppressor air chamber balances the line pressure. Under these normal operating conditions the air chamber is always partially filled with water to the extent necessary for the compressed air to balance the water pressure.
In use, even though the system is air and water tight, the air chamber may become water-logged and ineffective due to the gradual absorption of the air therein by the water, especially where well water is used which has a very low air content and because considerable agitation of the water occurs within the air chamber when the valve is closed. It is then necessary to drain the system in order to rejuvenate the suppressor. Also, in summer homes located in wintery climates which are unheated in the winter, it is necessary to drain water systems for the winter. For reasons to be described hereinafter, the air chamber of the suppressor frequently will not drain when the line piping is drained. At present the usual practice is to hammer the suppressor or otherwise physically jar it or the adjacent piping to disturb the forces holding the water in the suppressor. Since the suppressors are frequently located within walls and other inaccessible places this method of draining water hammer suppressors is less than satisfactory.
SUMMARY OF THE INVENTION
It is a basic object of this invention to provide mechanism associated with a water hammer suppressor of the type described which will cause the air chamber to drain automatically and instantaneously when the water line is drained without physical manipulation of any kind.
It is the further object of this invention to provide existing water hammer suppressors with the water release mechanisms of this invention.
These and other objects are accomplished by inserting a second tube of substantially smaller diameter than the aforesaid one-half inch reduced diameter portion into the suppressor and attaching it to the reduced diameter portion. This second tube extends from the outlet end of the one-half inch diameter portion to a point where it at least intersects or breaks through the lower meniscus of the water contained in the larger diameter portion or extends into the water. This point is approximately at the point where one inch diameter portion of the suppressor meets the frusto-conical portion. Preferably the second tube has an outside diameter not appreciably greater than three-eighths inch so as to avoid closing off the air chamber outlet unnecessarily. The internal diameter of the second tube preferably is not appreciably less than three-sixteenths inch for effective operation. It is also preferred to provide the second tube with ends which are cut at an angle of about fourty-five degrees to the transverse plane of the tube for most effective performance and most efficient use of material. For installation in an existing suppressor an adaptor is formed wherein the second tube is attached within a short section of one-half inch diameter tube similar to the one-half inch portion of the suppressor and an annular flange is provided on the one-half inch diameter section to form a bell-like structure for snugly receiving a substantial portion of the one-half inch diameter portion of the suppressor and is adapted to be brazed thereto. The second tube is located within the adaptor and is of a length so that when attached to the suppressor it extends from the adaptor opening to within the one inch diameter portion.
BRIEF DESCRIPTION OF THE DRAWINGS
Various objects and advantages will appear from the following detailed description of the invention with reference to the drawings in which:
FIG. 1 is an elevation view of a typical water hammer suppressor installation.
FIG. 2 is an elevation enlarged view of the suppressor of this invention.
FIG. 3 is the bottom end view of FIG. 2.
FIG. 4 is a section taken along line 4 of FIG. 3 with parts broken away and shown in cross section.
FIG. 5 is a bottom view similar to FIG. 3 showing a modified form of the invention.
FIG. 6 is an elevation cross sectional view of an adaptor embodying the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates a typical suppressor installation of the type involved in this invention including a one-half inch water line pipe 10 located between the inner panel 12 and the outer panel 14 of a building wall and connected to a conventional faucet 16 through a T fitting 18. Connected to the T fitting 18 is the hydraulic shock or water hammer suppressor 20. As is well known, the shock is caused by the quick closing of valves such as valve 16 and especially those closed by quick closing devices such as solenoids. The shock is caused by the water moving at a relatively high velocity being stopped by the valve 16. Preferably the suppressor 19 is located as close to the point of water impact of the valve 16 as practical on the pressure side thereof.
As previously mentioned, governmental codes usually require the line 10 to be one-half inch internal diameter which requires the suppressor 19 to be connected to a one-half inch line. FIG. 2 is an enlarged view of the suppressor 19 which includes my invention. The standard portions of the suppressor 19 include the main body portion 20 having a one inch internal diameter which is closed at its upper end by a generally conical portion 22 about one-half inch long and is reduced at its lower end to a one-half inch internal diameter tube portion 24 about one inch long through a frusto-conical portion 26 about one-half inch in length. The lower end 24 is reduced to the one-half inch portion to correspond in size to the line 10.
The design of this suppressor, particularly the frusto-conical portion 26 and the one-half inch section 24 has created a problem which under most installation conditions prevents the water from draining out of the air chamber 21 of the suppressor when the line is drained as previously described.
Under these conditions the water appears to form a lower meniscus 28 as shown by a broken line and an upper meniscus 30. It appears that the junction 31 of the one inch tube portion 20 with the frusto-conical portion 26 creates a surface tension area which prevents the flow of water through the one-half inch portion 26.
It is further understood that in closed chambers, adhesion forces exist between the water and the chamber surfaces and cohesion forces exist at the tube opening. These together with the partial vacuum above the water in the air chamber appear to overcome the force of gravity acting on the water and hence to prevent flow of the water from the chamber.
I have discovered that placing a smaller diameter tube 32 as shown in FIGS. 2 and 4, which extends from the base 34 of the tube portion 24 through a transverse plane or junction 31 where the larger diameter portion 20 joins the frusto-conical portion 26 so as to penetrate the meniscus 28 as shown, will effect an instantaneous draining of the water from the air chamber 21 when the water in the line 10 is drained. The tube 32 is attached to the one-half inch diameter portion 24 preferably by welding or brazing.
For the best performance with a suppressor as described having the one-half inch diameter portion 24, the tube 32 should not be smaller than three-sixteenths inch internal diameter and not more than about three-eighths inch outside diameter. If the tube is smaller than three-sixteenths, the adhesion or cohesion forces may render the tube inoperative. A tube 32 larger than three-eights inch appears to close off the air chamber outlet unduly for best performance.
In general it has been found that the cross sectional area of the small tube should be less than one-half the cross sectional area of the reduced diameter tube portion 24.
FIG. 3 is an end view illustrating the spatial relationships with the tube 32 being bonded or brazed to the one-half inch tube section 24 in the area 27. FIG. 5 is a modification showing the tube 37 corresponding to tube 32 of FIG. 3 to be somewhat flattened to provide a surface portion having a curvature similar to the curvature of the tube 24 over a substantial area so as to provide a greater area of contact between the tubes for improved attachment.
As shown in the FIGS. 2 and 4, the tube 32 is preferably cut at each end at a 45 degree angle to the transverse plane of the tube to form the upper oblique end 33 and the lower oblique end 36. This permits effective operation of the tube at minimum length and hence a saving of material which is usually copper. For effective operation it is only necessary for the internal diameter portion of the tip 25 to penetrate the meniscus 28. The tube height or length at which this occurs may readily be determined by filling an air chamber with water and determining the minimum length needed for effective draining by trial and error. For a particular suppressor construction this length will always be the same. The oblique lower end 36 of the tube 24 also facilitates drainage since it appears to prevent the formation of a drain interfering meniscus at the lower end thereof and is a preferred feature. A tube 32 having a bottom end which is at a right angle to the longitudinal axis of the tube is workable however. The use of the oblique ends described has the added advantage that in the manufacture of the suppressor, sections of the small diameter tubing may be cut from the tube stock without waste. Although a forty-five degree angle appears optimum, angles of 30 to 60 degrees are effective. Although it is preferred to minimize the length of the tube 32 for reasons stated this tube may extend to any extent within the water trapped therein and it is not essential that the tube end 33 be oblique under such conditions.
The invention may be incorporated in existing suppressors by the use of the adaptor 40 shown in FIG. 6 in which a one-half inch diameter tube section 38 corresponding in size to the tube section 24 is provided with a flange 42 of a diameter such as to snugly receive the tube section 24 of FIGS. 2 and 4 as shown in broken lines. The small diameter tube 32 is attached to the tube 38 portion in the area 27 in the same manner as the tube 32 is attached to tube section 24 in FIG. 2. In use the outlet section 24 of the suppressor is received in the flanged portion 42 preferably so as to form a continuation of the section 38 and is brazed to the flange 42. The length of the tube 32 is of course, adjusted to take into account the added effective length of the one-half inch diameter suppressor outlet portion caused by the addition of the adaptor to insure that the tube 32 penetrates the meniscus formed in the air chamber as above described. Although the invention has been described specifically in terms of a water distribution system, it will be apparent to those skilled in the art that it is applicable to the distribution of other liquids. Further, although the invention has been disclosed in terms of a specific size suppressor, it would be apparent to those skilled in the art that the invention may be readily adapted to other size suppressors varying, for example, from 14 to 30 inches in length with the air chamber portion varying from 1 to 2 inches and with the outlet end varying from 1/2 to 3/4 inches in diameter within the scope of the invention. | An improved water hammer suppressor which is generally in the form of a first vertical tube closed at its upper end connected into a water distribution piping system at its reduced lower end portion and which in normal operation eventually becomes water logged and must be drained. To facilitate efficient draining of the device when the piping system is drained, a second smaller diameter tube is attached to the tube wall in the reduced diameter portion which extends from the outer end thereof into the main larger diameter portion thereof so as to enter the liquid held therein and cause draining thereof from the suppressor. | 8 |
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