description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to quartz crystal resonators and methods for making same. More particularly, the invention relates to surface mount quartz crystal resonators, and methods of making such resonators, which are straightforward in construction, inexpensive to manufacture, and effective and durable in use.
[0002] Quartz crystal resonators, because of their frequency accuracy and stability, are indispensable in modern electronics, for example, in telecommunications, computers, entertainment equipment and the like, as well as in other applications, many of which are well known. As used herein, a quartz crystal resonator, is a device comprising a piezoelectric quartz crystal element in the form of a thin plate, for example, a circular or rectangular plate, and an enclosure which can be sealed by some means to form a hermetic seal. Electrical terminals are provided which pass into the enclosure to provide the means to apply an alternating voltage across the quartz crystal element causing the element to vibrate. The piezoelectric quartz element has a set of thin conductive metallic electrodes deposited onto its major surfaces. The over lapping area of the electrode on one side of the plate with that of the electrode on the other side of the plate defines the resonating portion of the quartz element. The piezoelectric quartz crystal element resonates when the alternating voltage has the frequency of the resonant frequency of the quartz element, is applied. The resonant frequency of the quartz crystal element is determined by the piezoelectric and elastic constants of quartz, the dimensions of the quartz element, the metallic electrodes and other secondary factors.
[0003] Conventionally, surface mount quartz crystal resonators were made up of an electroded piezoelectric quartz crystal plate and a ceramic enclosure or base. The quartz crystal resonator plate is fixed in or on the ceramic enclosure by electrically conductive epoxy applied at two points on one end of the quartz crystal plate. A metal cover is welded to a metal flange on the ceramic enclosure. Alternately, a ceramic cover, is joined to the ceramic enclosure or base by means of adhesive or by reflow of low melting point glass.
[0004] The ceramic enclosures or bases are of laminated ceramic construction which employs a combination of cofired metallic depositions, metal vias and ceramic-to-metal seals. These ceramic components require a high level of technology to manufacture, are comparatively expensive, and have historically been in short supply.
[0005] It would be advantageous to provide surface mount quartz crystal resonators which are straightforward in construction, inexpensive to manufacture and effective and durable in use.
SUMMARY OF THE PRESENT INVENTION
[0006] New surface mount quartz crystal resonators and methods for making same have been developed. The present resonators are straightforward in construction, relatively inexpensive to manufacture, effective in use, for example, in electronic equipment such as computers, handheld cell phones, wireless control and data transmission systems and the like, and do not rely on materials or components which have historically been in short supply. For example, the present surface mount quartz crystal resonators do not require, and preferably do not include, the ceramic enclosures or bases referred to above. Thus, the present invention avoids dealing with such ceramic enclosures or bases and the problems attendant thereto. Preferably, the present quartz crystal resonators are encapsulated in a base plate of quartz and a cover plate of quartz. Importantly, the present surface mount quartz crystal resonators when installed in the application circuit have substantial, preferably enhanced, resistence to shock and vibration. Also, the present resonators can be produced with a reduced height and/or profile relative to the resonators of the prior art. The present methods of producing surface mount quartz crystal resonators are straightforward to practice and provide a cost effective approach to producing surface mount quartz crystal resonators.
[0007] One important aspect of the present invention relates to resonator plates, which are a major component of the present quartz crystal resonators. In general, the present resonator plates comprise a quartz crystal-based plate or plate member including a central portion or region having a peripheral region, for example, around the width and length of the central portion. The central portion is adapted to resonate at a desired frequency, preferably in response to an alternating voltage being applied across the central region. A border or border portion is provided which substantially surrounds the peripheral region of the central portion. The border includes a first region physically separated or spaced apart from the central region, and a second region joined to the central portion.
[0008] In use, the central portion of the quartz crystal-based plate resonates at a desired frequency preferably in response to the application of an alternating voltage, while the border of the plate remains substantially stationary, as will be described hereinafter. Thus, only a portion of the quartz crystal-based plate resonates. The other portion, that is the border, of the plate is used to support the resonating central portion and to provide part of the housing or enclosure of the surface mount resonator.
[0009] The first region of the border which is physically separated from the central portion of the plate member preferably is formed by removal of quartz from a solid quartz crystal plate. In one embodiment, a solid quartz crystal plate is provided and a quantity of quartz is removed, for example, forming a slot, so that the first region of the border is spaced apart, for example, by the formed slot, from the resonating central portion.
[0010] The outer periphery of the quartz crystal-based plate may be of any suitable geometric shape, for example, suitable for use in a surface mount quartz crystal resonator. Particularly useful geometric shapes include a substantially circular shape, a substantially rectangular shape and the like. In one particularly useful embodiment, the quartz crystal-based plate has a rectangular outer periphery and includes a slot located between the central portion and the first region. The slot is located inwardly of the outer periphery along at least three sides of the rectangular outer periphery.
[0011] The central region of the quartz crystal-based plate preferably is provided with electrodes to facilitate the application of an alternating voltage. In one particularly useful embodiment, a first electrode is provided on the top surface of the central portion and a second electrode is provided on an opposing bottom surface of the central portion.
[0012] The thickness of the central portion may be substantially uniform or may be variable. In one very useful embodiment, the thickness of the central portion preferably is reduced in the region or regions of the central portion which are outside of the resonant region defined by the overlapping electrodes. For example, the thickness of the central region may be reduced in one or more regions of the central portion on which neither first nor second electrode is provided. This feature will be discussed in detail hereinafter.
[0013] In another very useful embodiment the thickness of the central portion is essentially uniform but is substantially or significantly reduced relative to the thickness of the border. This feature will be discussed in detail hereinafter.
[0014] In another broad aspect of the present invention, resonator assemblies are provided which comprise a quartz crystal-based plate or plate member, as described elsewhere herein, and a base plate secured to the plate so that the central portion of the plate is free to resonate relative to the base plate, for example, in response to an appropriate alternating voltage being applied thereto, across the plate. The base plate is secured to the border of the quartz crystal-based plate, preferably along substantially the entire outer portion of the border. This securement of the base plate to the border of the quartz crystal-based plate provides a substantially strong mechanical bond between the plate member and the base plate. This enhances the durability of the present resonators, for example, relative to the prior art resonators, which enhances the effective life of the present resonators.
[0015] Although the base plate and quartz crystal-based plate can be secured using various techniques, it is preferred that adhesives be employed. Thus, the assembly preferably includes an adhesive located between the base plate and the border of the quartz crystal-based plate. This adhesive is effective in securing the base plate to the border. A suitable adhesive may be employed. One particularly useful class of adhesives are epoxy-based adhesives.
[0016] Although the base plate may be comprised of any suitable material of construction, for example, metals, glasses, ceramics and the like, the preferred material of construction is quartz. The use of quartz is very effective in reducing costs while substantially matching the physical characteristics of the quartz crystal-based plate.
[0017] The base plate preferably includes a plurality of base electrodes positioned so that one base electrode is in electrical connection with the first electrode of the central portion of the plate member and another base electrode is in electrical connection with the second electrode of the central portion. Such base electrodes are very effective in providing the alternating voltage signal from a remote source to the resonating central portion of the plate member.
[0018] The electrodes described herein may be constructed of any suitable electrically conductive material. However, it is preferred that such electrodes comprise metals. The electrodes can be provided in any suitable manner. Preferably, the electrodes are provided by vacuum deposition onto the surface, as desired.
[0019] Quartz crystal resonators, in accordance with the present invention, include the quartz crystal-based plate and base plate, as described elsewhere herein, and, in addition, a cover plate secured to the quartz crystal-based plate so that the plate is located between the base plate and the cover plate. Preferably, the base plate and the cover plate are both secured to the border of the quartz crystal-based plate. More preferably, both the base plate and the cover plate are secured to substantially the entire outer portion of the border so that the resonator is firmly mechanically bonded together and the resonating central portion of the quartz crystal-based plate is hermetically sealed or enclosed.
[0020] In one embodiment, a first adhesive is provided which is located between the base plate and the border and is effective in securing the base plate to the border, and a second adhesive is provided and located between the cover plate and the border and is effective in securing the cover plate to the border. The compositions of the first and second adhesives may be the same or different, preferably the same.
[0021] Although any suitable material may be employed as the cover plate, the cover plate preferably comprises quartz. Thus, in one particularly useful embodiment, the quartz crystal-based plate, base plate and cover plate all comprise quartz. In one useful embodiment, at least one of the base plate and the cover plate includes an outwardly extending recess. This feature will be described in more detail hereinafter.
[0022] In another broad aspect of the present invention, methods for producing quartz crystal resonators are provided. Such methods include providing a solid quartz crystal plate. Quartz is removed from the solid quartz crystal plate to form a quartz crystal plate member including a central portion, a border and a space, preferably a slot, between the central portion and the border including a first region separated from the central portion and a second region joined to the central portion. First and second electrodes are placed on the top surface and the opposing bottom surface of the plate member, respectively. The plate member is secured to an electroded base plate so that the central region is free to resonate relative to the base plate, preferably in response to an alternating voltage being applied to the central region. The plate member is secured to a cover plate so that the plate member is located between the base and the cover plate.
[0023] In one embodiment, the base plate and the cover plate both comprise quartz and the securing steps include the use of adhesives to secure the plate member to the base plate and the plate member to the cover plate, respectively. The securing steps are effective to both mechanically bond the base plate, the plate member and the cover plate together, and form a hermetically sealed periphery. Electrically conductive adhesive, preferably electrically conductive epoxy adhesive, is employed to make contacts between the electrodes which are deposited on the central portion and the electrodes which are deposited onto the base plate which complete the electrical circuit of the resonator.
[0024] Each and every feature described herein, and each and every combination of two or more of such features, is included within the scope of the present invention provided that the features included in such a combination are not mutually inconsistent.
[0025] These and other aspects and advantages of the present invention are set forth in the following detailed description and claims, particularly when considered in conjunction with the accompanying drawings in which like parts bear like reference numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] [0026]FIG. 1 is a top front view, in perspective, of a piezoelectric quartz crystal resonator plate in accordance with the present invention;
[0027] [0027]FIG. 2 is a perspective illustration of the plate shown in FIG. 1 with conductive metallic electrodes coating the major surfaces;
[0028] [0028]FIG. 3A is a perspective illustration of the upper internal surface electrode pattern of a quartz base plate in accordance with the present invention;
[0029] [0029]FIG. 3B is a perspective illustration of the lower external surface electrode pattern of the quartz base plate in accordance with the present invention;
[0030] [0030]FIG. 4 is a perspective illustration of the piezoelectric quartz resonator plate shown in FIG. 2 bonded to the quartz base plate;
[0031] [0031]FIG. 5 is a perspective illustration of a surface mount quartz crystal resonator in accordance with the present invention;
[0032] [0032]FIG. 6 is a cross-sectional view of an alternate embodiment of a surface mount quartz crystal resonator in accordance with the present invention; and
[0033] [0033]FIGS. 7A and 7B are a partial top view and a cross-sectional view, respectively, of another piezoelectric quartz resonator plate in accordance with the present invention.
[0034] [0034]FIGS. 8A and 8B are a partial top view and a cross-sectional view, respectively, of a further piezoelectric quartz resonator plate in accordance with the present invention.
DETAILED DESCRIPTION
[0035] Referring now to FIG. 1, a rectangular piezoelectric quartz crystal plate 10 is shown. A decoupling slot 11 has been formed in the plate 10 by removing a narrow section of quartz along three sides of the plate 10 and partially along fourth side 14 . The forming of the decoupling slot 11 creates a central resonant part 13 of quartz and a border 12 of quartz around the peripheral region 13 A of central resonant part. The border 12 includes a first region 12 A which is spaced apart, by slot 11 , from resonant part 13 , and a second region 12 B which is joined to the resonant part. The amount of removal along the fourth side 14 of the plate 10 depends on how strong the second region 12 B joining the border 12 and the resonant part 13 is desired to be. Second region 12 B is strongest if no quartz is removed parallel to the fourth side 14 of the plate 10 . In the embodiment of the invention being described, the length of the quartz plate 10 is shown to be parallel with the X Axis, referred to as the crystallographic axes of the quartz crystal and the AT-cut of quartz crystal which is commonly employed for high frequency quartz crystal resonators. The width of plate 10 is parallel to the Z′ Axis and the thickness of the plate is parallel to the Y′ Axis.
[0036] Without wishing to limit the invention, typical dimensions of quartz plate 10 include a length in the range of about 3.2 mm to about 12 mm, for example, about 7.5 mm; a width in the range of about 2.5 mm to about 5.5 mm, for example, about 5 mm; and a thickness dependent on the resonating frequency according to the following relationship
t = 1.65 F EQN . 1
[0037] where t is thickness in mm and F is the resonating frequency in MHZ which can often range from about 8 MHz to about 50 MHz.
[0038] With the plate 10 formed as shown in FIG. 1, stresses which are applied to the sides of the plate 10 to the first region 12 A of border 12 outside of the decoupling slot 11 have no influence on the resonant characteristics of the resonant part 13 . Stresses applied to the fourth side 14 result in some strain in the resonant part 13 . However, because the resonant part 13 is free to move without interference from the other three sides of the border 12 of plate 10 , the effect of the strain from the fourth side 14 on the resonant characteristics are very small, if noticeable at all.
[0039] The forming of the quartz plate 10 in the way shown in FIG. 1 provides a resonant part 13 of the plate 10 which is substantially mechanically isolated from the border 12 of the plate so that the border of the plate may be incorporated into the enclosure structure of the quartz crystal resonator to be made from plate 10 without detriment to the resonant characteristics of the final product.
[0040] In order to apply an electrical signal across the resonant part 13 of the quartz plate 10 , conductive metallic electrodes 14 and 15 are vacuum deposited opposite each other, on the top or first major surface 13 B and the bottom or second major surface 13 C, respectively, of resonant part 13 of the quartz plate 10 , as is shown in FIG. 2.
[0041] The dimensions of the electrodes 14 , 15 depend on the values of the parameters of the equivalent electrical circuit which the final quartz crystal resonator is being designed to meet and the size limitations that may apply because of the application involved. However, the thickness of the electrodes 14 , 15 and the density of the metal that is employed for the electrodes 14 , 15 are primary factors that determine the reduction in frequency of the resonant part 13 of the quartz plate 10 from the frequency that is apparent when no electrodes have been applied to the resonant part 13 , which is referred to as the unelectroded frequency. The ratio of the amount of the reduction of the resonant frequency to the unelectroded frequency is commonly called the mass loading of the electrode, which is expressed by the equation,
Δ = f u - f e f u = mass loading , EQN . 2
[0042] where f u is the unelectroded frequency of the resonant part, and f e is the frequency of the electroded resonant part. A result of acoustic wave considerations shows that the thickness shear wave that is driven between the electrodes 14 , 15 at frequency f e cannot propagate into the unelectroded areas of the resonant part 13 and the amplitude of the acoustic displacement exponentially decreases as the wave radiates towards the edges 18 , 19 of the resonant part 13 .
[0043] Since the energy of the wave is proportional to the square of the acoustic displacement, the energy of the wave also exponentially decreases as it radiates from the electrode edges 16 , 17 toward the edges 18 , 19 of the resonant part 13 of the quartz plate 10 . This phenomenon is termed energy trapping and is well known in the quartz device industry. Energy that reaches the edges 18 , 19 of the resonant part 13 is lost from the resonator either by dispersion or absorption of the acoustic wave. The larger the value of Δ, the greater the rate of exponential decreasing of the amplitude of the acoustic displacement and the greater the amount of energy trapping. When the amount of acoustic energy which is lost by inadequate energy trapping is large, then the equivalent series resistance is large.
[0044] It is normally desired that a quartz crystal resonator have a relatively small equivalent series resistance. Therefore, the value of Δ and the length of quartz plate between the edges of the electrodes 16 , 17 and the edges 18 and 19 of the resonant part 13 are design considerations in determining the dimensions of the quartz plate 10 and the resonant part 13 so that the quartz crystal resonator meets the requirements of the intended application, such as they may be.
[0045] Conductive metallic appendages extend from the top electrode 14 and the bottom electrode 15 to terminal electrode areas 20 , 21 of the quartz crystal resonator plate 10 . The significance of the terminal electrode areas 20 , 21 is that they line up with base terminal electrode areas 26 , 27 on the upper internal surface 23 of the quartz base plate 22 which is shown in FIG. 3. Conductive epoxy is applied so that it connects the terminal electrode area 20 to base terminal electrode area 26 and terminal electrode area 21 to base terminal electrode area 27 .
[0046] The quartz plate 10 , including electrodes 14 and 15 , is bonded to quartz base plate 22 , which is shown in FIGS. 3A and 3B, using a conventional epoxy adhesive. The quartz base plate 22 has about the same crystallographic orientation as the quartz crystal plate 10 so that the thermal expansion characteristics of the base plate and the plate 10 are substantially or essentially the same. However, for applications having somewhat less stringent requirements or specifications, base plates of quartz having crystallographic orientations dissimilar from the plate 10 or of materials other than quartz can be employed. FIG. 3A shows the upper internal surface 23 of base plate 22 , while FIG. 3B shows the lower external surface 24 of the quartz base plate 22 .
[0047] The lateral dimensions of the quartz crystal plate 10 are essentially the same as the quartz base plate 22 . The metallic electrode pattern 25 , 28 on the upper internal surface 23 is such that metallic electrode leads extend from each of the terminal electrode areas 26 and 27 to metallic electrodes 25 and 28 , respectively, which in turn wrap around the edges of the base plate 22 to connect to terminal electrode areas 29 and 30 , respectively, on the lower external surface 24 of the quartz base plate 22 . A conventional conductive epoxy adhesive is applied so that it connects the terminal electrode areas 20 , 21 on the quartz plate 10 with base terminal electrode areas 26 , 27 on the upper internal surface 23 , which are in turn connected via the metallic electrode pattern with the terminal electrode areas 29 , 30 on the lower external surface 24 . The metallic electrodes 14 , 15 which drive the resonant part 13 of the quartz plate 10 are thus connected to terminals 29 , 30 on the lower external surface 24 of the base plate 22 .
[0048] In FIG. 3B, four terminal electrode areas 29 , 30 , 31 , 32 are shown on the lower external surface 24 of the quartz base plate 22 . However, only two terminal areas 29 , 30 are part of the electrical circuit. The two other terminal areas 31 , 32 are functional only in that they are soldered or fixed to the application printed circuit board and aid in locating and holding the final surface mount quartz resonator in place. The number of electroded terminal areas could be reduced to two and their location on the lower external surface 24 would be that which best fits the requirements of the application. The conductive metallic electrode patterns on the surfaces 23 and 24 of the quartz base plate 22 are vacuum deposited thin metallic films. However, they can be placed on the surfaces by other means as well.
[0049] The assembly of the quartz crystal plate 10 to the quartz base plate 22 utilizes conventional epoxy adhesive 34 as is shown in FIG. 4. Epoxy adhesive 34 is applied to the perimeter of either the plate 10 or the base plate 22 . The application of the epoxy adhesive around the plate perimeter forms epoxy adhesive 34 into a frame having a width is less than the width of the border 12 of the quartz crystal plate 10 . The plate 10 and base plate 22 are then positioned one on top of the other and seated so that the epoxy adhesive 34 completely contacts the facing surfaces of both plates. Care is taken to insure that no epoxy adhesive bridges the slot 11 in the quartz plate 10 between the border 12 and the resonant part 13 . The epoxy adhesive 34 has the dual purpose of mechanically bonding the two plates 10 and 22 together and forming a hermetic seal around the joining perimeter. Note that the outer perimeter 33 of adhesive layer 34 substantially coincides with the outer perimeters of plates 10 and 22 . The thickness of the epoxy adhesive layer 34 is sufficient to keep the resonant part 13 from touching or making contact with the quartz base plate 22 when the part 13 is resonating.
[0050] Conventional conductive epoxy 36 is applied so that it connects the terminal electrode areas 20 and 21 of the quartz plate 10 and the terminal electrode areas 26 and 27 , respectively, on the base plate 22 . After the application of the epoxy adhesive 34 and 36 , the adhesives are allowed to cure in accordance with the specification of the manufacturers of the adhesive. Adhesives 34 and 36 can be cured at the same time.
[0051] After the adhesives 34 and 36 have been properly cured, the assembly 39 of the plate 10 and base plate 22 may be tested before further processing. This can be accomplished by contacting the terminal electrode areas 29 , 30 and using the appropriate instruments for performing the tests that are required. As is normal in the case of quartz crystal resonators, the frequency preferably is adjusted to the required frequency before completing the assembly and sealing on the cover.
[0052] As shown in FIG. 5, the quartz cover plate 35 has essentially the same dimensions as the quartz base plate 22 but the quartz cover plate has no functional electrodes. The quartz cover plate 35 is transparent and the electrodes of the quartz crystal plate 10 and the quartz base plate 22 can be seen through the cover plate. However, the surface of the quartz cover plate 35 is used for marking the device for identification.
[0053] The quartz cover plate 35 is bonded to the assembly of the quartz plate 10 and the quartz base plate 22 in substantially the same way the quartz base plate 22 was joined to the quartz resonator plate. Conventional epoxy adhesive 38 is applied to the border 12 of the quartz plate 10 . The width of the application of epoxy adhesive 38 around the perimeter of the quartz plate 10 is narrower than the border 12 to insure that excess epoxy adhesive does not bridge the slot 11 between the border 12 and the resonant part 13 of the quartz plate 10 . If excess epoxy adhesive should be inadvertently placed onto the resonant part 13 the resonant characteristics would be detrimentally affected depending on how much epoxy adhesive was so placed. The outer perimeter 37 of epoxy adhesive 38 substantially coincides with the outer perimeter of plate 10 , base plate 22 , and cover plage 35 .
[0054] After the epoxy adhesive 38 is applied, the cover plate 35 is then placed on top of the assembly and seated so that the perimeter of the cover plate 35 is completely in contact with the epoxy adhesive 38 and no voids are present. This latter step is performed in a glove box which contains dry nitrogen gas so that the quartz crystal resonator part 13 is hermetically sealed and filled with the inert gas dry nitrogen. The epoxy adhesive 38 is cured in the same inert gas in accordance with the specifications of the adhesive manufacturer.
[0055] The epoxy adhesive has a certain viscosity and surface tension which supports the three quartz plates 22 , 10 and 35 during assembly and keeps them from touching after cure. It is important the central resonant part 13 not be in contact with either the quartz base plate 22 or the quartz cover plate 35 . Such contact may prevent resonance from occurring or result in high equivalent series resistance of the resonator. If for any reason the design may require that the central resonant part be thicker than the perimeter border then the central part of the quartz cover and base plate can be recessed sufficient, as described hereinafter, so that contact is avoided.
[0056] A feature of the invention lies in the fact that the temperature coefficients of expansion of the quartz crystal plate 10 , the quartz base plate 22 and the quartz cover plate 35 are the same so the stresses which arise from the use of dissimilar materials for the base and cover according to old art are avoided.
[0057] A feature of this invention, resulting from the structure of the resonator assembly 40 , is that the resonant part 13 of the quartz crystal resonator plate 10 is supported within the cavity which is formed by the border 12 of the quartz plate 10 , the quartz base plate 22 , the cover plate 35 and the thicknesses of the epoxy adhesives 33 and 38 around the perimeter bonding the assembly together. The quartz plate 10 is not separated from the base plate 22 and the cover plate 35 , as is often the case with the prior art. The strength of the quartz supporting the resonant part 13 is much greater than two small dots of conductive epoxy which supports the resonator element of surface mount quartz crystal resonators in the prior art.
[0058] [0058]FIG. 6 illustrates an alternate embodiment of a surface mount quartz crystal resonator assembly in accordance with the present invention. Except as expressly described herein, this alternate resonator assembly , shown generally at 140 , is structured and functions in a manner similar to that described previously with regard to resonator assembly 40 . Components of alternate resonator 140 which correspond to components of resonator assembly 40 are identified by the same reference numeral increased by 100 .
[0059] With reference to FIG. 6, the primary difference between alternate resonator assembly 140 and resonator assembly 40 is that the cover plate 135 and the base plate 122 include recesses. In particular, base plate 122 includes an outwardly extending recessed area 50 , and cover plate 135 includes an outwardly extending recess area 52 . These recessed areas or regions 50 and 52 can be produced by conventional methods. Such recessed areas are designed to provide additional space within which resonate part 113 can resonate without coming in contact with either the base plate 122 or the cover plate 135 . This embodiment is particularly useful when it is desired to reduce the size, for example, the profile, of the resonator.
[0060] [0060]FIGS. 7A and 7B illustrate another embodiment of a quartz crystal plate in accordance with the present invention. Except as expressly described herein, this other quartz crystal plate, shown generally at 210 , is structured and functions in a manner similar to that previously described with regard to plate 10 . Components of other plate 210 which correspond to components of plate 10 are identified by the same reference numeral increased by 200.
[0061] The other plate 210 deals with the energy trapping phenomenon, which has been previously discussed with reference to FIG. 2. In some applications, which require small overall size, the design of the resonant part 213 of the quartz resonator plate 210 require a very large value of Δ to achieve the necessary energy trapping for the design to result in an acceptably low value of the equivalent resistance. Normally the desired value of Δ, mass loading is achieved by the thickness of the electrode 14 which is deposited onto the resonant part 13 of the quartz plate 10 . However, because the metallic electrode material has a much lower internal mechanical Q than quartz, using electrodes which are relatively thick increases the equivalent resistance.
[0062] An alternative to increasing the electrode thickness is shown in FIGS. 7A and 7B. The frequency of the thickness shear mode which is employed in this embodiment of the invention is inversely proportional to the thickness of the quartz resonator plate 210 and can be expressed by the EQN. 1, noted above. If the thickness of the resonant part 213 is reduced, as shown in FIG. 7, between the edges of the electrode 216 , 217 and the edges of the resonant part 218 , 219 then the frequency in those regions 60 , 62 will be much higher than the frequency in the electroded region 64 . For example, if the thickness is decreased by 10% then the frequency, ignoring other factors, will increase by about 10%. Since the mass loading, Δ, as given by EQN. 2, is proportional to the difference between the frequency in the unelectroded region 60 , 62 and the frequency in the electroded region 64 , then the mass loading Δ can be increased without having excessively thick electrodes but by decreasing the thickness of the quartz plate outside of the electroded area 64 . This method enables the designs to achieve high levels of energy trapping and good values of equivalent resistance, and still be of small, compact size.
[0063] Quartz resonators of higher frequency are becoming of increased importance. However, as given in EQN. 1 as the frequency of the resonator increases its thickness must correspondingly decrease. The thinner the quartz plate the more fragile it becomes and the more difficult it is to process through the manufacturing process. One alternative is to use overtones of the fundamental frequency which allows for a thicker plate to be used for higher frequencies. However, the equivalent circuit of an overtone mode resonance has higher equivalent resistance and much lower motional capacitance than the fundamental mode resonance. For this reason in many applications the fundamental mode is required.
[0064] [0064]FIGS. 8A and 8B illustrate a further embodiment of a quartz crystal plate in accordance with the present invention. Except as expressly described herein, this further quartz crystal plate, shown generally at 310 , is structured and functions in a manner similar to previously described with regard to plate 10 . Components of further plate 310 which correspond to components of plate 10 are identified by the same reference numeral increased by 300.
[0065] As shown in FIGS. 8A and 8B, the central portion 313 of the quartz crystal plate 310 is reduced in thickness so that its resonant frequency meets that required by the application. This may be accomplished using any suitable technique, for example, by selectively etching the central portion 313 , while leaving the border 312 to be much thicker and stronger. The thickness transition 70 lies between the border region 312 B and the central portion 313 . Using this approach a very thin central portion 313 plate 310 having high resonant frequencies can be achieved without sacrificing the thickness and strength of the border 312 .
[0066] While this invention has been described with respect to various specific examples and embodiments, it is to be understood that the invention is not limited thereto and that it can be variously practiced within the scope of the following claims. | A surface mount quartz crystal resonator includes a quartz crystal-based plate including a central portion adapted to resonate at a desired frequency, and a border substantially surrounding a peripheral region of the central portion. The border includes a first region physically separated from the central portion, and a second region joined to the central portion. A base plate is provided which is secured to the plate so that the central portion of the plate is free to resonate relative to the base plate. A cover plate is provided and is secured to the plate so that the plate is located between the base plate and the cover plate. At least one, and preferably both, of the base plate and the cover plate are made of quartz. | 7 |
FIELD OF THE INVENTION
[0001] This invention relates to improved methods for subsurface exploration, and more particularly to an automated apparatus and methods for performing the standard penetration test.
BACKGROUND OF THE INVENTION
[0002] The Standard Penetration Test (SPT) is an in-situ testing technique that drives a sampler into the ground at the bottom end of a drill hole (or borehole) during subsurface exploration. The test can yield a measure of the soil resistance to the penetration of the sampler under the impact of a free drop hammer from a constant height.
[0003] There are two operators to conduct the test operations. As shown in FIGS. 1 and 2 , the primary operator uses the power of the drilling rig and the steel wireline above the derrick to lift or drop the hoist hook. The secondary operator couples or decouples the hoist hook either with the top of a drill rod ( FIG. 1 ) or with the steel chain of a impact hammer apparatus ( FIG. 2 ). The impact hammer apparatus includes the steel chain, a X-clamp, the hammer and the guide rod. The guide rod has a lower anvil at its bottom, an upper anvil at its top, and a steel chain. The hammer has a cap for clamping by the X-clamp. The testing at a drill hole depth follows the following three processes in a real time sequence.
[0004] At first, the sampler coupled to a drill rod in series has to be inserted into the drill hole ( FIG. 1 ). The sampler has to reach the bottom of the drill hole. If the length of the drill rod whose bottom end is coupled with the sampler cannot make the sampler tip to reach the bottom of the drill hole, a second drill rod will be added to the top of the first drill rod to make the sampler tip to reach the drill hole bottom. Similarly, a third drill rod will be added and coupled if the sampler tip still cannot reach the drill hole bottom. This adding, coupling and inserting process will be repeated until the sampler tip reaches the drill hole bottom. This process is the first process of sampler inserting.
[0005] Next, once the sampler is placed at the test depth, the impact hammer apparatus will be added to the top of the coupled drill rods and the sampler system. The hammer impact apparatus will be used to make the sampler penetrate into the ground at the drill hole bottom ( FIG. 2 ). The hoist hook will lift the X-clamp upward through the steel chain. The X-clamp will clamp the hammer cap and carry the hammer upward along the guide rod. Once the X-clamp impacts the upper anvil, the clamping at the hammer cap will be forced to open and release the hammer automatically. The hammer will drop freely along the guide rod. The flat bottom surface of the hammer will hit the lower anvil at its flat top surface. The lower anvil bottom is coupled to the drill rods. The induced shock force in the drill rods will make the sampler penetrate into the ground below the drill hole bottom. Once the hammer becomes stable on the lower anvil, the primary operator will drop the hoist hook to make the X-clamp drop onto the hammer cap along the guide rod. Then the operator will tighten the steel chain to make the X-clamp couple the hammer cap again. The operator will then lift the hammer quickly. Again, the hammer will drop freely once the X-clamp impacts the upper anvil. The hammer will hit the lower anvil to make the sampler to penetrate the soil again. The above operation process will be repeated several times until a test criterion is satisfied. This process is the second process of hammer impact and sampler penetrating.
[0006] Third, once the penetrating stage is completed, the operators will remove the hammer impact apparatus from the drill rods. The operators will then retrieve the drill rods from the drill hole one by one ( FIG. 1 ). The drill rods and the sampler will be lifted up. The top drill rod will then be decoupled from the remaining drill rods in the drill hole, and it will be placed on the ground nearby. Then the remaining drill rods will be removed from the drill hole. The second top drill rod will be decoupled and placed on the ground nearby. This lifting, decoupling and placing process will be repeated until the first drill rod with the sampler is retrieved from the drill hole. This process is the third process of sampler retrieving. Further drilling work will be then carried out until the bottom end of the drill hole reaches the subsequent test depth. Then the subsequent test will be conducted following the above three processes.
[0007] The hammer is made of steel and weighs 63.5 kg. The free drop height is 760 mm. The blow counts of the hammer falling on the anvil are recorded for each of 75 mm penetration between 0 and 450 mm penetrations. The first 150 mm penetration is regarded as a seating drive. The number of blows necessary to drive the sampler to penetrate 300 mm into the ground is known as the penetration resistance or N-value. A specification on how to determine the N-value is normally adopted by authorities for determining the soil shear strength and bearing capacity. A hammer efficiency can be further defined as the percentage ratio of a rod dynamic energy over the total potential energy of the hammer drop height (473 Joule). The rod dynamic energy is calculated from the axial shock force in the drill rod generated by the hammer blowing according to a specific equation such as the equation in ASTM (1995).
[0008] The SPT has been widely used and is a tool of choice in Hong Kong housing and infrastructure development as well as landslip preventive measures project. The SPT is included for most ground investigation contracts. The SPT has the following advantages: a) the test apparatus is simple and rugged; b) the test can be carried out in many different types of soils; c) the test has been widely adopted as a routine in-situ testing method throughout the world; and d) tremendous experience and empirical correlations have been obtained for geotechnical design and construction.
[0009] The SPT results, and more particularly the N-value and the test depth, however, have been obtained completely from manual measurements. Usually, two contractors conduct the manual measurements. For most tests, there is no full-time independent supervision or inspection. Furthermore, the testing and the drilling are destructive, non-repeatable and time consuming. More importantly, the test is often carried out in colluvium and weathered rock soils in Hong Kong. Gravel, cobbles, and boulders of high strengths and stiffness can appear randomly in the soil. They can substantially alternate the N-values. As a result, the N-values at a construction site can have a large range of variations in Hong Kong.
[0010] Therefore, the accuracy and quality of the manual test results have always been the main concern of many geotechnical engineers and contractors in Hong Kong. At present, there is no tool independently to check and verify the accuracy and quality of the manual test results. Therefore, it is believed that automation of the measurement monitoring and recording for SPT can solve the pressing issues and offer additional data for independently checking and verification of the manual test results.
SUMMARY OF THE INVENTION
[0011] The field observation and issue of the manual operations and measurements of the conventional standard penetration test have led to the present invention for automation of the test measurements. The inserting process, the impact hammer and sampler penetrating process, and retrieval process are carried out sequentially in time sequence. A first object of the present invention is to provide an automatic digital SPT monitor for recording and evaluating the inserting process of the rods and sampler into a drill hole in real time, which enables the assessment and verification of the test depth and its commencement time. A second object of the present invention is to provide an automatic digital SPT monitor for recording and evaluating the impact hammer and sampler penetration process in real time, which is able to assess the soil resistance and more particularly the N-value and the associated hammer efficiency in accordance with a specification [in the present configuration, the specification is the Hong Kong Housing Authority specification]. A third object of the present invention is to provide an automatic digital SPT monitor for recording and evaluating the retrieval process of the rods and sampler from a drill hole in real time, which enables the assessment and verification of the test depth and its completion time.
[0012] In order to accomplish the foregoing objects, the present invention provides an in situ digital SPT monitor for the standard penetration tests in association with an existing SPT apparatus and operation procedures. The digital SPT monitor comprises a tip depth transducer, a shock force transducer, a shock penetration transducer, and a micro-process controller for data acquisition and processing. The micro-process controller comprises a notebook computer, a data logger, and a battery. The data logger connects with the tip depth transducer, the shock force transducer and the shock penetration transducer with a first signal cable, a second signal cable and a third signal cable for transmission of a first electrical signal, a second electrical signal and a third electrical signal, respectively. The first and third electrical signals are digital signals. The second electrical signal is an analog signal.
[0013] Immediately before the commencement of the insertion process, the tip depth transducer is mounted onto the top of a drill hole casing and unlocked. The tip depth transducer senses the vertical movement (or non-movement) of the sampler and each of the coupled drill rods with respect to a fixed position (i.e., the casing) on the ground during the insertion process, and transmits the first electrical signal into the micro-process controller for storage and display at a first pre-selected sampling rate in real time. At the completion of the insertion process, the tip depth transducer is locked and dismounted from the casing and placed on the ground nearby. The lock makes the first electrical signal have no change with time.
[0014] Subsequently, the impact hammer apparatus together with the shock force transducer and the shock penetration transducer are mounted onto the top of the drill rod in series for the second process of impact hammer and sampler penetration. The shock force transducer senses the axial force in the rod and the shock penetration transducer senses the rod displacement with respect to a fixed position on the ground. They transmit the second and the third electrical signals to the micro-processor controller with the second and the third electric cables simultaneously and in real time. A triggering method is adopted for data acquisition and storage for a pre-selected duration of time in the micro-processor controller at a second pre-selected sampling rate. The criterion for triggering is that the shock force is equal or greater than a pre-selected magnitude in compression. The pre-selected interval of data acquisition is less than the time interval for hammer lifting and drop and is greater than the time interval for hammer rebound. At the same time, the micro-process controller counts and records one hammer blow. This auto-monitoring and data acquisition process is repeated for each hammer blow until the micro-processor controller finds that the test has reached one of the predetermined criteria for the N-value. At this moment, the computer of the micro-process controller alerts the operators. After the completion of the second process, the impact hammer apparatus, the shock force transducer, and the shock penetration transducer are removed from the drill rod.
[0015] At the beginning of the retrieval process, the tip depth transducer is re-mounted onto the casing and unlocked. The tip depth transducer senses the vertical movement or non-movement of the sampler and each of the coupled drill rods with respect to a fixed position (i.e., the casing) on the ground during the retrieval process and continues the transmission of the first electrical signal into the micro-process controller for storage and display at the first pre-selected sampling rate in real time. At the completion of the retrieval process, the tip depth transducer is again locked and dismounted from the casing and placed on the ground nearby.
[0016] In the present configuration, the pre-selected first sampling rate is 100 Hz for the first electrical signal and 50 kHz for the second and third electrical signals; the pre-selected magnitude of the triggering axial force is 50 kN; and the pre-selected duration of data acquisition for the second and third electrical signals is one second.
[0017] The present invention is portable and is applicable to any existing SPT apparatus. It monitors the three testing processes in real time. It further evaluates the SPT measurements and reports a summary of the test results from the monitored digital data in real time sequence. It is applicable to various ground conditions including extreme hard (N>200), normal (1<N<200) and extreme soft (e.g., N<1) ground conditions at any test depths.
BRIEF DESCRIPTION OF DRAWINGS
[0018] The foregoing and other objects, features and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0019] FIG. 1 is a prior art manual apparatus for the first process of inserting (or the third process of retrieving) a sample coupled with drill rods in series into and from a drill hole for SPT at a given test depth at field;
[0020] FIG. 2 is a prior art apparatus for hammer and sampler penetrating at the bottom of a drill hole to determine the soil N value at field;
[0021] FIG. 3 is a general schematic view of the measurement, automation, and recording of the first process of the sampler insertion or the third process of the sample retrieval of the prevent invention;
[0022] FIG. 4 is a general schematic view of the measurement, automation, and recording apparatus of the second process of the impact hammer and sample penetration in accordance with the present invention;
[0023] FIG. 5 is a detailed schematic view of the present invention for measurement, automation, and recording of the first process of the sampler insertion or the third process of the sample retrieval;
[0024] FIG. 6 is a detailed schematic view of the tip depth transducer of the present invention;
[0025] FIG. 7 is an example of actual measurement results of the present invention from the tip depth transducer for the first process of sample insertion and the third process of sample retrieval in real time series;
[0026] FIG. 8 is a detailed schematic view of the present invention for the measurement, automation, and recording of the second process of the impact hammer and sample penetration;
[0027] FIG. 9 is the axial shock force measurement with the shock force transducer in the drill rod for one second due to the impact of hammer drop at field;
[0028] FIG. 10 is a detailed view of the result of the shock force in FIG. 9 during its initial 0.05 second duration;
[0029] FIG. 11 is a detailed schematic view of the shock penetration transducer of the present invention;
[0030] FIG. 12 is a detailed schematic view of the gear box on the rack and along the two guide rods of the shock penetration transducer of the present invention;
[0031] FIG. 13 is a graph of the shock penetration transducer for the change of the gear box position on the rack with the time simultaneous to that for the shock force in FIG.9 ;
[0032] FIG. 14 is a detailed view of the typical result of the shock penetration transducer in FIG. 13 during its initial 0.05 second duration; and
[0033] FIG. 15 is a summary report for the measurement automation of the second process of hammer blow and sample penetration at the test depth showing in FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] The present invention will be described in further detail by way of example with reference to the accompanying drawings. As shown in FIGS. 3 to 8 , a digital SPT monitor 10 for measurement automation of standard penetration test according to the present invention comprises a micro-process controller 30 , a tip depth transducer 40 , a shock force transducer 60 , and a shock penetration transducer 70 . The micro-process controller 30 comprises a data logger 32 , a battery 33 , and a notebook computer 31 . The data logger 32 uses a power supply cable 34 to attach the battery 33 and uses a firewall cable 35 to communicate with the computer 31 . The battery 33 is used to supply the small amount of power required for the data logger 32 and the notebook computer 31 . The micro-process controller 30 further uses the first signal cable 36 to communicate with the tip depth transducer 40 , the second signal cable 37 to communicate with the shock force transducer 50 , and the third signal cable 38 with the shock penetration transducer 60 .
[0035] Referring to FIGS. 5 and 6 , the tip depth transducer 40 has the following components: a first circular wheel 41 with a first rotation sensor 42 and a lock, a second circular wheel 41 and a third circular wheel 44 , a hollow cylinder 43 , a footing plate 44 with a circular hole at the center, four screw blots 45 , four columns 46 , an inner cylinder 47 , a podium plate 48 with a circular hole, two springs 49 , and a travel shaft 50 . The first wheel 41 , the second wheel 41 and the third wheel 44 are vertically placed above the podium plate 48 and surround a common center at a spacing of 120° on horizontal plane. The footing of the travel shaft 50 is also welded on the podium plate 48 . The podium plate 48 has its bottom surface welded with the hollow cylinder 43 below. The hollow cylinder 43 has its base welded with the footing plate 44 . The footing plate 44 is welded above and with the inner cylinder 47 and the four columns 46 . The diameters of the circular holes in the podium plate and the footing plate are larger than the diameters of the drill rod 22 and sampler. The inner diameter of the hollow cylinder 43 is larger than the diameter of the casing. The inner diameter of the inner cylinder 47 is larger than the diameters of the drill rod and sampler and less than the diameter of the casing.
[0036] The tip depth transducer 40 uses the footing plate 44 to seat on the casing and the four screw bolts 45 to clamp the four columns onto the casing. Therefore, the tip depth transducer 40 can be firmly mounted onto or completely removed from the top of a casing in a drill hole. The coupled sampler and drill rods can be inserted into or retrieved from the tip depth transducer 40 as shown in FIGS. 5 and 6 . In the present configuration, the casing is used to support the tip depth transducer. Other means to support the tip depth transducer 40 can also be developed.
[0037] During insertion or retrieval, the sampler or a drill rod 22 frictionally contacts with the three wheels and causes them to rotate about their rotational axes. The rotational axis of the first wheel 42 is bolted to the travel shaft 50 . The first wheel 42 and the travel shaft 50 together can move horizontally above the podium plate. The two springs 49 urge the travel shaft and the first wheel against the drill rod 22 or the sample. When it is switched off, the lock stops the rotation of the first wheel 42 about its axis. When it is switched on, the first wheel can freely rotate about its axis.
[0038] The first electrical signal measures the degree of the rotation of the first wheel 42 about its axis. The first rotation sensor 42 captures the first electrical signal and transfers it into the micro-process controller through the first signal cable 36 in real time at a first pre-selected sampling frequency. The micro-process controller 30 further changes the first electrical signal into the amount of the length of the sampler coupled with the rods passing through the first wheel position in real time and displays it on the screen of the notebook.
[0039] FIG. 7 shows the first graph for an actual result of the present invention from the first digital signal, where the first pre-selected sampling frequency was 100 Hz. The first graph represents the first process of sampler inserting and the third process of sampler retrieving. The test was carried out between 15:14 and 15:29 in the afternoon of Jun. 29, 2005. The first process was between 15:14 and 15:17. Its graph has a down-staircase shape with the actual time, representing that four rods were being coupled with the sampler for inserting the sampler into the drill hole one by one. The total length of the four rods and the sampler inserting through the tip depth transducer was 10.625 m. Between 15:17 and 15:25, the graph is a horizontal line, representing that the first electrical signal had no change during the second process, when the first wheel of the tip depth transducer was locked. The third process was between 15:25 and 15:29. Its graph has an up-staircase shape with the actual time, representing that the four rods and the sampler were being lifted up and decoupled out of the drill hole one by one. The total length of the four rods and the sampler lifting up through the tip depth transducer was 11.033 m.
[0040] Referring to FIGS. 4 and 8 , the shock force transducer 60 is connected to the lower anvil 28 with the upper coupling 52 and the drill rod 22 with the lower coupling 52 at the bearing arm 81 . The shock force transducer 60 captures the second electrical signal and transfers it into the micro-process controller through the second signal cable 37 in real time at a second pre-selected sampling frequency. The second electrical signal is a voltage output. The micro-process controller 30 further changes the second electrical signal into the amount of the axial force due to the hammer impact in the drill rod 22 and displays it on the screen of the personal computer 31 in real time.
[0041] FIG. 9 shows the second graph for an actual result of the present invention from the second digital signal, where the second pre-selected sampling frequency was 50 kHz and the total sampling period was one second. The second graph represents the time variation of the shock force in the drill rod immediately after the hammer impact on the lower anvil. A third graph in FIG. 10 details the axial shock force within the first 0.05 second of the second graph in FIG. 9 . From the second and third graphs in FIGS. 9 and 10 , the following observations can be made: (a) the axial shock force increased quickly at the beginning and reached its maximum at a time less than 0.001 second; (b) the axial shock force vanished to zero at about 0.05 second; and (c) the axial shock force had the maximum value about 230 kN.
[0042] Referring to FIGS. 8, 11 and 12 , the shock penetration transducer 70 has the following main components: a right triangle steel frame 71 with four pulleys 72 , 73 , 74 , and 75 , a steel wire loop 76 , a gear box with a second rotation sensor 77 , an inclined rack 78 , two inclined guide rods 79 , a bearing arm 80 and other accessories. During monitoring, the shock penetration transducer 60 is coupled to the drill rod 22 with the bearing portion of the bearing arm 81 , as shown in FIGS. 8 and 11 . The shock penetration transducer 60 rests on a supporting beam 82 clamped on the two sleepers of the drilling rig, as shown in FIG. 4 .
[0043] The bearing arm 81 is tied to the steel loop wire 76 with a bolt 80 and transfers the rod's longitudinal movement to the steel loop wire 76 . The steel loop wire 76 is supported by the first pulley 72 , the second pulley 73 , the third pulley 74 and the fourth pulley 75 , and can smoothly slide on the four pulleys. The four pulleys are supported by the right triangle steel frame 71 . The steel loop wire 76 is also connected with the gear box 77 on the inclined rack 78 . The gear of the gear box 72 matches the rack gear. The two steel guide rods 79 guide the upward or downward movement of the gear box 77 on the rack 78 . The rack 78 and the two steel guide rods 79 are fixed with the right triangle steel frame 71 .
[0044] As it moves between the first pulley 72 and the fourth pulley 75 , the bearing arm 81 uses the steel loop wire 76 to bring the gear box 77 to slide correspondingly on the rack between the second pulley 73 and the third pulley 74 . The upper portion of the steel loop wire 76 on the first 72 and second 73 pulleys between the bearing arm 81 and the gear box 77 is always straight and in tension because it prevents the gear box 77 from sliding down on the rack 78 due to the weight of the gear box 77 . The gear box 77 typically weighs one to two kilograms. The lower portion of the steel loop wire 76 on the third pulley 74 and the fourth pulley 75 and between the gear box 77 and the bearing arm 81 is used to quickly damp and eliminate the free vibration of the gear box 77 on the rack 78 from the impact of the hammer.
[0045] The second rotation sensor associated with the gear box 77 obtains the third electrical signal and transfers it into the micro-process controller 30 through the third signal cable 38 in real time at the second pre-selected sampling frequency. The third electrical signal is the degree of the rotation of the gear of the gear box 77 on the rack 78 . The micro-process controller 30 further changes the third electrical signal into the position of the gear box on the rack and displays it on the screen of the notebook in real time. The gear box upward movement at its stable condition is equal to the permanent penetration of the sampler due to one blow from a hammer drop.
[0046] FIG. 13 shows the fourth graph for a typical result of the present invention from the third digital signal, where the second pre-selected sampling frequency was 50 kHz and the total sampling period was one second. This fourth graph represents the time variation of the gear box position on the rack immediately after the hammer blow onto the lower anvil. A fifth graph in FIG. 14 details the gear box position within the first 0.05 second of the fourth graph in FIG. 13 . From the fourth graph in FIG. 13 and the fifth graph in FIG. 14 , the following observations can be made: (i) the change of the gear box position due to the hammer blow vanished within 0.2 second; (ii) initially, the gear box monotonically moved upward to a maximum at a time between 0.045 and 0.005 second; (iii) subsequently, the gear box had its first downward movement; (iv) then, the gear box experienced small vibrations with magnitude less than 2 mm; and (v) after about 0.2 second, the gear box position had no change with time and stayed at a position 22 mm above the initial position.
[0047] The time in the second graph in FIG. 9 was exactly the same at that in the fourth graph in FIG. 13 . The time in the third graph in FIG. 10 was exactly the same at that in the fifth graph in FIG. 14 . The micro-process controller 30 collected the second and third electrical signals simultaneously at the second pre-selected time-sampling frequency in real-time sequence. The micro-process controller 30 also recorded the actual commencement time (i.e., the time 0) of the graphs in FIGS. 9, 10 , 13 and 14 in the form of year, date, hours, minutes and seconds, which are omitted in these figures.
[0048] Furthermore, the micro-process controller 30 of the present invention has a triggering mechanism for data acquisition and storage of the second and third electrical signals in real time. The criterion for the triggering mechanism is that the shock force from the shock force transducer 60 is equal or greater than a pre-selected magnitude in compression (50 kN at the present configuration). Once the shock force reaches a pre-selected or predetermined the criterion, the micro-process controller 30 acquires, stores and displays the second and third signals at the second pre-selected sampling frequency (50 kN at the present configuration) for a pre-selected period of time (one second at the present configuration). At the same time, the micro-process controller 30 records one hammer blow and the actual commencement time of the data acquisition, and checks the accumulated permanent penetration and the accumulated hammer blow number with the predetermined specification for alerting the completion of the testing. This automonitoring and data acquisition process is repeated for each hammer blow until the micro-process controller 30 finds that the test has reached the pre-determined specification. At this point, the micro-process controller 30 alerts the operators of the completion of the testing.
[0049] FIG. 15 shows a summary report of the present invention for the measurement automation of the second process of hammer blows and sampler penetration at the test depth showing in FIG. 7 . The micro-process controller 30 produced and displayed this summary report once the test was completed. In FIG. 15 , the actual date, the beginning and the ending time for the second process of the testing are reported. The numbers of the hammer blow for the 150 mm seating drive and each of the subsequent 75 mm main drives are shown in the table. The N value, the total blows and the total penetration depth are listed.
[0050] FIG. 15 also shows the sixth graph, the seventh graph and the eighth graph. The results shown in the sixth graph and the seventh graph were acquired simultaneously from the second electrical signal and the third electrical signal, respectively. The micro-process controller 30 was triggered 27 times for the data acquisition and evaluation at this test depth. Each triggering represents a hammer blow on the lower anvil in FIG. 4 . The total time for the data acquisition is 27 seconds, which is the abscissa of the sixth and seventh graphs. Accordingly, there were 27 hammer blows in total in FIG. 15 .
[0051] The actual commencement time of each of the one second sampling period was recorded but not shown in the sixth and seventh graphs. The portion of the sixth graph in FIG. 15 between any two nearby integers of the time seconds (say, [0,1], [1,2], . . . , [26,27]) represents the time variation of the axial shock force during the pre-selected sampling period of one second for each of the 27 hammer blows. Similarly, the portion of the seventh graph in FIG. 15 between any two nearby integers of the time seconds (say, [0,1], [1,2], . . . , [26,27]) represents the corresponding time variation of the gear box position during the pre-selected sampling period of one second for each of the 27 hammer blows. The time variation of the axial shock force during each of the 27 one-second data acquisition periods can be presented as those shown in the second and third graphs in FIGS. 9 and 10 . The time variation of the corresponding gear box position during each of the 27 one second data acquisition periods can also be presented as those shown in the fourth and fifth graphs in FIGS. 13 and 14 , respectively. All those graphs can be produced in the micro-process controller.
[0052] The micro-process controller also calculated the energy efficiency (%) from the acquired shock force in the sixth graph for each hammer blow, presented it in the eighth graph with respect to its corresponding blow number and displayed on the computer screen.
REFERENCES
[0000]
The following references are incorporated by reference as illustrative of the state of the art.
1. ASTM, 1995. Soil and Rock (1), Vol. 04.08: Standard Test Method for Penetration Test and Split - Barrel Sampling of Soils , D 1586-84, 1916 Race Street, Philadelphia, U.S.A., 129-133
2. ASTM, 1995. Soil and Rock (1), Vol. 04.08: Standard Test Method for Stress Wave Energy Measurement for Dynamic Penetrometer Testing Systems , D 4633-86, 1916 Race Street, Philadelphia, U.S.A., 775-778.
3. GEO, 1996. Section 21.2 Standard Penetration Test, in Guide to Site Investigation, Geoguide 2, Geotechnical Engineering Office (GEO) Civil Engineering Department, Hong Kong, pp. 111-113.
4. HKHA, 2003. HKHA General Specifications for Ground Investigation Contracts, 2003 Edition ( Revision A ), Hong Kong Housing Authority (HKHA), Hong Kong. p. 2.
5. Yue, Z. Q., Lee, C. F., Law, K. T. and Tham, L. G., 2004. Automatic monitoring of rotary-percussive drilling for ground characterization—illustrated by a case example in Hong Kong, International Joumal of Rock Mechanics & Mining Science, 41: 573-612.
6. U.S. Pat. No. 6,637,523 B2 (Lee) | An apparatus is used with an impact hammer penetration assemble such as standard penetration test (SPT) in geotechnical engineering. The impact hammer penetration assembly comprises a penetration sample, a series of rods coupled together and an impact hammer apparatus. The drop of the hammer from a constant height hits the coupled rods and sampler in series and forces the sampler deeper into the ground. The apparatus includes a tip depth transducer and sampler to output a first electrical signal that is a function of the sampler tip position. A shock force transducer communicates the axial shock force in the rod to output a second electrical signal that is a function of the rod shock force and hammer blows. A shock penetration transducer communicates the movement of the coupled rods and sampler to output a third electrical signal that is a function of the sampler penetration due to the hammer blows. A micro-process controller monitors and processes the first, second and third signals in real time. | 4 |
FIELD OF THE INVENTION
[0001] This invention is directed to a composition that may be used to treat a substrate. More particularly, the invention is directed to a composition that improves the characteristics of a substrate, like a fabric. The characteristics of the substrate are improved as a direct result of the composition and substrate coming into contact, and the improvements may be realized without the need to employ a mechanical washer, dryer, or ironing device.
BACKGROUND OF THE INVENTION
[0002] It is desirable in busy households to minimize the amount of work required to treat substrates. Particularly, it is very desirable to minimize the amount of work required to reduce or even eliminate, for example, wrinkles in substrates such as clothing. This is especially true when a consumer has worn clothing for a brief period of time and plans to wear the clothing a second time before having it, washed, dried and/or ironed.
[0003] Attempts to reduce wrinkles in clothing have been made, and especially with the introduction of durable permanent press treatments in the textile industry. Such treatments are known to employ polycarboxylic acids to strengthen the fibers of the textile, thereby rendering them less likely to wrinkle. Notwithstanding the above-described permanent press treatments, it is well settled that the effects of such treatments do not last long after the textiles (e.g., clothing) are subjected to a few washing cycles.
[0004] A need exists to reduce wrinkles in substrates, like clothing, that may not be subjected to washing, drying and/or ironing, even if the substrates have been subjected to permanent press treatments. This invention, therefore, is directed to a composition that improves the characteristics of a substrate as a direct result of the substrate coming into contact with the composition. The characteristics which are improved by the composition described in this invention include the reduction of substrate wrinkles and/or the reduction of substrate shape distortion.
[0005] Additional Information
[0006] Efforts have been disclosed for spraying surfaces. In U.S. Pat. No. 5,783,544, a spray composition for reducing malodor is described.
[0007] Still other efforts have been disclosed for spraying surfaces. In U.S. Pat. No. 5,663,134, a spray composition with less than 1.0% by weight of monohydric alcohol is described, and the composition is used to reduce malodor impressions on inanimate surfaces.
[0008] Even further, additional attempts have been made to spray surfaces. In U.S. Pat. No. 5,534,165, spray compositions with odor absorbing features are described.
[0009] None of the references above disclose a composition that may be sprayed on to a substrate in order to reduce wrinkle formation and/or shape distortion of the substrate. As used herein, substrate is defined to mean a textile having the capacity to wrinkle, including curtains, table cloths, upholstery, and especially, clothing. Substrate enhancing agent is defined to mean a compound (including oligomers and polymers) that results in a reduction in wrinkle formation and/or shape distortion of a substrate. Such a substrate enhancing agent is also meant to include a compound that enhances the wrinkle reducing properties of conventional wrinkle reducing additives.
SUMMARY OF THE INVENTION
[0010] In a first embodiment, this invention is directed to a composition for improving substrate characteristics, the composition comprising:
[0011] i) from about 0.1 to about 20.0% by weight of a least one substrate enhancing agent selected from the group consisting of a polyhydric alcohol, a polyether, a monohydric alcohol and a mixture thereof; and
[0012] (ii) greater than about 5.0% by weight water
[0013] wherein the polyhydric alcohol is at least a C 4 polyhydric alcohol, the polyether comprises at least one alkylene chain of at least 4 carbons and the monohydric alcohol is at least a C 5 monohydric alcohol.
[0014] In a second embodiment, this invention is directed to a method for reducing wrinkles and/or shape distortion of a substrate by using the composition described in the first embodiment of this invention.
[0015] In a third embodiment, this invention is directed to an article of manufacture comprising the composition described in the first embodiment of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, may be best understood by reference to the following description taken in conjunction with the accompanying drawing figure in which:
[0017] The Figure illustrates a side view of a trigger sprayer which may be used to dispense the composition for improving substrate characteristics of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] There is no limitation with respect to the type of polyhydric alcohol used in this invention other than that the polyhydric alcohol has at least a C 4 carbon chain. Polyhydric alcohol, as used herein, is defined to mean a compound with more than one hydroxy group and no ether links within its backbone. An illustrative list of the polyhydric alcohols which may be used in this invention includes C 4 to C 18 alkane diols, like 1, 4-butane diol, 1, 5-pentane diol and 1, 10-decane diol. Others include C 6 to C 18 cycloalkane diols like 1, 4-cyclohexane diol.
[0019] The polyhydric alcohols which may be used in this invention can be prepared, for example, by base-or-acid-catalyzed cleavage reactions of epoxides, or by the oxidation of alkenes. Such polyhydric alcohols are also made commercially available by suppliers like Aldrich Chemical.
[0020] Regarding the polyethers which may be used in this invention, these compounds may be oligomers or polymers and have, in their respective backbones, at least one alkylene chain having at least 4 carbon atoms. An illustrative list of the polyethers (e.g., polyalkylene glycols) which may be used in this invention includes polybutylene glycol, polypentylene glycol, polyhexylene glycol, and any copolymers (including terpolymers) of the same.
[0021] The polyethers used in this invention are typically made by conventional techniques which include the polymerization of alkylene oxides via a mechanism initiated by anions. Such polyethers are also made commercially available by suppliers like Dow Chemical, and typically have a weight average molecular weight (mw) from about 500 to about 20,000; and preferably, from about 1000 to about 10,000, including all ranges subsumed therein.
[0022] The monohydric alcohols which may be used in this invention are limited only to the extent that they include alcohols having at least 5 carbon atoms in a linear chain. The preferred monohydric alcohols include those which have greater than about 7 carbon atoms. The most preferred monohydric alcohols include those which have greater than about 15 carbon atoms, like cetyl alcohol, octadecyl alcohol, and mixtures thereof (e.g., tallow alcohol).
[0023] The monohydric alcohols that may be used in the present invention may be prepared by any conventional technique, such as those which react add chlorides with organometallic compounds. The monohydric alcohols which may be used in this invention may also be purchased from suppliers like Sigma.
[0024] There is no requirement for the substrate enhancing agent of this invention to be saturated, and therefore, such an agent may comprise sites of mono- or polyunsaturation. In an especially preferred embodiment, the substrate enhancing agent of this invention has a weight average molecular weight of greater than about 180 or a boiling point greater than about 216° C., or both.
[0025] There is no limitation with respect to how the composition of the present invention is made as long as the desired components are mixed to produce a composition that may be applied to a substrate. For example, the substrate enhancing agent may be added to a mixing vessel along with water. The amount of water in the composition that may be used to treat a substrate is greater than 5.0%, and typically, from about 70.0% to about 99.9% by weight of the total weight of the composition. Most preferably, however, water makes up from about 75.0% to about 97.0% by weight of total weight of the composition, including all ranges subsumed therein. The mixing of desired components may occur at conventional mixing rates. The temperature and pressure during mixing may vary, as long as the desired composition for improving substrate characteristics may be made. Typically, however, the composition of this invention may be made by mixing under conditions of moderate shear, with temperature being from about 25° C. to about 85° C. and pressure being atmospheric.
[0026] Optional additives which may be employed in the compositions of the present invention include low molecular weight alkanols (i.e., alcohols with a backbone of four (4) carbons or less). The low molecular weight alcohols which may be used in this invention may assist in improving the characteristics of the substrate being treated with the composition of this invention. Also, such low molecular weight alcohols can significantly decrease the drying time of the composition applied to the substrate, thereby enabling the consumer to, for example, use the substrate (e.g., clothing) shortly after being contacted with the composition. The amount of low molecular weight alcohols which may be used in this invention typically is from about 0.0% to about 10.0%, and preferably, from about 0.1 to about 9.0%, and most preferably from about 0.5% to about 5.0% by weight, based on total weight of the composition, including all ranges subsumed therein.
[0027] Other optional additives which may be used in conjunction with the substrate enhancing agents of the present composition include known lubricants like silicon comprising compounds, substituted vegetable oils, fatty acids or fatty acid esters and quaternary ammonium compounds and surfactants.
[0028] The silicon comprising compounds which may be used in this invention include those that may generally be classified as siloxanes, preferably those having a viscosity from about 10 to about one million centistokes at ambient temperature. The siloxanes which may be used in this invention include polydimethylsiloxane; ethoxylated organosilicones; polyalkyleneoxide modified polydimethylsiloxane; linear aminopolydimethylsiloxane polyalkyleneoxide copolymers; betaine siloxane copolymers; and alkylactam siloxane copolymers. Of the foregoing, the preferred siloxane is a linear aminopolydimethylsiloxane polyalkyleneoxide copolymer sold under the name Magnasoft SRS (available from Witco, Greenwich, Conn., USA). Silsoft A-843, another aminopolydimethylsiloxane polyalkyleneoxide copolymer available from Witco, is also a particularly preferred lubricant which may be used. The most preferred siloxane is, however, a polydimethylsiloxane sold under the name HV-600 by Dow Chemical.
[0029] Regarding the silicon comprising compounds, such compounds are preferably included in the compositions of the present invention in an amount from about 0.1 to about 10%, and preferably, from about 0.1% to about 5%, and most preferably, from about 0.3 to about 1.5% by weight silicon comprising compound (or mixtures of silicon comprising compounds), based on total weight of the composition for improving substrate characteristics, including all ranges subsumed therein.
[0030] The substituted vegetable oils which may be used in this invention include substituted canola, castor, palm, peanut and corn oil, including mixtures thereof. Regarding the substitution, any groups that increase the water solubility of the oil may be substituted thereon. Such groups include sulphate, sulphonate, phosphate and phosphonate groups as well as polyalkylene oxide groups like polyethylene oxide. As to the degree of substitution, the vegetable oil is substituted to the point where it is almost soluble in water, yet able to lubricate the fabrics it comes in contact with. Typically, from about 0.1 to about 15.0%, and preferably, from about 0.2 to about 10.0%, and most preferably, from about 0.3 to about 5.0% by weight substituted vegetable oil is used. Preferred substituted vegetable oils are sulfated caster oil such as SCO-50 and SCO-75, both made commercially-available by B.F. Goodrich.
[0031] The fatty acid or fatty acid ester which may be used in this invention includes fatty acids or there esters of stearic, oleic, palmitic, lauric, isostearic, myristic or behenic acids, as well as mixtures thereof. It is also understood that the fatty acid or esters thereof which may be used in this invention can comprise a mixture of compositions such as carnauba wax, candelilla wax, and natural or synthetic bees wax. The amount of fatty acid or esters thereof which may be used in the composition of this invention is typically from about 0.1 to about 10.0%, and preferably, from about 0.2 to about 5.0%, and most preferably, from about 0.3 to about 3.0% by weight fatty acid ester, based on total weight of the composition for improving substrate characteristics, including all ranges subsumed therein.
[0032] The quaternary ammonium compounds which may be used in this invention Include any of those typically found in fabric conditioning products. Such quaternary ammonium compounds include dialkyldimethylammonium chlorides and trialkylmethyl ammonium chlorides, wherein the alkyl groups have from about 12 to about 22 carbon atoms. Other quaternary ammonium compounds which may be used are, for example, ester containing quaternary ammonium compounds N,N-di(tallowyl-oxy-ethyl)-N,N-dimethyl ammonium chloride, N,N-di(tallowyl-oxy-ethyl)-N-methyl, N-(2-hydroxyethyl) ammonium chloride and mixtures thereof.
[0033] The amount of quaternary ammonium compound employed in the composition of this invention is typically from about 0.1 to about 5.0%, and preferably, from about 0.2 to about 4.0%, and most preferably, from about 0.3 to about 3.0% by weight quaternary ammonium compound, based on total weight of the composition for improving substrate characteristics, including all ranges subsumed therein.
[0034] The only limitation with respect to the surfactant which may be used in this invention is that the surfactant is compatible with the substrate enhancing agent used in the substrate treating compositions of this invention. The surfactants that may be used in this invention include commercially known nonionic, anionic, cationic, amphoteric and zwitterionic surfactants, including mixtures thereof. Such surfactants typically make up from about 0.5 to about 10 wt. % of the total weight of the substrate treating composition.
[0035] Nonionic surfactants are the preferred surfactants and they are defined to include those surfactants generally classified as fatty acid or alcohol condensates. Such surfactants are typically sold under the names Neodol, Plurafac, Dehypon and Synperonic and made commercially available from suppliers like Shell Chemical Company, Union Carbide, Condea, Stepan and BASF. The preferred nonionic surfactant used in this invention is an ethoxylated nonionic sold under the name Neodol 25-9 and made available by Shell Chemical Company.
[0036] It is also noted herein that odor reducing additives, like cyclodextrin, may be used in the composition of this invention. Cyclodextrin, as used herein is meant to include cyclodextrins containing from 6 to 12 glucose units; especially, alpha-cyclodextrin, beta-cyclodextrin, gamma-cycodextrin, derivatives thereof or mixtures thereof. The amount of cyclodextrin which may be used is typically from about 0.1 to about 7.0% by weight cyclodextrin, based on total weight of the composition for improving substrate characteristics, including all ranges subsumed therein. A more detailed description of such odor reducing additives may be found in International Application No. WO 98/56890.
[0037] Still other optional additives which may be used in this invention include well known and commercially available colorants, fragrances such as Koala Kool MOD-C made available by Takasago, preservatives, pH control agents, viscosity adjusting agents such as inorganic salts, hydrotropes such as sodium xylene sulfonate, anti-oxidants such as butylated hydroxy toluene, foam control agents, chelants, enzymes (e.g., lipases, amylases, proteases), dye transfer inhibitors and anti-clogging agents. When used, these optional additives, collectively, make up less than about 10.0% by weight of the total weight of the composition for treating a substrate.
[0038] The composition for treating a substrate of this invention may be applied to the substrate with, for example, a dispenser like roller, aerosol dispenser, pump sprayer or trigger sprayer. The figure depicts a trigger sprayer 10 having a head 12 , a neck 14 and a bottle 16 . The bottle 16 is connected to the neck 14 via twist connector 18 . Trigger 20 , when engaged, causes the composition for improving substrate characteristics 22 to be drawn through the delivery tube 24 and the exit nozzle 26 in order to deliver the composition for improving substrate characteristics 22 on to a substrate (not shown).
[0039] The composition for improving substrate characteristics of this invention is preferably applied on to a substrate at portions of the substrate that are most likely to wrinkle. If desired, however, the entire substrate may be subjected to the composition. When applying the composition for improving substrate characteristics, the amount of composition applied is enough to improve the characteristics of the substrate and just enough to allow the substrate to dry (at ambient temperature) in under about three (3) hours, and preferably, in under about one (1) hour, and most preferably, in under about one-half (½) hour. Also, it is noted that after applying the composition of the present invention to the substrate, little or no discernible markings (e.g., stains, water marks or rings) may be found on the substrate when the composition is completely dry.
[0040] Instructions may be provided with the composition for improving substrate characteristics of this invention. Such instructions, where applicable, educate an end user to apply the composition of this invention to a substrate and then to immediately (e.g., within about five (5) minutes) hang the substrate up or place the substrate on a flat surface. The instructions may also suggest to the end user to apply the composition of this invention to a substrate and then to either tension and smooth the garment or to iron the substrate before or after (preferably after) the composition for improving substrate characteristics dries.
[0041] The examples are provided to further illustrate and facilitate a better understanding of the compositions for improving substrate characteristics of this invention. The examples are not meant to limit the accompanying claims.
Component 1 2 3 4 5 6 Ethanol 5.0 5.0 2.0 — 4.0 3.0 Sulfated castor oil 0.5 2.0 — — — — Silicone B — — .5 1.0 — 2.0 Ethoxylated nonionic C 1.0 2.0 1.0 — 2.0 1.0 Tallow alcohol 3.0 1.5 — — 5.0 4.0 Methyl methoxy — 2.0 5.0 4.0 4.0 3.0 butanol Ditallow, dimethyl — — — — 2.0 — ammonium chloride Octadecyl alcohol — — 2.0 4.0 — — Fragrance D 0.5 0.5 — 0.5 02 0.5 Water To To To To To To 100% 100% 100% 100% 100% 100% | The present invention is directed to a composition for improving substrate characteristics. The composition has a substrate enhancing agent, like a monohydric alcohol, and the composition reduces wrinkles in substrates that have not been subject to ironing. | 3 |
[0001] This invention is a Continuation-In-Part of Design application Ser. No. 29/252,288 filed Jan. 20, 2006.
FIELD OF INVENTION
[0002] This invention relates to ceiling fans, and in particular to efficient traditionally appearing ceiling fan blades with aerodynamical upper surfaces and wide tip ends for ceiling fans with blades formed from plastic and/or wood and/or be separately attached as an upper surface, that run at reduced energy consumption that move larger air volumes than traditional flat shaped ceiling fan blades, and to methods of operating the novel ceiling fans.
BACKGROUND AND PRIOR ART
[0003] Existing flat planar appearing ceiling fans are the most popular type of ceiling fans sold in the United States, and are known to have relatively poor air moving performance at different operating speeds. See for example U.S. Pat. Des. 355,027 to Young and Des. 382,636 to Yang. These patents while moving air are not concerned with maximizing optimum downward airflow.
[0004] Additionally, many of the flat ceiling fan blades have problems such as wobbling, and excessive noise that is noticeable to persons in the vicinity of the fan blades. The flat planar rectangular blade can have a slight tilt to increase air flow but are still poor in air moving performance, and continue to have the other problems mentioned above.
[0005] Aircraft, marine and automobile engine propeller type blades have been altered over the years to shapes other than flat rectangular. See for example, U.S. Pat. Nos. 1,903,823 to Lougheed; 1,942,688 to Davis; 2,283,956 to Smith; 2,345,047 to Houghton; 2,450,440 to Mills; 4,197,057 to Hayashi; 4,325,675 to Gallot et al.; 4,411,598 to Okada; 4,416,434 to Thibert; 4,730,985 to Rothman et al. 4,794,633 to Hickey; 4,844,698 to Gomstein; 5,114,313 to Vorus; and 5,253,979 to Fradenburgh et al.; Australian Patent 19,987 to Eather.
[0006] However, these patents are generally used for high speed water, aircraft, and automobile applications where the propellers are run at high revolutions per minute (rpm) generally in excess of 500 rpm. None of these propellers are designed for optimum airflow at low speeds of less than approximately 200 rpm which is the desired speeds used in overhead ceiling fan systems.
[0007] Some alternative blade shapes have been proposed for other types of fans. See for example, U.S. Pat. Nos. 1,506,937 to Miller; 2,682,925 to Wosik; 4,892,460 to Volk; 5,244,349 to Wang; Great Britain Patent 676,406 to Spencer; and PCT Application No. WO 92/07192.
[0008] Miller '937 requires that their blades have root “lips 26 ” FIG. 1 that overlap one another, and would not be practical or useable for three or more fan blade operation for a ceiling fan. Wosik '925 describes “fan blades . . . particularly adapted to fan blades on top of cooling towers such for example as are used in oil refineries and in other industries . . . ”, column 1, lines 1-5, and does not describe any use for ceiling fan applications.
[0009] The Volk '460 patent by claiming to be “aerodynamically designed” requires one curved piece to be attached at one end to a conventional planar rectangular blade. Using two pieces for each blade adds extreme costs in both the manufacturing and assembly of the ceiling itself. Furthermore, the grooved connection point in the Volk devices would appear to be susceptible to separating and causing a hazard to anyone or any property beneath the ceiling fan itself. Such an added device also has necessarily less than optimal aerodynamic properties.
[0010] Tilted type design blades have also been proposed over the years. See for example, U.S. Pat. No. D451,997 to Schwartz.
[0011] However, none of the prior art modifies design shaped blades to optimize twist angles to optimize energy consumption and airflow, and reduce wobble and noise problems.
[0012] The inventors and assignee of the subject invention have been at the forefront of inventing high efficiency ceiling fans by using novel twisted blade configurations. See for example, U.S. Pat. Nos. 6,884,034 and 6,659,721 and 6,039,541 to Parker et al.
[0013] However, these fans have unique and to some a futuristic appearance as compared to traditional flat planar fan blades. Although, highly efficient, some consumers may tend to prefer the traditional flat planar blades that have been widely used as compared to the high efficiency ceiling fans that use twisted blades.
[0014] Thus, the need exists for better performing traditionally appearing ceiling fan blades over the prior art.
SUMMARY OF THE INVENTION
[0015] The first objective of the subject invention is to provide efficient ceiling fan blades, devices, apparatus and methods of operating ceiling fans, that preserve the traditional appearance of conventional flat planar ceiling fan blades when viewed underneath the ceiling fans.
[0016] The second objective of the subject invention is to provide efficient traditionally appearing ceiling fan blades, devices, apparatus and methods of operating ceiling fans, where the blades have aerodynamical upper surfaces.
[0017] The third objective of the subject invention is to provide efficient traditionally appearing ceiling fan blades, devices, apparatus and methods of operating ceiling fans, which move up to approximately 20% and greater airflow over traditional planar blades.
[0018] The fourth objective of the subject invention is to provide efficient traditionally appearing ceiling fan blades, devices, apparatus and methods of operating ceiling fans, that are less prone to wobble than traditional flat planar ceiling fan blades.
[0019] The fifth objective of the subject invention is to provide efficient traditionally appearing ceiling fan blades, devices, apparatus and methods of operating ceiling fans, that reduce electrical power consumption and are more energy efficient over traditional flat planar ceiling fan blades.
[0020] The sixth objective of the subject invention is to provide efficient traditionally appearing ceiling fan blades, devices, apparatus and methods of operating ceiling fans, designed for superior airflow at up to approximately 240 revolutions and more per minute (rpm).
[0021] The seventh objective of the subject invention is to provide efficient traditionally appearing ceiling fan blades, devices, apparatus and methods of operating ceiling fans, that are at least as aesthetically appealing as traditional flat planar ceiling fan blades.
[0022] The eighth objective of the subject invention is to provide efficient traditionally appearing ceiling fan blades, devices, apparatus and methods of operating ceiling fans, capable of reduced low operational speeds for reverse operation to less than approximately 40 revolutions per minute or less.
[0023] The ninth objective of the subject invention is to provide efficient traditionally appearing ceiling fan blades, devices, apparatus and methods of operating ceiling fans, capable of reduced low operational forward speeds of less than approximately 75 revolutions per minute or less.
[0024] The tenth objective of the subject invention is to provide efficient traditionally appearing ceiling fan blades, devices, apparatus and methods of operating ceiling fans, capable of reduced medium operational forward speeds of up to approximately 120 revolutions per minute, that can use less than approximately 9 Watts at low speeds.
[0025] The eleventh objective of the subject invention is to provide efficient traditionally appearing ceiling fan blades, devices, apparatus and methods of operating ceiling fans, that can have up to approximately 64 (sixty four) inch diameter (tip-to-tip fan diameter) or greater for enhancing air moving efficiency at lower speeds than conventional fans.
[0026] The twelfth objective of the subject invention is to provide efficient traditionally appearing ceiling fan blades, devices, apparatus and methods of operating ceiling fans, that can move air over large coverage areas compared to conventional flat appearing ceiling fan blades.
[0027] A preferred embodiment can include a plurality of efficient traditionally appearing ceiling fan blades, attached a ceiling fan motor. Diameter sizes of the fans can include but not be limited to less than and up to approximately 32″, 48″, 52″, 54″, 56″, 60″, 64″, and greater. The blades can be made from wood, plastic, and the like, and can include separately attachable upper aerodynamic surfaces.
[0028] A preferred embodiment of the high efficiency traditional appearing ceiling fan can include a hub with a motor, and a plurality of blades attached to the ceiling fan motor, each blade having a flat and planar lower surfaces that visually appear to be flat and planar when viewed underneath the fan, and aerodynamic upper surfaces, wherein the aerodynamic upper surfaces of the blades move greater amounts of air compared to blades having both upper and lower flat and planar surfaces. Each of the blades can have tip ends being wider than root ends that are adjacent to the motor.
[0029] The tip ends of the blades can have a width of approximately 5 to approximately 6 inches wide, and the root ends of the blades have a width of approximately 4 to approximately 5 inches wide. More preferably, the tip ends of the blades can have a width of approximately 5& ¾ inches wide, and the root ends of the blades have a width of approximately 4& ¾ inches wide. Each of the blades can have a rounded leading edge, and a blunt tipped trailing edge.
[0030] The upper surfaces of the blades can include a downwardly curving slope from the maximum thickness point to the blunt tipped trailing edge, and a mid-thickness along a longitudinal axis of the blade being thicker than both thicknesses along the leading edge and the trailing edge of the blades. The blades can be formed from molded plastic.
[0031] The aerodynamic upper surfaces can be made as part of the blades. Alternatively, the aerodynamic upper surfaces can be preformed and separately attachable to a base ceiling fan blade, the base ceiling fan blade having both upper and lower flat and planar surfaces.
[0032] A novel method of operating efficient traditionally appearing ceiling fan blades with aerodynamical upper surfaces ceiling fan, can include the steps of providing blades having a flat and planar lower surfaces that visually appear to be flat and planar when viewed underneath, and aerodynamic upper surfaces, the blades being attached to a ceiling fan motor, rotating the blades relative to the motor, and generating a CFM (cubic feet per minute) airflow of at least five (5) percent (%) greater than traditionally appearing ceiling fan blades that have both upper and lower flat and planar surfaces.
[0033] The method can further include the step generating an airflow of at least approximately 5% or greater CFM at a low rotational speed of approximately 0.15 meters per second (m/s) to approximately 0.40 meters per second (m/s) that is greater than the traditionally appearing ceiling fan blades that have both upper and lower flat and planar surfaces.
[0034] The method can include the step of generating an airflow of at least approximately 8% or greater CFM at a low rotational speed of approximately 0.15 meters per second (m/s) to approximately 0.40 meters per second (m/s) that is greater than the traditionally appearing ceiling fan blades that have both upper and lower flat and planar surfaces.
[0035] The method can include the step of generating an airflow of at least approximately 10% or greater CFM at a high rotational speed of approximately 0.50 meters per second (m/s) to approximately 0.85 meters per second (m/s) that is greater than the traditionally appearing ceiling fan blades that have both upper and lower flat and planar surfaces.
[0036] The method can include the step of generating an airflow of at least approximately 20% or greater CFM at a high rotational speed of approximately 0.50 meters per second (m/s) to approximately 0.85 meters per second (m/s) that is greater than the traditionally appearing ceiling fan blades that have both upper and lower flat and planar surfaces.
[0037] The method can include the step of generating an airflow of at least approximately 25% or greater CFM at a high rotational speed of approximately 0.50 meters per second (m/s) to approximately 0.85 meters per second (m/s) that is greater than the traditionally appearing ceiling fan blades that have both upper and lower flat and planar surfaces.
[0038] The method can include the step of generating an airflow of at least approximately 2,250 or greater total CFM (cubic feet per minute) below the rotating blades at a low rotational speed of approximately 0.15 meters per second (m/s) to approximately 0.40 meters per second (m/s). The method can further include the step of generating an airflow of at least approximately 2,500 or greater total CFM (cubic feet per minute) below the rotating blades at a low rotational speed of approximately 0.15 meters per second (m/s) to approximately 0.40 meters per second (m/s).
[0039] The method can include the step of generating an airflow of at least approximately 2,700 or greater total CFM (cubic feet per minute) below the rotating blades at a low rotational speed of approximately 0.15 meters per second (m/s) to approximately 0.40 meters per second (m/s).
[0040] The method can include the step of generating an airflow of at least approximately 5,900 or greater total CFM (cubic feet per minute) below the rotating blades at a high rotational speed of approximately 0.50 meters per second (m/s) to approximately 0.85 meters per second (m/s).
[0041] The method can include the step of generating an airflow of at least approximately 6,000 or greater total CFM (cubic feet per minute) below the rotating blades at a high rotational speed of approximately 0.50 meters per second (m/s) to approximately 0.85 meters per second (m/s).
[0042] The method can include the step of generating an airflow of at least approximately 6,300 or greater total CFM (cubic feet per minute) below the rotating blades at a high rotational speed of approximately 0.50 meters per second (m/s) to approximately 0.85 meters per second (m/s).
[0043] The method can include the step of generating at least approximately 160 or greater total CFM (cubic feet per minute) per Watts below the rotating blades at a low rotational speed of approximately 0.15 meters per second (m/s) to approximately 0.40 meters per second (m/s).
[0044] The method can include the step of generating at least approximately 175 or greater total CFM (cubic feet per minute) per Watts below the rotating blades at a low rotational speed of approximately 0.15 meters per second (m/s) to approximately 0.40 meters per second (m/s).
[0045] The method can include the step of generating at least approximately 189 or greater total CFM (cubic feet per minute) per Watts below the rotating blades at a low rotational speed of approximately 0.15 meters per second (m/s) to approximately 0.40 meters per second (m/s).
[0046] The method can include the step of generating at least approximately 100 or greater total CFM (cubic feet per minute) per Watts below the rotating blades at a high rotational speed of approximately 0.50 meters per second (m/s) to approximately 0.85 meters per second (m/s).
[0047] Further objects and advantages of this invention will be apparent from the following detailed descriptions of the presently preferred embodiments which are illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
First Embodiment Small Diameter Blades
[0048] FIG. 1A is a top perspective view of a first embodiment efficient traditionally appearing ceiling fan blade with aerodynamical upper surfaces and wide tip end.
[0049] FIG. 1B is a bottom perspective view of the blade of FIG. 1A .
[0050] FIG. 1C is a top planar view of the blade of FIG. 1A .
[0051] FIG. 1D is a bottom planar view of the blade of FIG. 1A .
[0052] FIG. 1E is a left side view of the blade of FIG. 1A along arrow 1 E.
[0053] FIG. 1F is a right side view of the blade of FIG. 1A along arrow 1 F.
[0054] FIG. 1G is a tip end view of the blade of FIG. 1A along arrow 1 G.
[0055] FIG. 1H is a root end view of the blade of FIG. 1A along arrow 1 H.
[0056] FIG. 2 is another top perspective view of the efficient traditionally appearing ceiling fan blade with aerodynamical upper surfaces and wide tip end of FIG. 1A with labeled cross-sections A, B, C, D, E, F, G, H, I
[0057] FIG. 3 is another top view of the efficient traditionally appearing ceiling fan blade with aerodynamical upper surfaces of FIG. 1A with labeled cross-sections A-I.
[0058] FIG. 4A shows the cross-section A of FIGS. 2-3 .
[0059] FIG. 4B shows the cross-section B of FIGS. 2-3 .
[0060] FIG. 4C shows the cross-section C of FIGS. 2-3 .
[0061] FIG. 4D shows the cross-section D of FIGS. 2-3 .
[0062] FIG. 4E shows the cross-section E of FIGS. 2-3 .
[0063] FIG. 4F shows the cross-section F of FIGS. 2-3 .
[0064] FIG. 4G shows the cross-section G of FIGS. 2-3 .
[0065] FIG. 4H shows the cross-section H of FIGS. 2-3 .
[0066] FIG. 4I shows the cross-section I of FIGS. 2-3 .
Second Embodiment Large Diameter Blades
[0067] FIG. 5 is a top perspective view of a second embodiment of a large efficient traditionally appearing ceiling fan blade with aerodynamical upper surfaces and wide tip end with labeled cross-sections A, B, C, D, E, F, G, H.
[0068] FIG. 6 is a top view of the large efficient traditionally appearing ceiling fan blade with aerodynamical upper surfaces of FIG. 5 with labeled cross-sections A-H.
[0069] FIG. 7A shows the cross-section A of FIGS. 5-6 .
[0070] FIG. 7B shows the cross-section B of FIGS. 5-6 .
[0071] FIG. 7C shows the cross-section C of FIGS. 5-6 .
[0072] FIG. 7D shows the cross-section D of FIGS. 5-6 .
[0073] FIG. 7E shows the cross-section E of FIGS. 5-6 .
[0074] FIG. 7F shows the cross-section F of FIGS. 5-6 .
[0075] FIG. 7G shows the cross-section G of FIGS. 5-6 .
[0076] FIG. 7H shows the cross-section H of FIGS. 5-6 .
[0077] FIG. 8A is a perspective bottom view of a ceiling fan and efficient blades of FIGS. 1-7I
[0078] FIG. 8B is a perspective top view of the ceiling fan and efficient blades of FIG. 8A .
[0079] FIG. 8C is a side perspective view of the ceiling fan and efficient blades of FIG. 8A .
[0080] FIG. 8D is a bottom view of the ceiling fan and efficient blades of FIG. 8A .
[0081] FIG. 8E is a top view of the ceiling fan and efficient blades of FIG. 8A .
Third Embodiment Rounded Wide Tip End Blades
[0082] FIG. 9A is a top perspective view of a third embodiment efficient traditionally appearing ceiling fan blade with aerodynamical upper surfaces and rounded wide tip end.
[0083] FIG. 9B is a bottom perspective view of the blade of FIG. 9A .
[0084] FIG. 9C is a top planar view of the blade of FIG. 9A .
[0085] FIG. 9D is a bottom planar view of the blade of FIG. 9A .
[0086] FIG. 9E is a left side view of the blade of FIG. 9A along arrow 9 E.
[0087] FIG. 9F is a right side view of the blade of FIG. 9A along arrow 9 F.
[0088] FIG. 9G is a tip end view of the blade of FIG. 9A along arrow 9 G.
[0089] FIG. 9H is a root end view of the blade of FIG. 9A along arrow 9 H.
Fourth Embodiment Curved Wide Tip End Blades
[0090] FIG. 10A is a top perspective view of a fourth embodiment efficient traditionally appearing ceiling fan blade with aerodynamical upper surfaces and curved wide tip end.
[0091] FIG. 10B is a bottom perspective view of the blade of FIG. 10A .
[0092] FIG. 10C is a top planar view of the blade of FIG. 10A .
[0093] FIG. 10D is a bottom planar view of the blade of FIG. 10A .
[0094] FIG. 10E is a left side view of the blade of FIG. 10A along arrow 10 E.
[0095] FIG. 10F is a right side view of the blade of FIG. 10A along arrow 10 F.
[0096] FIG. 10G is a tip end view of the blade of FIG. 10A along arrow 10 G.
[0097] FIG. 10H is a root end view of the blade of FIG. 10A along arrow 10 H.
Fifth Embodiment Separately Attachable Aerodynamic Surface
[0098] FIG. 11 is tip end exploded view of a separate attachable aerodynamic surface that can be attached to conventional flat-planar surface ceiling fan blades.
[0099] FIG. 12 is another view of FIG. 11 with the aerodynamic surface attached to the blade.
[0100] FIG. 13 is another version of the separately attachable aerodynamic surface with blade.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0101] Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
[0102] The subject invention is a Continuation-In-Part of Design application Ser. No. 29/252,288 filed Jan. 20, 2006, which is incorporated by reference.
[0103] Testing of novel ceiling fan blades were conducted in July-August 2005, and included three parameters of measurement data: airflow (meters per second (m/s), power (in watts) and speed (revolutions per minute (rpm)). Those novel ceiling fan blades far surpassed the operating performance of various traditional flat planar ceiling fans in operation.
[0104] The tested blade had a reverse taper as compared to conventional blades. The tested blade was wider at the tip than the root. The first one tested had a flat bottom, a pitch of approximately 10 to approximately 12 degrees and an air foil (aerodynamic upper surface) on top (the upper surface). It is essentially a flat ceiling fan blade with an engineered air foil. We tested these by running an evaluation of a Huntington III in our lab and then changing to the new blades with the air foil on top. The short of the attached test results is that air flow was increased by approximately 10% at high speed to over approximately 26% at low speed. Again, this innovation is potentially revolutionary relative to reaching the EnergyStar designation with standard ceiling fans which is described below in relation to Table 5.
[0105] While the novel blades look completely conventional when viewed from underneath, the novel blades perform considerably better relative to their air moving efficiency. Another test gave the novel blade a very slight twist.
[0106] The modified blade is intended to move more air than the flat paddle blade, with the same input power. The aerodynamic upper surfaces allow the blade to work efficiently at both higher and lower RPM (revolutions per minute). To work effectively at lower RPM the blades can also be set at a higher pitch. The mounting brackets on the modified set of blades can be set to either a higher or lower pitch setting.
[0107] The motor efficiency was expected to change with RPM. The modified aerodynamic blades were expected to work best in conjunction with a motor that has good efficiency at slower RPM.
[0108] To separate the effects of aerodynamics and electrical motor performance a dynamometer set up was used for the testing procedures. A dynamometer measures torque and RPM. A torque sensor can be used where the motor mounts to the ceiling. With no other torques on the motor, the torque on the mount is the same as the torque on the turning shaft. The mechanical power going from the motor to the fan is equal to the torque times the RPM times a constant factor.
[0109] In English units the torque in foot-lbs times the rotational speed in radians/second is the power in foot-lbs/second. In metric units the torque in newton-meters times the rotational speed in radians/second equals the power in watts. To convert RPM into radians/second, and rad/sec=2 PI×RPM/60.
[0110] Laboratory tests were conducted on a standard ceiling fan with flat planar blades such as a 52″ Diameter Huntington III from Hampton Bay, which is sold by Home Depot, and the 52″ Hunter Silent(S) Breeze from Hunter Fan Company and compared against the novel efficient traditionally appearing ceiling fan blades, having aerodynamical upper surfaces.
[0111] The novel efficient aerodynamic blades tested had dimensions of those described in reference to FIGS. 1A-1G below, where the blades had an overall length between root end 20 and tip end 10 of approximately 20 inches, where the root end can have a diameter of approximately 3.53 inches that widens outward along blade 1 to the tip end that can have a diameter of approximately 4.53 inches.
[0112] Measurements were taken in an environmental chamber under controlled conditions using solid state measurement methods recommended by the United States Environmental Protection Agency in their Energy Star Ceiling Fan program which used a hot wire anemometer which required a temperature controlled room and a computer for testing data.
[0000] http://www.energystar.gov/ia/partners/prod_development/revisions/downloads/ceil_fans/final.pdf
[0113] In the tables below, air flow in CFM stands for cubic feet per minute, and power is measured in Watts (W).
[0114] The tested aerodynamic novel efficient fan blades had an overall diameter of approximately 52 inches across five blades, powered by a triple capacitor Powermax 188 mm by 155 mm motor. The low speed RPM (revolutions per minute) of the HUNTINGTON III was approximately 88 RPM. The low speed of the HUNTER S BREEZE was approximately 55 RPM. The low speed of the EFFICIENT NOVEL BLADES was approximately 104 RPM.
[0115] The data yielded the following improvements in Tables 1 and 2 at Low Speed of the Huntington III and the Hunter S Breeze each running at approximately 55 to approximately 88 RPM (revolutions per minute) and the novel efficient blades having a low speed of approximately 104 RPM.
[0116] Table 1 indicates the velocity measured (m/s) underneath a ceiling mounted fan with measurement location (feet from center) for the three fans (Huntington III, Hunter S. Breeze and Novel Efficient Blades) for low speed operation of the fans. The measurements were made approximately 56″ inches above the floor, and a calibrated hot-wire anemometer was used to take the measurements.
[0000]
TABLE 1
Measurement
Velocity Measured
Location
(m/s)
(feet from center)
Huntington III
Hunter S. Breeze
Novel Efficient
0
0.440
0.270
0.820
0.5
0.270
0.240
0.910
1
0.420
0.370
0.990
1.5
0.520
0.480
0.780
2
0.510
0.400
0.460
2.5
0.330
0.080
0.200
3
0.160
0.010
0.180
3.5
0.100
0.000
0.120
4
0.100
0.000
0.090
4.5
0.080
0.000
0.080
5
0.030
0.000
0.080
5.5
0.030
0.000
0.030
[0117] TABLE 2 provides the average velocity (m/s), total CFM (cubic feet per minute), total Watts (power usage), and total CFM/Watts for the three fans (Huntington III, Hunter S. Breeze and Novel Efficient Blades) for low speed operation.
[0000]
TABLE 2
Hunter
Fan Type
Huntington III
S. Breeze
Novel Efficient
Average Velocity (m/s)
0.25
0.15
0.40
Total CFM
2136.6
1396.1
2711.8
Total Watts
14.3
8.9
14.3
Total CFM/Watts
149.4
156.9
189.6
[0118] As shown in Table 1 at low speed, absolute flow (CFM) (2711.8/2136.6) was increased by approximately 26.9% with efficiency (189/149.4) improved by a similar amount of approximately 26.5% when comparing the novel efficient fan blades over the Huntington III fan.
[0119] Also, at low speed, absolute flow (CFM) (2711.8/1396.1) was increased by approximately 94% with efficiency (189/156.9) improved by approximately 20.45% when comparing the novel efficient fan blades over the Hunter S. Breeze fan.
[0120] For Table 3, the high speed for the HUNTINGTON III was approximately 216 RPM, the high speed for the HUNTER S BREEZE was approximately 165 RPM. The high speed for the EFFICIENT NOVEL BLADES was approximately 248 RPM.
[0121] Table 3 has data of High Speed of the Huntington III and the Hunter S Breeze each running at approximately 165 to approximately 216 RPM (revolutions per minute) and the novel efficient blades having a low speed of approximately 248 RPM.
[0122] Table 3 indicates the velocity measured (m/s) underneath a ceiling mounted fan with measurement location (feet from center) for the three fans (Huntington III, Hunter S. Breeze and Novel Efficient Blades) for high speed operation of the fans.
[0000]
TABLE 3
Measurement
Velocity Measured
Location
(m/s)
(feet from center)
Huntington III
nter-Summer Breeze
Novel Efficient
0
0.790
1.135
1.040
0.5
0.770
1.905
1.330
1
1.430
2.065
2.110
1.5
1.450
1.505
2.130
2
1.250
0.580
0.960
2.5
0.850
0.185
0.690
3
0.500
0.165
0.370
3.5
0.280
0.115
0.230
4
0.170
0.130
0.200
4.5
0.130
0.120
0.200
5
0.130
0.135
0.200
5.5
0.110
0.160
0.200
[0123] TABLE 4 provides the average velocity (m/s), total CFM (cubic feet per minute), total Watts (power usage), and total CFM/Watts for the three fans (Huntington III, Hunter S. Breeze and Novel Efficient Blades) for high speed operation.
[0000]
TABLE 4
Hunter-
Novel
Fan Type
Huntington III
Summer Breeze
Efficient
Average Velocity (m/s)
0.66
0.68
0.81
Total CFM
5813.9
4493.6
6341.1
Total Watts
61.8
74.8
62.5
Total CFM/Watts
94.1
60.1
101.5
[0124] As shown in Table 4 at high speed, absolute flow (CFM) (6341.1/5813.9) was increased by approximately 9% with efficiency (101.5/94.1) improved by a similar amount of approximately 7.86% when comparing the novel efficient fan blades over the Huntington III fan.
[0125] Also, at high speed, absolute flow (CFM) (6341.1/4493.6) was increased by approximately 41.1% with efficiency (101.5/60.1) improved by approximately 68.88% when comparing the novel efficient fan blades over the Hunter S. Breeze fan Although medium speed operation is not shown, extrapolating speeds between low and high, would show that the invention would have similar benefits over the Huntington III and Hunter S. Breeze ceiling fans.
[0126] The United States government has initiated a program entitled: Energy Star (www.energystar.gov) for helping businesses and individuals to protect the environment through superior energy efficiency by reducing energy consumption and which includes rating appliances such as ceiling fans that use less power than conventional fans and produce greater cfm output. As of Oct. 1, 2004, the Environmental Protection Agency (EPA) has been requiring specific air flow efficiency requirements for ceiling fan products to meet the Energy Star requirements which then allow those products to be labeled Energy Star rated. Table 5 below shows the current Energy Star Program requirements for residential ceiling fans with the manufacturer setting their own three basic speeds of Low, Medium and High.
[0000]
TABLE 5
Air Flow Efficiency Requirements(Energy Star)
Fan Speed
Mininum Airflow
Efficiency Requirement
Low
1,250 CFM
155
CFM/Watt
Medium
3,000 CFM
100
CFM/Watt
High
5,000 CFM
75
CFM/Watt
[0127] Note, that Energy Star program does not require what the speed ranges for RPM are used for low, medium and high, but rather that the flow targets are met:
[0128] For Energy Star, residential ceiling fan airflow efficiency on a performance bases is measured as CFM of airflow per watt of power consumed by the motor and controls. This standard treats the motor, blades and controls as a system, and efficiency can be measured on each of three fan speeds (low, medium, high) using standard testing.
[0129] From Table 5, it is clear that the efficient novel blades with upper aerodynamic surfaces running at all speeds of low, medium and high meet and exceed the Energy Star Rating requirements.
[0130] Other embodiments can use as few as two, three, four, and even six efficient novel blades with upper aerodynamic surfaces. The blades can be formed from carved wood and/or injection molded plastic. The ceiling fan blades can have various diameters such as but not limited to approximately 42″, 46″, 48″, 52″, 54″, 56″, 60″ and even greater or less as needed.
First Embodiment Small Diameter Blades
[0131] The labeled components will now be described.
1 novel small diameter blade 5 dotted lines for motor mount arm connection 10 tip end 20 root end 30 LE leading edge 40 TE trailing edge 50 upper surface 60 lower surface
[0140] FIG. 1A is a top perspective view of a first embodiment efficient traditionally appearing ceiling fan blade 1 with aerodynamical upper surfaces 50 and wide tip end 10 . FIG. 1B is a bottom perspective view of the blade 1 of FIG. 1A with planar/flat appearing lower surface 60 . FIG. 1C is a top planar view of the blade 1 of FIG. 1A showing upper surface 50 . FIG. 1D is a bottom planar view of the blade 1 of FIG. 1A . FIG. 1E is a left side view of the blade 1 of FIG. 1A along arrow 1 E with leading edge 30 LE. FIG. 1F is a right side view of the blade 1 of FIG. 1A along arrow 1 F with trailing edge 40 TE FIG. 1G is a tip end 10 view of the blade 1 of FIG. 1A along arrow 1 G. FIG. 1H is a root end 20 view of the blade 1 of FIG. 1A along arrow 1 H. Referring to FIGS. 1A-1G , the novel blade can have an overall length between root end 20 and tip end 10 of approximately 20 inches, where the root end can have a diameter of approximately 3.53 inches that widens outward along blade 1 to the tip end that can have a diameter of approximately 4.53 inches. The tip end 10 and root end 20 can have flat generally flat face ends. The undersurface 60 of blade 1 can be flat and planar so as to appear to be a traditionally appearing flat sided blade when viewed from underneath the blades when mounted to a ceiling fan.
[0141] The upper surface 50 can have an efficient aerodynamic surface with a rounded leading edge 30 LE, and a blunt tipped trailing edge 40 TE. The upper surfaces of the blade 1 can include an upwardly curving slope from the rounded leading edge 30 LE to a point of maximum thickness, the point being closer to the leading edge 30 LE than to the trailing edge 40 TE. The upper surface can also include a downwardly curving slope from the maximum thickness point to the blunt tipped trailing edge 40 TE. The thickness along this maximum thickness point can run along a longitudinal axis from the root end to the tip end, and this maximum thickness can be thicker than the thickness along either or both of the leading edge 30 LE and the trailing edge 40 TE.
[0142] FIG. 2 is another top perspective view of the efficient traditionally appearing ceiling fan blade 1 with aerodynamical upper surfaces 50 and wide tip end 10 of FIG. 1A with labeled cross-sections A, B, C, D, E, F, G, H, I. FIG. 3 is another top view of the efficient traditionally appearing ceiling fan blade 1 with aerodynamical upper surfaces 50 of FIG. 1A with labeled cross-sections A-I.
[0143] Referring to FIGS. 2-3 , blade 1 has an overall length of approximately 20″ and a width that varies from the root end 20 being approximately 3.53″ to the tip end 10 being approximately 4.53″. Cross-section A is taken at the tip end 10 with cross-section B approximately 1″ in and cross-sections C, D, E, F, G, H spaced approximately 3″ apart from one another. Cross-section I is taken a root end 20 with cross-section H approximately 1″ from root end 20 . FIGS. 4A-4I are individual cross-sectional views of FIGS. 2-3 taken in the direction of arrow C
[0144] FIG. 4A shows the cross-section A of FIGS. 2-3 having a width of approximately 4.53″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 40 TE sloping upward along a convex curve to a halfway thickness of approximately 0.27″ to a maximum thickness of the section A being approximately 0.32″ that is spaced approximately 1.82″ from the rounded leading edge 30 LE. A halfway thickness of approximately 0.29″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 30 LE.
[0145] FIG. 4B shows the cross-section B of FIGS. 2-3 having a width of approximately 4.48″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 40 TE sloping upward along a convex curve to a halfway thickness of approximately 0.26″ to a maximum thickness of the section B being approximately 0.31″ that is spaced approximately 1.78″ from the rounded leading edge 30 LE. A halfway thickness of approximately 0.29″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 30 LE.
[0146] FIG. 4C shows the cross-section C of FIGS. 2-3 having a width of approximately 4.33″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 40 TE sloping upward along a convex curve to a halfway thickness of approximately 0.24″ to a maximum thickness of the section C being approximately 0.30″ that is spaced approximately 1.99″ from the rounded leading edge 30 LE. A halfway thickness of approximately 0.29″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 30 LE.
[0147] FIG. 4D shows the cross-section D of FIGS. 2-3 having a width of approximately 4.18″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 40 TE sloping upward along a convex curve to a halfway thickness of approximately 0.24″ to a maximum thickness of the section D being approximately 0.29″ that is spaced approximately 1.90″ from the rounded leading edge 30 LE. A halfway thickness of approximately 0.28″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 30 LE.
[0148] FIG. 4E shows the cross-section E of FIGS. 2-3 having a width of approximately 4.03″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 40 TE sloping upward along a convex curve to a halfway thickness of approximately 0.23″ to a maximum thickness of the section E being approximately 0.28″ that is spaced approximately 1.81″ from the rounded leading edge 30 LE. A halfway thickness of approximately 0.27″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 30 LE.
[0149] FIG. 4F shows the cross-section F of FIGS. 2-3 having a width of approximately 3.88″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 40 TE sloping upward along a convex curve to a halfway thickness of approximately 0.22″ to a maximum thickness of the section F being approximately 0.27″ that is spaced approximately 1.73″ from the rounded leading edge 30 LE. A halfway thickness of approximately 0.26″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 30 LE.
[0150] FIG. 4G shows the cross-section G of FIGS. 2-3 having a width of approximately 3.73″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 40 TE sloping upward along a convex curve to a halfway thickness of approximately 0.22″ to a maximum thickness of the section G being approximately 0.27″ that is spaced approximately 1.70″ from the rounded leading edge 30 LE. A halfway thickness of approximately 0.25″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 30 LE.
[0151] FIG. 4H shows the cross-section H of FIGS. 2-3 having a width of approximately 3.58″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 40 TE sloping upward along a convex curve to a halfway thickness of approximately 0.21″ to a maximum thickness of the section H being approximately 0.27″ that is spaced approximately 1.63″ from the rounded leading edge 30 LE. A halfway thickness of approximately 0.26″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 30 LE.
[0152] FIG. 4I shows the cross-section I of FIGS. 2-3 having a width of approximately 3.53″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 40 TE sloping upward along a convex curve to a halfway thickness of approximately 0.21″ to a maximum thickness of the section I being approximately 0.26″ that is spaced approximately 1.60″ from the rounded leading edge 30 LE. A halfway thickness of approximately 0.24″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 30 LE.
Second Embodiment Large Diameter Blades
[0153] The labeled components will now be described.
101 novel large diameter blade 105 dotted lines for motor mount arm connection 110 tip end 120 root end 130 LE leading edge 140 TE trailing edge 150 upper surface 160 lower surface
[0162] FIG. 5 is a top perspective view of a second embodiment of a large efficient traditionally appearing ceiling fan blade 101 with aerodynamical upper surfaces 150 and wide tip end 110 with labeled cross-sections A, B, C, D, E, F, G, H. FIG. 6 is a top view of the large efficient traditionally appearing ceiling fan blade 101 with aerodynamical upper surfaces 150 of FIG. 5 with labeled cross-sections A-H.
[0163] Referring to FIGS. 5-6 , blade 101 has an overall length of approximately 21.08″ and a width that varies from the root end 120 being approximately 4.85″ to the tip end 110 being approximately 5.95″Cross-section A is taken at the tip end 110 with cross-section B approximately 1″ in and cross-sections C, D, E, F, G spaced approximately 3.96″ apart from one another. Cross-section H is taken a root end 120 with cross-section G approximately 1″ from root end 120 . FIGS. 4A-4H are individual cross-sectional views of FIGS. 5-6 taken in the direction of arrow C.
[0164] FIG. 7A shows the cross-section A of FIGS. 5-6 having a width of approximately 5.95″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 140 TE sloping upward along a convex curve to a halfway thickness of approximately 0.33″ to a maximum thickness of the section A being approximately 0.41″ that is spaced approximately 2.70″ from the rounded leading edge 130 LE. A halfway thickness of approximately 0.39″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 130 LE.
[0165] FIG. 7B shows the cross-section B of FIGS. 5-6 having a width of approximately 5.90″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 140 TE sloping upward along a convex curve to a halfway thickness of approximately 0.32″ to a maximum thickness of the section B being approximately 0.41″ that is spaced approximately 2.70″ from the rounded leading edge 130 LE. A halfway thickness of approximately 0.39″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 130 LE.
[0166] FIG. 7C shows the cross-section C of FIGS. 5-6 having a width of approximately 5.70″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 140 TE sloping upward along a convex curve to a halfway thickness of approximately 0.31″ to a maximum thickness of the section C being approximately 0.40″ that is spaced approximately 2.60″ from the rounded leading edge 130 LE. A halfway thickness of approximately 0.38″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 130 LE.
[0167] FIG. 7D shows the cross-section D of FIGS. 5-6 having a width of approximately 5.50″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 140 TE sloping upward along a convex curve to a halfway thickness of approximately 0.31″ to a maximum thickness of the section D being approximately 0.39″ that is spaced approximately 2.46″ from the rounded leading edge 130 LE. A halfway thickness of approximately 0.36″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 130 LE.
[0168] FIG. 7E shows the cross-section E of FIGS. 5-6 having a width of approximately 5.30″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 140 TE sloping upward along a convex curve to a halfway thickness of approximately 0.31″ to a maximum thickness of the section E being approximately 0.37″ that is spaced approximately 2.38″ from the rounded leading edge 130 LE. A halfway thickness of approximately 0.35″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 130 LE.
[0169] FIG. 7F shows the cross-section F of FIGS. 5-6 having a width of approximately 5.10″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 140 TE sloping upward along a convex curve to a halfway thickness of approximately 0.29″ to a maximum thickness of the section F being approximately 0.36″ that is spaced approximately 2.29″ from the rounded leading edge 130 LE. A halfway thickness of approximately 0.35″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 130 LE.
[0170] FIG. 7G shows the cross-section G of FIGS. 5-6 having a width of approximately 4.90″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 140 TE sloping upward along a convex curve to a halfway thickness of approximately 0.30″ to a maximum thickness of the section G being approximately 0.36″ that is spaced approximately 2.24″ from the rounded leading edge 130 LE. A halfway thickness of approximately 0.33″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 130 LE.
[0171] FIG. 7H shows the cross-section H of FIGS. 5-6 having a width of approximately 4.85″, a flat bottom and an aerodynamic upper surface that starts from blunt trailing edge 140 TE sloping upward along a convex curve to a halfway thickness of approximately 0.29″ to a maximum thickness of the section H being approximately 0.35″ that is spaced approximately 2.22″ from the rounded leading edge 130 LE. A halfway thickness of approximately 0.33″ is located on a downwardly convex curve slope between the maximum thickness point and the rounded leading edge 13 OLE.
[0172] FIG. 8A is a perspective bottom view of a ceiling fan 200 and efficient blades 1 / 101 of FIGS. 1-7I , with the blades 1 / 101 attached a ceiling mounted motor 210 . FIG. 8B is a perspective top view of the ceiling fan 200 and efficient blades 1 / 101 of FIG. 8A . FIG. 8C is a side perspective view of the ceiling fan 100 and efficient blades 1 / 101 of FIG. 8A . FIG. 8D is a bottom view of the ceiling fan 200 and efficient blades 1 / 101 of FIG. 8A . FIG. 8E is a top view of the ceiling fan 200 and efficient blades 1 / 101 of FIG. 8A .
[0173] Referring to FIGS. 8A-8E , one viewing beneath the ceiling fan would see bottom surfaces 60 / 160 that appear to be traditionally flat/planar ceiling fan blades. With the aerodynamical upper surfaces 50 / 150 not visible from ground level. The novel blades 1 / 101 can be mounted at angles or twisted by respective mounting arms 250 to further maximize airflow.
Third Embodiment Rounded Wide Tip End Blades
[0174] The labeled components will now be described.
301 novel efficient aerodynamic blade with rounded tip end 305 dotted lines for motor mount arm connection 310 tip end 320 root end 330 LE leading edge 340 TE trailing edge 350 upper surface 360 lower surface
[0183] FIG. 9A is a top perspective view of a third embodiment efficient traditionally appearing ceiling fan blade 301 with aerodynamical upper surfaces 350 and rounded wide tip end 310 . FIG. 9B is a bottom perspective view of the blade 301 of FIG. 9A . FIG. 9C is a top planar view of the blade 301 of FIG. 9A . FIG. 9D is a bottom planar view of the blade 301 of FIG. 9A . FIG. 9E is a left side view of the blade 301 of FIG. 9A along arrow 9 E. FIG. 9F is a right side view of the blade of FIG. 9A along arrow 9 F. FIG. 9G is a tip end 310 view of the blade 301 of FIG. 9A along arrow 9 G. FIG. 9H is a root end 320 view of the blade 301 of FIG. 9A along arrow 9 H. Referring to FIGS. 9A , 9 H, the third embodiment has similar attributes to that of the preceding embodiments with the addition of having the tip end 310 being rounded.
Fourth Embodiment Curved Wide Tip End Blades
[0184] The labeled components will now be described.
401 novel efficient aerodynamic blade with curved tip end 405 dotted lines for motor mount arm connection 410 tip end 420 root end 430 leading edge 440 trailing edge 450 upper surface 460 lower surface
[0193] FIG. 10A is a top perspective view of a fourth embodiment efficient traditionally appearing ceiling fan blade 401 with aerodynamical upper surfaces 450 and curved wide tip end 410 . FIG. 10B is a bottom perspective view of the blade 401 of FIG. 10A . FIG. 10C is a top planar view of the blade 401 of FIG. 10A . FIG. 10D is a bottom planar view of the blade 401 of FIG. 10A . FIG. 10E is a left side view of the blade 401 of FIG. 10A along arrow 10 E. FIG. 10F is a right side view of the blade 401 of FIG. 10A along arrow 10 F. FIG. 10G is a tip end 410 view of the blade of FIG. 10A along arrow 10 G. FIG. 10H is a root end 420 view of the blade of FIG. 10A along arrow 10 H. Referring to FIGS. 10A-10H , the fourth embodiment has similar attributes to that of the preceding embodiments with the addition of having the tip end 410 being curved.
Fifth Embodiment Separately Attachable Aerodynamic Surface
[0194] The labeled components will now be described.
501 novel blade with attachable upper aerodynamic surface 560 tip end 570 root end 530 leading edge 540 trailing edge 550 Separately attachable aerodynamic upper surface 505 Lower traditional flat planar sided blade
[0202] FIG. 11 is tip end exploded view of a separate attachable aerodynamic surface form 550 that can be attached to conventional flat-planar surface ceiling fan blades 505 . FIG. 12 is another view of FIG. 11 with the aerodynamic surface 550 attached to the blade 505 . A traditional blade 505 can have existing flat/planar upper surface 510 and flat/planar lower surface 520 . A separate form 550 can have a flat lower surface 555 , and aerodynamic upper surface 557 . The lower surface 555 can be attached to the existing upper flat/planar surface 510 of the traditional blades 505 by glue, cement, and the like, and/or using fasteners such as but not limited to screws, and the like, where the resulting blade 501 can have similar dimensions and the resulting benefits as the previous embodiments described above.
[0203] FIG. 13 is another version 581 of the separately attachable aerodynamic surface 580 with blade 560 / 570 . The add-on 580 can have an upper aerodynamic surface that slopes upward from trailing edge 582 and curves down to an overhanging rounded leading edge 588 to fit about the leading edge of the underlying flat blade 560 / 570 . The add-on can be attached similar to the add-on previously described.
[0204] The preferred embodiments can be used with blades that rotate clockwise or counter-clockwise, where the blades can be positioned to maximize airflow in either rotational directions.
[0205] While the preferred embodiment includes providing aerodynamic surfaces on the upper surface of planar/flat bladed fans, the invention can be practiced with other ceiling fan blades that can achieve enhanced airflow and efficiency results. For example, design and aesthetic appearing blades can include upper surfaces that have the efficient aerodynamic efficient surfaces.
[0206] The blade mounting arms can also be optimized in shape to allow the blades to optimize pitch for optimal airflow with or without the efficient aerodynamic upper surface blades.
[0207] Although the preferred embodiments show the efficient aerodynamic surfaces on the top of the blades, the blades can alternatively also have aerodynamic efficient surfaces on the bottom side. Alternatively, both the top and bottom surfaces can have the novel aerodynamic efficient surfaces.
[0208] While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended. | Efficient traditionally appearing ceiling fan blades with aerodynamical upper surfaces and wide tip ends for ceiling fans with blades formed from plastic and/or wood and/or separately attached surfaces that run at reduced energy consumption that move larger air volumes than traditional flat shaped ceiling fan blades. And methods of operating the novel ceiling fans blades for different speeds of up to and less than approximately 250 rpm. The novel blades twisted blades can be configured for ceiling fans having any diameters from less than approximately 32 inches to greater than approximately 64 inch fans, and can be used in two, three, four, five and more blade configurations. The novel fans can be run at reduced speeds, drawing less Watts than conventional fans and still perform better with more air flow and less problems than conventional flat type conventional flat and planar upper and lower surface blades. | 5 |
RELATED APPLICATION
This divisional application is being filed in accordance with 35 U.S.C. §121 and claims priority to U.S. patent application Ser. No. 10/942,529, filed Sep. 16, 2004 now U.S. Pat. No. 7,204,277, the entire contents of which is incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates generally to compounder systems, and more particularly, to a compounder system having a bypass for transferring different types of solutions into separated chambers of a receiving receptacle.
BACKGROUND OF THE INVENTION
Hyperalimentation therapy is the intravenous feeding of nutrients to patients. A typical solution would include a protein-carbohydrate mixture. It is used primarily to meet the patient's protein and caloric requirements that are unable to be satisfied by oral feeding. The protein may be in the form of free-amino acids or protein hydrolysate and the carbohydrate commonly is dextrose. In addition to the protein and carbohydrate, vitamins (water-soluble and fat-soluble) and electrolytes also can be supplied in this therapy.
Each of these parenteral ingredients and the combination thereof are particularly susceptible to the growth of deleterious organisms and it is desirable that they be administered to the patient in a sterile condition. In addition, the solutions are tailor made to specific patient requirements under the direction of a physician. Thus, because these protein and carbohydrate solutions must be combined close, but prior, to their time of use, their compounding must be performed under sterile conditions to avoid organism growth.
As a part of this compounding, the solutions that are to be administered intravenously are transferred into a total parental nutrition bag (commonly referred to as a TPN bag). Such bags are designed for home use or use in a hospital or care facility. Once filled they can be stored for a limited period of time in a standard refrigerator. The bags are filled with the solutions by a pharmacist either by gravity or by a device known as a high speed bulk compounder. Such compounders typically are capable of supplying solutions from up to nine different source bags (and possibly more) or containers to a receiving product bag at relatively high flow rates.
The source containers may be hung from a framework of the compounder while the receiving bag is hung from a load cell that measures the weight of the receiving bag. A pump set consisting of a number of pump legs (for example, nine or more such legs) or flow paths is designed to be used with the compounder. Each of the pump legs includes flexible tubing and terminates on one end with a piercing administration spike or similar connector that is used to connect the leg of the pump set to one of the source containers. The other end of each leg is coupled to one of the inlet ports of a common manifold equipped with an exit port that is adapted to be coupled to a fill tubing connected to the receiving TPN product bag.
In those instances where a high-speed compounder is used, each leg of the pump set is associated with a different peristaltic pump or pump station of the compounder. A microprocessor in the compounder controls each of the peristaltic pumps or pump stations to thereby control the amount of solution being supplied from each source container through the particular pump leg and the manifold to the receiving product bag. The amount of solution being supplied from each source container is in part determined by information being supplied to the microprocessor of the weight being measured at selected times by the load cell from which the receiving bag is suspended. The peristaltic pumps draw solutions from each of the source containers sequentially under the control of the microprocessor and the solutions flow through the common manifold and the fill tubing into the receiving product bag.
A problem arises when one of the fluids to be introduced into the product bag is a lipid solution. Lipid solutions are essentially fat emulsions and typically are placed into a separate compartment within the product bag which is isolated from the remaining mixture until immediately before (or very soon before) the solution is administered to a patient. This isolation is necessary because the lipid solution, if mixed with the other ingredients ahead of time, clouds the overall solution mixture and renders it unusable. This phenomena is known in the art as “hazing.” Because of the undesirability of mixing lipids with the other solutions prior to the time of administration, a problem has existed in the prior art where a residual amount of the lipid solution is allowed to remain in a common volume of the manifold after a lipid solution is pumped through but before the next non-lipid solution is pumped through. When the subsequent solution is pumped through, the residual lipid solution is carried into the product bag and hazing results.
One solution has involved the use of a chambered product bag. By pumping the lipids into a separate chamber of the product bag, the lipids will not mix and “haze” the solution. Immediately before the solution is used, the separated chamber with the lipids is allowed to mix with the remaining solution to form the product solution. To fill the chambered bag using conventional compounders, one line of the compounder must be devoted specifically for lipids and be attached directly to the separated chamber of the product bag. By using the compounder in this manner, however, one line is not used if the overall solution does not require a lipid component.
SUMMARY OF THE INVENTION
The present invention is directed to a tube set for dispensing components into a product bag. The tube set comprises a plurality of tubing lines, a manifold, and a bypass. The manifold has a plurality of inlets, each inlet adapted for connection to a respective tubing line. The manifold also has an outlet connectable to a first feed tube of a product bag. The bypass is associated with at least one of the plurality of tubing lines. The bypass has a bypass inlet connectable to the tubing line associated with the bypass. The bypass also has at least two outlets. A first outlet is connected to a tube line in fluid communication with an inlet of the manifold and a second outlet is removably connectable to a second feed line in fluid communication with the product bag.
According to another embodiment, the present invention is directed to a bypass for a tube set. The tube set includes a manifold and a plurality of tubing lines for dispensing fluid components into a product bag. The bypass comprises an inlet fluid passage adapted for connection to a tubing line of the tube set, an outlet adapted to receive a tubing line in fluid communication with the product bag, and a bypass fluid passage adapted for connection to a tubing line in fluid communication with the manifold. The bypass is configured such that fluid enters the bypass inlet fluid passage and exits through the outlet only when the outlet is connected to a tubing line in direct fluid communication with the product bag.
An exemplary method of the present invention is a method for selectively dispensing fluid components into a product bag attached to a tube set of a bulk compounder. The bulk compounder includes a product bag attached to a tube set having a plurality of tube lines, a manifold, and a bypass having a fluid passage with an inlet and at least two outlets. The method includes providing liquid components to be dispensed into the product bag with one of the liquid components to be maintained separately from the other liquid components, inserting a tube line in fluid communication with the product bag into the bypass first outlet, blocking the bypass second outlet in fluid communication to the manifold, and dispensing the fluid component to be maintained separate from the other liquid components through the bypass and into the product bag, independent of the manifold.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an exemplary bulk compouder having a bypass according to an embodiment of the invention;
FIG. 2 illustrates an exemplary bypass according to another exemplary embodiment of the present invention; and
FIG. 3 is an enlarged view of an exemplary bypass according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.
Referring to the Figures where like numerals represent like features, FIG. 1 shows a pharmaceutical compounding system 10 . System 10 can be used for mixing or compounding two or more selected liquids and/or drugs intended to be administered to a human being or an animal. In use, system 10 serves to transfer two or more of individual prescribed liquids and/or drugs from multiple source containers (e.g., individual vials, bottles, syringes, or bags) into a single collecting container (e.g., a bottle, syringe, or bag), so that the mix of liquids and/or drugs can be administered (e.g., intravenously) to an individual in need.
As one example, due to injury, disease, or trauma, a patient may need to receive all or some of his or her nutritional requirements intravenously. In this situation, the patient will typically receive a basic solution containing a mixture of amino acids, dextrose, and fat emulsions, which provide a major portion of the patient's nutritional needs, which is called total parenteral nutrition, or, in shorthand, TPN. In this arrangement, a physician will prescribe a mixture of amino acids, dextrose, and fat emulsions to be administered, as well as the frequency of administration. To maintain a patient for an extended period of time on TPN, smaller volumes of additional additives, such as vitamins, minerals, electrolytes, etc., are also prescribed for inclusion in the mix. Using system 10 , under the supervision of a pharmacist, the prescription order is entered and individual doses of the prescribed liquids, drugs, and/or additives are accordingly transferred from separate individual source containers for mixing in a single container for administration to the individual.
There are other environments where system 10 is well suited for use. For example, in the medical field, system 10 can be used to compound liquids and/or drugs in support of chemotherapy, cardioplegia, therapies involving the administration of antibiotics and/or blood products therapies, and in biotechnology processing, including diagnostic solution preparation and solution preparation for cellular and molecular process development. Furthermore, system 10 can be used to compound liquids outside the medical field.
Tube set 15 is a part of system 10 . Tube set 15 includes lengths of transfer tubing line 20 , which are joined at one end to a common manifold 45 . At the opposite ends of the transfer tubing 15 are spikes or releasable couplings 100 . Couplings 100 can be inserted in conventional fashion through a diaphragm carried by the associated source solution container (not shown), which allows flow communication between the source solution container and the respective transfer tubing line 20 . From manifold 45 , a first feed line 50 is coupled to a product bag 80 . As shown in the embodiment of FIG. 1 , product bag 80 has two compartments, a lower compartment 70 in connection with first line 50 , and an upper compartment 65 in connection with a second feed line 60 . Transfer tubing lines 20 , first feed line 50 , and second feed line 60 can be made from flexible, medical grade plastic material, such as polyvinyl chloride plasticized with di-2-ethylhexyl-phthalate. Likewise, product bag 80 can be made from a flexible, medical grade plastic, semi-rigid plastic or glass.
FIG. 1 illustrates system 10 having a bypass 23 for directing liquids through manifold 45 or directly to upper compartment 65 of product bag 80 by way of second feed line 60 . As discussed above, once the lipid solutions are mixed with other types of solutions, the shelf life for the mixed solution (i.e., the amount of time before the solution needs to be used) is relatively short. Thus, there is a need to prepare dual-chambered bags having lipid solution dispensed into one compartment of the dual chambered product bag without wasting a tubing line or without the added need for a complete separate transfer tube line.
FIG. 2 illustrates an embodiment of bypass 23 of system 10 . Bypass 23 has inlet 25 of inlet fluid passage 220 , which can be adapted for fluid communication with transfer tubing line 20 (not shown in FIG. 2 ). Connected to inlet fluid passage 220 is bypass fluid passage 200 forming a three-way junction at outlet 30 . Bypass fluid passage 200 also has outlet 35 for connection with a tubing line (not shown in FIG. 2 ) to be in fluid communication with manifold 45 . Alternatively, bypass 23 can be described as having an inlet connectable to at least one tubing line 20 and two outlets, where one of the outlets is connectable to a tube in fluid communication with an inlet of manifold 45 . The second outlet is removably connectable to second feed line 60 of product bag 80 .
Also shown in FIG. 2 is flip-top cap 33 which is adapted to cover outlet 30 when second feed line 60 is not connected to outlet 30 . Disposed within outlet 30 is a resealable membrane 210 that is self-sealable when punctured, such as a diaphragm valve. Membrane 210 allows a male portion of first feed line 60 to be inserted into outlet 30 . Membrane 210 prevents fluids traveling through bypass 23 from escaping. Although membrane 210 is described as a membrane, it can be a washer or other suitable device that would prevent fluid from escaping the connection between second feed line 60 and outlet 30 as would be understood by one skilled in the art.
FIG. 3 is an enlarged and partially cut-away view of inlet fluid passage 220 and bypass fluid passage 200 at outlet 30 with second feed line 60 inserted into outlet 30 . According to this embodiment, second feed line 60 has a male connector at the end which meets bypass 23 at bypass outlet 30 , which is a female end. In the embodiment shown in FIG. 3 , the male end of second feed line 60 is a hollow penetrating probe 230 that pierces membrane 210 . As probe 230 is fully inserted into outlet 30 , probe 230 seals bypass fluid passage 200 from inlet fluid passage 220 . By sealing or blocking bypass fluid passage 200 , fluids flow into inlet fluid passage 220 and into second feed line 60 . The other end of second feed line 60 is adapted for connection to upper compartment 65 of compartmentalized product bag 80 as shown in FIG. 1 . Likewise, when probe 230 of second feed line 60 is removed from outlet 30 , resealable membrane 210 closes and fluid flows from inlet fluid passage 220 through to bypass fluid passage 200 . Bypass fluid passage 200 is in fluid communication with manifold 45 by way of a bypass to manifold tubing line 40 (shown in FIG. 1 ).
As shown in the embodiment of FIG. 3 , bypass 23 is shaped similar to a “y”. Bypass 23 is a three-way connector and may also be shaped like a “T”. Between inlet fluid passage 220 and bypass fluid passage 200 is the angle θ. Angle θ can be greater than 0° to less than 180°, preferable less than 90°. According to the embodiment shown in FIG. 3 , angle θ is 45°.
Referring again to FIG. 1 , fluid components from tube set 15 connected to individual fluid bottles (not shown) through couplings 100 , deliver liquids that flow to manifold 45 and through first feed line 50 into product bag 80 . When a composition of liquids calls for a component that must be maintained separate until just before use, one tube line 20 from tube set 15 is connected to inlet 25 of bypass 23 . A second feed line 60 is connected to outlet 30 of bypass 23 . Second feed line 60 is in direct fluid communication with upper compartment 65 of product bag 80 . In this configuration, the liquid to be maintained separate will flow through tube line 20 connected to bypass 23 and exit outlet 30 connected to second feed line 60 as shown by line A. In this configuration, the fluid (e.g. a lipid solution) will not pass through manifold 45 and prematurely mix with the other liquid components, but rather will directly flow to upper chamber 65 of product bag 80 independent of manifold 45 .
When a lipid solution is not used in the formulation, i.e., when components of the liquid need not remain separate from the other components, second feed line 60 may be removed from bypass 23 . Thus, the liquid in the tube line connected to bypass inlet 25 will flow to bypass 23 and will exit via bypass fluid passage 200 , which is connected via tubing 40 to manifold 45 . The fluid flow direction is shown by line B in FIG. 1 . Once the fluid enters manifold 45 , it exits manifold 45 by way of first feed line 50 , common to the other tubing lines 20 , and flows into lower compartment 70 of product bag 80 .
According to an embodiment of the present invention, tube set 15 connected to manifold 45 and bypass 23 can be fabricated independently and joined together to form a single device made up of these individual components. Preferably, these components can be ultrasonically welded to their respective mate. The means of joining the components are discussed in detail below. The primary advantage to such a construction is ease of manufacture.
Bypass 23 could be made from any of a number of suitable materials, including plastics, such as polycarbonates, that are suitable to handle the pharmaceutical and food preparations that will be passing therethrough. The suitable materials should also preferably be such that they can be injection molded to form the parts of the device, or the whole device, and one skilled in the art would know such materials.
While preferred embodiments of the invention have been shown and described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention. | A method for selectively dispensing fluid components through a bypass, the bypass having a fluid passage with an inlet, a first outlet that is unsealed, and a second outlet that is sealed, includes the steps of inserting a tubing line into the second outlet to unseal the second outlet, sealing the first outlet to prevent flow of fluid through the first outlet, and delivering a first fluid component into the inlet of the bypass and through the second outlet. | 0 |
This is a continuation of our copending application Ser. No. 874,728, filed Feb. 3, 1978, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention:
This invention relates to methods of erecting marine structures at an offshore site of a body of water, such as an ocean, by controlled submerging of the hollow tubular members associated with the structure. The lower portion of each of the members is closed by a watertight removable plug. Each plug is provided with a vent which is normally closed but which vent can be opened after the members are in contact with the bottom to substantially equalize the pressure on both sides of each of the removable plugs before the plugs are removed from their respective legs. Once the plugs are removed, piling are driven through the hollow legs into the bottom of the body of water to secure the structure in place.
2. Description of the Prior Art:
The increasing demand for oil and natural gas has resulted in a rapid increase in the drilling for oil and gas at offshore sites in bodies of water such as oceans, seas, lakes, straits, etc. and at steadily increasing depths of water. It is known to fabricate marine structures having hollow cylindrical members such as the main legs of the structure, skirt piles, conductors, etc. The bottom ends, or feet, of the main legs are adapted to contact the bottom of the body of water at the offshore site. The upper portions of the legs of the structure have, or are adapted to have, a platform secured to them. The lengths of the legs are chosen so that when the bottoms of the legs firmly engage the bottom of the body of water, the platform is above the highest waves likely to be encountered at the site.
Such structures are generally fabricated in shipbuilding facilities because of their size and weight, for example, the tubular members can be several hundred feet long. The structures are generally transported to the offshore site by barge, pontoons, or by towing the floating structure, normally in a horizontal position. To provide buoyancy when the structure is towed to its site, the tops and bottoms of the tubular members can be sealed to make them watertight.
At the site the structure is caused to float upright by selective flooding of the tubular members, by cranes lifting on the structure, or both. Then the structure is submerged until the bottoms of the legs contact the bottom surface of the body of water. Once the marine structure is in position with its legs firmly in contact with the bottom of the body of water, it is customary to drive skirt piling and/or piling through the legs into the earth to firmly secure the structure in place.
Removal of the plugs closing the bottom of the legs has presented problems. However, it is desirable to seal the bottom ends of the legs by plugs that can be readily removed and when the plugs are removed it is desirable that the interiors of the leg in which they were placed be left substantially clear of obstructions. Conductors and/or skirt piles may be built into the structure in the shipyard for convenience and to provide buoyancy to the erection site--plugs are useful in these tubular members. A zip-out plug is one such type of removable water-tight plug. A zip-out plug has a pressure vessel which is held in place in a tubular member of a marine structure by an elastomeric material, such as rubber, or a synthetic rubber, with a coil of wire rope embedded in the elastomeric material. The coils of the plug rope are substantially uniformly spaced apart so that a reasonable force applied to one end of the plug wire rope will cause the elastomeric material to fail progressively until the pressure vessel is no longer secured or attached to the inner wall of the tubular member. The other end of the plug wire rope used to disconnect the pressure vessel from the tubular member is secured to the pressure vessel to lift it out of the tubular member.
A zip-out plug solves many problems encountered in erecting marine structures such as providing a means for buoyancy that can be conveniently regulated, preventing silt and debris from entering into a tubular member while the plug is in position and reducing the remnants of the elastomeric material of the plug adhering to the inner wall of the tube after the plug is removed to a small, or negligible, amount which does not interfere with driving piling through the member. One set of problems not solved by such plugs is caused by the pressure differential which can, and generally does, exist across a zip-out plug at the time it is disconnected. Such a pressure differential can force, or drive, the pressure vessel of the plug up through the interior of the hollow, tubular member and possibly blow it out the top with a risk of damaging the marine structure and the men who may be working on or in its vicinity. If the pressure within the tubular member is greater, then the pressure vessel will be forced downwardly and could be forced out of the tubular member so that it would be difficult, if not impossible, to recover the pressure vessel particularly if the plug wire rope fails. A pressure vessel embedded in the earth could interfere with driving piling through the tubular member. A difference of pressure across the pressure vessel when the zip-out plug is disconnected from the tubular member can also cause the pressure vessel to become wedged, damaging the member, the pressure vessel and effectively blocking the tubular member to prevent piling from being driven through it.
Prior Art Statement
The following references are submitted under the provisions of 37 CFR 1.97(b): U.S. Pat. Nos. 2,979,910, Crake; 3,533,241, Bowerman et al; 3,577,737, Burleson; 3,613,381, Cox.
Crake (U.S. Pat. No. 2,979,910) discloses an offshore platform structure having hollow steel columns each of which is closed, or sealed, by a thin knock-out plate which is welded to the bottom of a column. The knock-out plates are ruptured by driving piling through them.
Bowerman et al (U.S. Pat. No. 3,533,241) discloses a rupturable seal assembly for closing the lower ends of the upright tubular members of marine drilling platforms. The seal assembly is provided with a circular flexible diaphragm of reinforced rubber which is readily rupturable by the piling used to secure the platform in place.
Burleson (U.S. Pat. No. 3,577,737) discloses a watertight plug assembly removably mounted in each of the tubular wells of an offshore platform. A rubber member is confined and compressed between a lower disc and an upper disc to engage the inner surfaces of the tubular wells. Pins on the plug assembly fit into sockets in the walls of the wells to fixedly position the assembly in a well until the assembly is to be removed.
Cox (U.S. Pat. No. 3,613,381) discloses a lower closure member for a hollow jacket column of an offshore structure which closure member has a truncated metallic cone whose periphery is welded to the wall of a jacket column. The truncated cone is provided with a tearing arm and a tearing strip. The tearing arm is connected to a wire rope and when the wire rope is pulled with adequate force the truncated cone is torn into smaller pieces prior to its being removed.
SUMMARY OF THE INVENTION
The present invention provides a method of erecting at an offshore site of a body of water a marine structure utilizing improved removable watertight zip-out plug assemblies to close the bottom portion of the hollow tubular members of the structure. Each zip-out plug is provided with at least one vent plug, or vent valve, which when removed, or opened, permits the pressure on both sides of the zip-out plug to equalize before the zip-out plug is disconnected from the tubular member in which it is positioned. Removal of the plugs from the piles and legs permits the driving of skirt piles and the driving of pilings through the legs to secure the marine structure to the bottom of the body of water so that the structure can withstand wind and wave action that may occur at the site.
It is therefore an object of this invention to provide a method of erecting marine structures in which the pressure on both sides of a removable watetight plug closing the bottom portion of a tubular member of such structure is substantially equalized before the watertight plug is removed with significantly reduces the risk of damage to the structure, to equipment used in erecting the structure, and to the pressure vessel of the removable plug as well as reducing the risk of injury to the men erecting the structure.
It is another object of this invention to provide a removable watertight zip-out plug for the tubular members associated with marine structures which plug is provided with normally closed vents, which vents can be releaseably and safely opened from the top of such members to equalize the pressure on both sides of the zip-out plug prior to removing a zip-out plug from its position in the tubular member.
Still another object of this invention is to provide a safer, more reliable and more economical method of erecting marine structures in relatively deep bodies of water.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the invention will be readily apparent from the following description of certain preferred embodiments thereof, taken in conjunction with the accompanying drawings, although variations and modifications may be effected without departing from the spirit and scope of the novel concepts of the disclosure, and in which:
FIG. 1 is a fragmentary perspective view of a marine structure with the lower portions of its hollow tubular legs resting on the bottom of a body of water with one leg broken away to show the improved removable watertight plug;
FIG. 2 is an enlarged section taken on line 2--2;
FIG. 3 is an enlarged section taken on line 3--3;
FIG. 4 is a greatly enlarged section taken on line 4--4 of FIG. 3 showing details of one embodiment of the vent with which a removable watertight plug can be provided;
FIG. 5 is a view in section similar to that of FIG. 4 of another embodiment of a vent for a removable watertight plug;
FIG. 6 is a view in section of still another embodiment of a vent that can be incorporated in a removable watertight plug;
FIG. 7 is a front view of a marine structure with the lower portions of the hollow-tubular members resting on the body of water. The legs, skirt piling, and conductors are broken away to show the improved removable watertight plug;
FIG. 8 is an enlarged section taken on line 5--5 of FIG. 7;
FIG. 9 is a representation of an embodiment of a vent for a removable watertight plug.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 marine structure 10 has a plurality of hollow tubular legs, or piling guides, 12, four in the embodiment illustrated. A platform 14 is secured to the upper portion 16 of legs 12. A conventional drilling rig 18 is illustrated as being mounted on platform 14. Obviously marine structure 10 can be used for purposes other than supporting an oil rig, but this is the most common use for such structures at this time.
Marine structure 10 is erected at some offshore site of a body of water, such as an ocean, sea, lake or strait, so that the depth of the water at the site can be determined. The length of legs 12, on the order of hundreds of feet, for example, is chosen so that when the bottom portion, or foot, 20 of each leg 12 is in firm contact with the bottom 22 of the body of water, platform 14 will be well above the highest waves expected at that site. Suitable bracing beams 24 and struts 26 are provided to make structure 10 more rigid. The structure can have skirt piles 100 and conductors 102, illustrated in FIG. 7, installed on the structure.
Referring now to FIG. 2, removable watertight plug or zip-out plug 28 with which each of the legs 12 is provided is illustrated--it is to be understood that plug 28 may be located in the skirt piles 100 and/or conductors 102 instead of the legs 12. Plug, or seal, 28 has a pressure vessel 30 which is fabricated preferably out of steel. Vessel 30 has a semi-hemispherical pressure dome 32 and a cylindrical skirt 34. In a preferred embodiment dome 32 is welded to skirt 34. The outside diameter of pressure vessel 30 is slightly less than the inside diameter of leg 12. In one embodiment of the invention the inside diameter of leg 12 is 46 inches and the outside diameter of pressure vessel 30 is 40 inches so that a three-inch gap exists between skirt 34 of pressure vessel 30 and legs 12 when pressure vessel 30 is substantially positioned in the center of leg 12, its normal position.
A plug wire rope 36 is coiled in space 38 between vessel 30 and the inner wall 40 of leg 12. Space 38 is filled with an elastomeric material 42 such as natural rubber or an artificial rubber to secure pressure vessel 30 in leg 12 at the pressures that it is expected to encounter when in use. Coils 44 of plug wire rope 36 are substantially uniformly spaced vertically as illustrated in FIG. 2 with the space between coils 44 filled with elastomeric material 42. Wire rope 36 is long enough so that one end 46 extends to the tope of leg 12a, for example, as seen in FIG. 1 where it can be connected to a winch, for example, which is not illustrated. The other end 48 of plug wire rope 36 is looped through eye 50 of eye bolt or padeye 52 and secured to plug wire rope 36 by clips, or clamps 54 (also see socket connectors 112 in FIG. 8). Eye bolt 52 is secured to pressure dome 32.
When elastomeric material 42 has set, or when an appropriate amount of cross linking has occurred between the polymers of elastomeric material 42, pressure vessel 30 is securely held in position in leg 12 and provides a watertight seal to prevent water from entering the interior 58 of leg 12 through or around plug 28 while plug 28 is in place. Elastomeric material 42, pressure vessel 30 and coils 44 of rope 36 together constitute plug 28. Seal 28 is illustrated as being located substantially at the bottom of leg 12a, in FIG. 2, but it can be placed anywhere in leg 12, pile 100 or conductor 102 or any other tubular member as circumstances may dictate. As long as zip-out plug 28 is in place, it prevents not only water from entering the interior 58 of leg 12 through it or around it but also prevents any silt or debris that may be located on the bottom 22 of the body of water in which structure 10 is placed from entering the interior 58 of leg 12.
Applying an appropriate force by means of a winch, for example, which is not illustrated, to the upper end 46 of plug wire rope 36 will cause wire rope 36 initially to rip out the portion of the elastomeric material 42 between the first coil 44a of wire rope 36 and the interior 58 of leg 12. Continued pulling on wire rope 36 will pull out each coil 44b-n in turn until the last coil, 44n, is removed which substantially disconnects pressure vessel 30 from wall 40. Continued pulling on rope 36 will apply a lifting force to eye bolt 52 to lift pressure vessel 30 out of leg 12. When pressure vessel 30 is no longer attached by elastomeric material 42 to inner wall 40 of leg 12, only a small amount of elastomeric material 42 will adhere to wall 40, of leg 12a, not enough to interfere with driving piling through leg 12.
To equalize the pressure on both sides of plug 28 before disconnecting pressure vessel 30 from wall 40 which unplugs, or unseals, the bottom portion 20 of leg 12, pressure dome 32 is provided with a normally closed vent or vents 60. Vents 60 have a cylindrical hollow vent pipe, or tube, 62 which extends through and is welded to dome 32. In the embodiment illustrated in FIG. 4, tube 62c is closed or sealed by vent plug 64c which is provided with a vent eye bolt 65c having an eye 66c and a shank 68c. A cylindrical flange 70c is formed, preferably integrally, on shank 68c. Vent bolt 65c is held in vent tube 62c by an elastomeric material 72 which can have the same or a similar composition as that of elastomeric material 42 used to hold plug 28 in position. When set, material 72 is sufficiently strong to easily withstand the pressure likely to be encountered at the site. Eye bolt 65c and material 72 as illustrated in FIG. 4 form vent plug 64c. Vent wire rope 74 passes through the eye 66c of vent eye bolt 65c. A vent clip 76c is secured to rope 74 to transmit sufficient force from vent cable 74 to pull vent plug 64c out of tube 62c.
In the preferred embodiment, as illustrated in FIG. 3, four vents 60a, b, c, d are uniformly arranged around the center, eye bolt 52, of pressure dome 32. The interior diameter of vent tubes 62a, b, c, d is two inches in a preferred embodiment. Vent rope 74 extends in series through the eyes 66a, b, c, d of each of the four vent eye bolts 65a, b, c, d. Four clips 76a, b, c, d are secured to rope 74 with enough slack between clips 76 so that when the upper end of vent rope 74, which extends to the top of leg 12, is attached to a winch, for example, the force applied to rope 74 by the winch is transmitted to the eye bolts 65 in sequence so that vent plug 64a of vent 60a is pulled out of its vent tube 62a first, then vent plug 64b from its vent tube 60b, etc. The vent plugs 64a-d are removed from the interior of leg 12 by lifting, or removing, vent wire rope 74 to which plugs 64a-d are attached by clips 76a-d.
In FIG. 5 vent plug 77, which is a different embodiment of the vent bolt illustrated in FIG. 4 has an eye bolt 78 which is provided with an eye 79 and a shank 80. Bolt 78 differs from bolt 64 in that cylindrical flange 81 of bolt 78 has a greater height and also a greater outside radius than flange 70c of bolt 65c illustrated in FIG. 4. In addition bolt 78 has two frustums of a cone 82, 84 on either side of flange 81, or describing bolt 78 another way, it has a frustoconical enlargement, or flange, 86 which is substantially encapsulated in elastomeric material 87 to hold vent bolt 78 in place within tube 62 until it is removed by force exerted by vent rope 74 and vent clip 76 acting against eye 79 of bolt 78. Bolt 78 and elastomeric material 87 together form vent plug 77. Vent plug 77 illustrated in FIG. 5 operates and functions in essentially the same manner as vent plug 64c illustrated in FIGS. 3 and 4 and can be substituted for vent plugs 64a-d.
In FIG. 6 still another embodiment of a vent 60 is illustrated. Hollow cylindrical vent tube 88 has bolted to its inner end 89 a conventional ball valve 90. When ball 92 of ball valve 90 is in its closed position, the position illustrated in FIG. 6, communication through vent tube 88 with the interior 58 of a leg 12 is blocked. Conventional solenoid actuator 94, when energized, causes ball 92 to rotate 90° to place valve 90 in its open position so that passae 96 through ball 92 is aligned with vent tube 88 and communication with the interior 58 of a leg 12 can occur through vent tube 88 and ball valve 90 to substantially equalize the pressure on both sides of pressure dome 32 of zip-out plug 28. Energization of solenoid 94 is by wires 98 which extend from the top of leg 12a, for example. Valve 90 is removed from leg 12 with pressure dome 32 to which it is fixedly attached.
FIG. 9 is another embodiment of a vent 60 having substantially the same elements as the embodiment of FIG. 6 except that in FIG. 9, conventional ball valve 90 is actuated by a conventional pneumatic actuator represented by 200. Energization of pneumatic actuator 200 is by a pneumatical conductor line 210 which extends from the top of leg 12a, for example.
FIG. 7 shows a structure with legs 12, skirt piles 100, and conductors 102. Skirt pile guides 104 guide the piles 100 as they are driven. The legs, conductors, and piles are broken away to show the zip-out plug in place. As mentioned previously, the zip-out plug can be placed on one or all of the legs, conductors, piles, but preferably the zip-out plug is placed in the skirt piles 100 and/or conductors 102. Of course, the zip-out plug can be placed in legs 12, however, a conventional diaphragm may be more practical for the legs.
FIG. 8 is an enlarged section taken on lines 5--5 of FIG. 7. It shows a preferred method of connecting the vent rope 74 to vent plug 64. For example, vent rope 74 can be shackled to vent rope 106, vent rope 108 (which can be twice as long as vent rope 106), and vent rope 100 (which can be three times as long as vent rope 106). Also shown is the preferred method of connecting the vent ropes, i.e. by socket connectors 112.
The platform 14 may be secured to the legs at the time it is fabricatd or after the structure has been placed at the offshore site. Normally the upper portions of the tubular members are sealed, or made watertight, by conventional means, particularly if the structure is to be towed to its site while floating in the water. The manner of sealing the upper portions or ends can be by any suitable conventional way such as by welding a metal plate, etc. Once the marine structure reaches the site at which it is to be erected, it is set in a substantially upright manner by selective and controlled flooding of legs 12, skirt piles 100 and conductors 102, by the use of floating cranes, or by both. Once the structure has substantially the correct attitude in the water, it is further flooded by opening valves or by pumping water into legs 12, for example, to submerge the structure and cause the bottoms, or feet, 20 of legs 12 to contact or come to rest on the bottom 22 of the body of water at the offshore site at which marine structure 10 is to be erected.
When the structure is in contact with bottom 22, vent wire rope 74 can be attached to a winch, for example, and vent plugs pulled from their respective vent tubes. After the pressures are substantially equal on both sides of pressure vessel 30, plug wire rope 36 may be connected to a winch to unzip or remove zip-out plug 28 by disconnecting it from the inner wall of leg 12, pile 100, conductor 102, for example. Rope 36 is also used to remove pressure vessel 30 from the tubular member once pressure vessel 30 is disconnected from the inner wall of the tubular member.
From the foregoing, it is believed obvious that this invention provides a method of erecting marine structures that eliminates any pressure differential that exists across the pressure dome of a zip-out plug before the plug is unzipped, or disconected, and reduces the risk of damage to the structure, and the men erecting it and makes possible the recovery of the pressure vessel of the plug with a minimum risk of damage to the pressure vessel so that it may be used repetitively.
It should be evident that various modifications can be made to the described embodiment without departing from the scope of the present invention. | A method of erecting a marine structure at an offshore site of a body of water. The structure has a plurality of hollow tubular members associated with it. Examples of such members include skirt piles, conductors, legs, etc. The bottom portion of at least some of the members is sealed by a watertight removable plug with each plug provided with a plurality of normally closed vents. The vents, when opened, permit the pressure on both sides of the removable plugs to become substantially equal. After the structure is transported to the site, the tubular members are oriented substantially vertically with the bottom portion of the members extending downwardly. The structure is then submerged, preferably the bottoms of the tubular members engage the bottom surface of the body of water at the site. The vents in the plugs are opened, and after the pressure on both sides of each removable plug is substantially equal, the plugs are disconnected from the tubular members and are removed through the tops of their respective members by wire ropes to clear the interior of each of the members. Piling can then be driven to secure the structure to the bottom of the body of water. | 4 |
FIELD OF THE INVENTION
This invention relates to sheet materials including papers and like materials formed by depositing fibres onto a support surface. More particularly, the invention relates to sheet materials having partially embedded therein an elongate element which is partially disposed within the thickness of the sheet but exposed at spaced locations.
By the term `exposed` is meant that the elongate element is substantially more visible at `exposed` areas than when disposed in the thickness of the sheet by virtue of being overlaid by little or none of the fibre material making up the sheet. It is, however, permitted that the sheet includes a transparent or translucent overlay which covers the `exposed` areas of the elongate element.
The visual effect provided by the exposure of the elongate element may be for purely decorative purposes but in preferred embodiments of the invention the sheet is a security paper and the elongate element is a security feature.
BACKGROUND OF THE INVENTION
It is known to include elongate elements such as threads or ribbons of material such as plastics film, metal foil, metallised plastics and metal wire in the thickness of paper to render imitation of documents produced from the paper more difficult. To increase the security given by the included element, it has been proposed to endow the element itself with one or more verifiable properties over and above its presence or absence. Such properties include magnetic properties, electrical conductivity, the ability to absorb X-ray strongly and fluorescence.
Also it has been proposed in British Specification No. 1552853 to use a dichroic filter material as the elongate element and to provide apertures in the sheet so that the dichroic material is exposed on both sides at the same location and viewable by reflected or transmitted light. The dichroic material will have a different appearance when viewed in these different ways.
The techniques proposed for providing the said apertures all however suffer from the disadvantage that they are applied after the sheet containing the security element has been made.
SUMMARY OF THE INVENTION
The present invention provides a method for making a sheet which method comprises depositing fibres onto a support surface whilst providing an elongate element overlying the support surface, the deposition of fibres being carried out in such a manner that as fibres are deposited on the support surface to form the sheet the elongate element becomes generally incorporated in the sheet but is left at least substantially exposed as at least one surface of the sheet at a plurality of spaced locations.
The method of the invention may be carried out in a number of ways for instance, one method comprises depositing fibres onto a support surface having portions which are raised relative to adjacent areas of the surface, and providing an elongate element extending over the raised portions, the deposition being in such a manner that substantially no fibres are deposited between the raised portions and the overlying elongate element, whereby the elongate element becomes disposed within the thickness of the sheet formed by the deposition of fibres but at least substantially exposed at at least one surface of the sheet at a plurality of spaced locations.
Preferably, the fibres are deposited from a suspension in a fluid onto a fluid permeable support surface through which the fluid is withdrawn.
Preferably, the raised portions of the support surface are fluid permeable.
Preferably, the fibres are paper making fibres and are deposited from a suspension in a liquid.
Preferably, the elongate element is contacted with each raised portion of the support surface prior to any substantial amount of fibres being deposited over that raised portion.
Preferably, the support surface extends over a continuous path and is moved over the path so as to pass through a suspension of paper making fibres and the fibres are continuously deposited thereon to form a sheet which is continuously removed therefrom and an elongate element is continuously introduced to contact the support surface and lie over the raised portions of the support surface in turn before any substantial amount of fibres are deposited on the said raised portions.
The support surface may be provided by a wire mesh and in that case the raised portions thereon may be formed by embossing the wire mesh.
The raised portions may however be additions to the support surface, such as blocks attached to a wire mesh surface or `arches` of wire or similar material mounted on the support surface.
The invention also provides a method of forming a sheet having an elongate element disposed within the thickness of the sheet but at least substantially exposed at at least one surface of the sheet at a plurality of spaced locations, which method comprises bringing the elongate element to lie over a support surface, and depositing sheet forming fibres on the support surface to form a sheet containing the elongate element within the thickness thereof, wherein means are provided on the support surface to produce a lesser rate of fibre deposition thereon at a plurality of spaced locations so as to cause the elongate element to be at least substantially exposed at at least one surface of the sheet at said locations.
The invention also provides a method for making a sheet which method comprises depositing fibres from a fluid suspension onto a surface of a pervious support by removal of the fluid through the support, the support comprising a plurality of spaced impervious portions, and providing an elongate element extending over the impervious portions, the deposition being such that the impervious portions restrict fibre deposition immediately above themselves so that the elongate element becomes disposed within the thickness of the sheet formed by the deposited fibres but at least substantially exposed at at least one surface of the sheet at a plurality of spaced locations.
The impervious portions may be raised above adjacent regions of the support surface or may not be so raised as desired.
Once again the support surface is preferably provided by a wire mesh.
Preferably the fibres are paper making fibres.
Preferably, in either of the methods described above the sheet is made on a cylinder mould paper making machine.
The invention includes a sheet made by a method of the invention described above.
Preferably the sheet is a paper sheet.
The paper may be a security paper and the elongate element may be a security element.
Such a security element may be a thread or ribbon of plastics or of metal and may be a thin film dichroic filter element, a magnetic element, an electrically conductive or phosphorescent element, a strongly X-ray absorbing element, a fluorescent element, an element incorporating a hologram or halographic effect, or a prismatic effect or incorporating a diffraction grating, or an element combining two or more of these properties. Other properties which may be possessed by the element include colour, emblems or messages thereon and variations in texture. Suitable elements are described in our British Patent Specification No. 1127043 and Application No. 51047/76. Dichroic materials are described in Specification No. 1552853.
Preferably, where the sheet is of paper, the elongate element lies in a watermark area of the paper.
Preferably, the locations at which the elongate element is exposed are in predetermined longitudinal register with some other marking or feature on the paper.
The sheet may be provided with a transparent or translucent overlay extending over at least the exposed portions of the elongate element. The overlay may be applied in register with exposed portions of the elongate element so as to cover substantially only each exposed portion. Alternatively the overlay may be applied over a larger area of the sheet, e.g. along a strip so as to cover a number of exposed portions of the elongate element and the areas of the surface between those exposed portions. If desired the overlay may extend over the whole of one or more of the surfaces of the sheets.
The overlay may be a film which is applied over the sheet and caused to adhere thereto, e.g. by adhesive. The overlay may be applied as a liquid and subsequently form a film adherent to the surface of the sheet. In such a case, the liquid may be applied in register with exposed portions of the elongate element e.g. by printing, more particularly "ink-jet" printing.
Where the overlay is applied as a film, it may for instance be a plastics film such as a polyethylene, or polyester film.
If the overlay is to be applied as a liquid it may be in the nature of a varnish, e.g. a polyurethane varnish, or may be a film forming latex such as will form a transparent or translucent film e.g. a polyvinylacetate latex. The liquid may be a solution of a polymer which forms a film upon evaporation of solvent. The liquid may be a liquid monomer or polymer precursor which cures to form a film in situ.
The provision of such an overlay helps to prevent the elongate element becoming detached from the sheet where it is exposed and forming loops which could lead to the elongate element becoming broken or being pulled out of the sheet
The invention includes a security document comprising or produced from a sheet according to the invention and includes such security documents as banknotes, cheques, warrants, identity cards, guarantee cards and credit cards.
In addition to security papers, the invention is applicable to sheet materials generally, including wall coverings including wallpapers in which the partially enclosed elongate element may be a decorative feature, and also fibrous laminates. Decorative laminates often comprise several layers of resin impregnated Kraft paper with a decorative layer of fine quality paper which is printed with the desired pattern. This has a protective transparent layer thereover such as onion skin. The printed layer may be a sheet according to the present invention and the included elongate element may be a decorative feature.
When a sheet according to the invention has been formed with the elongate element substantially but not wholly exposed at spaced locations, steps may be taken to enhance the exposure of the elongate element by removing some or all of the fibres which are overlying it. Such steps may include brushing or sweeping the surface or directing a jet of fluid onto the surface of the sheet to dislodge such fibres.
Where a jet of fluid is exployed, the sheet may be caused to move through an exposure enhancement station and the jet of fluid may be activated only when a substantially exposed portion of the elongate element is in position in the station to be struck by the jet.
DESCRIPTION OF THE DRAWINGS
The invention will be illustrated by the following description of preferred embodiments with reference to the appended drawings in which:
FIG. 1 is a schematic section through a cylinder mould paper making machine in normal operation inserting a security thread into the paper being made.
FIG. 2 is a schematic section through the machine of FIG. 1 modified for use in one method of the present invention.
FIG. 3 shows the profile of an embossed wire mesh which may be used as the support surface in the apparatus of FIG. 2 making sheets according to one method of the invention.
FIG. 4 is an enlarged view of the circled area of FIG. 2.
FIG. 5 is a cross-section through the paper produced by the machine of FIG. 2.
FIG. 6 shows a profile of a wire mesh mould cover useable in accordance with the invention.
FIG. 6a and FIG. 6b show cross-sections through paper producible by methods according to the invention.
FIG. 7 shows apparatus for enhancing the exposure of an elongate element.
FIG. 8 shows a cross-section through a further sheet made in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
As seen in FIG. 1, a cylinder mould paper making machine comprises a vat containing a suspension of paper making fibres 1 in which dips the major portion of a cylinder 2 arranged with its axis horizontal. The surface of the cylinder 2 is provided by a wire mesh. Generally there are several layers of mesh employed, the outermost being the finest. Liquid is drawn through the mesh as the cylinder 2 is rotated causing paper making fibres to deposit on the mesh and form a sheet which is couched from the cylinder by couch roll 3 and conveyed away. A security thread 4 is continuously implanted in the paper. The thread is supplied from a bobbin and passes over a guide 5 e.g. a roller, and into the vat to contact the paper on the cylinder at such a depth that approximately half the desired thickness of paper fibres have been despoited. As the cylinder rotates, further paper fibres are deposited over the whole surface of the cylinder and the thread is buried. Although the term "thread" is employed in this description of specific embodiments, it is to be understood to include ribbons of film or foil, wires and any other suitable elongate elements for inclusion in paper.
It should be noted particularly that the thread is arranged to enter the liquid in the vat prior to contacting the cylinder so that the cylinder surface has already acquired a substantial coating of paper fibres before the thread makes contact.
In the modified machine shown in FIG. 2 and in detail in FIG. 4, the roller 5 is shifted so that the thread contacts the cylinder at a substantially higher point. The support surface provided by the wire mesh cylinder cover is provided with raised portions 6 by embossing (see FIG. 3). The thread is led into the vat so as to contact each raised portion 6 as the raised portion enters the vat so that the thread is lying over the raised portion as fibres begin to deposit, i.e. whilst still above the water level 6a (FIG. 4). Fibres are progressively deposited over the thread and also below the level of the thread except at the raised portions 6.
The effect on the paper produced is shown in FIG. 5 on a vertically exaggerated scale. Where the thread contacted a raised portion 6, the thread lies exposed on one surface of the paper (the mould side). The thread is continuously covered on the other side of the paper.
In FIG. 4, it will be observed that the thread is shown bridging the gap between successive raised portions 6. To achieve this effect it may be necessary to apply somewhat greater tension to the thread than is conventional. The use of less tension can result in the thread conforming more to the surface of the valley between the raised portions 6. The exposed portion of the thread may then be longer than desired or, in extreme cases continuous. As an example, a 0.5 mm. wide ribbon of metallised plastics film might normally be at a tension of 100 grammes or less at the point of contact with the support surface. However, in order to cause such a ribbon to bridge the projections of the support surface as shown in FIG. 3, a tension in excess of 100 grammes may be required. For example, the required tension may be between 125 to 150 grammes. The actual tension required in practice will depend upon the nature of the elongate element employed and the effect desired. The tension may be provided by the resistance to turning of a bobbin from which the thread is continuously withdrawn by the rotation of the mould. Alternatively the thread may be delivered through a driven delivery means such as a pair of nip rolls having a surface speed slightly less than is required to match the demand of the mould.
The support surface shown in FIG. 3 is a wire mesh provided with raised portions 6 which are each about 0.75 mm high and 2 mm long in the paper making direction and which are separated by a valley 7 with a radiused cross-section at each end. Care should be taken that the valley 7 is not too small to permit sufficiently free entry of fibres from the paper making furnish to lie under the thread or else the exposed portion provided by the raised portions 6 will not be divided. In the surface illustrated, the radius of curvature at each end of the valley is approximately 1 mm. This pattern has been found suitable for use with a heavily beaten cotton furnish designed to produce an 80 g am dry paper. The dimensions of the valley needed to ensure deposition of fibres therein beneath the elongate element will naturally depend upon the average fibre length.
Although only three raised portions 6 are shown, it is preferred that there be a continuous line of such raised portions around the cylinder 2. The visual effect produced in the paper is then a line of short exposed sections of the thread on one side of the sheet.
The raised portions 6 used to produce the exposed portions of thread may form part of a more complex embossing on the wire cover of a cylinder mould, which more complex pattern produces the watermark of a watermarked paper.
In particular, at either side of the raised portions, small valleys whose lowest points lie below the general level of the support surface and valleys 7 may be incorporated. These cause an increase in paper thickness at each side of the exposed portion of the thread which serves to enhance the appearance, to define the exposed portion more clearly and to reinforce the sheet.
As described above the raised portions 6 shown in FIG. 3 are themselves permeable. However, these raised portions may if desired be impermeable and for instance may be provided by attaching plastics or metal to a nonembossed wire mould cover.
An example of a support surface in the form of a wire mesh mould cover bearing impervious raised portions is shown in FIG. 6. FIG. 6a shows the effect of such a support surface on the paper produced.
In FIG. 6, a row of impervious projections 10 are shown. When such a mould surface is used in apparatus as shown in FIG. 2 with sufficient tension being applied to the thread to make it bridge the valleys between the projections 10, the thread comes to lie on the top of the projections 10 before paper fibres are deposited and becomes embedded in the paper as it is formed. The projections shown each occupy a sufficiently small area of the mould surface that they have little effect on the local rate of fibre deposition and the surface of the paper remote from the mould is largely unaffected. The impervious projections act in the same manner as the pervious projections in the embodiment of FIG. 3.
FIG. 6b shows the effect on the paper of making the impervious projections of FIG. 6 larger relative to the mean fibre length of the paper making stock.
As before, the thread is exposed on the mould side of the paper through contact with the projections. However, the size of the projections is now sufficient to affect the local rate of fibre deposition and fibres are in fact not deposited above the projections because of the lack of drainage of the suspending fluid at those points. Fibres deposited over the permeable parts of the mould are not sufficiently long the bridge over the non-permeable parts. Thus holes 11 are formed in the paper over the impervious projections 10 and the thread is exposed on both sides of the finished paper.
It should be observed that when the impervious projections are so large in transverse area that they block fibre deposition thereabove, it is not necessary that the thread be arranged to lie over the projections before fibre deposition commences in order that the thread be exposed on the mould side of the paper.
Indeed, where impervious areas of the mould surface are employed which are of sufficient size relative to the fibres to be deposited, there may be no need for these portions to be raised above adjacent parts of the mould surface. It is possible to rely entirely on the blocking of drainage by the impervious regions to provide exposure of the elongate element on one or both surfaces of the sheet.
When raised portions are provided, they may be partially pervious and partially impervious. For instance pervious raised portions may have impervious bodies such as bars mounted at their tops. Similarly, the same support surface may incorporate raised and/or depressed pervious portions in some locations and impervious portions in others.
It is desirable that the position of the exposed portions be in fixed register relative to the sheet so that document sized portions of the sheet may be cut at predetermined positions in such a way that the edges of the cut portions do not coincide with an exposed portion of the element.
FIG. 7 illustrates one method of enhancing the exposure of the elongate element.
FIG. 7 shows the paper 12 after couching being conveyed on a conveyor 13. The paper 12 passes through the nip of a pair of press rolls 14 where water is expelled and the paper emerges considerably compressed. The thread 4 is substantially exposed at periodic locations 15 but is still overlaid by a small amount of paper. The paper enters an enhancement unit 16 wherein it runs under a flexible tongue 17, weighted to contact the paper with the desired force by weight 18. A jet 19 sprays water onto the paper just before it runs under tongue 17 in order to lubricate the tongue and to mobilise the paper fibres.
The paper emerges from the unit 16 with the thread 4 fully exposed at spaced locations 20.
FIG. 8 shows a cross-section through a further paper made according to the invention. This paper is obtained by depositing fibres onto a wire mesh cover of the kind shown in FIG. 3 but having higher raised portion 6, sufficiently high indeed to extend out from the mesh surface by more than the normal sheet thickness. The thread has been laid into the sheet under relatively low tension and has been introduced into the furnish so as to contact the raised portion after some deposition of paper fibres has occured on their top surfaces. No substantial deposition occurs over the thread 4 at the top of each raised portion because of washing off and other effects. Deposition will occur to bury the remainder of the thread however. The result is that the thread is periodically exposed on the couching side of the finished paper. The raised portions are sufficiently large to constitute means to cause a decrease in the rate of fibre deposition locally resulting in an exposed thread. Due to the low tension the thread does not lie straight from high point to high point but conforms to the valleys between raised portions.
Although the invention has been illustrated with reference to security papers, the methods described above are readily adaptable to the making of other products in which the exposed elongate element has a different role, e.g. a decorative function.
Furthermore, the use of a cylinder mould paper making machine is not essential to the manufacture of products according to the invention and a suitable manner of using other types of machines, such as Fourdrinier machines, generally employed for making paper and like materials will readily occur to those skilled in the art. For instance. a paper making machine of the kind described in our British Patent No. 1447933 may be employed. | A sheet material such as paper is provided during manufacture with an elongate element partially disposed within the thickness of the paper sheet but exposed at spaced locations one one side of the sheet. The paper may be used in making security documents such as banknotes and checks. | 3 |
This application is a Continuation of international application PCT/ES2010/070498, filed Jul. 19, 2010, which is hereby incorporated by reference in its entirety.
OBJECT OF THE INVENTION
The invention refers to a device for limiting the speed of moving traffic. The device comprises at least one protruding element positioned on the surface of a road that is open to traffic.
The protruding element wherein the shape and dimensions thereof are such that it only affects vehicles of certain sizes, the speed of which is going to be controlled. Likewise, vehicles travelling at an acceptable speed and along an appropriate path are also not affected by the device of the invention.
BACKGROUND OF THE INVENTION
Among the systems for limiting the speed of moving traffic, we can find different elements, devices and techniques. There are some actions that imply a change of the ground path of the vehicles and others that imply a modification of the cross section. The most common methods involve a change in the slope of the road by adding prefabricated elements, or “in situ” actions that require vehicles to pass them reducing their speed, but they are uncomfortable to the occupants, noisy in the environment, they produce mechanical breakdowns and they even cause accidents sometimes. Another disadvantage is that most of the protruding elements are applied equally to all types of vehicles, causing delays in response times for emergency vehicles such as fire engines, ambulances, etc.
The object of the present invention is the provision of devices for limiting the speed of moving traffic in order to minimize the inconvenience to all light vehicles that run at an appropriate speed, public transport vehicles, heavy goods vehicles and emergency service vehicles, such as fire engines and ambulances.
DESCRIPTION OF THE INVENTION
In places where the road designs in order to maximize flows and speeds, i.e. mobility, still exist, it can be found that most users reject devices for liming speed. In those places, it is wrongly thought that when the speed goes up, the travelling times always decrease, or, on the contrary, that when the speed goes down, there are more traffic jams.
Supposedly, the speed reduction reduces the space available for possible crossings or overtaking of vehicles. However, these concepts are taken from the “continuous traffic flow” theory, while in cities it is clear that due to the intersections and interactions with other elements, such as pedestrians or cyclists, there is an intermittent traffic flow.
The models applied just in urban roads and other studies show how the maximum operating speeds are between 30 km/h and 60 km/h, peaking at about 45 km/h.
Although the impact on the road capacity is not significant, it is on the quality of life in cities, where the implications arising from the reduction of operating speeds are important.
Speed reduction reduces the risk of accidents because at a fast speed, the events happening near the sides of the vehicle, such as pedestrians crossing the street or children playing on sidewalks, go unnoticed. On the other hand, if the speed is high, the severity of accidents is higher too. Pedestrian safety mostly depends on the speeds of the vehicles: a speed of 50 km/h increases the risk of death almost eight times compared to 30 km/h, and 2.6 times compared to 40 km/h.
Speed is also an important factor in fuel consumption of vehicles, in their polluting emissions and in the noise levels. However, in an urban area, the speed reduction is not so directly translated into the reduction of these factors as much as in increasing road safety.
Finally, the reduction of the number of vehicles and speed reduction can solve the problems caused by environmental and social conflicts related to traffic.
The device for limiting the speed of moving traffic comprises at least one protruding element designed to be positioned on the surface of a road that is open to traffic in such a way that it can intervene in the path and, as a consequence, in the speed of the vehicle.
The protruding element wherein it comprises:
A directrix line which in a plan view has a curve shape and it is positioned in the direction of the vehicle in such a way that the width of the projection of the protruding element on a transverse plane to the lane is greater than the width between wheels of the same axis of the largest vehicle whose speed is going to be controlled; A cross-section to the directrix line that is reduced at the ends of the protruding element and bulged outward in the center, and the maximum width of the cross-section being less than or equal to the width between wheels of the same axis of the smallest vehicle whose speed is going to be controlled.
The device object of the invention is an element for limiting the speed of moving traffic that belongs therefore to the category “actions on the track in plan view”, as well as “actions on the track in elevation” and, to a lesser extent, “actions on the cross section” because it comprises some discontinuous transverse protruding elements whose geometry in plan view allows the flow of certain vehicles without them being affected either by their size or because they follow a curved path in relation to the directrix line of the protruding element. This curved path is therefore similar to that applied in a chicane, but with the advantage that no action is required on the design of the road.
The maximum width of the cross section of the protruding element will therefore be less than or equal to the vehicle with the narrowest width between axes so that it can pass by without going up the protruding element when following the curved path of the directrix of the protruding element.
The curved shape in plan view avoids the direct flow of vehicles because it guarantees that the width of its projection on the transverse plane to the road is greater than the width of the axes of the largest vehicle whose speed is going to be controlled. Therefore, if a light vehicle intends to follow a straight path will have to go up the protruding element, feeling the inconvenience that it produces. In contrast, if it is a heavy vehicle with a greater separation of the wheels of its own axes, it will be able to do it, but always with caution and, therefore, with some speed reduction.
The cross-section to the directrix is reduced at the ends of the protruding element and bulged outward in the center also has the advantage that it facilitates the vehicle to follow the path along the protruding element since the effect of gravity helps the vehicle in falling to the road and therefore in following the path designed by the bulged protruding element.
The devices can be built “in situ” or be prefabricated and installed not only on those streets functionally classified as “local streets”, but also in collector roads and side streets. Unlike the transverse protruding elements, they can be installed regardless of the composition of the traffic flow because they have no negative impact on heavy vehicles, motorcycles or bicycles.
With these devices for limiting the speed of moving traffic in this invention, several objectives are achieved, including:
To moderate the speed of vehicles with more than two wheels. To reduce the speed of light vehicles (cars). To minimize the inconvenience to the occupants of any vehicle when driving at the proper speed. To reduce breakdowns and damages in vehicles due to the fact that they do not have to deal with bumps in height. To avoid side effects that moderators of traffic have on emergency vehicles and public transport vehicles. To allow that the emergency vehicles can continue running at normal speeds, reducing their emergency response times, To improve road safety by moderating speeds.
DESCRIPTION OF DRAWINGS
This descriptive memory is completed with some illustrative plans of the preferred embodiment but not limiting.
FIG. 1 is a horizontal schematic representation of an embodiment of the device of the invention, which comprises two protruding elements, one on each direction of the road.
FIG. 2 is a perspective view of an embodiment in which a car is on a protruding element, following its path and curved geometry.
FIGS. 3 a , 3 b , 3 c and 3 d are horizontal schematic representations of the protruding element and the hump placed on a single lane road where the hump comprises a half ellipse shape or a semicircle shape or a triangular shape or a rectangular shape.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The device for limiting the speed of moving traffic in the embodiment shown in the figures comprises two protruding elements ( 1 ) placed on each lane of the road in both directions. The curvature of each protruding element ( 1 ) determines a path to the left in each direction, so that the protruding elements ( 1 ) are presented symmetrically in relation to the axis of the road, but this does not necessarily have to be like this because, for example, the protruding elements ( 1 ) does not necessarily have to have all its length to complete its longitudinal symmetry. The curved path of the protruding elements ( 1 ) does not have to be necessarily to the left according to the direction of the road. However, this path to the left is preferred because in a two-way road the tangent of the protruding element ( 1 ) in the approach area of the vehicle does not run towards the opposite lane, which improves traffic safety.
Other arrangements are possible. For example: the provision of a single protruding element ( 1 ) on one-way roads or the provision of several protruding elements ( 1 ) on each lane of a multi-lane road in the same direction. In this case, the protruding elements ( 1 ) being placed in parallel instead of symmetrically, although the symmetrical arrangement would also be possible.
The protruding elements ( 1 ) consist of a directrix line ( 1 . 1 ) that has a curved shape and is located in the direction of the road.
The width ( 1 . 2 ) of the projection of the protruding element ( 1 ) on a transverse plane ( 5 ) to the road is greater than the width between the wheels of the largest vehicle axis ( 3 ) whose speed is going to be controlled. The maximum width ( 1 . 3 ) of the cross section is also less than or equal to the width between the wheels of the same minor axis of the vehicle whose speed is going to be controlled. In the illustrated embodiment, the cross section of the directrix ( 1 . 1 ) is constant throughout the length of the protruding element ( 1 ), but it could also be variable. This with the necessary transitions in height at the entrance and exit.
The protruding element's length must allow the development of its horizontal curvature to comply with the two aforementioned conditions in width. However, the protruding element ( 1 ) must not necessarily be symmetric, nor transversely or longitudinally.
The cross section is the usual section for the existing protruding elements ( 1 ), in other words, they are of a certain height so as to dissuade drivers from passing by, but not being an obstacle for the smallest ones, with the usual wedged side transitions of its height.
The device of the invention can or cannot include an additional protruding element (or “hump”) ( 2 ) to avoid that a vehicle run between a protruding element ( 1 ) and the curb, or between two protruding elements ( 1 ) through the corresponding free space, which is unaffected by them ( 1 ). In the case of very narrow roads, the additional protruding element ( 2 ) would not be necessary.
The additional protruding element ( 2 ) would be placed on at least one side of the lane or lanes, so that the distance ( 2 . 2 ) between the protruding element ( 1 ) and the additional protruding element ( 2 ) is less than the one between the wheels of the same minor axis of the vehicle whose speed is going to be controlled.
In the event that the additional protruding element ( 2 ) is placed on a road with more than one lane, the longitudinal axis ( 2 . 1 ) of the additional protruding element ( 2 ) would coincide with the separation lines of traffic lanes or directions, depending on the case. Thus, it also has the function of separator between lanes, apart from the function stated above. Furthermore, if there is a possibility that the vehicles can run on the axis ( 4 ) of the road or the line separating the lanes, the maximum width of the additional protruding element ( 2 ) will be greater than the separation of wheels of the same axis of the largest vehicles whose speed is going to be controlled.
The additional protruding element (or “hump”) ( 2 ) in the embodiment shows an elongated elliptical shape, but since it is an accessory that does not depend on the functionality of its shape, it can be of any shape provided that it prevents the traffic flow between protruding elements ( 1 ). In the event that it is located on a single lane road, that could be of a half-ellipse shape, of one or more semicircles shape, of a triangular shape, of a rectangular shape, etc., and in the case of being located between two lanes, may be of an elliptical shape, of one or more circles shape, of a triangular shape, of a rectangular shape, etc.
The corners of the protruding element ( 1 ) shown in the figures are rounded, but they may be of different shapes, for example, bevelled edge or cornered, depending on the construction or manufacturing process.
No building materials, or colours or types of signs are specified because their functionality does not depend on them, but on their shape and arrangement.
In the case of roads with narrow lanes, it may be possible to install the protruding elements changing the alignment of the curbs in order to take a concave curved shape similar to the geometry of the protruding element. | The invention relates to a device for limiting the speed of moving traffic. The device comprises at least one protruding element positioned on the surface of a road that is open to traffic. The protruding element wherein the shape and dimensions thereof are such that it affects only vehicles of certain sizes, the speed of which is going to be controlled. Likewise, vehicles travelling at an acceptable speed and along an appropriate path are also not affected by the device of the invention. | 4 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/407,112 filed Aug. 30, 2002, and U.S. Provisional Application No. 60/ 409,492 filed Sep. 10, 2002, which are both currently still pending, the entire contents of each of which are herein incorporated fully by reference thereto.
FIELD OF THE INVENTION
[0002] The present invention relates to epoxy resins. More particularly it relates to amine curing agents useful in curing epoxy resins. More particularly still, the invention relates to amine curing agents which display reduced reactivity as a curing agent, which translates to an increased “working time” associated with the manufacture of articles from epoxy resins.
BACKGROUND INFORMATION
[0003] Manufacturing processes commonly used in conjunction with the production of epoxies include filament winding, pultrusion, infusion molding, resin transfer molding (RTM), vacuum assisted RTM (VARTM), and wet lay-up or vacuum bag techniques. Polyoxyalkylene amines, or “polyetheramines” as they are sometimes called, are useful as curing agents in epoxy systems to improve flexibility, and to lengthen working time in the manufacture of fiber-reinforced composites. The “working time” is defined as the time period between when the reactive components of the epoxy resin are first mixed with one another and when the mixture is no longer suitable for processing. During the working time, the resin or article containing the resin remains in a pourable, flexible, pliable or otherwise mouldable form.
[0004] The use of epoxy binders is preferred by many manufacturers of fiber-reinforced composite wind turbine generator (“WTG”) propellers, which propellers each typically comprise three individual epoxy-composite blades having lengths from 20-40 meters each. Unfortunately, the working times provided for by currently-available amine curing agents are insufficient for the preparation of blades having optimal properties. In addition to a longer working time, the materials from which a WTG blade material is made must also maintain good heat resistance when cured.
[0005] Many WTG blade manufacturers today use the VARTM process when working with liquid epoxy systems or epoxy polyester systems. These resin systems must cure slowly in a controlled fashion and allow sufficient working time to wet-out the fiberglass, aramid fiber, carbon fiber, or other fibers that are used as reinforcing materials in the wind turbine blades. In some cases, prepreg epoxy systems may be used. In these instances, fibers pre-impregnated with a reasonably latent epoxy resin system may be used to form the turbine blade. The use of polyetheramines as epoxy curing agents is not common in the prepreg materials, but is common practice by some using VARTM and other liquid molding processes, where JEFFAMINE® D-230 amine (Huntsman Corporation, Houston, Tex.) is used in large quantities. However, manufacturers understand that the working time for using such materials is too short for optimum production, mainly when manufacturing individual blades of greater than 30 meters in length. Since the tendency in the WTG industry is to go to longer blade length to increase the ability of each WTG to produce more power/unit, a need has arisen in the art for curing agents which can make the manufacture of such blades commercially viable.
SUMMARY OF THE INVENTION
[0006] The present invention provides polyamines useful as a curing agent in epoxy resins having the structure:
wherein L is an oxyalkoxo group having the structure:
—O—R 1 —O— (II)
in which R 1 is any group selected from the group consisting of: C 1 to C 5 alkylene; 2-methyl propylene; 2,2-dimethyl propylene; —CH 2 CH 2 —O—CH 2 CH 2 —; —CH 2 CH 2 CH 2 —O—CH 2 CH 2 CH 2 —; the group
[0007] The invention also includes a process for. preparing a cured epoxy resin comprising the steps of: a) providing a polyamine per the above, or mixtures thereof with each other or with one or more materials selected from the group consisting of: N-aminoethylpiperazine; diethylenetriamine; triethylenetetramine; tetraethylenepentamine; 2-methylpentamethylene;1,3-pentanediamine; trimethylhexamethylene diamine; a polyamide; a polyamidoamine; a Mannich-base type hardener; bis(aminomethyl)cyclohexylamine; isophorone diamine; menthane diamine; bis(p-aminocyclohexyl)methane; 2,2′-dimethyl bis(p-aminocyclohexyl)methane; dimethyldicyclohexylmethane); 1,2-diaminocyclohexane; 1,4-diaminocyclohexane; meta-xylene diamine; norbomanediamine; meta-phenylene diamine; diaminodiphenylsulfone; methylene dianiline; JEFFAMINE® D-230; JEFFAMINE® D-400; JEFFAMINE® T-403; and diethyltoluenediamine;
b) providing an epoxy precursor comprising a material having at least two epoxy end groups; and c) contacting said epoxy precursor and said polyamine with one another.
[0010] Suitable polyfunctional epoxy precursors are those which have at least two epoxy end groups and include the following:
in which n may be any integer between 0 and about 4; DGEBF (diglycidylether of bisphenol F) having the following structure:
such as D.E.R.(R) 354 epoxy resin from The Dow Chemical Company; and tri-functional epoxy resins such as TACTIX(R) 742 epoxy from Huntsman Applied Materials:
Higher functional epoxy resins such as epoxy novolacs (D.E.N.® 438 epoxy resin, ARALDITE® EPN 1180 epoxy NOVOLAC D.E.N.® 431 epoxy resin are also suitable for use in a process according to the present invention. All materials which contain at least two epoxy groups in their molecular structure are suitable for use in this invention, including without limitation those described above, and such materials are conveniently referred to as “polyfunctional epoxy precursor” in the claims appended hereto.
DETAILED DESCRIPTION OF THE INVENTION
[0011] This invention involves the preparation of hindered polyetheramines. It also relates to the use of hindered polyetheramines for curing standard epoxy resins. An epoxy resin cured using a polyetheramine according to the invention has a longer working time those made using prior art amine curing agents.
[0012] The present invention provides primary polyetherdiamines and polyethertriamines which are preferably prepared by reductive amination of alcohols such as those in formulae (III)-(XI) below:
[0013] According to one preferred form of the invention, a polyol according to those specified in formulae (III)-(XI) is first prepared via alkoxylation of a suitable initiator. The reaction may be carried out by heating the initiator and the corresponding higher alkyl-substituted oxirane in a closed reaction vessel at relatively low pressures. Reaction temperatures of 100-110° C. are used in the presence of a base catalyst, such as a tertiary amine or alkali metal hydroxide for several hours. Then the mixture is vacuum stripped of any excess unreacted oxirane and the catalyst to leave the resulting polyol mixture. It is preferred that polyols of the invention be prepared wholly or partially from oxiranes, having alkyl groups with carbon numbers of C 2 to C 10 . The alkyl group may be branched or linear in structure. One preferred and more readily available oxirane in this class is 1,2-butylene oxide, which may be self-polymerized with base catalysts, using water as an initiator, to produce low-molecular weight polyoxybutylene diols or glycerin as an initiator to produce similar triols of 200-400 MW. Polyols with larger pendant alkyl groups would have more steric crowding about the mainly secondary hydroxyl groups at the end of the polyol chains. A mixture of oxiranes may also be used in the process of polyol preparation, but the oxirane of higher alkyl substitution should be added on to the end of each polyol chain prior to the neutralization and reductive amination steps. Examples of other oxiranes to be used in the internal polyol backbone are ethylene oxide and propylene oxide. Thus, the starting materials for the polyol precursors of the polyamines of the invention may consist of 1,2-glycols, such as ethylene glycol and propylene glycol, or higher diols, such as diethylene glycol or dipropylene glycol. In addition, longer carbon chain diols, such as 1,3-propanediol, 1,4-butanediol or 1,6-hexanediol may be used as starting material for the addition of the higher oxirane to prepare the hindered polyols for reductive amination to the hindered polyetheramines. Multifunctional initiators, such as glycerin, trimethylol- propane (TMP), pentaerythritol, and alpha methyl glucoside (AMG), may also be alkoxylated with the higher oxiranes to prepare polyols for reductive amination. After neutralization, the polyols may be purified by distillation, and subsequently aminated reductively in the presence of hydrogen and excess ammonia at pressures up to 2000 psi and temperatures about or in excess of 200° C. using a suitable metal catalyst as described by Yeakey et al. 1). Examples of the preferred preparatory methods for these polyols are now set forth.
Polyol (Formula III)-Ethylene Glycol+Butyleneoxide
[0014] To a dry, nitrogen purged reactor were added 2500 grams of ethylene glycol and 12.5 grams of 1,1,3,3-tetramethylguanidine (TMG). 5809 grams butyleneoxide were then added while agitating. The kettle was then heated to 80° C. and temperature control was initiated. The kettle was then held at 80° C. for 10 hours, followed by an additional 10 hours at 100° C. The product was then stripped for one hour at 100° C. using nitrogen and the product was then collected. The reaction was followed by gas chromatography during the process.
Polyol (Formula IV)-Propanediol+Butyleneoxide
[0015] To a dry, nitrogen purged reactor were added 2500 grams of propanediol and 12.5 grams of 1,1,3,3,-tetramethylguanidine (TMG). 4270 grams butyleneoxide were then added while agitating. The kettle was then heated to 80° C. and temperature control was initiated. The kettle was then held at 80° C. for 10 hours, followed by an additional 10 hours at 100° C. The product was then stripped for one hour at 100° C. using nitrogen and the product was then collected. The reaction was followed by gas chromatography during the process.
Polyol (Formula V)-2-Methyl-1,3-Propanediol+Butyleneoxide
[0016] To a dry, nitrogen purged reactor were added 2000 grams of 2-methyl-1,3-propanediol and 10.0 grams of 1,1,3,3,-tetramethylguanidine (TMG). 3361 grams butyleneoxide were then added while agitating. The kettle was then heated to 80° C. and temperature control was initiated. The kettle was then held at 80° C. for 10 hours, followed by an additional 10 hours at 100° C. The product was then stripped for one hour at 100° C. using nitrogen and the product was then collected. The reaction was followed by gas chromatography during the process.
Polyol (Formula VI)-1,4-Butanediol+Butyleneoxide
[0017] To a dry, nitrogen purged reactor were added 3000 grams of 1,4-butanediol and 30.0 grams of potassium hydroxide as catalyst. 4321 grams butyleneoxide were then added while agitating. The kettle was then heated to 80° C. and temperature control was initiated. The kettle was then held at 80° C. for 10 hours, followed by an additional 10 hours at 100° C. The product was then stripped for one hour at 100° C. using nitrogen and the product was then collected. The reaction was followed by gas chromatography during the process.
Polyol (Formula VII)-Diethylene Glycol+Butyleneoxide
[0018] To a dry, nitrogen purged reactor were added 2500 grams of diethylene glycol and 12.5 grams of 1,1,3,3,-tetramethylguanidine (TMG). 2973 grams butyleneoxide were then added while agitating. The kettle was then heated to 80° C. and temperature control was initiated. The kettle was then held at 80° C. for 10 hours, followed by an additional 10 hours at 100° C. The product was then stripped for one hour at 100° C. using nitrogen and the product was then collected. The reaction was followed by gas chromatography during the process.
Polyol (Formula VIII)-Trimethylolpropane+Butyleneoxide
[0019] To a dry, nitrogen purged reactor were added 2268 grams of 1,1,1-trimethylolpropane and 11.34 grams of 1,1,3,3,-tetramethylguanidine (TMG) as catalyst. 4266 grams butyleneoxide were then added while agitating. The kettle was then heated to 80° C. and temperature control was initiated. The kettle was then held at 80° C. for 10 hours, followed by an additional 10 hours at 100° C. The product was then stripped for one hour at 100° C. using nitrogen and the product was then collected. The reaction was followed by gas chromatography during the process.
[0020] Polyol (Formula X)-Tris(Hydroxymethyl)Ethane+Butyleneoxide
[0021] To a dry, nitrogen purged reactor were added 2500 grams of tris(hydroxymethyl)ethane and 12.5 grams of 1,1,3,3,-tetramethylguanidine (TMG). 6002 grams butyleneoxide were then added while agitating. The kettle was then heated to 80° C. and temperature control was initiated. The kettle was then held at 80° C. for 10 hours, followed by an additional 10 hours at 100° C. The product was then stripped for one hour at 100° C. using nitrogen and the product was then collected. The reaction was followed by gas chromatography during the process.
Conversion of Butoxylates to Amines
[0022] The polyols in formulas (Ill)-(XI) above were reductively aminated using ammonia to the corresponding amines in a 100 cc continuous unit using a catalyst as described in U.S. Pat. Nos. 3,151,112 and 3,654,370. The catalyst, in the form of ⅛×⅛ inch tablets, was charged to the 100 cc tubular reactor. The polyol and ammonia were pumped separately and mixed in-line with hydrogen and fed through the catalyst bed. The polyol and ammonia were kept in an approximate 1:1 wt feed ratio, while the ammonia to hydrogen mole ratio was kept at about 20:1. The reactor pressure was held at about 2000 psig and the temperature was maintained at about 220° C. The polyol and ammonia feed rates used in each run varied between about 65 g/hr to 100 g/hr. The products were collected over 2-3 days and stripped of excess ammonia, water and light amines. In some of the amination runs, the material was passed through the reactor a second time to bring up the amine level in the product. Reductive amination of these polyols yields the polyamines having predominantly the structures shown below in formulae (XII)-(XX) below:
[0023] Thus, the polyamine of formula XII is represented by formulas (I) and (II) wherein R 1 is an ethylene group. The polyamine of formula XIII is represented by formulas (I) and (II) wherein R 1 is a propylene group. The polyamine of formula XIV is represented by formulas (I) and (II) wherein R 1 is a 2-methyl propylene group. The polyamine of formula XV is represented by formulas (I) and (II) wherein R 1 is a butylene group. The polyamine of formula XVI is represented by formulas (I) and (II) wherein R 1
is a —CH2CH2—O—CH2CH2—group. The polyamine of formula XVII is represented by formulas (1) and (II) wherein R 1 is a group.
[0024] The polyamine of formula XVIII is represented by formulas (I) and (II) wherein R 1 is a
group. The polyamine of formula XIX is represented by formulas (I) and (II) wherein R 1 is a
group. The polyamine of formula XX is represented by formulas (I) and (II) wherein R 1 is a 2,2-dimethyl propylene group.
[0025] The gel times of an epoxy blend are longer for amines having ethyl groups on the carbon atom alpha to the amine vs. those having methyl groups on the carbon atom alpha to the amine. The polyetheramines of the invention offer more than 50% longer working time, when used to cure standard epoxy resins than is afforded using amine curing agents of the prior art. We were surprised to find that some of the polyetheramines took almost twice as long to cure epoxy resins as the standard products now used in the current wind blade manufacture, specifically, the amine of formula XIV.
[0026] Conditions useful for preparing a composition relating to the present invention include: A temperature range of 50-120° C. for the polyol preparations; and 180-220° C. for the reductive amination of polyols. The useful pressures are: 40-100 psi for the polyol preparations, and 1500-2500 psi for the reductive aminations.
[0027] A polyamine according to the formulas (XII) through (XX) can be reacted with an organic di-isocyanate to form a polyurea. These di-isocyanates include standard isocyanate compositions known to those skilled in the art. Preferred examples of di-isocyanates include MDI-based quasi prepolymers such as those available commercially as RUBINATE® 9480, RUBINATE® 9484, and RUBINATE® 9495 from Huntsman International, LLC. Liquified MDI such as MONDUR® ML may be used as all or part of the isocyanate. The isocyanates employed in component (A) are generally known to one skilled in the art. Thus, for instance, they can include aliphatic isocyanates of the type described in U.S. Pat. No. 4,748,192. Accordingly, they are typically aliphatic diisocyanates and, more particularly, are the trimerized or the biuretic form of an aliphatic diisocyanate, such as hexamethylene diisocyanate, or the bifunctional monomer of the tetraalkyl xylene diisocyanate, such as the tetramethyl xylene diisocyanate. Cyclohexane diisocyanate is also to be considered a preferred aliphatic isocyanate. Other useful aliphatic polyisocyanates are described in U.S. Pat. No. 4,705,814 which is fully incorporated herein by reference thereto. They include aliphatic diisocyanates, for example, alkylene diisocyanates with 4 to 12 carbon atoms in the alkylene radical, such as 1,12-dodecane diisocyanate and 1,4-tetramethylene diisocyanate. Also described are cycloaliphatic diisocyanates, such as 1,3 and 1,4-cyclohexane diisocyanate as well as any desired mixture of these isomers, 1-isocyanato-3,3,5-trimethyl-5-isocyanato metbylcyclohexane (isophorone diisocyanate); 4,4′-,2,2′- and 2,4′-dicyclohexylmethane diisocyanate as well as the corresponding isomer mixtures, and the like. Further, a wide variety of aromatic polyisocyanates may be used to form the foamed polyurea elastomer of the present invention. Typical aromatic polyisocyanates include p-phenylene diisocyanate, polymethylene polyphenylisocyanate, 2,6-toluene diisocyanate, dianisidine diisocyanate, bitolylene diisocyanate, naphthalene-1,4-diisocyanate, bis(4-isocyanatophenyl)methane, bis(3-methyl-3-iso-cyanatophenyl)methane, bis(3-methyl-4-isocyanatophenyl)methane, and 4,4′-diphenylpropane diisocyanate. Other aromatic polyisocyanates used in the practice of the invention are methylene-bridged polyphenyl polyisocyanate mixtures which have a functionality of from about 2 to about 4. These latter isocyanate compounds are generally produced by the phosgenation of corresponding methylene bridged polyphenyl polyamines, which are conventionally produced by the reaction of formaldehyde and primary aromatic amines, such as aniline, in the presence of hydrochloric acid and/or other acidic catalysts. Known processes for preparing polyamines and corresponding methylene-bridged polyphenyl polyisocyanates therefrom are described in the literature and in many patents, for example, U.S. Pat. Nos. 2,683,730; 2,950,263; 3,012,008; 3,344,162 and 3,362,979, all of which are fully incorporated herein by reference thereto. Usually, methylene-bridged polyphenyl polyisocyanate mixtures contain about 20 to about 100 weight percent methylene diphenyldiisocyanate isomers, with the remainder being polymethylene polyphenyl diisocyanates having higher functionalities and higher molecular weights. Typical of these are polyphenyl polyisocyanate mixtures containing about 20 to about 100 weight percent diphenyldiisocyanate isomers, of which about 20 to about 95 weight percent thereof is the 4,4′-isomer with the remainder being polymethylene polyphenyl polyisocyanates of higher molecular weight and functionality that have an average functionality of from about 2.1 to about 3.5. These isocyanate mixtures are known, commercially available materials and can be prepared by the process described in U.S. Pat. No. 3,362,979. A preferred aromatic polyisocyanate is methylene bis(4-phenylisocyanate) or “MDI”. Pure MDI, quasi-prepolymers of MDI, modified pure MDI, etc. are useful to prepare a polyurea according to the invention. Since pure MDI is a solid and, thus, often inconvenient to use, liquid products based on MDI or methylene bis(4-phenylisocyanate) are used herein. U.S. Pat. No. 3,394,164, incorporated herein by reference thereto, describes a liquid MI product. More generally, uretonimine modified pure MDI is included also. This product is made by heating pure distilled MDI in the presence of a catalyst. The liquid product is a mixture of pure MDI and modified MDI. The term isocyanate also includes quasi-prepolymers of isocyanates or polyisocyanates with active hydrogen containing materials. “Organic di-isocyanate” as used herein includes all of the foregoing isocyanates.
[0028] In addition to the use of the pure polyamines shown above in formulae (XII)-(XX), the present invention contemplates the use of these amines in each combinations with one another, and with amines of the prior art. Amines of the prior art useful in combination with those of formulae (XII)-(XX) include, without limitation: N-aminoethylpiperazine (“AEP”); diethylenetriamine (“DETA”); triethylenetetramine (“TETA”); tetraethylenepentamine (“TEPA”); 2-methylpentamethylene diamine (Dytek® A—DuPont);1,3-pentanediamine (Dytek®EP—DuPont); trimethylhexamethylene diamine (1:1 mix of 2,2,4-, and 2,4,4-isomers is called Vestamin® TMD—Creanova); polyamide hardeners; polyamidoamine hardeners; Manniche-base type hardeners; bis(aminomethyl)cyclohexylamine (“1,3-BAC”); isophorone diamine (“IPDA”); menthane diamine; bis(p-aminocyclohexyl)methane (“PACM”); 2,2′-dimethyl bis(p-aminocyclohexyl)methane (“DMDC”);dimethyldicyclohexylmethane); 1,2-diaminocyclohexane (“DACH”); 1,4-diaminocyclohexane (“DACH”); meta-xylene diamine (“m-XDA”); norbornanediamine (“NBDA”); meta-phenylene diamine (“m-PDA”); diaminodiphenylsulfone (“DDS” or “DADS”); methylene dianiline (“MDA”); JEFFAMINE® D-230 (Huntsman); JEFFAMINE® D-400 (Huntsman); JEFFAMINE® T-403 (Huntsman); and diethyltoluenediamine (“DETDA”).
[0029] The amines, combinations, and processes provided herein are particularly beneficial in providing epoxy systems having an increased cure time over compositions and processes of the prior art. During the manufacture of particular composite articles, such as wind turbine blades, a long curing time is desirable in order to enable the actively curing resin to penetrate the interstices of the fibers which are part of the composite, while also permitting enough time for molding to place all the material in its desired location. It is often desirable for the resin/catalyst mixture to remain at a viscosity of less than 1000 centipoise at 25 degrees C. for 8 hours.
[0030] Consideration must be given to the fact that although this invention has been described and disclosed in relation to certain preferred embodiments, obvious equivalent modifications and alterations thereof will become apparent to one of ordinary skill in this art upon reading and understanding this specification and the claims appended hereto. Accordingly, the presently disclosed invention is intended to cover all such modifications and alterations, and is limited only by the scope of the claims which follow. | Provided herein are polyamine precursors useful in the manufacture of epoxy resins. Use of a polyamine precursor according to the invention provides an epoxy resin formulation having an increased working time over prior art amines used for curing epoxies. Increased working times translate to the ability to manufacture composites which could not be made using conventional epoxy curing agents, such as composite blades for wind-driven turbines. Such polyamines are also useful in polyurea formulations for lengthening reaction time, thus allowing more flow of applied polyurea coatings prior to gellation. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of copending application Ser. No. 749,184, filed Dec. 9, 1976, now abandoned, which in turn is a continuation of application Ser. No. 631,244, filed Nov. 12, 1975, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a fiber-forming random polyamide consisting of recurring units of the formulas: ##STR1## wherein R is a C 3 to C 10 alkylene and wherein from 30 to 40% of the units are 6IA units and from 2-15% of the units are 6RA units. These polyamides can be prepared and shaped into fibers by conventional melt polymerization and melt extrusion techniques.
2. Description of the Prior Art
U.S. Pat. No. 4,022,756 describes a batch process for preparing fibers of a polyamide consisting essentially of recurring 6TA and 6IA units in a mole ratio of between 50:50 and 80:20, respectively. In carrying out the process, an aqueous solution of an appropriate mixture of hexamethylene diammonium terephthalate (6TA salt) and hexamethylene diammonium isophthalate (6IA salt) is heated in a suitable vessel (e.g. autoclave) under conditions of controlled time, temperature and pressure to provide molten polymer (referred to herein as 6TA/6IA). Then, the molten 6TA/6IA is extruded directly from the base of the autoclave into fibers which are heat treated in the manner described in U.S. Pat. No. 4,022,756. The heat treated 6TA/6IA fibers are dimensionally stable and are characterized in having a relatively high moduli (e.g. 80-110 gpd) and the dye performance and adhesion-to-rubber characteristics of nylon 66. The 6TA/6IA fibers are particularly useful in carpet, wrinkle-resistant apparel fabrics and reinforcing structures such as tire cord.
One difficulty encountered in extruding 6TA/6IA (particularly 6TA/6IA consisting of 60 mole % or more 6TA) into fiber by the batch process described in U.S. Pat. No. 4,022,756 is that a small amount of 6TA/6IA remains as a shell on the inner wall and agitator of the autoclave after extrusion. Unfortunately, the 6TA/6IA shell, unlike a nylon 66 shell, does not entirely melt during the next polymerization. Particles of the 6TA/6IA shell disperse in the molten 6TA/6IA formed in the next polymerization to yield heterogeneous 6TA/6IA, a condition referred to herein as "polymer heterogeneity". Attempts to provide useful fibers by melt extrusion (melt spinning) of heterogeneous 6TA/6IA has not been entirely successful. In those instances where fibers are obtained, the fibers contain opaque particles of noticeable size, and generally have unacceptable properties. Therefore, high quality fibers can be obtained only by cleaning the autoclave between each run (i.e. polymerization and extrusion) to remove the 6TA/ 6IA shell that remains therein after extrusion. Cleaning of the autoclave is time consuming and costly and, therefore, is not feasible for commercial operations.
Accordingly, it is an object of the present invention to provide a modified fiber-forming 6TA/6IA which can be extruded into fibers by a batch process without encountering polymer heterogeneity and without cleaning the extrusion vessel between successive runs to remove the polymer shell therefrom.
Another object of the invention is to provide a modified 6TA/6IA fiber which has properties, such as modulus and boiling water shrinkage, comparable to the 6TA/6IA fiber described in U.S. Pat. No. 4,022,756.
SUMMARY OF THE INVENTION
In accordance with the present invention the foregoing objects are accomplished by modifying 6TA/6IA to provide a polyamide consisting essentially of recurring units of the formulas: ##STR2## wherein R is a C 3 to C 10 alkylene and wherein from 30 to 40% of the units are 6IA units and from 2-15% of the units are 6RA units; the remaining units of the polymer (45 to 68 percent) are 6TA units. Polymers of this description are referred to herein as "6TA/6IA/6RA".
Fibers prepared from the 6TA/6IA/6RA of the present invention have properties substantially the same as the 6TA/6IA fibers described in U.S. Pat. No. 4,022,756, for example, 6TA/6IA/6RA fibers have dimensional stability as evidenced by boiling water shrinkage values (BWS) of less than about 10% (e.g. 1 to 10%), adhesion and dye performance comparable to nylon 66 fibers, and moduli ranging from about 80-110 gpd.
Terpolyamides composed of 66 units ##STR3## 6TA units and 6IA units, wherein at least 50% by weight of the terpolyamide is 66 units and from 20-40% by weight is 6TA units, are described in U.S. Pat. Nos. 3,621,089 and 3,926,924. Fibers of these terpolymers, however, have low moduli (22-43 gpd) in comparison to the fibers of the present invention and, therefore, lack wrinkle-resistant properties.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
6TA/6IA/6RA may be prepared by melt polymerization of a salt mixture consisting of hexamethylenediammonium terephthalate (6TA salt), hexamethylenediammonium isophthalate (6IA salt) and 6RA salt, for example hexamethylenediammonium adipate (66 salt). The salts may be used in proportions ranging from 30 to 40 mole % 6IA salt, 2 to 15 mole % 6RA salt, 45 to 68 mole % 6TA salt. Instead of 66 salt, another salt or salts of hexamethylenediamine and a dicarboxylic acid of the formula HOOC--R--COOH may be used where R is a C 3 to C 10 alkylene. The conversion of each salt of the mixture to its corresponding polymer unit is substantially 100%.
In order to effectively eliminate polymer heterogeneity, at least about 2 mole % of the salt mixture must consist of 6RA salt. On the other hand, if more than about 15 mole % of the salt mixture consists of 6RA salt, the boiling water shrinkage values, tensile properties and moduli of fibers prepared from the resulting polymers are adversely affected. Satisfactory results are generally obtained when from 7 to 12 mole % of the salt mixture used in preparing polymers of the invention consists of 6RA salt. In general, if more than about 40 mole % of the salt mixture consists of 6IA salt, fibers prepared from the resulting polymers are difficult to crystallize, whereas if less than about 30 mole % of the salt mixture consists of 6IA salt, it is difficult to shape fibers from the resulting polymer due to the high melting point of the resulting polymer.
6RA salts useful in preparing copolyamides of the invention include the hexamethylene diamine salts of glutaric, adipic, azelaic, suberic, sebacic or dodecanedioic acids. If desired, a mixture of two or more 6RA salts may be used. Hexamethylenediammonium adipate (66 salt) is a preferred 6RA salt for use in preparing polymers of the invention.
The salts used in preparing polymers of the invention should be of the highest possible purity and may be made by conventional techniques commonly employed in making simple polyamide salts, for example, hexamethylene diammonium adipate (66 salt).
Fibers may be shaped from 6TA/6IA/6RA by melt spinning techniques utilizing the batch process described in U.S. Pat. No. 4,022,756, wherein an aqueous solution of the 6TA, 6IA, 6RA salts are polymerized in a batch autoclave to provide molten 6TA/6IA/6RA which is extruded through a spinneret attached to the base of the autoclave to provide fiber. Successive runs (i.e. batches) can be made with the copolymers of this invention in a autoclave without removing the polymer shell from the autoclave between runs and without encountering polymer heterogeneity.
The resulting essentially amorphous fibers are drawn and heat treated in the manner described in U.S. Pat. No. 4,022,756 to increase their crystallinity and to otherwise enhance their physical properties. The heat treatment of the essentially amorphous fiber may be accomplished during or after the fiber is drawn to a desired denier. Generally, the fiber is drawn a total of 3.0 to 5.0 times its original length. When the fiber is drawn prior to heat treatment, it may be drawn in a single stage over a heated pin (85°-115° C.). Drawing of the essentially amorphous fiber without heat treatment results in orientation of the polymer molecules in the direction of the fiber axis but does not significantly increase the crystallinity of the fibers. However, after the drawn, essentially amorphous fiber is heat treated, the fiber has a relatively high degree of crystallinity. Heat treatment of the fiber is conveniently accomplished by heating the fiber to a temperature which is above the glass transition temperature (Tg) of the polymer and below the temperature at which the fiber becomes molten and, preferably, at a temperature above about 160° C. Annealing of the fiber may be accomplished by subjecting the fiber to a heated environment, such as heated inert fluid (e.g. steam, air or nitrogen) or a heated surface such as a hot shoe. A preferred means for heating the fiber is accomplished by continuously advancing the fiber through an electrically heated tube blanketed with steam or heated nitrogen. Other means include continuously advancing the fiber through a chamber equipped with an infrared heater or over a heated curved surface. If desired, the fiber may be merely placed in an oven and heated. The length of time that the fiber is in contact with the heated environment will depend on factors such as the temperature of the heated environment and denier of the fiber. Various means and conditions that may be used in heat treatment of the fibers will be apparent to those skilled in the art.
It has been found that the physical properties of the fibers are influenced by the amount of tension the fibers are under during heat treatment. For example, drawn fibers which are slack when heat treated will have minimum boiling water shrinkage (BWS) values, for example lower than 2%, while drawn fibers which are under considerable tension when heat treated (e.g., when further drawn at a draw ratio of 1.12 to 1.2 during heat treatment) generally will have BWS values between 8% and 10%. Accordingly, drawn fibers which are under intermediate tensions when heat treated will have BWS values ranging from 2% to 8%. The strength of the fibers on the other hand is directly proportional to the amount of tension the fibers are under during heat treatment. Fibers which are under tension when heat treated will have greater strength than fibers which are slack when heat treated.
The following examples are given for purposes of further illustrating the invention but are not intended to in any way limit the scope of the invention.
Tensile properties of fibers given in the examples were measured on an Instron Tester (Instron Engineering Corporation, Canton, Mass.) providing a constant extension rate of 120% per minute with a gauge length of 25 cm. being used. Intrinsic viscosities [η] given in the examples are defined by the following equation: ##EQU1## where RV represents the relative viscosity and C represents a concentration of 0.4 gram of the polymer in 100 ml. of solvent. The relative viscosity is determined by dividing the flow time in a capillary viscometer of a dilute solution of the polymer by the flow time for pure solvent. The dilute solutions used herein for determining RV are of the concentration expressed by (C) above; flow times are determined at 25° C. using 95%-98% concentrated sulfuric acid as the solvent. Percent boiling water shrinkage (% BWS) values given in the examples were determined by the following procedure. Two clamps are secured along a length (L 1 ) of fiber so that the distance between the clamps when the fiber is extended is between 15 and 50 cm. The fiber with the clamps secured thereto is then immersed in boiling water for 10 minutes. The fiber is then removed and dried under ambient conditions. The distance between the clamps when the fiber is extended is again measured (L 2 ). The % boiling water shrinkage (BWS) is determined by the following equation:
EXAMPLE 1
This example illustrates the preparation of 6TA/6IA/66(60/35/5) polymer, i.e. 6TA/6IA/6RA polymer consisting of 60 mole % of 6TA units, 35 mole % of 6IA units and 5 mole % of 66 units, and the melt spinning thereof into yarn. 90.0 g. (0.3188 mole) of 6TA salt, 52.5 g. (0.1859 mole) of 6IA salt, 7.0 g. (0.0267 mole) 66 salt, and 100 g. of deionized water were charged to a stainless steel autoclave. After thoroughly purging the autoclave and its contents with nitrogen, the autoclave was pressurized to 250 psig (18 atm) with nitrogen. The autoclave was then heated to 220° C. over a period of 25 minutes while stirring and maintaining the pressure constant at 250 psig. The temperature was then increased to 300° C. over a period of 27 minutes while maintaining the pressure at 250 psig. The pressure was then reduced to atmospheric over a period of 25 minutes while increasing the temperature to 316° C. A 14-hole spinneret was then attached to the base of the autoclave and the polymer ([η])=0.824) was extruded through the spinneret by the application of 250 psig (18 atm) nitrogen. The resulting yarn was collected on a bobbin using a conventional winder. The yarn was then drawn 3.60X over a 2" pin at 100° C. to provide an 80 denier yarn having an elongation of 18% and a tenacity of 3.8 gpd.
EXAMPLE 2
This example illustrates the preparation of 6TA/6IA/66(60/30/10) polymer ([η])=0.81) and the melt spinning thereof into yarn. The polymer and yarn were prepared according to the procedure of Example 1. In this instance the polymer was prepared from a mixture of 6TA, 6IA and 66 salts in which the salts were present in a molar ratio of 60:30:10, respectively. The yarn was collected and then drawn 3.70 times to a denier of 80. The drawn yarn had an elongation of 18% and a tenacity of 3.7 gpd.
EXAMPLE 3
This example illustrates the preparation of 6TA/6IA/66(55/35/10) polymer ([η])=0.80) and the melt spinning thereof into yarn. The polymer and yarn were prepared according to the procedure of Example 1. In this instance the polymer was prepared from a mixture of 6TA, 6IA and 66 salts in which the salts were present in a molar ratio of 55:35:10, respectively. The yarn was collected and then drawn 3.95 times to a denier of 71. The drawn yarn had an elongation of 16% and a tenacity of 3.7 gpd.
EXAMPLE 4
This example illustrates the preparation of 6TA/6IA/66(50/35/15) polymer and the melt spinning thereof into yarn. The polymer and yarn were prepared according to the procedure of Example 1. In this instance the polymer was prepared from a mixture of 6TA, 6IA and 66 salts in which the salts were present in mole ratio of 50:35:15, respectively. The yarn was collected and then drawn 3.80 times to a denier of 74. The drawn yarn had an elongation of 20% and a tenacity of 2.8 gpd.
EXAMPLE 5
A sample of each of the yarns of Examples 2-4 was annealed by continuously advancing the yarn at constant length (draw ratio of 1.0) and at a speed of 125 feet (38.1 meters) per minute through a chamber having a length of 30.5 cm and containing infra-red heaters. The chamber was maintained at a temperature of about 300° C. For purposes of comparison a 70 denier, 14 filament yarn prepared from 6TA/6IA(65/35) was also annealed under the same conditions. The % BWS of each of the yarns was determined before and after annealing and is given in Table I.
TABLE I______________________________________Molar Composition % BWS6TA/6IA/66 Before Annealing After Annealing______________________________________65/35/0 22.0 6.660/30/10 22.2 5.655/35/10 21.9 8.750/35/15 38.7 9.5______________________________________
The results in Table I show that yarns made from polymers of the present invention may be annealed to provide dimensionally stable yarns which are comparable to annealed yarns of 6TA/6IA polymer.
EXAMPLE 6
This example illustrates that fibers of polymers of the present invention can be made by a batch process in an autoclave without cleaning the autoclave between successive runs to remove the polymer shell from the autoclave and without encountering polymer heterogeneity. In the batch process two successive runs were made without cleaning the autoclave after the first run. In each run a mixture of 6TA, 6IA and 66 salts were polymerized in the autoclave to form molten polymer. The molten polymer was then extruded from the base of the autoclave into water, recovered and, where possible, melt spun into yarn.
6TA/6IA/66(55/35/10) polymer was prepared by charging 825 g. (2.922 mole) of 6TA salt, 525 g. (1.859 mole) of 6IA salt, 140 g. (0.534 mole) of 66 salt, and 1000 g. H 2 O to a clean autoclave. After purging thoroughly with purified nitrogen, the autoclave was sealed and heated to 200° C. while stirring and allowing the pressure to increase to 200 psig (14.6 atm). The temperature and pressure were then held constant for 15 minutes. The temperature was then increased to 218° C. over a period of 3 minutes while allowing the pressure to increase to 250 psig (18 atm) and remain constant. The temperature was then raised to 300° C. (250 psig or 18 atm) over a period of 30 minutes. The pressure was then reduced to atmospheric pressure over a period of 65 minutes while increasing the melt temperature to 320° C. The polymer was then extruded from the autoclave and quenched in water. The extruded polymeric mass was clean and homogeneous. Following extrusion about 150 g. of polymer were left in the autoclave as a shell on the walls and agitator. A second polymerization was then carried out in the autoclave in the presence of the polymer shell using substantially the same procedure and conditions that were used in the first polymerization. The extruded polymeric mass was clear, homogeneous and easily melt spun into yarn. After the second polymerization about 145 g. of polymer remained in the autoclave after extrusion.
For purposes of comparison 6TA/6IA(65/35) polymer was prepared by charging 975 g. (3.453 mole) of 6TA salt, 525 g. (1.859 mole) of 6IA salt, and 1000 g. H 2 O to a clean autoclave. Polymerization was accomplished using substantially the same procedure and conditions that were used above. About 145 g. of polymer remained in the autoclave after extrusion. A second polymerization was then carried out in the autoclave in the presence of the polymer shell using substantially the same procedure and conditions that were used in the first polymerization. The resulting extruded polymeric mass contained lumps of white, opaque material dispersed in a clear polymer matrix, i.e. the polymeric mass was heterogeneous. The heterogeneities prevented melt spinning of the polymer into the yarn.
EXAMPLE 7
In this example fibers of the present invention were prepared and the tensile properties thereof were determined.
In this example, four fibers were prepared from polymers of the present invention using the same monomers and general procedure described in Example 1. The tensile properties of each of these fibers as well as the composition of the fiber are given in Table II. For purposes of comparison a 6TA/6IA(65/35) fiber was also prepared and tested.
TABLE II______________________________________Yarn Polymer Composition Tenacity Elongation ModulusNo. Mole % 6TA/6IA/66 gpd % gpd______________________________________1 56/33/11 3.7 7 932 56/33/11 3.5 9 863 58/32/10 4.6 7 994 58/32/10 4.5 9 925 65/35 2.5 5 90______________________________________
The foregoing examples illustrate that fibers comparable to 6TA/6IA fibers can be prepared in a batch autoclave from polymers of the present invention without encountering polymer heterogeneity. | Fiber-forming polymers are prepared from a mixture of the hexamethylene diamine salts of terephthalic acid, isophthalic acid, and a small amount of at least one aliphatic dibasic acid (e.g. adipic acid) having from 5 to 12 carbon atoms. The polymers can be prepared in a batch autoclave and extruded therefrom without cleaning the autoclave between successive runs. | 2 |
FIELD OF THE INVENTION
The present invention relates to an active matrix liquid crystal display and method of forming the same. In particular, the present invention relates to a liquid crystal display having low temperature polysilicon pixel thin film transistors with reduced leakage current and method of forming the same.
BACKGROUND OF THE INVENTION
An active matrix liquid crystal display (LCD) typically comprises a glass or quartz substrate having formed thereon a plurality of pixel electrodes and switching devices. The pixels are defined by connected gate lines and data lines. Each pixel comprises a storage capacitor and a pixel electrode connected to the switching devices. An LCD employing thin film transistors (TFTs) as the pixel switching devices, provides advantages of low power consumption, thin profile, light weight and low driving voltage. With applications in desktop computer and other monitors, and notebooks, TFT LCDs are presently the most common type of display.
To provide an affordable active matrix LCD, it is desirable to reduce the cost associated with the fabrication of the integrated circuits which drive the pixel TFTs. To this end, low temperature polysilicon (LTPS) TFT LCDs have been developed. In LTPS, an amorphous silicon is deposited onto a substrate and then annealed with laser energy provided, for example, by an excimer laser. The laser annealing process crystallizes the amorphous silicon thereby forming polycrystalline silicon (polysilicon) with large, uniform grains. With LTPS TFT technology, the driver and other related circuits, that are usually located external to the substrate, may be fabricated on a peripheral circuit region of the substrate adjacent to the pixel TFTs (which are fabricated on a pixel region of the substrate).
For an active matrix LCD, the LTPS TFTs of the peripheral circuit region should have high mobility and on-state current characteristics and the LTPS TFTs of the pixel region should have low leakage current characteristics. However, because the polysilicon grains are large, the polysilicon is not conducive to making TFTs with low leakage current characteristics.
Thus, in order to achieve such characteristics, prior art active matrix LCDs employed LDD or offset structures to reduce leakage current of the pixel LTPS TFTs. Such structures, however, undesirably require additional mask and implantation processes and equipment. In addition, these structures reduce the device mobility of the peripheral circuit TFTs.
SUMMARY OF THE INVENTION
A first aspect of the invention comprises a method of forming a liquid crystal display device. The method comprises the steps of: providing a substrate; forming an amorphous silicon layer over the substrate; forming a light reflecting layer only over a first portion of the amorphous silicon layer; irradiating the amorphous silicon layer with light to convert it to a polysilicon layer, the light reflecting layer partially reflecting the light away from the first portion of the amorphous silicon layer wherein a first portion of the polysilicon layer has a first polysilicon grain size and a second portion of the polysilicon layer has a second polysilicon grain size, which is larger than the first polysilicon grain size, the first portion of the polysilicon layer being derived from the first portion of the amorphous silicon layer; and forming a first plurality of thin film transistors from the first portion of the polysilicon layer.
A second aspect of the invention is a liquid crystal display device. The display device comprises: a substrate; a polysilicon layer disposed over the substrate, the polysilicon layer having a first portion with a first polysilicon grain size and a second portion with a second polysilicon grain size, which is larger than the first polysilicon grain size; and a plurality of thin film transistors formed from the first portion of the polysilicon layer.
A third aspect of the invention is a method of crystallizing amorphous silicon formed over a substrate to form a polysilicon layer having regions of different polysilicon grain sizes. The method comprises the steps of: forming a light reflecting layer only over a first portion of the amorphous silicon layer; and irradiating the amorphous silicon layer with light to convert it to a polysilicon layer, the light reflecting layer partially reflecting the light away from the first portion of the amorphous silicon layer wherein a first portion of the polysilicon layer has a first polysilicon grain size and a second portion of the polysilicon layer has a second polysilicon grain size, which is larger than the first polysilicon grain size, the first portion of the polysilicon layer being derived from the first portion of the amorphous silicon layer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A–1C , 2 , 3 , 4 , and 5 are sectional views illustrating the use of a reflection layer to form pixel thin film transistors with reduced leakage current characteristics on a substrate forming an LCD panel of an active matrix LCD device.
FIG. 6 is a sectional view illustrating laser light being reflected from a reflection layer formed of a single film of dielectric material.
FIG. 7 is a sectional view illustrating laser light being reflected from a reflection layer formed of multiple films of dielectric material.
FIG. 8 is a graph showing the relationship between polysilicon grain size (y-axis) and excimer laser annealing (ELA) energy density (x-axis).
FIG. 9 is a graph showing the relationship between drain current and gate voltage for TFTs of varying polysilicon grain size.
DETAILED DESCRIPTION
Referring to FIG. 1A , an insulating substrate 10 is provided which will form an LCD panel of an active matrix LCD device. The substrate 10 is made, for example, of glass and includes a pixel region 12 upon which pixel TFTs will be formed and a peripheral circuit region 14 upon which driver and other TFTs will be formed. A buffer layer 20 made of one or more films of dielectric material, such as silicon oxide, silicon nitride and combinations thereof, is formed over the substrate 10 . The films of the buffer layer 20 may be formed using, for example, a chemical vapor deposition process and/or a physical vapor deposition process, and may have a thickness ranging between about 0.15 microns and about 0.3 microns.
In FIG. 1B , a semiconductor layer 30 of amorphous silicon (a-Si) is formed over the buffer layer 20 . The a-Si layer 30 may be formed using a chemical vapor deposition or physical vapor deposition process, and may have a thickness ranging between about 0.04 microns and about 0.06 microns.
In FIG. 1C , a dielectric reflection layer 40 is formed over the a-Si layer 30 . The dielectric reflection layer may be made from one or more dielectric films. These dielectric films may include, for example, silicon oxide, tantalum oxide, silicon nitride, and combinations thereof. The number and composition of the films depend upon the amount reflection that is desired and the wavelength of the light to be reflected thereby. The films of the dielectric reflection layer 40 may be formed using a plasma enhanced chemical vapor deposition process or evaporation process, and the overall thickness of the dielectric typically ranges between about 0.07 microns and about 1.5 microns.
As shown in FIG. 2 , a portion of the reflection layer 40 covering the peripheral circuit region 14 of the substrate 10 is removed. Reflection layer portion may be removed using a wet etch process, for example. Remaining portion 42 of the reflection layer 40 covers the an area of the a-Si layer 30 disposed over the pixel region 12 of the substrate 10 .
In FIG. 3 , a laser annealing step is performed to crystallize the a-Si layer 30 thereby converting it to polycrystalline silicon (polysilicon). This may be accomplished by irradiating the a-Si layer 30 with a laser including, for example, an excimer laser or a green laser, having a wavelength of, for example, 308 nm for the excimer laser or 532 mm for the green laser. Lasers with other wavelengths may also be used, e.g., 247 nm. The laser annealing step is performed at a temperature less than 600° C., which is conventional for LTPS.
The remaining portion 42 of the reflection layer 40 operates to a reflect some of the laser light away from portion 31 of the a-Si layer 30 covering the pixel region 12 of the substrate 10 , thus reducing the energy density encountered by a-Si layer portion 31 , and therefore, converting a-Si layer portion 31 of the a-Si layer 30 to polysilicon having a reduced polysilicon grain size, e.g., less than about 0.1 microns in diameter. Portion 32 of the a-Si layer 30 covering the peripheral circuit region 14 of the substrate 10 encounters the full energy density of the laser light, therefore, a-Si layer portion 32 is converted to polysilicon having polysilicon grains of a large size, e.g. about 0.3 to 0.4 microns in diameter. Accordingly, the dielectric film or films which form the reflection layer 30 should be capable of reflecting the wavelength of the laser light used in the laser annealing process. The amount of reflectance provided by the reflection layer 30 , which can be anywhere for about 1 to about 99 percent, depends upon the refractive index (n) and the overall thickness of the reflection layer 30 .
Referring to FIG. 4 , if the film or films of the reflection layer 40 is composed of a nitride material, then the reflection layer 40 is removed (as shown) in a wet etch process, and the polysilicon layer is patterned into islands 50 a–d (only four islands are shown for purposes of clarity only). If the film or films of the reflection layer 40 is an oxide material, then the reflection layer 40 may form a layer in the final pixel TFT structure. Pixel TFTs are constructed on the pixel region 12 of the substrate 10 from polysilicon islands 50 a and 50 b having the reduced size polysilicon grains and peripheral circuit TFTs are constructed on the peripheral circuit region 14 of the substrate 10 from polysilicon islands 50 c and 50 d having the large size polysilicon grains.
FIG. 5 is a sectional view through a pixel TFT structure 60 made according to the present invention. The pixel TFT structure 60 comprises a complementary transistor structure including PMOS transistor 70 formed from polysilicon island 50 a ( FIG. 4 ) and NMOS transistor 80 formed from polysilicon island 50 b ( FIG. 4 ). The PMOS transistor 70 includes source region 71 , channel region 72 , and drain region 73 formed in the polysilicon island 50 a , and the NMOS transistor includes source region 81 , channel region 82 , and drain region 83 formed in the polysilicon island 50 b . Gate electrodes 74 and 84 for PMOS transistor 70 and NMOS transistor 80 respectively, are formed on a first insulating layer 62 . Source and drain connections 75 and 76 for PMOS transistor 70 and source and drain connections 85 and 86 for NMOS transistor 80 are formed over second insulating layer 63 . A pixel electrode 90 is formed over third insulating layer 64 and may be electrically connected with the drain region 83 of the NMOS transistor. The TFT structure 60 operates to switch the pixel electrode 90 on and off when appropriate voltages are applied to structure 60 .
FIG. 6 depicts laser light being reflected from a reflection layer (medium 2 in FIG. 6 ) formed of a single film of dielectric material. The reflectance of a single film reflection layer may be determined, assuming laser light of a normal incidence angle (0 degrees), according to the following formulas:
R (reflectance)=[( n E −n 1 )/( n E +n 1 )] 2 =[( n 2 2 /n s )− n 1 )]/[( n 2 2 /n s )+ n 1 )] 2 where, n 2 is the refractive index of the single film of the reflection layer, and n 1 is the refractive index of air (n=1 for all wavelengths of light);
n 2 *d=λ/ 4
where, d is the thickness of the single film of the reflection layer, and λ is the wavelength of incidence laser light; and
n E =n 2 2 /n S
(n S the index of the glass substrate).
Using the above formulas, if the single film of the reflection layer is silicon oxide, which has a refractive index of 1.46, then R=[(1.46 2 /1.52−1)/(1.46 2 /1.52+1)] 2 =2.7 percent. If the single film of the reflection layer is silicon nitride, which has a refractive index of 2, then R=[(2 2 /1.52−1)/(2 2 /1.52+1)] 2 =45.0 percent.
As can be seen from the above results, dielectric film materials with higher refractive indexes have greater reflectance than dielectric film materials with comparatively lower refractive indexes.
FIG. 7 depicts laser light being reflected from a reflection layer formed of multiple films of dielectric material. The reflectance of a multi-film reflection layer may be determined according to the following formulas:
n E =( n 1 ×n 3 ×n 5 ) 2 /[( n 2 ×n 4 ) 2 ×n s ],
n i refractive index of the ith layer,
R =[( n 0 −n E )/( n 0 +n E )] 2
Using the above formulas, if the wavelength of the incident laser light=308 nm, n 1 =2.15 , n 2 =1.46, the index of the substrate (n S )=1.52 at λ=308 nm, n 1 =n 3 =n 5 , n 2 =n 4 , and the refractive index of air (n 0 )=1, then R=76.0 percent.
FIG. 8 is a graph showing the relationship between polysilicon grain size (y-axis) and excimer laser annealing (ELA) energy density (x-axis). As can be observed, Ec is the optimal ELA energy density (the energy density that produces the largest polysilicon grain size).
FIG. 9 is a graph showing the relationship between drain current Id in amps (A) and gate voltage Vg in volts (V) for TFTs of varying polysilicon grain size wherein ED stands for energy density, ED 1 , ED 2 , and ED 3 are different energy densities and ED 1 is greater than ED 2 and ED 2 is greater than ED 3 . This graph demonstrates that TFTs with larger grain size exhibit higher leakage currents.
While the foregoing invention has been described with reference to the above, various modifications and changes can be made without departing from the spirit of the invention. Accordingly, all such modifications and changes are considered to be within the scope of the appended claims. | A method of forming a liquid crystal display device includes forming an amorphous silicon layer over a substrate and forming a light reflecting layer only over a first portion of the amorphous silicon layer. The amorphous silicon layer is then irradiated with a laser to convert it to a polysilicon layer. The light reflecting layer partially reflects the light away from the first portion of the amorphous silicon layer such that a first portion of the polysilicon layer has a first polysilicon grain size and a second portion of the polysilicon layer has a second polysilicon grain size, which is larger than the first polysilicon grain size. A first plurality of thin film transistors having reduced leakage current characteristics may then be formed from the first portion of the polysilicon layer. | 7 |
This is a division of application Ser. No. 08/292,855 filed Aug. 19, 1994, now U.S. Pat. No. 5,468,093.
FIELD OF THE INVENTION
The present invention relates generally to safety barriers, railings, and supports incorporating mountings that will absorb substantial impact without permanent deformation. More specifically, the present invention relates to barriers, railings, and supports that will, on a continuing and reliable basis, without frequent repair or replacement, protect personnel from injury and plant and facilities from damage.
BACKGROUND OF THE INVENTION
Almost every dangerous curve on a highway has some sort of a crash barrier or guardrail intended to keep an out-of-control vehicle on the highway right-of-way. After a crash, such a barrier is often sufficiently damaged to require repair in order to restore its strength to try to save the next unlucky driver.
Most factories that have indoor vehicular traffic have crash barriers to confine the vehicles to designated paths and to keep them out of areas where they are not wanted. Unless such a barrier has been exceedingly overdesigned for the weight and expected speed of the vehicles used in the factory, in time the barriers will become bent, twisted, loose from the factory floor, and otherwise deformed so as to impair their appearance and probably even impair their effectiveness.
Hand railings and other edge supports are usually placed on stairwells and ramps for the support and safety of pedestrians using those facilities. If hand trucks and perhaps larger vehicles also use those facilities, the railings, etc., must either be seriously overdesigned for pedestrian purposes or will in time become bent and deformed from impacts by the much heavier, and less yielding wheeled vehicles.
Therefore, what is needed is a low-cost barrier, guardrail, or hand railing system which can receive and shrug off, without permanent deformation, the inevitable, occasional impacts from vehicles, without the need for massive overdesign of the barrier system, while maintaining a clean and neat appearance.
SUMMARY OF THE INVENTION
The present invention contemplates a resilient safety barrier that is resiliently supported on a base of some sort comprising a barrier member with the resilient support having a perimeter calculated to resiliently support the perimeter of the barrier member, and the barrier member being biased toward the resilient support and the base, so as to allow limited, non-destructive, shock-absorbent movement of the barrier member with respect to the base.
The present invention also contemplates a resilient mounting for a post structure on the surface of a base which includes a plurality of peripherally-arranged fastening facilities, with a plurality of peripherally-arranged fastening means also associated with the post, and a plurality of individual resilient bushings supporting the post, each such bushing associated with one of the plurality of peripherally-arranged fastening facilities associated with the base and, with one of the plurality of peripherally-arranged fastening means associated with the post, so as to allow limited, non-destructive, shock absorbent movement of the post with respect to the base.
The present invention further contemplates a resilient mounting for a barrier rail on at least two upright support members, with a rail member extending substantially between the two upright support members, a resilient gasket located between the rail member and each upright support member, so as to allow limited, non-destructive, shock-absorbent movement of the rail member relative to the upright support member, and with a clamp for squeezing the resilient gasket between the rail member and the upright support member.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present invention will be had from the following detailed description when considered in conjunction with the accompanying drawings, wherein the same reference numbers refer to the same or corresponding parts shown throughout the several views, in which:
FIG. 1 is an elevation of an upright barrier member shown partially cut away in cross section to illustrate the mounting of rails to the barrier member and the resilient support on which the barrier member is mounted to a base;
FIG. 2 is an alternative arrangement for mounting the barrier member to the resilient support;
FIG. 3 is another alternative arrangement for mounting the barrier member to the resilient support;
FIG. 4 is a partial view, in cross section, of the barrier member of FIG. 1 but showing a top resiliently held onto the barrier member;
FIG. 5 is a detail, in cross section, of an alternative top held in an alternative manner to the barrier member;
FIG. 6 is a partial cross sectional view showing one way to hold a rail to the barrier member;
FIG. 7 is a partial cross sectional view showing another way to hold a rail to the barrier member;
FIG. 8 is a cross sectional view taken along line 8--8 of FIG. 7;
FIG. 9 is an elevational view in cross section of a lightweight, resilient post-mounting structure;
FIG. 10 is a detail view of a collar used for flexibly mounting a post, with a fragment of the post shown in cross section; and
FIG. 11 is a view, taken along line 11--11 of FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and particularly to FIG. 1, an upright, steel support member or barrier 20 of cylindrical shape is shown partially broken away in cross section. Two circular steel barrier rails or guardrails 22 are also shown, one shown in cross section. The guardrails 22 extend between the barrier 20 and another, similar barrier, not shown.
The bottom end of the upright support member or barrier 20 is preferably bent or otherwise formed inward to include a circular lip 24. A circular block 26 of an elastomer such as resilient urethane is preferably molded around the bottom end of the barrier 20 and the lip 24 with approximately the same circular shape as the barrier 20. The bottom of the urethane block is shaped flat so as to rest on a suitable base 30, usually of concrete or other paving or flooring material.
While urethane is preferred, any resilient material with advantageous mechanical properties and a strong resistance to taking a permanent set under stress can be used.
A domed steel plate 34 is preferably molded into the inside of the urethane block 26. A central hole 35 in the plate 34 accommodates a mounting bolt or stud 36 that is rigidly anchored into the base 30. The central hole 35 in the plate 34 is made slightly oversize for the stud 36, in order to allow manual adjustment of the barrier 20 and to accommodate manufacturing and installation tolerances.
While the domed plate 34 is shown molded into the inside of the urethane block 26, alternatively, a step could be formed in the inner, upper perimeter of the block 26; and the domed plate 34 could be nested into that step.
One or more (preferably three) spring washers 38 are placed around the stud 36 and on top of the plate 34. These spring washers 38 are generally dome-shaped and are compressed when, during installation of the barrier 20, a nut 40 is tightened onto the stud 36, in order resiliently to apply a substantial downward force on the plate 34 and thus hold the barrier in place. The pile-up of spring washers 38 is made by putting each spring washer in an alternating orientation as they are placed down about the stud 36.
Thus, the first spring washer 38 is placed in an orientation so that its periphery contacts the plate 34. This orientation of the first spring washer 38 has the advantage of having the periphery of the spring washer 38 extend beyond the oversize perimeter of the hole 35. The second spring washer 38 is then placed upside down with respect to the first spring washer and on top of the first spring washer, with the edge of its central aperture touching the edge of the central aperture of the first spring washer. Then the third spring washer 38 is oriented just like the first spring washer and is placed down on top of the second spring washer with the outer peripheries of the second and third spring washers in contact. In this way, the tightening of the nut 40 partially compresses the three spring washers 38 and forces or presses the plate 34 down and thus yieldably holds or biases the barrier 20 and the block 26 down to the floor or base 30.
If the base 30 is slightly uneven, such that the barrier 20 would stand tipped slightly to one side, the installer can move the barrier toward the lower side of the base 30, using some of the oversize diameter space allowed in the hole 35 through which the stud 36 extends. Then, when the nut 40 is tightened, the downward pressure is applied more strongly on the uppermost or higher side of the urethane block 26. That tends to compress the higher side of the urethane block 26 more than its lower side. That differential compression of the urethane block 26 tends to straighten the barrier 20, bringing it into a more vertical or plumb condition.
The barrier 20 is preferably made from a length of common steel pipe of sufficient diameter and thickness to do the job. It is preferred that a standard, stock size of pipe be used and cut to the desired length. Therefore, preferably, the upright barrier 20 is open at the top in order to provide access to the inside of the barrier for on-site assembly and installation. However, the barrier 20 should preferably be capped for safety and cleanliness, as a final step in the on-site assembly process. Preferably, a cap 44 of pressed steel, molded thermoplastic rubber or any other crack-resistant, sturdy material can be mounted on the top of the upright support member or barrier 20 in order to protect anyone casually touching the barrier and to keep out dirt and moisture. Any removable mounting can be used for the cap 44. FIGS. 4 and 5 show two preferred mountings for a cap 44 and will be explained in greater detail hereinafter.
If the barrier 20 is struck by a vehicle, it will yield under the impact. The steel barrier cylinder 20 will not noticeably BEND under the impact so much as the barrier cylinder 20 will ROCK and squeeze the far side of the resilient, elastomeric urethane block 26, which will act as a high-hysteresis spring and absorb the energy of impact. The spring washers 38 will also yield slightly as the plate 34 rocks, so as to accommodate the selective squeezing of the block 26 that results from an impact. All of this is calculated to let the barrier resist the impact but yet yield under the impact without permanent deformation.
The barrier 20 can be either painted or covered by slipping a molded plastic cover over it, in order to reduce rust and defacing of its surface that would inevitably result from numerous impacts from vehicles.
The barrier 20 can stand alone to protect a corner or can be one of many vertical barriers used to protect a wall or line. Alternatively, the barrier 20 can be linked to another barrier, not shown, by a pair of guardrails 22 which provide a continuous barrier to traffic and thus protect a wall or line without necessitating an unreasonable number of individual vertical barriers.
The guardrails 22 can also be resiliently mounted to the barrier 20, as shown in FIG. 1. Preferably, the guardrails 22 are made of circular steel pipe of standard, off-the-shelf size and wall thickness. A stepped urethane gasket or plug 50 is slipped into each end (only one end shown) of the guardrail 22. Each plug 50 has a central hole which accommodates a rod or shaft 54, which extends into the interior of the barrier 20. The shaft 54 has threads at least at each end thereof for cooperating with a nut 56 which pulls on the two barriers 20 that support the ends of the guardrail 22 and compresses the gasket or plug 50 at each end of the guardrail 22.
The on-site installation of the barrier 20 and guardrails 22 (if fitted to the barrier 20) can preferably be done with the cap 44 off of the cylindrical barrier 20 and only mounted on the barrier 20 as nearly the final step in the on-site installation procedure. Therefore, all of the internal assembly, such as tightening the nuts 40 and 56, can be done through the open top of the barrier 20, before the cap 44 is installed.
Alternatively, but not preferred, the cap 44 can be either integrally formed with the cylindrical barrier 20 or can be welded to the cylindrical barrier 20 at the factory and preferably not welded on site but possibly welded on site. If the cap 44 is an integral part of the barrier 20, either by integral forming or by welding, as it is delivered to the installation site, access should be provided for tightening the installation nuts 40 and 56 on site. Therefore, an access opening (not shown) can be provided on the side of the barrier 20 opposite from the expected impacts, with machine screw or other fasteners for closing the door of the access opening.
When a guardrail 22 is struck by a vehicle, not only does the upright support member or barrier 20 yield under the impact, by reason of the block 26; but the gasket or plug 50 also yields slightly in order further to absorb the energy of impact.
ALTERNATIVES
Referring now to FIG. 2, if production volume is not adequate to justify tooling to form the lip 24 at the lower end of the barrier 20, the plate 34 can be welded, for example at a weld bead 60, onto the inside of the bottom or lower end of the barrier 20. The plate 34 can be a flat circle and need not be domed. Also, the weld bead 60 can be either on the top or on the bottom of the plate 34, although the bottom might be easier and thus cheaper. Without the need to mold the lip 24 and the plate 34 (FIG. 1) into the urethane block 26, the urethane block 26 can be cut and minimally shaped from flat, but thick, urethane stock. The base 26 can be cut with a shelf 62 to support the plate 34 and the barrier 20 and to accommodate the weld bead 60, if necessary. The bottom end of the barrier 20, together with the perimeter of the plate 34 and perhaps also With the weld bead 60, thus also constitutes a shelf which rests on the shelf 62 that is formed on the resilient mounting support or block 26.
Referring now to FIG. 3, if production volume is adequate to justify significant tooling, the lip 24 at the bottom of the barrier 20 can be formed into a plurality of lips 24 bent in alternate directions around the periphery of the bottom end of the barrier 20, much like the teeth of a saw are "set" to alternate sides of the blade.
Referring now to FIG. 4, the center and one side of the barrier 20 are shown in cross section with an example of a molded cap 44 of thermoplastic rubber. In order to removably hold the cap 44 in place on top of the barrier 20, a hole 70 is preferably formed in a web or boss on the inside of the cap 44. A hook or a cut or "jump" ring 72 (not shown in cross section, for clarity) is passed through the hole 70 and preferably through a hole 74 in the top end of a resilient rubber tarp strap or "bungee" strap 76. Another hook or jump ring 78 is passed through a hole 80 at the bottom end of the resilient strap 76 and through a hole 82 formed near the top end of the stud 36. Alternatively, a loop or an eye can be formed at the top end of the stud 36 or can be welded, screwed on, or otherwise formed on the top of the nut 40.
If a hook or a cut or jump ring 72 and 78 is cut or open at one point in its circumference, the entire load that it carries resolves to a bending stress that is at a peak on the side of the ring opposite from the cut. Therefore, the rings 72 and 78 should be designed accordingly. Such cut or jump rings are commonly used, albeit on a much smaller size scale, in the jewelry art. The hooks or jump rings 72 and 78 can be installed on site or can be factory installed with the last connection to the hole 82 being done on site. It will be evident to one skilled in the art that there are any number of alternate ways resiliently to hold the cap 44 to the barrier 20.
FIG. 5 shows, in fragmentary cross section, an alternate cap 44, in the form of a steel dome, and means for holding it in place.
A plurality of angle irons 90 are riveted around the inside edge of the cap 44 in the factory using rivets 92 having flat, recessed heads in countersunk holes on the exposed surface of the cap 44. The other arm of each angle iron 90 has a threaded hole. Flat-head machine screws 94 extend through countersunk holes around the top end of the barrier 20 to fasten the angle irons 90 and thus the cap 44 to the top end of the barrier 20.
FIG. 6 shows in cross section an alternate embodiment of the end treatment of the guardrail 22. Instead of the rod or shaft 54 (FIG. 1) with threaded ends and a nut 56 to tension the shaft 54, a larger central hole is formed in the gasket or plug 50 and a pipe or tube 100--the functional and structural equivalent of the rod or shaft 54--passes through the plug 50. With a tube 100 of larger diameter than the shaft 54, significantly higher friction can be achieved between the plug 50 and the tube 100 than is possible with the shaft 54. Therefore, it is more feasible to preassemble at the factory a plug 50 in each end of the guardrail 22 with the tube 100 firmly pressed into both plugs to hold them tightly in place. That subassembly can then be shipped to the assembly or job site with little fear that it will fall apart. The tube 100 is preferably on the order of a steel water pipe with either a galvanized or black oxided finish and internal threads formed at each end.
Consequently, at the assembly or job site, the guardrail 22 subassembly is placed into position between two barriers 20 and a bolt 102 is inserted through a hole in each barrier and threaded into each internally threaded end of the tube 100. In this way, the two barriers 20 don't have to be forced apart to allow the insertion of the ends of the shaft 54, which must be a bit longer than the distance between adjacent barriers.
FIGS. 7 and 8 show in cross section another alternative embodiment for holding the guardrail 22 to a barrier 20. The purpose of this embodiment is to obviate the long shaft 54 (FIG. 1) and the long tube 100 (FIG. 6). The whole idea is to grip the inside of each end of the guardrail 22. In this embodiment, the plug 58 is shaped with preferably six slots 106 (see FIG. 8) extending axially part way from the end of the plug 50 that is inside of the guardrail 22. At least one (but preferably three) hard steel slugs 110 are placed into each slot 106. The slugs 110 are long enough so that they will always be at an acute angle with respect to the axis of the guardrail 22. An inner edge of each slug bears against the unthreaded portion of a bolt 112 that extends out through the end of the guardrail 22 and the plug 50 and into the interior of the barrier 20. The slots 106 are just a bit smaller than the width of the slugs 110 so as to frictionally capture and hold the slugs in place.
At the assembly or job site, the slugs 110 are pressed into the slots in the plug 50, around the bolt 112, to form a subassembly. That subassembly is then pushed into the end of the guardrail 22, with the bolt 112 loosely in place or even pushed slightly into the plug 50 so as not to cause the slugs 110 to bind as they are eased into the end of the guardrail 22. When the plug 50 is as far into the end of the guardrail 22 as it should go, the bolt 112 is pulled tight to set the slugs, as shown in FIG. 7, into engagement with both the inside of the guardrail 22 and the unthreaded portion of the bolt 112. The bolt 112 can still be pushed in and out slightly to allow easy assembly of the guardrail 22 to the barrier 20.
When in place between two barriers 20, the threaded end of the bolt 112 is pulled into the interior of the barrier 20 and the nut 56 is threaded onto the bolt 112. The bite of the slugs 110 against the bolt 112 keeps it from rotating while the nut 56 is tightened, drawing a washer 114 on the head 116 of the bolt 112 against the slugs 110, wedging them into place, which causes the slugs 110 to bite into the interior surface of the guardrail 22 which prevents their axial movement out of the guardrail 22. If the bolt initially tends to rotate with the nut 56, a screwdriver slot can be formed at the threaded end of the bolt 112 to enable the assembler to keep the bolt 112 from rotating until the wedging action of the slugs 110 comes into play to apply great gripping force on the bolt 112.
The slugs 110 are preferably inexpensive, rectangular chunks of steel. While not fully shown in FIG. 7, the edges of the slugs 110 are not curved but are squared off, as more nearly illustrated in FIG. 8, where the slugs 110 meet the inside surface of the guardrail 22. Therefore, each slug 110 actually meets that inside surface of the guardrail 22 only at two points. Similarly, each slug 110 actually meets the unthreaded portion of the bolt 112 at only one point.
The inside diameter of the guardrail 22, the unthreaded portion of the bolt 112 and the slugs 110 are all sized such that the slugs 110 are all oriented much as shown in FIG. 7, whether tighten into place or just barely touching each other. Each slug 110 touches the inside of the guardrail 22 at one of its edges. That slug 110 also touches the unthreaded portion of the bolt 112 at the diagonally opposite edge of the slug 110 (see FIG. 7). Once installed in the guardrail 22, an imaginary diagonal line along the side of the slug 110 that extends between those two diagonally opposite edges should never be allowed to be perpendicular to the axis of the guardrail 22. That imaginary diagonal line should preferably be about ten degrees from the perpendicular.
While a pipe is an inexpensive and convenient structure for the guardrail 22, it will be evident that tubing of square or rectangular or any other suitable cross section can be equivalently used. Also, it will be evident that the ends of the guardrail 22 can be either squared off or can be curved on top and bottom to define a more uniform spacing between the ends of the guardrail 22 and the outside of the upright barrier 20.
While not specifically illustrated in FIGS. 6, 7, and 8, it will be evident to one skilled in the art that an equivalent of the clamping means shown in those three figures could strongly expand the portion of the urethane plug or gasket 50 within the inside of the guardrail 22 so as firmly to grip by friction the inside of the guardrail 22. For example, a frustoconical, 3-D wedge nut at the end of the plug 50 inside of the guardrail 22 could be internally threaded to cooperate with the threads of the bolt 102 so as to press inwardly at that inside end of the plug 50 as the bolt 102 is tightened, thereby tending strongly to expand that inside end of the plug 50 as well as biasing outwardly the entire length of the plug 50 within the guardrail 22. In may even be useful to either insert or mold into the plug 50 a second frustoconical wedge, with a clearance hole to accommodate the bolt 102. That second frustoconical wedge could be arranged in the reverse direction from the first wedge and located at or near the end of the plug 50 that is nearest to the upright barrier 20. The result would be even stronger expansion and pressing by the plug 50 on the inside surface of the guardrail 22.
The inside of the guardrail 22 can be coated with epoxy or other material to enhance the frictional grip of the elastomeric or urethane plug 50 on the inside of the guardrail 22. As an alternative, the resilient elastomeric plug 50 can even be bonded to the inside of the guardrail 22.
In order to enhance the resilience of the mounting of the guardrail 22 to the upright barrier 20, the clearance hole formed in the upright barrier 20 in order to accommodate the bolt 102 can be made larger than the minimum size necessary to accommodate the bolt 102. Then an elastomeric, eg., urethane, spacer can be placed in the bolt clearance hole, around the bolt 102 and between the head of the bolt 102 and the inside of the upright barrier 20.
It will be evident to one skilled in the applicable art that all of the embodiments disclosed for attaching the rail member or guardrail 22 to the upright support member or barrier 20 constitute some form of clamp for squeezing the resilient gasket or plug 50 between the guardrail 22 and the barrier 20.
While a resiliently-mounted upright barrier 20 has been disclosed herein with respect to a plurality of guardrails 22 between adjacent upright barriers, it will be recognized that one or more guardrails 20 could be installed in a free-standing condition, without any guardrails 22 between them. Also, any number of guardrails 22 can be used, besides the two shown.
LIGHTWEIGHT EMBODIMENT
Referring now to FIG. 9, a lightweight resilient barrier support is shown for such uses as resiliently supporting hand railings along a pedestrian concourse or other passageway. A post 120 extends up from the area of the floor or base 122 which can be concrete or other material as in the case of the base 30 of FIG. 1. A base plate 124 rests on a resilient isolator pad 126, thereby locating the base plate 124 slightly above the base 122.
The base plate 124 and the isolator 126 have a central hole at least large enough to accommodate a stud 128 that is firmly anchored into the base 122. A nut 130 is threaded onto the stud 128 and is tightened to bear down on a steel washer 132 which in turn bears down on a resilient washer 134 (not shown in section) that presses the base plate 124 onto the isolator 126 and holds the base plate 124 firmly but with a slight resilience over the base 122.
The central hole in the base plate 124 is preferably somewhat larger than necessary to accommodate the stud 128. A portion of the resilient isolator 126 extends up through the central hole in the base plate 124, between the material of the base plate 124 and the stud 128 for resiliently locating the base plate 124 laterally with respect to the stud 128. The use-of the resilient isolator pad 126 and the resilient washer 134 allow a little bit of impact-absorbing movement of the base plate 124 and with it the post 120, but not enough movement for purposes of the present invention.
Four square holes placed at 90-degree positions about the base plate 124 accept and hold four carriage-type bolts 138 that extend upward from the base plate 124. A thick, resilient urethane block or bushing 140 (not shown in section), of preferably about 90-95 durometer stiffness, is placed around each of the four bolts 138 and on top of the base plate 124. A post support plate 142 (see FIGS. 10 and 11) rests on top of the four bushings 140, with the four bolts 138 extending through four holes 144 in four ears 146 on the support plate 140. A nut 148 is threaded onto each of the four bolts 138 and tightened down to squeeze the resilient bushings 140 between the support plate 142 and the base plate 124. It will be evident to one skilled in the art that a single, large resilient urethane block having the necessary four holes therein can be used in place of the four bushings 140.
The ears 146 on the support plate 142 are all in the same plane (see FIG. 11). The support plate 142 has a large central hole 150 large enough to accommodate the outside diameter of the post 120. There are four webs 152 between the four ears 146 (see FIGS. 10 and 11). The webs 152 are twisted so as to expose a slightly curved, interior surface that preferably engages the exterior of the post 120 (see FIG. 9). There is a hole 154 in each web 152. As shown in FIGS. 9 and 10, four bolts 156 extend through the holes 154 in the webs 152 and through matching holes in the post 120--a fragment of which is shown in cross section in FIG. 10--and are threaded into square nuts 158 on the inside of the post 120. The post 120, with the bolts 156 and the nuts 158, are preferably assembled to the support plate 142 before putting the support plate on the four bushings 140.
Preferably, the support plate 142 and the post 120 can be bolted together at the factory. However, if they are to be shipped separately to the installation site, preferably, there is a slight interference or press fit between the large central hole 150 and the outside diameter of the post 120. The interference fit should be loose enough to allow easy on-site assembly to bring the bottom of the support plate 142 even with the bottom of the post 120 by light tapping with a mallet or tapping of the post and plate on the base 122. However, the interference fit should be tight enough to hold the plate 142 tightly enough to the post 120 so that four holes can be drilled in the post 120 in direct alignment with the holes 154 in the webs 152, using the holes 154 as guides for free-hand drilling.
If the material of the support plate 142 is too thick for easy forming or for cost and scrap saving on low-volume production, the support plate 142 can be fabricated from four pieces of thinner strip that would then be spot welded together. For example, each strip would be the width of the ear 146. Each strip would be twisted (and holes punched) to form a single web 152 in the center with an ear 146 on each end. The two ears 146 would be 90 degrees apart, and the two ears would be offset by the thickness of the material. After electroplating for corrosion resistance, four such strips would be arranged in a spot welding jig. The web 152 of each strip would be 90 degrees away from its neighbor and the offset ears 146 from adjacent webs 152 would overlap. For example, the ear from the web to the right would be above and would overlap the ear from the web on the left, in each case. Then, the ears would be spot welded to the extent necessary in order to achieve the desired cantilever beam strength of each ear 146.
In order to get the post 120 to stand vertically or plumb, the nuts 148 are selectively tightened to bias the support plate 142 in two directions.
A dust cover 160 of urethane or some other type of rubber can be snapped over the entire structure shown in FIG. 9, extending from the post 120 to the base 122, using a groove molded into the lower, inner edge of the dust cover 160 to cooperate with a corner or ridge molded onto the periphery of the resilient isolator 126 to hold the dust cover 160 in place.
While this embodiment of the present invention is referred to as the "lightweight" embodiment, its size can be scaled up or down to almost any extent. Besides hand railings, the lightweight embodiment can be used to mount such diverse things as partitions and room dividers, turnstiles, wire fencing, time clocks and time card racks, signs of all kinds, parking meters, etc., etc.
While the form of apparatus herein described constitutes a preferred embodiment of this invention, it is to be understood that the invention is not limited to this precise form of apparatus, and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims. | A resilient mounting system for safety barriers, including guard rails, hand rails, etc., includes a urethane rubber or other resilient material substantially between the periphery of the barrier and a floor or base. The barrier is biased against the base so as to provide an initially stiff yet resilient impact resistance that yields to absorb the energy of impact, such as from a vehicle, rather than requiring the structural material of the barrier itself to absorb and perhaps become deformed by the impact. The resilient material can be shaped generally like the periphery of the barrier or it can be a standard shape that is replicated and arranged to engage a support for the barrier. | 4 |
FIELD OF THE INVENTION
The invention relates to an installation for parking motor vehicles in a space-saving manner in parking spaces arranged one above the other, with a lifting tower rotatable about a vertical axis for transporting the motor vehicles to the individual parking spaces, a horizontal transport device and a turning device for the lifting tower.
DESCRIPTION OF THE RELATED ART
Parking garages are known, in which vehicles go to the parking spaces by way of ramps and roadways. Also known are multi-level systems having parking spaces arranged on a plurality of storeys and with at least one vertically displaceable inter-storey conveyor for transporting the motor vehicle from one storey to another. In this system, the individual motor vehicles can be set down on pallets. Transport installations are also known in which the motor vehicles can be transported horizontally.
DE-B 38 30 136 discloses a parking building for motor vehicles having a central elevator. The elevator has a rotatable tower provided with a rotary support structure. The rotary support structure is part of the tower. Maneuvering devices are also provided for displacing the vehicles horizontally.
SUMMARY OF THE INVENTION
The object of the present invention is to improve on installations of the kind set forth above, in such a way that the surface area requirement of the parking building can be kept small with a maximum number of parking spaces. The object of the invention is attained in that the turning device is formed by a turntable which is separate from a lifting tower, the lifting tower being horizontally displaceable on the turntable.
In this case, the turntable may be arranged so that it is stationary or it may be displaceable by its own traveling chassis arrangement, for example, a shelf operating assembly. It is preferably provided that a lifting fork is displaceable on the lifting tower.
In order to improve the stability of the lifting device, a support roller is advantageously provided at an end of the chassis arrangement remote from the lifting tower. In order to facilitate unloading of the motor vehicles in the respective lowermost parking spaces, it is advantageously provided that the lowermost parking spaces have a base whose height corresponds to the height of the turning device.
A further embodiment of the invention provides that the lifting tower is telescopically extendable.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are described hereinafter with reference to the Figures of the drawings.
FIG. 1 is a diagrammatic elevational view of an installation according to the invention.
FIG. 2 shows an elevational view of the lifting device when delivering a motor vehicle to a parking space.
FIG. 3 shows a plan view of the installation.
FIG. 4 is a diagrammatic view showing the arrangement of the parking spaces.
FIGS. 5 through 11 show plan and elevational views of the various stages in vehicle-transfer and discharge, and
FIGS. 12a-c are side views of parking spaces arranged in mutually superposed relationship. Illustrating various support configurations for the motor vehicles.
FIG. 13 is a diagrammic view of a second embodiment of an installation according to the invention.
FIGS. 14-17 are schematic illustrations of horizontal displacement drives.
DETAILED DESCRIPTION OF THE INVENTION
The installation according to the invention comprises at least two vertical rows 1 of parking spaces 2 arranged in mutually superposed relationship and a lifting device 3 . The embodiment shown in FIG. 3 has three rows 1 of parking spaces 2 arranged in vertically mutually superposed relationship. It would however also be readily possible to provide a fourth row 1 , in which case a region, (door opening) 14 is left free only at the first floor level to permit the motor vehicles 5 to go to the lifting device 3 .
The lifting device 3 has a lifting tower (mast) 6 on which a lifting fork 7 is vertically displaceable. The lifting tower 6 is arranged on a turntable 8 . The turntable 8 is provided with a rotary track ring and can be turned through 360 °.
The lifting tower 6 has a traveling chassis arrangement 9 which is provided at its free end with a support roller 10 . The lifting device 3 or the traveling chassis arrangement 9 thereof is mechanically connected to the turntable 8 . Horizontal displacement of the lifting device via a horizontal transport device is advantageously effected by way of a spindle drive 20 a (FIG. 14) or a toothed rack drive 20 b (FIG. 15 ). It is however also possible to use a hydraulic drive 20 c (FIG. 16) or pneumatic drive 20 d (FIG. 17) for the horizontal transport device. The drive for the spindle drive or the toothed rack drive is afforded by way of electric motors, preferably servomotors.
Provided below the parking spaces 2 of the lowermost row 1 is a base 11 , the height of which corresponds to the height of the turntable 8 , so that the traveling chassis arrangement 9 can be moved from the receiving position for the motor vehicle 5 , as shown in FIG. 1, into the delivery position shown in FIG. 2 at the parking space 2 .
The feed of motor vehicles 5 is effected as described hereinafter. The motor vehicle 5 drives onto two drive-on channels 12 or a drive-on pallet which rests on the lifting fork 7 of the lifting device 3 . The turntable 8 with the lifting mast 6 is then turned until the motor vehicle 5 is oriented in the desired direction. Thereupon the motor vehicle 5 is raised by means of the lifting fork 7 and moved to the desired parking space 2 .
When the desired height is reached, the lifting mast 6 with the traveling chassis arrangement 9 is moved into the position shown in FIGS. 10 and 11. The drive-on channels 12 are put down onto shelf profile members 13 and thus the motor vehicle 5 is stored at the parking space. It is also possible to provide pallets instead of the drive-on channels 12 . In principle it would also be possible for the motor vehicle 5 firstly to be raised to the desired storey and then for the lifting device 3 to be turned.
The lifting device 3 moves back again into its central receiving position shown in FIGS. 5, 6 and 7 and the lifting fork 7 is oriented with respect to the door opening 14 .
The reversed procedure is involved in fetching each motor vehicle 5 from its parking space 2 . Storage of the motor vehicle 5 does not have to be effected by way of drive-on channels 12 or by way of a drive-on pallet. The parking spaces 2 can also be in the form of cantilever-arm shelf assemblies 15 .
In this case, the motor vehicle 5 is lifted by channels 16 which are mounted on the lifting fork 7 and which are oriented transversely with respect to the longitudinal axis of the vehicle and on which it rests with its wheels (see FIG. 12 a ). After the desired parking space 2 is reached the motor vehicle is set down with the chassis thereof directly onto the cantilever arms 15 .
The installation according to the invention is preferably provided with three or four vertical rows 1 of parking spaces 2 arranged in mutually superposed relationship, as shown in FIG. 3 . It is however also possible for the turntable 8 to be arranged with its drive on its own traveling chassis arrangement so that the lifting device 3 is displaceable, in a similar manner to a high-level shelf in a movable shelf assembly. It is likewise possible, as shown in FIG. 4, to provide more than four rows 1 of parking spaces 2 which can be served by the lifting device. In that case, the rows 1 are arranged substantially in a polygonal array. It is further possible, as shown in FIG. 13, to have a lifting device 21 with a telescopically extendable lifting tower 22 to lift the vehicle 5 . | The invention relates to an installation for parking motor vehicles ( 5 ) in a space-saving manner, having a plurality of parking spaces ( 2 ) arranged on top of each other and designed to hold the motor vehicles ( 5 ). The invention provides for a lifting device ( 3 ) for transporting the motor vehicles ( 5 ) to the individual parking spaces ( 2 ), the lifting device being mounted on a turntable ( 8 ). In addition, the lifting device ( 3 ) can be horizontally displaced on the turntable ( 8 ). | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to a rotary combustor for burning waste material (e.g., municipal solid waste material), and more particularly, to an axial seal system for defining separate passages for providing combustion air to selected portions along the periphery of the rotary combustor.
2. Description of the Related Art
Numerous types of systems have been developed for solid waste disposal. One type of system for solid waste disposal employs a rotary kiln or combustor formed by a plurality of pipes defining an inner cylindrical surface in which solid waste is burned. The cylinder is rotated about its axis while the solid waste is burned, and the pipes are interconnected to permit a coolant (i.e., water) to flow through the pipes. The water flows through the pipes and is circulated to a heat exchanger for a heat exchange operation, so that the heat created by the burning of the waste materials may be used in generating electricity. Examples of such rotary combustors are disclosed in U.S. Pat. No. 3,822,651 to Harris et al., U S. Pat. No. 4,066,024 to O'Connor and U.S. Pat. No. 4,226,584 to Ishikawa.
FIG. 1A is a schematic plan view of a rotary combustor and FIG. 1B is a schematic cross-sectional view taken along line B--B in FIG. 1A with the outer casing removed and showing connection of the rotary combustor to a heat exchanger and heat exchange fluid supply apparatus. Referring to FIGS. 1A and 1B, a rotary kiln or combustor 20 includes a combustion drum 22 formed by a plurality of tubes 24 which are interconnected to permit the flow of a heat exchange fluid (e.g., water) through the tubes 24. An outer casing 25 surrounds the combustion drum 22. A pair of cylindrical bands 26 are positioned about the periphery of the combustion drum 22 at opposite ends of the combustion drum 22, and the cylindrical bands 26 and 28 are positioned on rollers 30 and 32, respectively. The combustion drum 22 is rotated by any suitable drive arrangement. For example, at least one of the rollers 30 and 32 may be driven by a motor (not shown) to cause the combustion drum 22 to rotate at a relatively slow rate (e.g., in the range of 1.5 to 3 rpm). Alternatively, rollers 30 and 32 may be freely rotating rollers and the combustion drum 22 may be driven through a gear drive arrangement.
Solid waste 34 is fed into a waste receiving end 36 of the combustion drum 22. As the combustion drum 22 is rotated, the waste material 34 travels from the waste receiving end 36 to a waste exit end 38. As the waste material 34 is transported from the waste receiving end 36 to the waste exit end 38, combustion fluid (e.g., air) is provided to the interior of the combustion drum 22 via a combustion fluid supply means 40 to cause burning of the waste material 34. It should be noted that when the rotary combustor 20 is initially started up, an auxiliary fuel is employed to ignite the initial batch of waste material 34. The combustion fluid supply means 40 supplies combustion air under pressure from a blower (not shown) and includes an air duct 42 and three combustion fluid supply zones 44. Each of the combustion fluid supply zones includes control ducts 46 and 48, wherein the control ducts 46 and 48 are employed to supply combustion air to two windboxes (described below) which are included in each of the combustion fluid supply zones 44. The combustion fluid supply zones 44 are separated from each other by division plates 50 to maintain a fluid seal between the combustion fluid supply zones 44.
In order to prevent damage to the rotary combustor 20 due to high temperatures, the combustion drum 22 is cooled by the tubes 24 via a heat exchange fluid which is supplied to the tubes 24 via supply pipes 56 and 57. The supply pipe 57 is coupled to a joint 58 which serves as a rotary coupler for the supply pipe 57, so that heat exchange fluid can be supplied to and from the combustion drum 22 while the combustion drum 22 is being rotated. A pump 60 is connected to the joint 58 via supply pipes 62, and is also connected to a heat exchanger 64 via supply pipes 66. Thus, the heat exchange fluid which is heated by the heat from the burning of the waste material 34, is supplied to the heat exchanger 64 which extracts the heat for purposes of generating electricity, thereby reducing the temperature of the heat exchange fluid before it is returned to the tubes 24 of the combustion drum 22 via the pump 60, the joint 58 and the supply pipes 66, 62, 57 and 56. The heat exchanger 64 may be a steam turbine for generating electricity. At the waste exit end 38 of the combustion drum 22, solid combustion products 52 and exhaust gases 54 are discharged. The heat extracted from the heat exchanger 64 may be supplemented by the heat from the exhaust gases 54 which travel up a flue 68 positioned over the waste exit end 38 of the combustion drum 22.
Referring to FIG. 2 which is a schematic cross-section of FIG. 1A taken along line 2--2, windboxes 70 and 72 which provide 450° F. combustion air to the rotary combustor 20 in one of the combustion fluid supply zones 44, are illustrated. As illustrated in FIG. 2, the combustion drum 22 is a rotatable cylindrical drum which is rotated in the direction of the arrow W in FIG. 2. Further, as the combustion drum 22 is rotated, all of the waste material 34 is shifted to one side of the drum as it travels from the waste receiving end 36 to the waste exit end 38 of the combustion drum 22. The combustion drum 22 is formed by welding perforated steel plates 73 in between the tubes 24. The perforations in the plates 73 allow the combustion air to be blown into the interior of the combustion drum 22. Windbox 70 provides overfire combustion air through the perforations to the interior of the combustion drum 22 in the direction of arrow X in FIG. 2, while windbox 72 provides underfire combustion air through the perforations to the interior of the combustion drum 22 in the direction of arrow Y in FIG. 2. It has been determined that the provision of both underfire and overfire combustion air results in the most complete combustion of the waste material 34. The windboxes 70 and 72 provide separate air passages so that combustion air is provided at predetermined portions along the periphery of the combustion drum 22, as the combustion drum 22 is rotated. The means for defining these passages (by providing a fluid seal at the periphery of the rotating combustion drum 22) includes axial seals 74 which extend from the tubes 24 along the outer periphery of the combustion drum 22. Dividers 76 define the windboxes 70 and 72, and extending from each of the dividers 76 is a T-shaped rigid shoe 78 which is positioned adjacent the periphery of the combustion drum 22, so that the axial seals 74 contact the rigid shoe 78 as the axial seals 74 are rotated past the rigid shoe 78. As a result, gross air seals are provided for the windboxes 70 and 72.
While currently available axial seal systems such as that depicted in FIG. 2, are capable of providing sufficient air seals for the windboxes 70 and 72, these systems require final adjustment of the axial seals 74 in the field and are difficult to assemble and to adjust to provide an adequate seal. That is, the position of each of the axial seals 74 must be adjusted to ensure an adequate seal when the axial seal 74 is rotated past the rigid shoe 78. A typical axial seal 74 will have 15 to 20 nuts and bolts which must be adjusted and tightened in the field. Thus, a typical rotary combustor 20 will have 2,000 or more nuts and bolts to adjust and tighten once the axial seals 74 are positioned in place.
In addition to the above-described problem presented by the required field adjustments, is the related problem of thermal growth of the rotary combustor 20 in the radial direction. That is, because the combustion drum 22 will tend to expand and contract with temperature, the axial seal 74 may not contact the rigid shoe 78 (in which case no seal is provided) or the axial seal 74 may be bent and damaged by the rigid shoe 78 if too large a portion of the axial seal 74 comes in contact with the rigid shoe 78. As a result, proper adjustment of the axial seal 74 requires consideration of the radial expansion and contraction of the combustion drum 22, making the proper adjustment of the axial seal 74 even more difficult. Thus, there is a need in the art for an improved axial seal system which is simple to install and which compensates for thermal expansion and contraction in the radial direction by the combustion drum 22.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an axial seal system for a rotary combustor, which overcomes the deficiencies of prior art seal systems.
In particular, it is an object of the present invention to provide an axial seal system which is simple to install and which compensates for thermal growth of the rotary combustor as a result of the high temperatures employed in the rotary combustor.
It is a further object of the present invention to provide an axial seal system for a rotary combustor, which has relatively few parts and requires litle maintenance.
The rotary combustor of the present invention comprises a rotatable cylindrical drum having axial seals extending from the outer periphery thereof, and means for defining a plurality of passages for providing combustion fluid to portions along the outer periphery of the rotatable cylindrical drum. The means for defining a plurality of passages includes a plurality of means for resiliently engaging the axial seals as the rotatable cylindrical drum is rotated, so that when two of the axial seals come into contact with a respective pair of the resilient engaging means, a passage for providing combustion fluid to a portion of the periphery of the rotatable cylindrical drum is formed.
In the preferred embodiment, each of the resilient engaging means comprises a movable shoe positioned along one portion of the periphery of the rotatable cylindrical drum, and means for biasing the movable shoe so as to urge the movable shoe into contact with at least one axial seal. The biasing means includes a support positioned at a predetermined distance from the axial seals along one portion of the outer periphery of the rotatable cylindrical drum, and two spring units for urging the movable shoe into contact with the at least one axial seal.
According to the present invention, it is not necessary to provide adjustable axial seals, and the axial seals can instead be permanently affixed to the tubes which make up the rotatable cylindrical drum, thereby avoiding the requirement of having numerous nuts and bolts which must be tightened and adjusted after positioning the axial seals in place. Further, because the movable shoe which contacts the axial seals is spring biased, it is ensured that the axial seal strips will contact the movable shoe to provide the necessary air seal, even though the position of the axial seals will vary with the thermal expansion and contraction of the rotatable cylindrical drum. Further, because the movable shoe is resiliently held in place, if the rotatable cylindrical drum expands, the axial seals will not be bent or damaged. Thus, the axial seal system of the present invention is a low maintenance system having relatively few parts and minimal field installation requirements compared to current axial seal systems. Further, replacement of any parts can be carried out quickly and easily.
These together with other objects and advantages which will become subsequently apparent, reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A s a schematic plan view of a rotary combustor;
FIG. 1B is a schematic cross-sectional view of the rotary combustor of FIG. 1B, taken along line B--B of FIG. 1A with the outer casing removed and showing the connection of the rotary combustor to a heat exchanger and heat exchange fluid supply apparatus;
FIG. 2 is a schematic cross-sectional view of the rotary combustor of FIG. 1A, taken along line 2--2 of FIG. 1A;
FIG. 3 is an enlarged fragmentary sectional view of a portion of the combustion drum 22 and the arrangement of the axial seal system of the present invention as it is employed with the rotary combustor of FIG. 2; and
FIG. 4 is a cross-sectional view taken alone line 4--4 in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention will be described with reference to FIGS. 3 and 4. The combustion drum 22 includes tubes 24 for carrying the heat exchange fluid, and the tubes 24 are welded to steel sheets 80 having perforations 82, which are arranged between the tubes 24. As described above, the perforations 82 provide a path for the combustion air. In the axial seal system of the present invention, the adjustable axial seals 74 of FIG. 2 are replaced by axial seals 84 extending from every other tube 24, wherein each of the axial seals 84 includes a seal support 86 and an axial seal strip 88. In the preferred embodiment, each seal support 86 is tack welded to the corresponding tube 24 and each axial seal strip 88 is welded to the corresponding seal support 86. Further, in the preferred embodiment, each axial seal strip 88 is formed by 1/8 inch carbon steel and has an angled shape, so that the axial seal strip 88 is flexible. In the present invention, the rigid shoes 78 of FIG. 2 are replaced by sealing structures 90 (only one of which is shown in FIG. 3). The axial seal system of the present invention is formed by the axial seals 84 and the sealing structures 90 which form a means for resiliently engaging the axial seals 84 as the combustion drum 22 is rotated, so that when one of the axial seals 84 comes into contact with one of the sealing structures 90, an air seal is formed along the area of contact.
Each sealing structure 90 includes a divider 76 similar to the divider 76 in FIG. 2, and a bottom plate 92 which is welded to (and held stationary by) the divider 76. A pair of spring units 94 and 96 are coupled to the bottom plate 92 and serve as biasing means. Since the spring units 94 and 96 are identical, only the spring unit 94 will be described in detail. Spring unit 94 includes a spring housing 98 which is threaded through a hole in the bottom plate 92 and which is adjustably positioned with respect to the bottom plate 92 by an offset plate 100. The spring housing 98 has an internal abutment 102 and has a cylindrical opening formed therein for holding a spring 104. An adjustable guide and stop 106 and a retaining bolt 108 are inserted through the spring housing 98 and through the middle of the spring 104. The retaining bolt 108 is adapted to be threaded through the adjustable guide and stop 106 into a threaded hole 109 provided in a bar 110 which is welded to the bottom of a movable shoe 112. A washer 114 is positioned on one end of the bar 110 adjacent the threaded hole, so that when the retaining bolt 108 is screwed into the threaded hole 109 of the bar 110, the spring 104 is held between the internal abutment 102 of the spring housing 98 and the washer 114. The movable shoe 112 is provided with an inclined surface 112a and a top surface 112b, so that as the combustion drum 22 is rotated in the direction of the arrow Z in FIG. 3, each axial seal strip 88 will initially contact the inclined surface 112a of the movable shoe 112 to create an air seal and will slide along (i.e. wipe) the inclined surface 112a until reaching the top surface 112b of the movable shoe 112. The air seal is maintained as the axial seal strip slides along the top surface 112b. By providing the inclined surface 112a, the initial contact force applied to the axial seal strip 88 is reduced, so that the possibility of damage to the axial seal strip 88 (e.g., due to bending) is reduced. The movable shoe 112 is also provided with sidewalls 112c which are sufficiently long to maintain a gross air seal and to protect the spring units 94 and 96 from damage due to combustion products which might fall from the combustion drum 22. Since the axial seals 84 are permanently positioned with respect to the tubes 24, if the combustion drum 22 expands or contracts due to temperature, the position of the axial seals 84 with respect to the rigidly held bottom plate 92 will vary. However, because the spring units 94 and 96 support the movable shoe 112, the movable shoe 112 resiliently engages the axial seal strips 88 of the axial seals 84, and the position of the movable shoe 112 (with respect to the bottom plate 92) when it engages one of the axial seals 84 will vary with the expansion and contraction of the combustion drum 22.
The sealing structure 90 also includes a bracket 116 which is welded to the bottom of the movable shoe 112 and a shoe guide 118 which is welded to the bottom plate 92 in between the spring units 94 and 96. The shoe guide 118 is an L-shaped member and extends through an aperture 120 in the bracket 116 (see FIG. 4), so that the movable shoe 112 is pivoted about the shoe guide 118 as each axial seal 84 initially engages the inclined surface 112a of movable shoe 112, moves across the top surface 112b of the movable shoe 112 and disengages the movable shoe 112. It should be noted that the components of the sealing structure 90 are formed of materials which are sufficiently heat resistant to allow for their use in the environment of the rotary combustor 20. For example, structural elements such as the movable shoe 112, the bottom plate 92 and the dividers 76 are made of carbon steel. Similarly, the spring 104 is a high temperature, corrosion resistant spring which may be, for example, a model MP35NC Duer's spring manufactured by Duer Spring Manufacturing Company of Coraopolis, Penna.
Referring to FIGS. 1B and 2-4, each of the combustion fluid supply zones 44 includes two windboxes 70 and 72. Thus, a total of three sealing structures 90 are positioned in each of the combustion fluid supply zones 44 for an overall total of nine sealing structures 90 for the rotary combustor 20. That is, each sealing structure 90 replaces one of the rigid shoes 78 illustrated in FIG. 2. However, in the preferred embodiment, each movable shoe is approximtely 3 feet long and one foot wide and has side edges (112c) which extend approximately 7 to 8 inches. Since each movable shoe 112 is only approximtely 3 feet long, in practice, it is necessary to use two sealing structures 90, end-to-end, to replace each of the rigid shoes 78 illustrated in FIG. 2. This is because each zone is approximately 6 feet in length (for a total of 18 feet). Thus, each axial seal 84 is approximately 6 feet in length (i.e., one zone), so that a particular axial seal 84 will contact two side-by-side movable shoes 112 simultaneously as the axial seal 84 is rotated.
Referring to FIGS. 2 and 3, in operation, the axial seals 84 are rotated with the combustion drum 22 in a counterclockwise direction. As an axial seal 84 approaches a sealing structure 90, the axial seal strip 88 contacts the inclined surface 112a of the moveable shoe 112. Then, as the combustion drum 22 continues rotation, the axial seal strip 88 is wiped across the inclined surface 112a and the top surface 112b of the moveable shoe 112 until the axial seal strip 88 has travelled across the entire moveable shoe 112. Depending upon the position of the axial seal strip 88 on the movable shoe 112 (and depending upon whether one or two axial seal strips 88 are in contact with the movable shoe 112) the movable shoe 112 will pivot about the L-shaped shoe guide 118. When the axial seal strip 88 contacts the inclined surface 112a it begins to compress the spring units 94 and 96. That is, the bar 110 will be forced downward, compressing the spring 104 against the internal abutment 102 of the immovable spring housing 98 which is attached to the bottom plate 92. The spring 104 continues to be compressed further until the axial seal strip 88 reaches the top surface 112b of the moveable shoe 112, at which point the spring 104 is compressed to its fullest extent. After the axial seal strip 88 has completed its travel across the top surface 112b of the moveable shoe 112, the spring 104 and the moveable shoe 112 return to their normal positions. While the axial seal strip 88 is in contact with the moveable shoe 112, an air seal is provided along the axial seal 84, the moveable shoe 112 and the divider 76. It should be noted that in the embodiment illustrated in FIG. 3, the axial seals 84 are arranged such that two axial seals 84 are simultaneously in contact with the movable shoe 112. This ensures that at least one axial seal 84 is always in contact with a portion of the moveable shoe 112, thereby providing a continuous air seal for the combustion air.
Although a preferred embodiment of the present invention has been described with respect to the drawings, it should be noted that the present invention can be implemented by any suitable type of means for resiliently engaging the axial seals 84 as the combustion drum 22 rotates, so that a sealed wall is formed for a combustion fluid passage. Although the invention has been described with reference to combustion air, any suitable type of combustion fluid may be employed. Further, although the sealing structure 90 and the axial seals 84 have been described as being formed of particular types of materials, it should be noted that the present invention may be implemented by using any type of material which is sufficiently heat resistant for use in the environment of the rotary combustor 20. In addition, although the rotary combustor 20 has been described as having tubes 24 which carry water, any suitable type of heat exchange fluid may be employed, and the heat which is extracted from the heat exchange fluid may be used for purposes other than generating electricity (e.g., for use as a heat source).
The many features and advantages of the present invention are apparent from the detailed specification, and thus it is intended by the appended claims to cover all such features and advantages of the system which fall within the true spirit and scope of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described and, accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A rotary combustor includes a rotatable cylindrical drum having axial seals extending from the outer periphery of the drum, and sealing structures for forming passages for providing combustion fluids along portions of the rotatable cylindrical drum. Each sealing structure includes a movable shoe positioned along the periphery of a portion of the rotatable cylindrical drum, a support positioned at a predetermined distance from the axial seals along a portion of the periphery of the rotatable cylindrical drum, and first and second spring units coupled between the support and the movable shoe. The spring units urge the movable shoe into contact with at least one of the axial seals. As a result, an air seal is continuously provided between the axial seal and the movable shoe even though the rotary combustor expands and contracts with temperature. | 5 |
PRIORITY CLAIM TO RELATED APPLICATION
This application claims the benefit of the earlier priority filing date of commonly owned and co-pending U.S. Provisional Patent Application No. 60/924,833 filed Jun. 1, 2007, which was filed in the name of the sole and common inventor, Charles G. WAGNER, which is entitled METHOD AND APPARATUS FOR MONITORING POWER CONSUMPTION, and which is hereby incorporated by reference in its entirety as though fully set forth in the present application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of devices, methods, and systems for monitoring electric power consumption of electrically powered appliances, devices, and equipment as well as power consumption of residential, commercial, and/or industrial buildings and facilities as well as organizational or business campuses of any size or configuration. The invention described herein further relates to a method and apparatus for the monitoring of electricity consumption, and more particularly, to a system including one or more current and/or power sensing devices connected to a remote monitor that enables home, business, and/or any electricity users to monitor their power consumption to enable such adjustments as are necessary or desirable to reduce and/or proactively manage and optimize electricity usage and to reduce or control associated costs.
2. Description of Related Art
The inventor herein has previously invented, with others, a power and current-sensing device disclosed and claimed in U.S. Pat. No. 4,754,218 (hereafter “the '218 Patent”) and a monitoring device disclosed and claimed in U.S. Pat. No. 4,717,872 (hereafter “the '872 Patent”), both of which are incorporated herein by reference in their entirety as though fully set forth herein. The '218 Patent discloses a magnetically permeable core suitable to be disposed around a power feeder cable, such as is typically used to supply power to a residence or business from the main power grid.
A coil situated upon the core generates an induced voltage proportional to the feeder cable current without ohmic contact being required. In addition, the wrapping of a core around the current-carrying cable balances the unbalanced magnetic fields surrounding the cable, which unexpectedly reduces power loss. The '872 Patent discloses and claims a device to monitor the power being supplied to a building, such as a residence or business, using a magnetically permeable core, including a read-out unit calibrated to convert the current sensed from the core into units of power being consumed by the building.
The core and monitoring device disclosed and claimed in the '218 and '872 Patents enable a user to sense current and thus monitor the power being consumed in a building on a real-time basis. Studies have shown that when power consumption is monitored on a real-time basis, consumers reduce their consumption by an average of ten to twenty percent.
For example, a consumer may realize that a light or other appliance has been left on, or a freezer door left open, unintentionally. Alternatively, the consumer may realize that certain appliances he or she is using are not energy-efficient and may be spurred to replace those appliances with more efficient models. As energy prices skyrocket and concerns grow about power generation and consumption contributing to global warming (especially where the grid power is derived from fossil fuels), becoming more energy efficient and thus reducing power consumption is both an economic and a climatic imperative.
While the core and device disclosed and claimed in the prior art '218 and '872 Patents assist in accomplishing the goal of decreasing power consumption, they do suffer some deficiencies. For example, using the prior art devices, one can monitor only the total power being consumed in the building. At most times, more than one electrically powered appliance is being used in the building; therefore, it can be difficult to pinpoint exactly which appliance is the most inefficient.
Also, while the prior art devices include a monitor with units calibrated to show the amount of power being consumed, the monitor displays only the present power consumption and cannot provide any information as to past usage, averages per different times of day, or other information that might be useful in profiling and reducing power consumption. Further, the prior art core transmitted the data to the monitor via a wire, necessitating either locating the monitor outside the building, or running a wire into the building.
What has long been needed in the field of art is a core and monitoring system that allows for a core wrapped around a current-carrying cable to balance unbalanced magnetic fields to reduce power consumption. Preferably, such a system could be adapted in varied configurations to monitor the current-carrying cable non-invasively to enhance safety during installation and operation.
More preferably, such monitoring systems would be optionally compatible for use with a plurality of core sensors so that the consumption of individual appliances may be monitored periodically and/or in real-time. In even more optionally preferred variations, monitoring systems could be modified to communicate with and/or receive information transmitted from the cores to the monitoring hardware via a wireless method.
In additionally preferred alternative variations, the monitoring system may be augmented to sense power consumption and to communicate such information in a display or read-out scaled to and/or configured to display dimensional units that accommodate any type of electric load. In further modified embodiments, the monitoring system may also be adapted to sense power consumption periodically and/or continuously and to transmit such consumption information instantaneously, on demand, occasionally, or periodically.
Even more preferably, certain alternative power consumption monitoring systems may incorporate software and/or circuitry configured to operate, collect, display, and analyze information about power consumption either on-site, proximate to, and/or remote from the location of the electric loads. In other preferred or optional variations, the monitoring system may be implemented whereby the software can interface with the system and can correlate the monitored information with a user's electric utility bill. In this way, new, innovative, and heretofore unavailable capabilities can be established whereby power consumers and producers, distributors, traders, resellers, suppliers, and/or utility service providers or organizations or municipalities may more accurately ascertain power consumption or usage, availability, quality, and/or reliability so as to better control, manage, increase availability and quality, and/or reduce or optimize power consumption to minimize inefficiencies.
SUMMARY OF THE INVENTION
Many heretofore unmet needs are met and problems of the prior art are solved with the innovative power consumption monitoring devices, methods, firmware, software, and systems of the invention, many embodiments of which enable and establish previously unavailable features. Such features and capabilities may preferably or optionally include, among other elements and for purposes of illustration and example but not for purposes of limitation, improved and more accurate power consumption monitoring, new ways to adjust electric loads in view of more timely awareness of consumption and/or anomalies, and new power consumption sensor arrangements and monitoring capabilities. Such novel and innovative features and capabilities may also further preferably or optionally incorporate more readily configurable, reconfigurable, and easily adaptable sensors and monitors and combinations and arrangements thereof, all of which enable consumers and/or producers, distributors, traders, resellers, or suppliers to protect against and to quickly remedy low quality power or unavailability, and/or inefficient, unnecessary, and less than optimal consumption of power.
In one preferred configuration of the invention, a power consumption monitor and/or monitoring system includes at least one, and more preferably a plurality of magnetic cores adapted to be respectively situated around one or more wires, cables, conductors, and/or cords that are transmitting electric power to residential, commercial, and/or industrial equipment, appliances, buildings, facilities, and campuses. Preferably, one or all of the plurality of magnetic cores incorporates or is in communication with one or more signal transceivers or transmission circuits, which accompany or are incorporated with one or more of the plurality of magnetic cores.
Even more preferably, each of the one or more transmission circuits is configured to transmit current and power information wirelessly to at least one monitoring device and/or to receive information therefrom. In one optionally preferred configuration of any of the embodiments of the invention, the monitoring device may be adapted to wirelessly receive transmissions from any of the contemplated transmission circuits and/or to communicate information thereto. In another alternative configuration, the monitoring device may be further configured to display the current and power information and/or to retransmit such information to another device. In yet more optionally preferred configurations, the monitoring device or another component in communication therewith collects, modifies, retransmits, and/or analyzes the power and current information and displays and/or communicates modified or converted power consumption information.
For purposes of example but not for purposes of limitation, such modified and/or converted information may be ascertained through any of a number of ways that include passive, reactive, inductive, ohmic, impedance, resistive, and/or combination-type sensors. Such modified and/or converted information may describe or be further converted to describe power use, quality, availability, voltage, current, frequency, power factor, and any desired or related information. In turn, this modified and/or converted information may also be useful to compute, describe, estimate, and/or predict total, instantaneous, and/or average power consumption for a period of time, total or average power consumed per unit time, maximum and minimum power consumed at any moment in time, and/or total or average power consumed.
Preferably, any or all of such modified and/or converted information may also be attributable to and/or identifiable with respect to a specific one and/or any or all of the monitored residential, commercial, and/or industrial equipment, appliances, devices, buildings, or facilities. Such modified information may also preferably include optional information such as information that may be mathematically, statistically, or algorithmically derived from power consumption information, and which may include voltage, current, frequency, cost of power use, projected or estimated power use and cost, as well as reliability, availability, and quality of any aspect of the consumed power, and any combination thereof.
The invention further comprises, in various of its aspects and embodiments, a software program or programs and elements thereof, which may be resident on each, every, and/or any component of the power consumption monitoring system, including for purposes of example without limitation, a power consumption sensor, a sensor monitoring device, the consumption monitoring system, a computer, a computing device, and/or components and elements thereof. The components containing such resident software program and/or programs may be proximate to, remote to, and/or inside or integrated with the residential, commercial, and/or industrial equipment, appliances, devices, buildings, facilities, and/or campuses. In additionally preferable or optional configurations to any of the embodiments of the invention, such components may also be integrated with circuit breakers, subcircuit or branch conductors, as well as in appliances, devices, equipment, and any other type of electric load.
In other optionally preferred novel embodiments, any of the monitoring devices, sensors, computers, or computing devices, may be connected with any of the other components wirelessly or with a wire. Any of the contemplated components may also be in communication with any of the other components across a network, through a phone line, a power line, conductor, or cable, and/or over the internet. In other alternatively preferred configurations of the invention, the resident software program may have numerous features that, for purposes of example without limitation, enable a user or consumer to compare current power use to historical use and to evaluate or compare current costs to previous or historical costs, to compare current or prior costs to such costs for similar facilities, and/or to evaluate, compare, and/or audit such current or prior costs with respect to producer, supplier, distributor, trader, and/or utility company invoices.
More preferably, such resident software program and/or programs may enable any of the contemplated information to be communicated by text, voice, fax, and/or e-mail messages to a user or consumer either periodically, when certain predefined or predetermined conditions occur such as predefined alarm events or conditions, and/or when anomalous, unexpected, or expected power readings occur and/or are detected. One such example that may preferably create an instance when the contemplated information may be communicated by the resident software may include unexpected power use at a time when a commercial facility is closed or when personnel should not should be in the building, or when power outages or brownouts occur, or when unusually high or low consumption occurs.
Also, such resident software program and/or programs may be optionally or preferably further modified to enable special capabilities that can assist disabled, ill, or special needs individuals that reside in their own home or in any other facility and who need to manage and/or monitor their power consumption, availability, quality, and/or anomalies related thereto. More specifically and for purposes of example without limitation, the resident software and related components contemplated by the present invention may be engineered to special needs computing device that enable voice response, eye-movement response, and/or large print display or loud audio annunciator and spoken text capabilities. Additionally preferable options may include engineered adaptations of any of the variations of the inventive monitoring system that communicate any of the contemplated information, including for illustration purposes without limitation, power consumption monitoring information, in response to remote polling, on demand, occasionally, and/or periodically to such individuals and/or to their care providers, power service providers, medical providers, and/or others. Such communications can be by any of the means, modes, and methods described elsewhere herein and can preferably or optionally be used to communicate alerts regarding routine power consumption, unexpected anomalies, expected occurrences, or predetermined information related to monitoring system and component and sensor performance, power supply conditions, power consumption, and/or power quality, reliability, and/or availability.
With this optionally preferred capability, users as well as utility service providers, power service providers, medical providers, and/or others can be notified and/or alerted to existing or prospective issues regarding use, maintenance, and/or other power service issues or needs. Such notification and alerting capabilities may enable routine preventative maintenance, may prevent equipment failures and may enable faster remedy of existing or exigent issues.
In certain possibly extraordinary but optionally preferred and/or necessary circumstances, the disabled, ill, and/or special needs individuals may have a need to ensure continuous and/or maximized availability of high-quality electricity so that special needs equipment and/or appliances is/are always available for exigent, periodic, occasional, and/or continuous use. For further purposes of example, but not for purposes of limitation, such special needs equipment can include medication dispensers, intravenous and food supply pumps, defibrillators, cardiac and/or respiratory assistance machines, oxygen supply machines, hepatic and gastric and renal filtering and assistance machines, medical condition monitoring devices, emergency medical services communications devices including radio and telecommunications devices, and all sorts of similarly important, special needs equipment, devices, components, and appliances.
Even more preferably, the resident software program or programs or any element thereof may be configured to generate power consumption and usage histories and/or predicted use estimates for periods of time to create historical and/or predictive load profiles, which a user, consumer, producer, supplier, distributor, utility service provider, trader, reseller, or other person or entity may use to establish best power supply and/or consumption practices and to ascertain whether various equipment, devices, electricity metering devices, appliances, buildings, or facilities, are using power inefficiently or are otherwise experiencing anomalous power consumption or calibration issues. Such historical or predictive power consumption information may also be preferably useful in further optional configurations of the resident software that enable auditing power costs and utility service invoices and billings to ensure actual use and costs meet contractual rates and/or anticipated costs and consumption. This type of information collection and analysis capability may also preferably enable the capability to detect electric service meter malfunctions and/or calibration errors that may otherwise go undetected.
In variations of any of the optional and preferred embodiments of the invention, a power consumption monitoring system is also contemplated for monitoring the power transmitted by one or more electrical conductors. The system preferably includes one or more current-to-voltage transformers or CVTs that have a passive, open-circuit electromagnetic force (EMF) sensor or concentrator. The EMF concentrator or sensor is positioned near, adjacent, or next to one of the current-carrying electrical conductors. The open-circuit EMF concentrator can preferably include a ferromagnetic core that is wound with a wire coil, which responds to or captures the electromagnetic field or signal produced by the electrical conductors. The CVT is adapted to generate a voltage potential or an amplitude or scalar signal that is proportional to the power being transmitted through the conductor(s).
The power consumption monitoring system also may preferably include one or more first programmable radios on a chip or PROCs that are electrically connected to and which communicate with the CVT(s). The first PROC(s) are configured to transmit the amplitude signal and/or other information to other devices in the monitoring system and/or to receive information therefrom. The first PROCs include software or programming instructions or firmware that reside(s) in a storage or nonvolatile memory on the first PROC(s). The resident software of the first PROC, among other capabilities, is operative to periodically sample, store, and convert the amplitude signal to a digital quantity that represents the amplitude of the power being transmitted through the conductor(s). Also, the PROC(s) are responsive to and communicate with other devices in the monitoring system to transmit the digital quantity for further analysis or use or retransmission, and/or to receive information from other devices for configuration purposes and/or for collection, A monitoring device is also preferably included as a component of the power consumption monitoring system and includes, among elements, a second PROC, one or more second programmable systems on a chip or second PSOC(s), a multi-digit, numeric, alphanumeric, graphical, rectilinear, and/or multidimensional information display, and in some preferably optional arrangements, input, selection, manipulation, and/or configuration switches operative to control some capabilities of the monitoring device. The second PROC and the PSOC(s) may also include monitoring software that is programmed into the second PROC and/or the second PSOC(s), and which is operative to periodically communicate with the first PROC(s) to receive and store the scalar or amplitude signal or digital quantity and to display the digital quantity on the display in a unit of power consumption, and to respond to the input switch(es), and/or to receive information from other devices. In additionally preferred and optional embodiments of the novel power monitoring system, the monitoring device can also have the monitoring software adapted to collect a plurality of the digital quantities and to convert the collected plurality of digital quantities into an historical power consumption quantity, which can be shown on the display, and that can be communicated to other devices.
In yet other alternatively preferred configurations, the inventive power consumption monitor may further incorporate a radio frequency booster module, which can also include a third PROC and a third PSOC and which may communicate with any of the first and second PROC(s) to receive and retransmit the amplitude signal and/or the digital quantity an additional distance to the monitoring unit. Also, optionally preferred booster software that may reside on the third PROC and/or the third PSOC, and which operates to calibrate, quantify, and/or store the received amplitude signal and/or digital quantity, and to periodically retransmit the digital quantity the additional distance to the monitoring unit, and/or to receive and/or retransmit any other information from other devices within and without the contemplated monitoring system. Any of the first, second, and/or third PROCs may also further preferably include optional signal strength and quality information gathering capabilities that may be collected, stored, analyzed and retransmitted to any other device within or outside the power consumption monitoring system, which information can be further used to assess and/or improve the accuracy of any of the contemplated information of the monitoring system.
Particularly preferred embodiments of the innovative power monitoring system may include a computing device or a computer that may typically include a storage device, a memory, a display, one or more input devices such as a keyboard and/or a mouse pointing device, and any number of wired and/or wireless communications ports. Preferably, the computer or computing device incorporates or contains one or more software programs or elements thereof, which are resident on the computer or computing device.
Such software programs or elements are optionally and changeably configured to occasionally, upon demand, periodically, and/or continuously record the amplitude signal and/or digital quantity to an historical database of power consumption information on the storage device. The software program or programs or elements or routines thereof may acquire, be populated with, and/or access power cost information from a utility supplier, and may also compute an actual, total, average, estimated, or predicted cost of power that has been or is expected to be consumed per unit time by an entire facility and/or an individual appliance and/or group of equipment or appliances or devices, using the information stored in the historical database. Further variations enable comparison of such actual and predicted consumption information to comparable facilities, equipment, and appliances so that consumers, producers, suppliers, distributors, utility service organizations or entities, and any interested party may better assess and manage the efficiency of power use and associated costs.
In further optionally contemplated alternatives, the software programs or elements thereof may also contain or be populated with one or more predetermined and/or predefined alarm conditions or event notification parameters, and may be enabled to compare such alarm conditions or event parameters with the amplitude signal, digital quantity, and/or any other contemplated information to determine if the alarm condition is met. If so, then an alarm event or event parameter notification can be triggered and communicated to other devices in the power monitoring system, or to users or consumers by electronic message, a voice response alert system, a displayed or audio-visually annunciated alarm, a text message, an audio or visual alarm annunciator or klaxon, fax or other means of communication described elsewhere herein. Additionally preferred variations of the invention may also communicate with automated emergency power generator systems and equipment to enable instantaneous and/or rapid backup power supply augmentation or replacement as needed to accommodate power grid service interruptions, brown-outs, or unavailability.
As also described elsewhere herein, such communications may preferably have special importance in the special situations relevant to individuals or organizations that provide services to such individuals who may be experiencing short or long-term disabilities, acute or chronic illnesses, or that have other extraordinary or special needs requirements related to their electricity and power use and consumption.
These variations, modifications, and alterations of the various preferred and optional embodiments may be used either alone or in combination with one another and with the features and elements already known in the prior art and also herein contemplated and described, which can be better understood by those with relevant skills in the art by reference to the following detailed description of the preferred embodiments and the accompanying figures and drawings.
BRIEF DESCRIPTION OF THE DRAWING(S)
Without limiting the scope of the present invention as claimed below and referring now to the drawings and figures, wherein like reference numerals across the drawings, figures, and views refer to identical, corresponding, or equivalent elements, methods, components, features, and systems:
FIG. 1 shows a main sensor unit in accordance with the present invention.
FIG. 2 shows the main sensor unit of FIG. 1 removed from its housing.
FIG. 3 is a schematic of a signal generator or transceiver or transmission circuit in accordance with the present invention.
FIG. 4 shows a clip-on sensor in accordance with the present invention.
FIG. 5 shows a monitoring and display unit connected with a computing device in accordance with the present invention.
FIG. 6 is a schematic of a radio frequency signal generating or transceiver or transmission circuit of the monitoring and display unit in accordance with the present invention.
FIG. 7 is a functional schematic of an RF repeater or booster module of the power consumption monitoring system in accordance with the present invention.
FIGS. 8 and 9 are functional schematics and flow diagrams illustrating the polling operation and flow of communications and information of the power consumption monitoring system in accordance with the present invention.
FIG. 10 is an example of information that may be displayed by the software resident on a computing device of the power consumption monitoring system in accordance with the present invention.
FIG. 11 is an example of a utility cost information input screen of the resident software of the system in accordance with the present invention.
FIG. 12 is an example of an additional utility, device, and appliance information input screen of the resident software of the system in accordance with the present invention.
FIG. 13 shows a graphic representation of power consumption displayed by the resident software of the system in accordance with the present invention.
FIGS. 14 and 15 are graphic representations of alarm condition parameter input screens of the resident software of the system in accordance with the present invention.
FIG. 16 shows an entry screen to select graphic display parameters of the resident software of the system in accordance with the present invention.
FIG. 17 shows a graphical comparison of total power consumption of a facility along with power consumption of individual appliances for a period of time as displayed by the resident software of the system in accordance with the present invention.
FIG. 18 is a graphical representation of a utility-rate overlap graph displayed by the resident software of the system in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, the expression “CVT” means a current-to-voltage transformer, which is described in more detail elsewhere herein and in the above noted U.S. Pat. Nos. 4,717,872 and 4,754,218. The term “EMF” means electromagnetic force. The abbreviation “PROC” means programmable radio on a chip, which is a transceiver capable of bidirectional communications and which is described in more detail elsewhere herein. The term “PSOC” means programmable system on a chip and an example is described elsewhere herein. The term “RF” denotes the phrase “radio frequency”.
Referring now to the various figures and illustrations, those skilled in the relevant arts should appreciate that each of the preferred, optional, and alternative embodiments of the inventive power consumption monitoring system 10 contemplates interchangeability with all of the various features, components, modifications, and variations illustrated throughout the written description, claims, and pictorial illustrations.
With this guiding concept in mind, and with reference now to FIG. 1 , one possible embodiment of a main sensor unit 12 is illustrated, which is attached to a current-carrying, electrical power supply conductor “C” that may be located on an exterior of a building or facility and that supplies power to an electric service meter E. In other arrangements not shown here but likely apparent to those knowledgeable in the arts, the main sensor unit 12 may also be positioned proximate to or may be attached to the conductor C in interior locations such as inside a circuit breaker panel or other type of distribution enclosure or service junction, and/or branch conductor or subcircuit.
In further preferred but optional configurations contemplated by the inventive system 10 , the sensor unit 12 may be integrated into circuit breakers, circuit breaker panels, subcircuit or branch conductors. The sensor unit 12 and other devices of the novel monitoring system may also preferably be reconfigured for use in all types of peripheral monitoring applications including integration into or with discrete power-consuming equipment, electric loads of all kinds, and/or any electric power-consuming appliance or device. The main sensor unit 12 may also preferably include a non-conductive and weather-proof housing 14 that protects the components of the unit 12 , and which can be attached to the conductor C with a fastening device such as, but not limited to, hook and loop type straps 16 that are also known as VELCRO® straps.
With continued reference to FIG. 1 and now also to FIGS. 2 and 3 , it can be understood that the main sensor unit 12 may incorporate a signal transceiver, communication and/or transmission circuit or radio frequency (RF) signal generator 20 that includes an amplitude signal generator or core 22 similar to that disclosed and claimed in the previously noted '218 patent. The signal transceiver or transmission circuit 20 may be powered by a replaceable and/or rechargeable battery or batteries B, such as one, two, or more AA-sized batteries, or by a solar cell (not shown), or by any other suitable power source including inductive and other types of power supplies that may parasitically obtain power from the conductor that is being monitored.
The core 22 may be a Hall Effect sensor or a CVT that incorporates a passive, open-circuit EMF sensor or concentrator. Preferably, the core 22 is positioned in the housing 12 so that when the housing 12 is affixed to the conductor C, the core 22 is proximate to the conductor C. In this arrangement, the CVT or core 22 will generate an amplitude signal across the terminals 24 ( FIG. 3 ) in the form of a voltage differential or potential, which is proportional to the power being transmitted through the current-carrying conductor C.
More preferably, and as may be comprehended with continued reference to FIGS. 1 , 2 , and 3 , and with reference now also to FIG. 4 and the '218 and '872 Patents, the open-circuit EMF sensor or concentrator or core 22 may be formed as a ferromagnetic core that is wound with a wire coil to be responsive to the electromagnetic field or signal produced by and proximate to the electrical conductors C. The response of the open-circuit coil results in a voltage differential across terminals 24 , which establishes the contemplated amplitude or scalar signal.
The described signal-generating transceiver or transmission circuit 20 may incorporate a number of discrete components and/or single chip-type combined or integrated components. In one optionally preferred arrangement, the signal transceiver or transmission circuit 20 incorporates a power supply circuit 24 that incorporates a voltage regulator 26 configured to protectively supply power to the circuit 20 . Any number of equally suitable power supply circuits may also be used, and one possibly preferred type of voltage regulator can be the ON Semiconductor LM2931 series Low Dropout Voltage Regulator, model LM2931-5.0, which is described for purposes of example but not limitation.
The signal communication and/or transmission circuit of FIG. 3 may also further incorporate either a single, first PROC in the form of a discrete component, or may incorporate both the first PROC as well as a PSOC that can augment the capabilities, programmability, and reconfigurability of the main sensor unit 12 . In one exemplary arrangement of the signal transceiver or transmission circuit 20 , the EMF concentrator 22 is in bidirectional communication with the PSOC 34 , which can be a Cypress Semiconductor Corporation PSOC Mixed Signal Array, model CY8C27143. In this possibly preferred arrangement, the PSOC 34 receives the amplitude signal at terminals 24 and communicates with the first PROC 32 , which may be any number of suitable PROC transceiver components such as, for purposes of example without limitation, a Cypress Semiconductor Corporation PROC transceiver, model CYWUSB6953. This and other similarly capably PROCs may preferably be modified to generate and to capture signal strength information that may be sampled, collected, and used to establish signal reliability indicia and related information that can be further used to assess quality and reliability of the other contemplated information described elsewhere herein. (See, e.g., FIG. 17 ).
In any of the optionally preferred arrangements of the signal transceiver or transmission circuit 20 , the first PROC 32 and/or PSOC 34 may be programmed with firmware or software instructions contained in the nonvolatile flash memory of either component 32 , 34 , which instructions are operative to periodically sample the amplitude signal and to convert and store the sampled amplitude signal, in a portion of the nonvolatile memory, as a digital quantity that represents the magnitude of the power being transmitted through the conductor C. Additionally, the software instructions may be further operative to periodically communicate with and to transmit the digital quantity and/or receive information from other devices, via an antenna 36 that is typically integrated with the PROC 32 , to other devices or components of the power consumption monitoring system 10 as described elsewhere herein.
Any of the various optionally preferred embodiments of the inventive signal transceiver or transmission circuit 20 may further be adapted with software instructions that enable the circuit 20 to hibernate for a majority of the time to conserve power, to receive calibration, configuration, and/or other information, and/or to periodically transmit the scalar or amplitude signal and/or the digital quantity after a preset amount of time has elapsed, or to transmit only in response to occasionally and/or periodically received polling requests from other devices and/or components of the power consumption monitoring system as described elsewhere herein, or in any combination of periodic time intervals and/or polling requests.
With continued reference to the various figures and now also specifically to FIG. 4 and the '218 patent, the main sensor unit 12 may be replaced by or accompanied by a peripheral and/or clip-on sensor or clip 40 , which may be sized to be smaller or to have a different three-dimensional geometry than the main sensor unit 12 . The possibly preferable modified geometry may be identical or similar to sensor unit 12 , and may be further modified to be more suitable for attachment to smaller power cables or cords. In other optionally preferable variations of any of the contemplated embodiments, the peripheral or clip sensor 40 may also be integrated into individual circuit breakers, subcircuit and/or branch conductors, individual equipment, as well as individual devices and appliances.
In any of such contemplated arrangements, the peripheral or clip sensor 40 may be customized to monitor the power consumption of a particular machine, a single appliance, or other device in any number of configurations that may be best suited to the particular preferences of consumers or suppliers or the relevant power-monitoring application. It may also be possibly preferred to have the peripheral sensor or clip 40 attach to such power cables or cords with a spring or spring-clamp fastener 42 or the hook and loop-type straps or fasteners 16 described elsewhere herein.
Peripheral sensor or clip 40 may preferably incorporate the same EMF sensor or core 22 or RF signal generator or signal transceiver or transmission circuit 20 or a similar circuit. In additional variations to the contemplated peripheral sensor or clip 40 and the main sensor unit 12 , each or either may be further adapted to produce the amplitude signal and/or digital quantity, or to ascertain and transmit the on-and-off state or condition of equipment or any device that is to be monitored.
In this way, either or both the main sensor unit 10 or the peripheral sensor or clip 40 can transmit the on-or-off status of anything that is being monitored for power consumption. In this possibly desirable, alternative configuration, it may be further preferred to employ multiple peripheral or clip sensors 40 and/or one or more additional main or peripheral sensor units 12 attached to a primary grid supply conductor, and/or to subcircuit or branch conductors so that power consumption can be compared to determine the difference in power consumption between the on and off conditions of anything that is being monitored, which enables a determination of power use by groups of equipment and/or individual appliances.
With reference now also to FIGS. 5 and 6 , the new power consumption monitoring system of the invention also incorporates a RF signal monitor and display, or monitoring device or unit 50 that is integrated with one or more communications ports that may include universal serial bus ports, fire wire or 1394 ports, serial ports, IC2 ports, network ports, infrared ports, and/or any other desired communications ports readily known to those skilled in the relevant arts. The monitoring device 50 may further include one or more display panels 52 that may preferably include a multiple digit, numeric, alphanumeric, graphical, rectilinear, and/or multidimensional information display 54 , which also may include one or more device on-off condition or state graphical icons or pips 56 , and one or more input or configuration or selection switches 58 adapted to manipulate or modify or configure or convert the information shown on the display 54 and/or to modify the configuration and/or the operation of the monitoring device 50 and/or the resident software and/or monitoring system 10 . The monitoring device also preferably incorporates a RF signal generating or transceiver or transmission circuit 60 ( FIG. 6 ) that may further include a second PROC 62 .
With respect to the contemplated switches 58 , one possible type of such manipulation that can be enabled by switches 58 may be to convert the displayed dimensional units of power consumption information or to select or change what or which portion of type of information is displayed. Other capabilities of such switches may preferably include the optional modification of the periodicity of polling of the sensor devices 12 , and/or any other aspect of the function and/or operation of the monitoring system 10 . The exemplary illustrations and figures reflect a limited number of such switches 58 . However, further contemplated and optionally preferred embodiments of the instant invention may also incorporate a greater or lesser number of such switches ranging from zero switches to an alphanumeric and function keyboard having all possible combinations of alphanumeric characters in any language, and which may be similar to any known alphanumeric and function keyboard presently known and contemplated by those having skills and knowledge in the relevant arts and as depicted in connection with the illustrations reflecting computing device 80 (See, e.g., FIG. 5 ).
The monitoring device 50 may further include a second PSOC 64 to be in communication with the second PROC 62 and the display 54 . The contemplated second PROC 62 and PSOC 64 may be selected from any of the discrete components or combinations thereof described as being suitable for use with the signal transceiver or transmission circuit 20 , or may be selected from any number of similarly capable or configured devices, sensors, or discrete components.
The monitoring device 50 also preferably includes monitoring software resident on or contained in the nonvolatile flash-type memory that is typically or optionally available for use with the second PROC 62 . More preferably, the monitoring software is configured to occasionally, on demand, or periodically communicate with, send information to, and/or to poll the first PROC 32 to request transmission of the scalar or amplitude signal or digital quantity or other information, which is then received and stored by the second PROC 62 and/or PSOC 64 .
The monitoring software is preferably further operative to convert the digital quantity to a unit of power consumption, such as a number referred to herein as a “Power Equivalent,” which may be, for purposes of illustration but not for purposes of limitation, a four-digit number from 0000 to 9999. This power equivalent number may represent the power being consumed in arbitrary units, a unitless number, a “true” reading of actual power usage in kilowatts, as a number that represents the cost per unit time of power being consumed, a running or historical average or total of power being consumed, and/or a cumulative or periodic total of power consumed, or any other conceivable quantity that represents desired or relevant power consumption information. The contemplated Power Equivalent may be translated or converted into an actual kilowatt amplitude of total facility power consumption or individual appliance consumption, a ratio or percent of power consumed by a respectively monitored appliance, an actual total facility cost of power consumed, a cost or cost ratio or cost percentage for an individually monitored appliance or for all monitored appliances, or a cost per kilowatt number as also described elsewhere herein. See, e.g., FIGS. 5 and 9 .
In even more preferable modified embodiments of the inventive power consumption monitoring system 10 ( FIGS. 5 , 7 , 8 , 9 ), the monitoring and display device 50 is configured as a master device wherein the second PROC 62 and the second PSOC 64 control and poll the first PROC 32 and the first PSOC 34 as slaves. Even more preferably, the master second PROC 62 and second PSOC 64 control one or more or a plurality of slave first PROCs 32 and PSOCs 34 in the main sensor unit or plurality of units 12 as well as the clip-on sensor 40 and a plurality thereof.
In one optionally preferred mode of operation, the second PROC 62 and/or
PSOC 64 of master monitoring and display device 50 transmits requests for data to the main sensor unit(s) 12 and the clip(s) 40 . The master second PROC 62 and PSOC 64 also may be configured to hibernate between polling requests to conserve energy, and to occasionally or upon demand/or periodically activate or “wake up”, such as once every second, to poll or request information from the slave first PROCs 32 and/or PSOCs 34 . With continued reference to FIGS. 1 through 5 and now also to FIGS. 6 , 7 , 8 , and 9 , the contemplated master-slave arrangement and polling and information request operations are illustrated in more detail in schematic and functional representations.
Any of the optional and preferred embodiments of the invention may be further modified to operate in combination with an RF repeater or booster module 70 , which is functionally depicted in FIGS. 7 and 9 in operation with other components of the contemplated power consumption monitoring system 10 of the invention. More specifically, the contemplated RF repeater or booster module 70 may preferably incorporate a third PROC 72 and a third PSOC 74 that may be the same as or similar to the PROCs and PSOCs described in connection with the first and second PROCs 32 , 62 and PSOCs 34 , 64 .
The third PROC 72 and PSOC 74 are adapted to communicate with the first and second PROCs 32 , 62 and PSOCs 34 , 64 to receive and retransmit the amplitude signal or other information 76 ( FIGS. 7 , 8 , 9 ) an additional distance 78 to the monitoring unit 50 . As also discussed elsewhere herein, bidirectional communications may preferably or optionally be incorporated so that the booster software or any other contemplated device or component of the invention may communicate calibration, configuration, polling requests, and other information between any other contemplated device of the monitoring system 10 . Further, booster software is preferably loaded into the nonvolatile flash memory of the third PROC 72 and/or PSOC 74 and/or other element, and may be operative in one aspect to poll or request the amplitude signal and/or digital quantity information and/or other information from the first PROC 32 and PSOC 34 .
More preferably, the contemplated booster software may preferably receive signals and information from the main and peripheral sensors 12 , 40 and use those received signals and information to calibrate and/or normalize the information to enable more accurate reporting and computation of the contemplated power consumption and related information. In optionally preferred configurations, the booster software or portions or routines therein receives and stores the amplitude signal, digital quantity, signal strength, and/or other received information obtained from the main sensor unit or units 12 and the peripheral or clip-on sensor or sensors 40 .
In further preferred variations, the booster software also may periodically retransmit the scalar or amplitude signal and/or digital quantity, and/or any other information the additional distance 78 to the monitoring unit 50 . When needed or as preferred, the monitor unit 50 may be physically remote from the booster module 70 and the sensors 12 , 40 . In other equally preferred and optional variations, the monitor unit 50 may be situated proximate to the booster module 70 and/or the main and peripheral sensors 12 , 40 . The booster software calibrates the amplitude signal and/or digital quantity to a reference value in units of power consumption that for purposes of example but not limitation can be kilowatt-hours.
In additionally preferred and optionally suitable variations of any of the configurations of the monitoring system 10 , the booster module 70 is more preferably arranged with an ohmic connection to the monitored power grid. In other modifications, reactive, inductive, and/or other types of connections may be more suitable. The optionally preferred ohmic connection may in certain applications enable more accurate sensing of power grid reference or baseline or nominal voltages, currents, frequencies, or other parameters. The ohmic connection may be accomplished by positioning or mounting the booster module 70 in a standard power outlet or receptacle, and may also be connected in any other way such as with an alligator-type spring clip, a soldered connection, a clamp-on connector, an inline connector, or other similar means.
The booster module also preferably includes what is often referred to by those skilled in the relevant arts as a precision resistor or similar connoted device, which may be occasionally, on demand, and/or periodically switched on to enable very accurate load, power, voltage, and/or current information to be ascertained. Such very accurate information can then be captured and compared to the signals and similar information received from the main and peripheral sensors 12 , 40 .
During initial installation and with continued operation, the resident software of the various components and the booster software include a portion or a routine that ascertains the nominal amplitude and/or digital quantity linear power response slope of each of the main and peripheral sensors 12 , 40 . The booster software uses the respective response slopes and the periodic signals and information received from each main and peripheral sensor 12 , 40 , as well as the very accurate load information obtained using the precision resistor to calibrate, baseline, normalize, and/or correct the signals and information received from each main and peripheral sensor 12 , 40 . In this way, each sensor 12 , 40 is periodically recalibrated to maximize accuracy. The resident and booster software may be configured to regularly sample and accumulate signal and other information from one, some or all such sensors 12 , 40 and to apply well-known statistical methods to optimize calibration and accuracy of the signals and other information.
Even more preferably, the RF signal generator and booster module 70 is configured to be used so that the third PROC 72 and PSOC 74 will automatically seize control from the monitoring device 50 of the slave first PROCs 32 and PSOCs 34 . Most preferably, the booster software and the monitoring software are preconfigured to automatically detect the mutual presence of one another. Thus, when the booster module 70 is operationally positioned within the range of the signal transceiver or transmission circuit(s) 20 of the main sensor unit(s) 12 , the clip-on sensor(s) 40 , and the monitor and display unit 50 , the monitor unit 50 automatically relinquishes its master polling status. More preferably, the monitor unit 50 will then also display the information communicated by the booster module 70 , and may even more preferably retransmit such information via wired or wireless communications to other components and devices of the monitoring system 10 .
The main and peripheral sensor unit(s) 12 and the peripheral clip-on sensors 40 assume what can be referred to as a primary slave status that operates in response to communications from or polling or information requests from the booster module 70 . Further, the monitor and display unit 50 may also be manually relegated or may automatically relegate itself to a secondary slave status whereby it passively receives transmissions from the booster module 70 and responds by recording, processing, displaying, and communicating the received amplitude signals and/or digital quantity information. Once the monitor and display unit 50 receives and records the amplitude signals and/or digital quantity information, such can be displayed or further communicated to other components of the power consumption monitoring system as described elsewhere herein.
Any of the embodiments of the novel and inventive power consumption monitoring system may be further modified to incorporate one or more computing devices and/or computers 80 ( FIGS. 5 , 8 , 9 ) that may be proximate or remote to any of the system components already described. The one or more computing devices and/or computers 80 may preferably include a storage device, a nonvolatile and/or volatile memory, a display, a keyboard and pointing device, and any of a number of communication ports already described elsewhere herein.
More preferably, the computing device or computer 80 is in communication with the monitoring device 50 via any one or more of the contemplated communications ports and contains a software program and/or elements thereof resident on one or more of the storage device and/or the volatile and/or nonvolatile memory. The storage device and/or the volatile and/or nonvolatile memory may be selected from what are known to those skilled in the art as hard disk drives, flash memory drives, volatile random access memories (RAMs), and any other type of nonvolatile RAMs and similarly capable devices.
Even more preferably, and with reference now also to FIGS. 8 , 9 , and 10 , the resident software program and/or elements thereof includes one or more routines to receive the amplitude signal and/or digital quantity information or other information from the monitoring device 50 and to periodically record this information to an historical database of power consumption information on one or more of the storage device or memories, and to display such information in various forms. As also described elsewhere herein, the resident software program or programs may be configured to enable auditing of utility service bills and invoices and may further be used to compare actual power use adduced by the monitoring system 10 to the use recorded by the electric meter E ( FIG. 1 ), which can enable detection of malfunctioning or improperly calibrated electronic or mechanical utility service meters.
Most preferably, the software program and elements thereof may optionally or preferably include routines to input, store, and/or access local or remote power cost information such as utility supplier cost rates ( FIGS. 11 , 12 ), and to compute actual and projected costs for power consumption as a function of the amplitude signal and/or digital quantity information and the historical database power consumption information. Further, such computed and projected costs may be displayed as shown in FIGS. 5 , 9 , and 10 . As may also be seen in FIGS. 10 , 13 and 16 , such current, historical, and projected power consumption information may be numerically and/or graphically displayed on the display of the computer 80 by additional routines of the resident software program.
Additionally preferred variations of any of the embodiments of the invention may also contemplate the resident software program and elements thereof to include one or more routines that (a) input, store, and access one or more predefined alarm conditions, (b) compare the amplitude signal and/or digital quantity information to each such condition, and (c) communicate an alarm event when such conditions are met by the amplitude signal and/or the digital quantity information.
The power consumption monitoring system contemplates many possible alarm conditions, FIG. 14 , that can be predefined as desired and that may include, for purposes of non-limiting examples, a facility or campus-wide total power consumption alarm condition that may be triggered if the total power being consumed exceeds a predetermined amount. An example of this total power condition may be modified so that any power consumption above zero triggers the alarm event if power is consumed during time periods when no power consumption is expected, such as in a commercial facility that is usually inoperative during nights, weekends, or holidays. (See, e.g., FIGS. 9 and 14 ).
In this way, the facility can be protected against unauthorized, off-hours use. Further, such a facility can be protected against unexpectedly wasteful or inefficient power consumption due to malfunctioning equipment or devices by setting the total power consumption alarm condition to a predetermined maximum amount. A residential property may be similarly protected by setting a total power consumption alarm condition that corresponds to a maximum power consumption expectation. Any type of residential or other facility may also be monitored with similarly configured alarms that can trigger an audit of utility service bills, and may be profiled to establish baseline or nominal power consumption profiles or expectations.
The resident software program and elements thereof may also include routines configured to monitor single devices and/or appliances as can be understood with reference to FIGS. 9 and 15 . Individual appliances may be associated with one or more main sensor units 12 and/or clip-on sensors 40 so that power on and off conditions maybe be identified, and so that actual power consumption may be ascertained and stored. Also, predefined alarm conditions may be established so that an inefficient and/or malfunctioning appliance or other device may be readily identified, which can avoid wasted power consumption. As discussed in more detail herein, such predetermined or predefined alarms may preferably be set to trigger notifications to service providers seeking to obtain early warnings of possible issues related to individuals with special needs that are associated with a disability, illness, or other extraordinary set of circumstances.
In yet even more preferred or alternative modifications to any of the preceding resident software and elements thereof, as may be comprehended with reference now also to FIGS. 16 , 17 , and 18 , routines may be incorporated that enable and contemplate numerous graphical display capabilities that may be arranged by selected periods of time ( FIG. 16 ), that enable review and comparison of power consumption of an entire building or facility with individual appliances or devices ( FIG. 17 ), and which enable comparison of power consumption per unit time against actual utility supplier rates that may also vary during the overlapping period of time ( FIG. 18 ).
Such utility supplier rates and historical power consumption information such as total kilowatt-hours used gleaned from monthly electric utility supplier invoices or bills may be input via a data entry routine of the resident software as illustrated by the input screens of FIGS. 11 and 12 , and which also enables the association of specific devices or appliances with respective main sensor units 12 and/or clip-on sensors 40 . Using the information entered from such electric bills, and using the historical power consumption database information, the resident software program may convert the power equivalent units established by the power consumption monitoring system into actual kilowatt hours, a ratio or percent of power consumed by a respectively monitored appliance, an actual total facility cost of power consumed, a cost or cost ratio or cost percentage for an individually monitored appliance or for all monitored appliances, or a cost per kilowatt number as also described elsewhere herein. This will have great prospective benefit for the user, as the user can proactively modify the power consumption profile of the building and/or appliances to conserve power and reduce costs.
The first time that the user inputs information from the electric bill using the software, the conversion from power equivalents to kilowatt hours may have a predictive margin of error of, for example, perhaps approximately 10 percent. However, each time that a user inputs additional information from a new electric bill, the margin of error will be reduced, as the resident software program gains a larger and more statistically robust sample size of historical billings or actual power usage and costs.
The graph of FIG. 18 enables users and consumers to adjust power consumption to periods of time when costs for power are less expensive. In operation, the graphical representation of FIG. 17 illustrates the varying power usage during the course of the selected period of time, which can enable users to identify and adopt power use expectations or baselines of times and durations of operation of equipment or devices, which in turn enables the user to identify unexpectedly operating and/or inefficiently performing appliances, equipment, and devices.
Additional functionality of the resident software and elements and routines thereof may preferably include the capability to send periodic usage data and alarm events or alerts to the user via e-mail, text message, voice mail using a voice response capability, by fax, by remote web server communicating with remote user web-browser applications, and by any other desired communication method. (See, e.g., FIG. 9 ). Such additional communication capabilities may be of increased significance in the aforementioned special needs situations where it may be important to enable early warning or immediate intervention for those individuals or facilities needing a reliable and uninterrupted supply of electricity. In this way, any anomalous power consumption may be readily identified and redressed. The software may also preferably access and store power consumption usage information pertaining to devices, appliances, homes, and/or businesses having similar profiles to those being monitored so that the user can compare his or her power usage with a typical or comparable power usage profile.
Using various arrangements of the contemplated main sensor units 12 , clips 40 , monitor units 50 and resident software program routines of the present invention, users may gain information about power consumption in a variety of applications and environments, which enables users to make adjustments and take corrective action regarding possibly inefficient power consumption. For example, the user may have learned over the course of time that an oven in a house usually consumes 40 Power Equivalents when in use, but that it is now consuming significantly more or less, leading to a determination that one of the burner coils is malfunctioning.
In another example, parents may use the system to determine whether their children are using too many electronic devices at one time, such as having a TV, stereo, air conditioner, and computer all in use at the same time, and perhaps unnecessarily. Parents can thus use the system to enable children to manage their power consumption within a predetermined “power budget” for a given period of time such as a week, and can increase or decrease allowance or other incentives to gain cooperation.
INDUSTRIAL APPLICABILITY
The embodiments of the present invention are suitable for use in many applications that involve the requirement to monitor power consumption of residential, commercial, and industrial equipment, appliances, devices, buildings, facilities, and campuses. The various configurations and capabilities of the inventive power consumption monitoring devices, systems, and methods of use can be modified to accommodate nearly any conceivable power consumption monitoring requirement. The arrangement, capability, and compatibility of the features and components of the novel monitoring devices, systems, and methods of use described herein can be readily modified according to the principles of the invention as may be required to suit any particular power supply or power consuming device, or power consumer or user, and can be especially modified to accommodate applications involving individuals and service providers in special needs situations that require a reliable and an uninterrupted supply of electricity.
Such modifications and alternative arrangements may be further preferred and/or optionally desired to establish compatibility with the wide variety of possible applications that are susceptible for use with the inventive and improved power consumption monitoring devices, systems, and monitoring methods that are described and contemplated herein. Accordingly, even though only few such embodiments, alternatives, variations, and modifications of the present invention are described and illustrated, it is to be understood that the practice of such additional modifications and variations and the equivalents thereof, are within the spirit and scope of the invention as defined in the following claims. | A power consumption monitor, system, and method for monitoring power consumed by equipment, appliances, devices, buildings, and campuses is accomplished by passive sensors ( 12, 40 ) that detect power transmitted by individual conductors (C), and which include a current to voltage transformer with a passive, open-circuit electromagnetic force concentrator ( 22 ) positioned near the conductor (C). The sensor ( 22 ) generates an amplitude signal proportional to the power passing through the conductor (C). Programmable radios on a chip ( 32, 62, 72 ) and systems on a chip ( 34, 64, 74 ) are used to transmit the amplitude signal to a monitor ( 50 ) that displays the power being consumed along with actual and estimated cost and historical information. Software programs are implemented across the sensors ( 12, 40 ) and monitors ( 50 ) and a remote computer ( 80 ) to enable real-time monitoring power consumption with a resolution that spans from entire campuses down to single devices. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention describes the use of recombinant DNA technology for the design and synthesis of novel, modified interferons. More specifically the invention relates to interferons not known in nature, which are intended for use in viral and neoplastic diseases, and immunosuppressed and immunodeficient conditions.
2. Description of the Prior Art
The interferons are a class of proteins that occur in vertegrates and act as biological regulators of cell function which include increasing resistance to pathogens, limiting cell growth and modulating the immune system. The most studied property of the interferons is their ability to convert cells into an "antiviral state" during which they are more resistant to virus replication (Lengyel, Annual Review of Biochemistry, 51, 251, 1982). In addition to conferring antiviral resistance to target cells, interferon (IFNs) have antiproliferative (antigrowth) properties (Stewart, 1979, The Interferon System, Springer, Berlin). It has clearly been shown that interferons produced naturally act as antiviral and antiproliferative agents (Gresser et al, Biochim. Biophys. Acta, 516, 231, 1978; J. Exp. Med., 144, 1316, 1976).
The IFNs, by virtue of their antigenic, biological and physico-chemical properties, may be divided into three classes: type I, IFN-α ("leucocyte") and IFN-β ("fibroblast"); and type II, IFN-γ ("immune") (Stewart et al, Nature, 286, 110, 1980). Both genomic DNA and cDNA clones of type I and type II IFNs have been isolated and sequenced, and the potential protein sequences deduced (e.g. Pestka, Arch. Biochem. Biophys, 221, 1, 1983). Whilst in man only one IFN-β and IFN-γ gene are known, human IFN-α is specified by a multigene family comprising at least 20 genes. The classification of IFN-β and IFN-α as type I interferons is in part determined by their significant degree of homology, >23% at the protein level (Taniguchi et al, Nature, 285, 547, 1980).
Whilst the mechanism of action of interferons is not completely understood, certain physiological or enzymatic activities respond to the presence of the interferons. These activities include RNA and protein synthesis. Among the enzymes induced by interferons is (2'-5') (A)n synthetase which generates 2'-5' linked oligonucleotides, and these in turn activate a latent endoribonuclease, RNAse L, which cleaves single-stranded RNA, such as messenger RNA (mRNA) and ribosomal RNA (rRNA). Also induced by IFNs is a protein kinase that phosphorylates at least one peptide chain initiation factor and this inhibits protein synthesis (Lengyel, ibid, p. 253). IFNs have been shown to be negative growth regulators for cells by regulation of the (2'-5') An synthetase activity (Creasey et al, Mol. and Cell Biol., 3, 780, 1983). IFN-β was indirectly shown to be involved in the normal regulation of the cell cycle in the absence of inducers through the use of anti-IFN-β antibodies. Similarly, IFNs have been shown to have a role in differentiation (Dolei et al, J. Gen. Virol., 46, 227, 1980) and in immunomodulation (Gresser, Cell. Immunol., 34, 406, 1977). Finally, IFNs may alter the methylation pattern of mRNAs and alter the proportion of fatty acids in membrane phospholipids, thereby changing the rigidity of cell membranes.
These and other mechanisms may respond to interferon-like molecules in varying degrees depending on the structure of the interferon-like polypeptide. Preliminary evidence (UK Patent No. GB 2 090 258A) suggests that members of the multigene IFN-α family vary in the extent and specificity of their antiviral activity (Pestka, ibid.). For example, combination of IFN-αA with IFN-αD resulted in "hybrid" genes which show antiviral properties that are distinct from either parent molecule (Weck et al, Nucl. Acids Res., 9, 6153, 1981; De La Maza et al, J. IFN Res., 3, 359, 1983; Fish et al, Biochem. Biophys. Res. Commun., 112, 537, 1983; Weck et al, Infect. Immuno., 35, 660, 1982). However, hybrid human IFNs with significantly increased human cell activity/specificty have not yet been developed. One Patent has been published describing IFN-β/α hybrids (PCT/US83/00077). This patent describes three examples, none of which have significantly improved activity. The three examples were constructed using two naturally occurring restriction sites. The resulting hybrid interferons were (1) alpha 1 (1-73)-beta (74-166); (2) beta (1-73)-alpha 1 (74-166); and (3) alpha 61A (1-41)-beta (41-166). These three examples differ structurally from the examples of the present invention. These three examples were based upon the accidental location of two restriction sites and not upon the intentionally designed DNA and amino acid sequences of the present invention.
It is envisaged that a modified interferon will display a new advantageous phenotype. The design and synthesis of new interferon-like polypeptides composed of portions of IFN-β and other amino acid sequences is advantageous for the following reasons:
1. New IFNs can be created which show a greater antiproliferative to antiviral activity (and vice versa) resulting from the selective activation of only some of the normal interferon-induced biochemical pathways.
2. The affinity of hybrid or modified IFNs for cell surface receptors will differ from that of naturally occurring interferons. This should allow selective or differential targeting of interferons to a particular cell type, or increased affinity for the receptor--leading to increased potency against a particular virus disease or malignancy.
3. It will be possible to design novel IFNs which have an increased therapeutic index, thus excluding some of the undesirable side effects of natural IFNs which limit their use (Powledge, T. M., Biotechnology, 2, 214, March 1984).
4. Novel IFNs include in the design structures which allow increased stability to proteolytic breakdown during microbial synthesis.
5. Novel IFNs can be designed to increase their solubility or stability in vivo, and prevent non-specific hydrophobic interactions with cells and tissues.
6. Novel IFNs can be designed which are more readily recovered from the microbial supernatant or extract, and more easily purified.
Additional Relevant Patent Applications
UK No. GB 116 556A--Animal interferons and processes for their production.
U.S. Pat. No. 4 414 150--Hybrid human leukocyte interferons.
SUMMARY OF THE INVENTION
Recombinant DNA technologies were successfully applied to produce modified beta interferon-like polypeptides, nucleic acids (either DNA or RNA) which code for these modified beta interferons, plasmids containing the DNA coding for the modified beta interferons and procedures for the synthesis of these modified beta interferons. Each of the amino acids 115-145 of human beta interferon may individually be replaced by any other amino acid. This replacement may be accomplished in groups of three to twenty-eight amino acids. One preferred embodiment is the replacement of amino acids 115 to 130 of human beta interferon by four to sixteen other amino acids. Another preferred embodiment is the replacement of beta interferon amino acids 121 to 145 by four to twenty-five other amino acids. The beta interferon amino acids 115 to 130 and 121 to 145 may be replaced by corresponding human alpha interferon amino acids. Among the alpha interferons are alpha 1, alpha 2 and alpha H. The alpha and beta interferons from any mammal may be used, including but not limited to humans or other primates, horses, cattle, sheep, rabbits, rats, and mice. Yet another embodiment of the invention discloses the use of the modified beta interferons where in one or more of the antiviral, cell growth regulatory, or immunomodulatory activities is substantially changed from that of the unmodified beta interferon. Particularly preferred embodiments are the amino acid sequence of IFNX411 and 424. Yet another preferred embodiment of the invention is DNA or RNA sequences which code for the synthesis of IFNX411 or 424. Still another embodiment is a plasmid or a cell containing a DNA sequence capable of coding for the synthesis of IFNX411 or 424. Yet another embodiment of the invention is a pharmaceutical composition containing an effective amount of IFNX411 or 424. A final embodiment of the invention is the use of pharmaceutical compositions containing the modified beta interferons in a method of treating viral infections, regulating cell growth or regulating the immune system.
Novel, modified IFNs with increased or decreased biological activity or increased target cell specificity can result in an improved therapeutic index. This should exclude some of the side effects cause by the use in humans of naturally occurring IFNs.
This invention relates to the production in sufficient amounts of novel highly active, and/or highly specific interferon-like molecules suitable for the prophylactic or therapeutic treatment of humans--notably for viral infections, malignancies, and immunosuppressed or immunodeficient conditions.
BRIEF DESCRIPTION OF THE CHARTS AND TABLES
FIG. 1 shows the Sternberg-Cohen 3D model of α 1 and β interferons (Int. J. Biol. Macromol, 4, 137, 1982).
Chart 2 (a and b) shows the ligated oligonucleotides used in the construction of the novel, modified IFN genes.
Chart 3 (a and b) shows the complete nucleotide sequences of the novel, modified IFN genes and the encoded amino acid sequences.
Chart 4 shows the nucleotide sequence of the trp promoter used to initiate transcription of the novel, modified IFN genes.
Table 1 compares expression, antiviral and antiproliferative activities in bacterial extracts for the novel, modified IFNs.
Tables 2-4 compare the antiviral, antiproliferative and immunostimulting activities of purified IFN-β and IFNX411.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Introduction
The IFN-β gene is a unique gene but shows some significant homologies to the multigenic IFN-α family (Rubinstein, Biochim. Biophys. Acta, 695, 5, 1982). Sternberg and Cohen (Int. J. Biol. Macromol., 4, 137, 1982) have proposed a similar secondary structure for IFN-β and IFN-α 1 . Structure prediction studies suggest four α-helices which can be "packed" into a right-handed bundle (FIG. 1) similar to that observed in several unrelated protein structures as determined by X-ray crystallography. The design of some of the modified interferons described herein is derived from our interpretation of the Sternberg/Cohen model. Since IFNs are believed to bind to the same receptor at the cell surface it is possible to introduce variability into IFN-β by replacing specific areas with IFN-α segments.
Each amino acid in the 115 to 145 region can be replaced by any other naturally occurring amino acids. The naturally occurring amino acid and their nomenclature are: alanine (Ala or A); valine (Val or V); leucine (Leu or L); isoleucine (Ile or I); proline (pro or P); phenylalanine (Phe or F); tryptophan (Trp or W); methionine (Met or M); glycine (Gly or G); serine (Ser or S); threonine (Thr or T); cysteine (Cys or C); tyrosine (Tyr or Y); asparagine (Asn or N); glutamic acid (Glu or E); lysine (Lys or K) arginine (Arg or R); and histidine (His or H).
The field of the present invention in the design, synthesis and characterization of interferon-like molecules related to IFN-β which may have amino acid sequences between IFN-β residues 115 and 145 replaced with any other amino acid sequence, unrelated protein sequence, or sequences similar to those of IFN-α's, IFN-β or IFN-γ found in mammals and other vertebrates.
Though binding of hybrid IFN-α's (α 1 and α 2 in Streuli et al, Proc. Natl. Acad. Sci. USA, 78, 2848, 1981), an attempt was made to analyse the number and nature of idiotypes involved in the receptor binding site of IFN-α's. Two sites were proposed as constituting the binding site, one in the amino-terminal half and the other in the carboxy-terminal half of IFN-α. The two major regions of partial homology between IFN-α's and IFN-β occur between amino acid residues 28-80 and 115-151 which may well correspond to the above mentioned idiotypes. Evidence that the 28-80 region may be important in receptor binding come from the finding that polyclonal antibodies raised against a synthetic peptide composed of IFN-α 2 amino acids 24-81, bind to IFN-α 2 and prevent it interacting with its cell receptor (Dreiding, TNO Interferon Meeting, Rotterdam, 1983). Little is known about the function of the 115-151 region of IFN-β, which includes the most highly conserved amino acid residues between β and α IFNs.
Below are examples of novel, modified IFNs (hereafter called group IV IFNs) wherein amino acid residues between IFN-β amino acids 115 and 145 are replaced by other amino acids, e.g. the equivalent amino acid residues from IFN-α 1 . The examples are to illustrate the invention, and are not intended to limit the scope of the invention in any way. Altered antiproliferative activities are among the novel properties displayed by the group IV IFNs. The following techniques used in the design, chemical synthesis and insertion of DNA fragments in the 115-145 region of the human IFN-β gene will be familiar to anyone skilled in the art [see also Molecular Cloning, A Laboratory Manual, eds. Maniatis et al, Cold spring Harbor Laboratories].
Design of the synthetic gene fragments
The nucleotide sequences of each synthetic DNA fragment (Charts 2a and b) were designed utilizing the following criteria:
1. Codon utilization (where it deviates from natural IFN-β gene sequence) was optimized for expression in E. coli. Natural IFN-β gene sequences were used as far as possible in order to obtain levels of expression of novel IFNs as high as that of IFN-β from plasmid pGC10 (˜4,440 bp) expresses the natural IFN-β gene at a high level and is identical to p1/24 (UK Patent Application No. GB 2 068 970A, hereby incorporated by reference) except for the ribosome binding site sequence shown in Chart 4 and the deletion of the ˜546 bp BglII-BamHI fragment.
2. Sequences which might anneal to each other in the assembly of the chemically synthesized fragment (Chart 2) were not included in the design (within the limits allowed by the redundancy in the genetic code).
Chemical Synthesis of Gene Fragments
Oligodeoxyribonucleotides were synthesized by the phosphoramidite method (M. H. Caruthers in "Chemical and Enzymatic Synthesis of Gene Fragments", ed. H. G. Basen and A. Lang, Verlag Chemie, 1982, p. 71) on controlled pore glass (H>Koster et al, Tetrahedron, 40, 103, 1984). Fully protected 2'-deoxyribonucleotide 3'-phosphoramidites were synthesized from the protected deoxyribonucleotide and chloro-N,N-(diisopropylamino)methoxyphosphine (L. J. McBride and M. H. Caruthers, Tetrahedron Lett., 24, 245, 1983 and S. A. Adams et al, J. Amer. Chem. Soc., 105, 661, 1983). Controlled pore glass supports were synthesized as described (F. Chow et al, Nucl. Acids Res., 9, 2807, 1981) giving 30-50 μmol deoxynucleoside per gram.
The functionalised controlled pore glass (50 mg) was treated in a sintered glass funnel at ambient temperature sequentially with:
1. dichloromethane (3 ml, 10 s)
2. 3% (v/v) dichloroacetic acid in dichloromethane (2 ml, 120 s)
3. dichloromethane (3 ml, 10 s)
4. anhydrous acetonitrile (3 ml, 10 s)
5. phosphoramidite monomer (0.06M)/tetrazole (0.23M) in anhydrous acetonitrile (1 ml, 120 s)
6. acetonitrile (3 ml, 10 s)
7. dimethylaminopyridine (0.07M) in acetic anhydride/2,6-lutidine/acetonitrile (1/2/6/ v/v) (1 ml, 60 s)
8. acetonitrile (3 ml, 10 s)
9. iodine (0.2M) in 2,6-lutidine/tetrahydrofuran/water (1/2/2 v/v) (1 ml, 30 s)
10. acetonitrile (3 ml, 10 s)
The cycle was repeated with the appropriate phosphoramidite monomer until the immunogenetic chain was complete. The coupling efficiency of each cycle was monitored by spectrophotometric assay of the liberated dimethoxytrityl alcohol in 10% (w/v) trichloroacetic acid/dichloromethane at 504 nm. After completion of the synthesis, the protecting groups were removed and the oligomer cleaved from the support by sequential treatment with 3% (v/v) dichloroacetic acid/dichloromethane (12 s), thiophenol/triethylamine/dioxan (1/1/2 v/v) (1 h) and concentrated ammonia at 70° C. (4 h). The deprotected oligonucleotides were purified either by HPLC on a Partisil 10 SAX column using a gradient from 1M to 4M triethylammonium acetate pH 4.9 at 50 intracellular or by electrophoresis on a denaturing 15% polyacrylamide gel (pH 8.3).
Ligation of Oligonucleotide Blocks
500 pmole aliquots of the oligonucleotides were phosphorylated with 1 unit of T4 induced polynucleotide kinase in 20 μl of a solution containing 1000 Ci/pmole [ 32 p]γ-ATP (2.5 Ci/mMole), 100 μM spermidine, 20 mM DTT, 10 mM MgCl 2 , 50 mM Tris-HCl (pH 9.0) and 0.1 mM EDTA for 60 minutes at 37° C. The mixtures were then lyophilized and each oligonucleotide purified in a denaturing 15% polyacrylamide gel (pH 8.3). After elution from the gel, the recovery was determined by counting the radioactivity.
Blocks (length 30-50 bases) were assembled by combining 25 pmole of each phosphorylated component with equimplar amounts of the unphosphorylated oligomers from the complementary strand. The mixtures were lyophilized and then taken up in 15 μl water and 2 μl 10×ligase buffer (500 mM Tris-HCl pH 7.6, 100 mM MgCl 2 ). The blocks were annealed at 100° C. for 2 minutes, then slowly cooled to room temperature (20° C.). 2 μl 200 mM DTT and 0.5 μl 10 mM ATP were added to give final concentrations of 20 mM DTT and 250 μM ATP in 20 μl. 1.25 untis of T4 DNA ligase were also added. After 18 hours at 20° C., the products were purified in a 15% polyacrylamide gel under denaturing conditions.
Two duplex blocks were then constructed from the single-stranded pieces. (These were 150 base pairs and 75 base pairs). 1.5 pmole of each block were taken and the mixtures lyophilized. Annealing was carried out in 15 μl water and 2 μl 10×ligase buffer at 100° C. for 2 minutes, then slowly cooled to 10° C. 2 μl 200 mM DTT, 0.5 μl 10 mM ATP and 1.25 units T4 DNA ligase were added. The reaction was left at 10° C. for 18 hours. The products were then purified in a 10% native polyacrylamide gel.
The final product was assembled by combining 0.4 pmole of the two duplexes. The mixture was lyophilized and then taken up in 15 μl water and 2 μl 10×ligase buffer. It was annealed at 50° C. for 2 minutes and then slowly cooled to 10° C. 2 μl 20 mM DTT, 0.5 μl 10 mM ATP and 1.25 units ligase were then added and the reaction left at 10° C. for 18 hours. The final product was purified in a 5% native polyacrylamide gel. After elution and ethanol precipitation, the product was taken up in 10 μl water. 0.5 μl were removed for counting to calculate the recovery. 2 μl 10×ligase buffer, 2 μl 200 mM DTT, 2 μl 1 mM spermidine, 1 μl 10 mM ATP, 3 μl water and 0.5 units kinase were added to the rest (total volume 20 μl). The reaction was left at 37° C. for 1 hour and stopped by heating at 90° C. for 2 minutes. The final product was ethanol precipitated.
Construction of plasmids expressing novel, modified interferons
This section lists and identifies the vectors employed in the cloning of the synthetic DNA fragments (Chart 2) into the IFN-β coding region, the restriction enzyme sites* used for the insertion, and the rationale for the construction. the positions of these sites* are shown relative to the complete coding nucleotide sequences of the group IV novel IFN genes (Chart 3). The IFN-β (or novel IFN) coding region is shown as a heavy line and would be translated from left to right. The vector sequences between the BamHI site and the EcoRI site are the same as those in pAT153 (equivalent to pBR322 with a 705 bp HaeII fragment deleted--nucleotides 1,646-2,351 on the map). The E. coli trp promoter (Chart 4) lies between the EcoRI site and ClaI site.
1. IFNX411 IFN-β[β 121-145 →α 1 119-143 ]
This novel, modified IFN was designed to investigate the function of the 115-145 region of IFN-β by substituting an equivalent region from IFN-α 1 .
Starting vector: pGC206 This vector expresses IFN-β from a part natural (amino acids 1-46) and part synthetic IFN-β gene (amino acids 47-166). It was constructed by replacing the 257 bp EcoRI-PvuII fragment of pMN47 with the equivalent fragment from pl/24C. pMN47 contains an entirely synthetic IFN-β gene (Chart 3c) inserted between the ClaI and BamHI sites of pl/24C, the plasmid containing the entirely natural IFN-β gene. [pl/24C is identical to pl/24 (UK Patent Application No. GB 068 970A) except for the underlined sequences in Chart 4.]. ##STR1## A synthetic oligonucleotide (Chart 2a) was inserted between the SacI* and MluI* sites of pGC206 to give the nucleotide sequence shown in Chart 3a. The resultant IFNX411 gene is expressed on plasmid pGC218.
2. IFNX424 IFN-β[β 115-130 →α 1 113-128 ]
The rationale and starting vector was the same as for IFNX411 above. ##STR2## A synthetic oligonucleotide (Chart 2b) was inserted between the SacII* and MluI* sites of pGC206 to give the nucleotide sequence shown in Chart 3b.
The resultant IFNX424 gene is expressed on plasmid pGC217.
Expression of Novel, Modified IFNs in Escherichia coli
All the above mentioned plasmids were grown in E. coli HB101 in the presence of a low level of tryptophan to an OD 600 of 0.5, then induced for IFN synthesis. The medium (200 ml) contained: M9 salts, 0.5% glucose, 0.1 mM CaCl 2 , 0.5% Casamino acids, 1 mM MgSO 4 , 0.1 mg/ml vitamin B 1 , 2.5 μg/ml tryptophan and 100 μg/ml carbenecillin.
200 ml of medium was inoculated with 2-4 ml of an overnight culture of each clone (in the host E. coli HB101) grown in the above medium except for the presence of 42.5 μg/ml tryptophan, and grown at 37° C. with vigorous aeration. At OD 600 of 0.5, indole acrylic acid, the inducer of the E. coli trp promoter and therefore also of IFN synthesis, was added to 20 μg/ml. At 4-5 hours after induction 3 ml of culture was withdrawn (OD 600 =0.75-1.2 range) and split as follows: 1 ml was for estimation of total ¢solubilized" IFN antiviral or antiproliferative activity (the activity regained after a denaturation/renaturation cycle); and 1 ml was for display of the total accumulated E. coli proteins plus IFN in a polyacrylamide gel.
(a) Estimation of TOTAL "solubilized" IFN antiviral activity
For recovery of TOTAL "solubilized" IFN antiviral activity, the pellets wre vortexed in 20 μl "lysis buffer" per 0.1 OD 600 per ml of culture. ("Lysis buffer" is 5M urea, 30 mM NaCl, 50 mM Tris-HCl pH 7.5, 1% SDS, 1% 2-mercaptoethanol, 1% HSA). The mixture was heated for 2-3 minutes at 90° C., frozen at -70° C. for 15 minutes, thawed and centrifuged at 17 K rpm for 20 minutes. The supernatant was diluted in 1 log steps to 1:10 5 , and appropriate dilutions immediately assayed for IFN antiviral activity by monitoring the protection conferred on Vero cells against the cytopathic effect (cpe) of EMC virus in an in vitro micro-plate assay system (e.g. see Dahl and Degre, Acta. Path. Microbiol. Scan., 1380, 863, 1972). The diluent was 50 mM Tris-Hcl pH 7.5, 30 mM NaCl, 1% human serum albumin (HSA).
(b) Polyacrylamide gel electrophoresis of total polypeptides
Cells from 1 ml of culture were mixed with 10 μl per 0.1 OD 600 per ml of final sample buffer: 5M urea, 1% SDS, 1% 2-mercaptoethanol, 50 mM Tris-HCl pH 7.5, 30 mM NaCl and 0.05% bromophenol blue. The mixture was heated at 90° C. for 5 minutes, centrifuged for 10 minutes and 5-7 μl loaded on a 15% acrylamide/0.4% bisacrylamide "Laemmli" gel. Electrophoresis was at 70 V for 18 hours. The gel was fixed and stained with Coomassie brilliant blue, then dried and photographed.
(c) Antiproliferative assays of novel, modified interferons
Antiproliferative activity was assessed by the ability of the IFN to inhibit the replication of Daudi lymphoblastoid (Horoszewics et al, Science, 206, 1091, 1979). Daudi cells (in log phase) were cultured for 6 days in 96 well plates in the presence of various dilutions of interferon. The phenol red indicator in the medium changes from red to yellow (more acid) with progressive cell growth. Liquid paraffin was added to prevent pH change on exposure to the atmosphere and the pH change in the medium measured colorimetrically on a Dynatech plate reader. Interferon inhibition of cell growth is reflected by a corresponding reduction in the colour change.
Comparison of IFN protein expression, antiviral activity and antiproliferative activity in bacterial extracts
Table 1 sets out the expression levels and antiproliferative and antiviral activities of the group IV novel, modified IFNs in crude bacterial extracts. A range of activities may be given, reflecting natural variation in a biological system or assay. The activity quoted is that which is regained after SDS/urea/mercaptoethanol treatment, by diluting the extract in 1% human serum albumin, as above.
It may be seen in Table 1 that for the control, IFN-β, antiviral (AV) and antiproliferative (AP) activity vary over not more than a 4-fold range (>20 experiments).
TABLE 1__________________________________________________________________________ Expression EMC/Vero Daudi cell Anti- (% of total Antiviral activity proliferative activityNovel, modified IFN IFNX No. cell protein) IU/L/OD.sub.600 U/ml at IC.sub.50 *__________________________________________________________________________IFN-β[β.sup.115-130 →α.sub.1.sup.113-128 ] 424 3-5 9.6 × 10.sup.6 <10.sup.3IFN-β[β.sup.121-145 →α.sub.1.sup.119-143 ] 411 10 0.3-1.8 × 10.sup.8 3.5 × 10.sup. 3IFN-β control -- 10 0.5-2 × 10.sup.8 3.4 × 10.sup.3__________________________________________________________________________ *U/ml at IC.sub.50 = dilution of sample assayed for antiviral activity giving 50% inhibition of cell growth.
Purification and biological properties of IFNX411
One liter culture was induced and grown to OD 600 1-2 as described above. The cell pellet was resuspended in 30 ml 50 mM Tris-HCl pH 8.0 and sonicated on ice, 4×1 min. at 100 W and then centrifuged for 1 hr at 15 K rpm. 30 ml boiling extraction solution (50 mM Tris-HCl pH 8.0, 50 mM DTT and 1-2% SDS) was added, mixed and the solution was sonicated. The solution was then boiled for 5 min., centrifuged for 1 hr at 15 K rpm, and to the supernatant was added (NH 4 ) 2 SO 4 to 40% saturation. After 15 min. the precipitate was collected by centrifugation at 10 K rpm for 20 min. The pellet was redissolved by adding 5 ml warm 50 mM Tris-HCl pH 8.0. Following a 15 K rpm spin for 1 hr, the solution was re-reduced in 50 mM DTT by boiling for 5 min.
The IFNs were fractionated on a 2.35 cm×70 cm column of LKB AcA44 in 0.1% SDS, 50 mM Tris-HCl pH 8.0, and the peak fractions containing 1-2 mg IFN were pooled.
To remove SDS and deplete pyrogens, either (a) the protein was acetone precipitated and redissolved in 50% formic acid, 10% isopropyl alcohol (solvent A); or (b) 6 parts formic acid and 1 part isopropyl alcohol were premixed and added to 3 parts sample. The mixture was applied to C-18 Sep-Pak (capacity greater than 3 mg) or to a C-18 Bond Elut (Anachem). The columns were first washed with solvent A (2-4 ml) and the IFN eluted with 50% formic acid, 50% isopropyl alcohol.
The eluted IFN was dialysed against water to remove formate and then into GuHCl (6M), 100 mM Tris-HCl pH 8.0. To renature the IFN, the sample was reduced in 10 mM DTT at 100° C., then diluted 100-fold into 100 mM Tris-HCl pH 8.0, 200 mM KCl, 1 mM EDTA and either 0.1% Tween 20 or 1% HSA. Protein was estimated prior to biological assay.
Antiviral assays of purified, modified interferons
A single virus (encephalomyocarditis--EMC) was used to determine antiviral activity in primate cells. Determinations were made with a virus cytopathic effect (cpe) assay following challenge of cells of Monkey (Vero) and human (Chang conjunctiva and Searle 17/l fibroblast) origin (Dahl and Degre, ibid.) Table 2 shows that IFNX411 has similar activity to IFN-β.
TABLE 2______________________________________Antiviral Activity of Purified Interferon IFNX411(U/mg IFN Protein)______________________________________ 17/1 CELL LINE CHANG VERO______________________________________IFNX411 1.1 × 10.sup.5 1.6 × 10.sup.6 1.6 × 10.sup.6BETA 1.9 × 10.sup.5 7.2 × 10.sup.5 9.1 × 10.sup.5______________________________________ RATIOIFNX411/BETA 0.6 2.2 1.8______________________________________
Antiproliferative assays of purified, novel interferons
Antiproliferative activity was assessed by the ability of the IFN to inhibit the replication of three human cell lines (Horoszewicz et al, Science, 206, 1091, 1979)--Daudi (lymphoblastoid), HEP-2 (carcinoma) and RD (rhabdomyosarcoma). Daudi cells (in log phase) were cultured for 6 days in 96 well plates in the presence of various dilutions of interferon. The phenol red indicator in the medium changes from red to yellow (more acid) with progressive cell growth. Liquid paraffin was added to prevent pH change on exposure to the atmosphere and the pH change in the medium measured colorimetrically on a Dynatech plate reader. Interferon inhibition of cell growth is reflected by a corresponding reduction in the colour change. HEP-2 and RD in log growth were cultured for 3 days in 96 well plates in the presence of interferon. The cells were then fixed with 0.25% glutaraldehyde and stained with methylene blue. After extraction into ethanol the colour intensity was measured on a Dynatech plate reader. Once again colour intensity can be related proportionally to cell growth. In vitro antiproliferative activity of the novel, modified IFNs in crude bacterial extracts was also measured (Daudi cell line only). Table 3 shows that this Daudi cell line is relatively more sensitive to IFNX411 than to IFN-β.
TABLE 3______________________________________Antiproliferative Activity of Purified IFNX411(U/mg IFN Protein)______________________________________ HEP-2 CELL LINE RD DAUDI______________________________________IFNX411 7.1 × 10.sup.3 9.1 × 10.sup.3 1.2 × 10.sup.6BETA 1.3 × 10.sup.4 1.9 × 10.sup.4 2.5 × 10.sup.5______________________________________ RATIOIFNX411/BETA 0.5 0.5 4.8______________________________________
Stimulation of Antibody-Dependent Cellular Cytoxicity by novel, modified interferons (ADCC)
ADCC represents a cellular system which is immunologically specific, the effect being mediated by antibody. There are several possible versions of this assay. 51 Cr-labelled human red cells (GpA, Rh+ve) sensitised with anti-A antibody using the serum from a Group O individual were incubated with buffy coat cells from a Group O individual. Interferon was assessed by prior overnight incubation with buffy coat cells and its effects compared with those of parallel untreated controls (McCullagh et al, J. IFN Res., 3, 97, 1983). Table 4 shows IFNX411 to have a similar activity to IFN-β with all six donors of buffy coat cells.
TABLE 4__________________________________________________________________________Immunomodulatory (ADCC) Activity of Purified IFNX411(U/mg IFN Protein) 1 2 3 4 5 6__________________________________________________________________________ DONORIFNX411 1.4 × 10.sup.3 3.4 × 10.sup.4 1.1 × 10.sup.3 4.7 × 10.sup.3 3.2 × 10.sup.3 2.5 × 10.sup.3BETA 1.5 × 10.sup.3 2.4 × 10.sup.4 9.3 × 10.sup.2 3.0 × 10.sup.3 4.0 × 10.sup.3 2.6 × 10.sup.3 RATIOIFNX411/BETA 0.9 1.4 1.1 1.6 0.8 1.0__________________________________________________________________________
Pharmaceutical formulation and administration
The novel, modified interferons of the present invention can be formulated by methods well known for pharmaceutical compositions, wherein the active interferon is combined in admixture with a pharmaceutically acceptable carrier substance, the nature of which depends on the particular mode of administration being used. Remington's Pharmaceutical Sciences by E. W. Martin, hereby incorporated by reference, describes compositions and formulations suitable for delivery of the interferons of the present invention. For instance, parenteral formulations are usually injectable fluids that use physiologically acceptable fluids such as saline, balanced salt solutions, or the like as a vehicle. Oral formulations may be solid, e.g. tablet or capsule, or liquid solutions or suspensions.
The novel, modified interferons of the invention may be administered to humans or other animals on whose cells they are effective in various ways such as orally, intravenously, intramuscularly, intraperitoneally, intranasally, intradermally or subcutaneously. Administration of the interferon composition is indicated for patients with malignancies or neoplasms, whether or not immunosuppressed, or in patients requiring immunomodulation, or antiviral treatment. Dosage and dose rates may parallel those employed in conventional therapy with naturally occurring interferons--approximately 10 5 to 10 8 units daily. Dosages significantly above or below these levels may be indicated in long term administration or during acute short term treatment. A novel, modified interferon may be combined with other treatments or used in association with other chemotherapeutic or chemopreventive agents for providing therapy against the above mentioned diseases and conditions, or other conditions against which it is effective.
Modifications of the above described modes for carrying out the invention such as, without limitation, use of alternative vectors, alternative expression control systems, and alternative host micro-organisms and other therapeutic or related uses of the novel interferons, that are obvious to those of ordinary skill in the biotechnology, pharmaceutical, medical and/or related fields are intended to be within the scope of the following claims.
CHART 2a______________________________________Chemically synthesized sequence for IFNX411______________________________________ ##STR3## ##STR4## ##STR5##______________________________________
CHART 2b__________________________________________________________________________ Chemically synthesized sequence for IFNX424__________________________________________________________________________ ##STR6##GGTAATGCAGA CTCTATTCTGGC TGTAAAGAAA TACTTCCGTCGTA TCACCCATTACCTCGCCATTACGTCTGAGATAAGACCGACATTTCTTTATGAAGGCAGCATAGTGGGTAATGGAGAAAGCTAAAGAATACTCT CACTGCGCATGGA CTATTGTA ##STR7##__________________________________________________________________________
CHART 3a__________________________________________________________________________IFNX411 ##STR8##__________________________________________________________________________ ##STR9## ##STR10## ##STR11## ##STR12## ##STR13## ##STR14## ##STR15## ##STR16## ##STR17## ##STR18## ##STR19## ##STR20## ##STR21## ##STR22## ##STR23## ##STR24##__________________________________________________________________________
Chart 3b__________________________________________________________________________IFNX424 ##STR25##__________________________________________________________________________ ##STR26## ##STR27## ##STR28## ##STR29## ##STR30## ##STR31## ##STR32## ##STR33## ##STR34## ##STR35## ##STR36## ##STR37## ##STR38## ##STR39## ##STR40## ##STR41##__________________________________________________________________________
CHART 3c______________________________________Synthetic IFN-β gene______________________________________ ##STR42## ##STR43## ##STR44## ##STR45## ##STR46## ##STR47## ##STR48## ##STR49## ##STR50## ##STR51## ##STR52## ##STR53## ##STR54## ##STR55## ##STR56## ##STR57## ##STR58## ##STR59## ##STR60##R<AMSYNLLGFLQRSSNFQCQKLLWQLNGRLEYCLKDRMNFDIPEEIKQLQQFQKEDAALTIYEMLQNIFAIFRQDSSSTGWNETIVENLLANVYHQINHLKTVLEEKLEKEDFTRGKLMSSLHLKRYYGRILHYLKAKEYSHCAWTIVRVEILRNFYFINRLTGYLRN<GS______________________________________
CHART 4__________________________________________________________________________Nucleotide sequence of trp promoter region of IFN-βexpression plasmid pl-24/C__________________________________________________________________________ ##STR61## ##STR62## ##STR63##__________________________________________________________________________ | Modified beta interferons containing amino acid substitutions in the beta interferon amino acids 115 to 145 are described. These modified beta interferons exhibit changes in the antiviral, cell growth regulatory or immunomodulatory activities when compared with unmodified beta interferon. | 8 |
CROSS-REFERENCE
[0001] The present United States patent application claims priority from U.S. provisional patent application No. 61/435,698, filed Jan. 24, 2011, entitled ELECTROCOAGULATION FOR TREATING LIQUIDS, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to a method for treating liquid with electrocoagulation. More precisely, the present invention relates to a method, a system and an apparatus for treating colloidal solutions with electrocoagulation in an agitated environment.
BACKGROUND OF THE INVENTION
[0003] Nowadays water pollution is a significant issue and efforts are made to improve wastewater treatments. Water treatment processes commonly used are mainly based mechanical filtration and on bacterial activity. Many microorganisms belonging to five different classes (e.g. bacteria, virus, protozoa, fungi and helminth) are found in wastewater and wastewater process treatments. Disinfection processes are divided into two main groups, namely the physical and chemical processes (Metcalf and Eddy, 2003). The physical processes include: electromagnetic radiation, ultrasonic waves, heat, visible light and ultraviolet (UV), ionizing radiation (gamma and X), electron beam and electric current. Chemical methods use different compounds including: halogens and their derivatives (Cl 2 , Br 2 , I 2 , HOCl, OCl, ClO 2 , HOBr, HOI, . . . ), oxygenated compounds and highly oxidizing (ozone, hydrogen peroxide, phenols, alcohols, percarbonates and persulfates, peracetic acid, potassium permanganate, . . . ), dyes, quaternary ammonium compounds, acids and bases as well as enzymes. Some contaminants, like colloidal contaminants, are difficult to separate from liquid because of their electrical barrier.
[0004] Electrocoagulation was already proposed in the late 19th and early 20th century. The use of electrocoagulation with aluminum and iron was patented in 1909 in the United States (Stuart, 1947; Bonilla, 1947, Vik et al. 1984). Matteson et al. (1995) described an “electronic coagulator” in the 1940s, using aluminum anodes, and in 1956 a similar process in Great Britain using, in turn, iron anodes.
[0005] Coagulation is essentially to neutralize, or reduce, the electric charge of colloids and hence promote the aggregation of colloidal particles. To destabilize a suspension it is necessary that the attractive forces between particles are greater than the repulsive forces thereof. Attractive forces are mainly van der Weals forces, which act at a short distance thereof. In general, the total energy that controls the stability of the energy dispersion comprises attractive van der Weals energy of repulsion at short distance, the electrostatic energy and energy due to the steric effect of molecules solvent.
[0006] Coagulation can be done by chemical or electrical means. Alun, lime and/or polymers have been used as chemical coagulants. Chemical coagulation is becoming less popular today because of high costs associated with the chemical treatments of a significant volume of sludge and hazardous heavy metals such as metal hydroxides generated thereof in addition to the cost of chemical products needed for coagulation itself. Chemical coagulation has been used for decades.
[0007] Although the electrocoagulation mechanism resembles chemical coagulation, although, some differences benefit electrocoagulation. Indeed, electrocoagulated flocs differ from those generated by chemical coagulation. Flocs created with the electrocoagulation process tend to contain less bound water, are more resistant to shearing and are more easily filterable.
[0008] Flocs are created during the electrocoagulation water treatment with oxydo-reduction reactions. Currents of ions and charged particles, created by the electric field, increase the probability of collisions between ions and particles of opposite signs that migrate in opposite directions. This phenomenon allows the aggregation of suspended solids to form flocs.
[0009] The electrolytic reactions that take place at the electrodes are accompanied by production of micro bubbles of hydrogen (at the cathode) and oxygen (at the anode). These micro bubbles heading up will result in an upward movement of the flocs formed thereof that are recovered at the surface (this mechanism is named flotation).
[0010] The complexity of the mechanisms involved in the process of electrocoagulation in the treatment of water is not well scientifically elucidated (Yusuf et al., 2001). There are various features of the mechanism of the process and the geometry, or design, of the reactor in the literature. The different physico-chemical treatment, the shape of the reactor and the shape and size of electrodes affect the performance of the treatment (M. Bennajah, 2007). The wide variety of processing parameters reported in the literature and the lack of scientific data for efficient model processing and optimal processing conditions translate into a lack of development in this field. At this time, electrocoagulation is still problematic and therefore not popular (Holt et al. 2002, 2006).
[0011] The existence of an electric current in a body of water implicitly requires Faraday reactions surrounding the electrodes. The formation of chemical gradients depends on the electrolysis magnitude. The consequences of chemical reactions become more pronounced and significant in the prolonged application of electrokinetic. The effects include electrolysis of water with the simultaneous development of pH gradients and the transfer of electrolytic dissolution of the anode producing metal ions (Fe 3+ , Al 3+ , Mg 2+ , etc.) or cations of the electrolyte from the anode to the cathode. Chemical reactions can, in ion exchange or precipitation, form new mineral phases for cleaning water for instance.
[0012] At the cathode, the main reaction is:
[0000] 4H 2 O+4e − →2H 2 +4OH − (Equation 1)
[0013] The increase in hydroxyl ions can increase the precipitation of metal hydroxide. The pH of the cathode's region is basic. The following equations describe the chemical reactions at the anode:
[0000] 2H 2 O→O 2 +4H + +4e − (Equation 2)
[0014] If the anode is made of magnesium:
[0000] Mg→Mg 2+ +2e − (Equation 3)
[0015] It is noted that twice as many water molecules are electrolysed at the cathode compared to the anode for the same quantity of electricity.
[0016] Legacy electrocoagulation systems are associated with several issues. One of the issues is related to gas accumulation that damages the recipient. Other issues can include a wrong alignment and distance between the electrodes, the use of wrong electrode materials, a wrong electrode geometry, the thickness of the electrodes is not proper and the amount of energy used is not suited for the treatment of a specific fluid. Also, legacy electrocoagulation systems are not convenient for commercial or industrial uses.
[0017] Therefore, there exists a need in the art for an improved method, system and apparatus for treating a liquid over the existing art. There is a need in the art for such a method, system and apparatus for treating a liquid that can be easily installed, economically manufactured and operated. And there is a very perceptible need for an improved method, system and apparatus for treating wastewater over the existing art.
SUMMARY OF THE INVENTION
[0018] The present invention alleviates one or more of the drawbacks of the background art by addressing one or more of the existing needs in the art.
[0019] Accordingly, the present invention provides a method of treating liquid, especially, but not limited to, water, with electrocoagulation, using magnesium or other materials, in an agitated environment, in accordance with at least one embodiment of the invention.
[0020] The present invention provides a method and an apparatus for destabilizing colloidal solutions using turbulent fluid to overcome the energetic barrier of the colloidal solution, facilitate colloid agglomeration and facilitate solid-fluid separation, in accordance with at least one embodiment of the invention.
[0021] The present invention provides a method and an apparatus for treating industrial wastewater, food processing wastewater, dairy production greywater, leachate, domestic greywater, the reduction of ammonia nitrogen and ortho-phosphate and reduction of soluble chemical oxygen demand (hereinafter COD) with electrocoagulation in accordance with at least one embodiment of the invention.
[0022] The present invention provides a method and an apparatus for treating liquid with electrocoagulation that agglomerate and filter colloidal solutions in accordance with at least one embodiment of the invention.
[0023] The present invention provides a method of treating liquid with electrocoagulation that injects magnesium in the liquid in accordance with at least one embodiment of the invention.
[0024] The present invention provides a method and an apparatus for treating liquid with electrocoagulation that provides severe electrolytic conditions capable of attacking organic molecules responsible of soluble DCO, inter alia, phenols in accordance with at least one embodiment of the invention.
[0025] The present invention provides an apparatus for treating liquid with electrocoagulation provided with a modular electrocoagulation apparatus that can be easily installed and/or replaced in a process in accordance with at least one embodiment of the invention.
[0026] The present invention provides an apparatus for treating liquid with electrocoagulation that uses an electrocoagulation module including an anode module and a cathode module in accordance with at least one embodiment of the invention.
[0027] The present invention provides an apparatus for treating liquid with electrocoagulation provided with a modular anode that can be easily replaced, like a cartridge in accordance with at least one embodiment of the invention.
[0028] The present invention provides an apparatus for treating liquid with electrocoagulation that uses a movable anode adapted to add kinetic energy in the liquid to treat in accordance with at least one embodiment of the invention.
[0029] The present invention provides an apparatus for treating liquid with electrocoagulation that uses an anode module including of a plurality of anodic materials in accordance with at least one embodiment of the invention.
[0030] The present invention provides an apparatus for treating liquid with electrocoagulation that uses an anode module including of a plurality of anodes equally disposed thereabout in accordance with at least one embodiment of the invention.
[0031] The present invention provides an apparatus for treating liquid with electrocoagulation that uses an anode module including a plurality of anodes geometrically disposed thereabout in accordance with at least one embodiment of the invention.
[0032] The present invention provides a method of treating liquid with electrocoagulation that uses an anode module made of a plurality of replaceable anodes adapted to react and agglomerate different types of contaminants in accordance with at least one embodiment of the invention.
[0033] The present invention provides a method of treating liquid with electrocoagulation that uses an anode module including a plurality of anodes having various geometrical section like, but not limited to, oval, conical, frustoconical, square, round, triangular, . . . to react in various fashion with cathode to agglomerate different types of contaminants, each anode being adapted to be consumable or inert, in accordance with at least one embodiment of the invention.
[0034] The present invention provides a method of electro destruction and weakening of refractory molecules responsible for soluble COD. Electro destruction is an oxidation process assisted with the action of electric current that weakens refractory molecules that are then easier to destroy. Generally, they are attacked by the action of oxidizing agents that can be added (adding hydrogen peroxide or per carbonate) or generated in situ by the action of electric current on acids such as sulphuric acid or simply water (production of free radicals and persulfates) in accordance with at least one embodiment of the invention.
[0035] The present invention provides a method of electro destruction and reduction of toxic molecules such as polychlorinated biphenyls (PCBs), with or without chemical assistance in accordance with at least one embodiment of the invention.
[0036] The present invention provides an electrocoagulation module functioning on the principle of a sacrificial anode (Al, Fe, Mg, Ca . . . ), subjected to the application of a potential difference between the anode and a cathode. The cathode can either be made of steel or other metal identical to the anode depending of the fluid parameters and under the application of a potential difference that causes an agglomeration of particles in the fluid around the released ion. The particles formed thereof are evacuated with the flow of fluid in accordance with at least one embodiment of the invention.
[0037] The present invention provides a method of electro-synthesis and preparation of calco-magnesio hydroxyled and fluorided apatite Ca 10-x Mg x (PO 4 ) 6 F 2 , Ca 10-x Mg x (PO 4 ) 6OH OH 2 . Apatites are a family of isomorphs compounds of fluorapatite: Ca 10 (PO 4 )6F 2 .
[0038] The present invention provides a method for electro-synthesis apatites using a synthetic chemical that is a reacted solution containing Mg 2+ and Ca 2+ with a solution containing the PO 4 3− . The method is a synthesis in which the electrolysis process injects Mg 2+ through the application of electric current in accordance with at least one embodiment of the invention.
[0039] The present invention provides a combination of electrocoagulation and mechanical agitation of the anodes for better performance. Agitation of the anode can be made in a circular fashion by rotating or reciprocating motion and can also be done inside or outside the electrocoagulation module in accordance with at least one embodiment of the invention.
[0040] The present invention provides a method for dephosphating industrial wastewater, municipal wastewater and food processing wastewater by formation of Mg 3 (PO 4 ) 2 complex in accordance with at least one embodiment of the invention.
[0041] The present invention provides a method and an apparatus providing a pre-thickened industrial liquid sludge, municipal liquid sludge, and food processing liquid sludge with 1% initial dryness to more than 8% final dryness without adding polymer therein. Raw sludges have a dry content of 1-2% and should be pre-thickened with polymers before being dehydrated. The addition of polymers increases the amount of sludge and makes them viscous. A pre-thickening with electrocoagulation-electro flotation would decrease or eliminate the amount of polymer to be added in accordance with at least one embodiment of the invention.
[0042] The present invention provides a method and an apparatus capable of heat recovery in cases of heat-polluted industrial wastewater treatment. The present invention is an efficient method to treat this type of wastewater with the possibility to recover at least a portion of the electrocoagulation exothermic energy, in accordance with at least one embodiment of the invention.
[0043] The present invention provides a method and an apparatus for applying an electric current to procure bacterial reduction that can be achieve as follows: disintegration of cell wall (that causes osmotic lysis); membrane permeability modification; modification of intercellular constituents; nucleic acids alteration; protein synthesis interference; abnormal redox processes induction; and enzyme activity inhibition in accordance with at least one embodiment of the invention.
[0044] The present invention provides a kit comprising an anode module, a cathode module adapted to be operatively secured to the anode module, an anode agitation module, a fluid agitation module and at least one replaceable anode adapted to be mounted to the anode module in accordance with at least one embodiment of the invention.
[0045] The present invention provides a method of treating a colloidal fluid to remove contaminants contained therein, the method comprising injecting the colloidal fluid containing contaminants in an electrolytic system including an electrocoagulation module comprising an anode; and a cathode, the anode and the cathode being adapted to be electrically connected to perform electrolysis of the fluid; providing an electric current, between the anode and the cathode, to form electro-coagulated contaminants flocs in the fluid; separating the electro-coagulated flocs from the fluid; and extracting the fluid from the electrolytic system in accordance with at least one embodiment of the invention.
[0046] The present invention provides a modular electrolysis system for treating fluid for removing colloid contaminants contained therein, the modular electrolysis system comprising an electrocoagulation module including an inlet and an outlet, the electrocoagulation module being adapted to include a removable anode module therein and a cylindrical cathode module for performing electrolysis of the fluid in the electrocoagulation module in accordance with at least one embodiment of the invention.
[0047] An electrolysis kit for treating a fluid to remove colloid contaminants contained therein, the kit comprising an electrolytic module; an anode module adapted to be operatively inserted in the electrolytic module; and at least one anode adapted to be assembled to the anode module, the anode material being defined to produce one electrolytic process selected from electrocoagulation and electro-floatation.
[0048] Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
[0049] Additional and/or alternative advantages and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, disclose preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] Referring now to the drawings which form a part of this original disclosure:
[0051] FIG. 1 is a schematic illustration of a modular electrolysis apparatus 10 in accordance with at least one embodiment of the invention;
[0052] FIG. 2 is a schematic illustration of a modular electrolysis apparatus in accordance with at least one embodiment of the invention;
[0053] FIG. 3 is a schematic illustration of a modular electrolysis apparatus in accordance with at least one embodiment of the invention;
[0054] FIG. 4 is a schematic illustration of a modular electrolysis apparatus in accordance with at least one embodiment of the invention;
[0055] FIG. 5 is a schematic illustration of a modular electrolysis apparatus in accordance with at least one embodiment of the invention;
[0056] FIG. 6 is an illustrative flow chart of an exemplary series of steps in accordance with at least one embodiment of the invention;
[0057] FIG. 7 is a schematic illustration of a modular electrolysis apparatus in accordance with at least one embodiment of the invention;
[0058] FIGS. 8 a ), b ) and c ) is a schematic illustration of an anode module in accordance with at least one embodiment of the invention;
[0059] FIGS. 9 a ), b ) and c ) is a schematic illustration of an anode module in accordance with at least one embodiment of the invention;
[0060] FIGS. 10A and 10B are schematic illustrations of possible anodes configurations on the anode module in accordance with embodiments of the invention;
[0061] FIG. 11 is an illustrative fluid flow illustration of an exemplary electrolysis system in accordance with at least one embodiment of the invention;
[0062] FIG. 12 is an illustrative illustration of an exemplary electrolysis system in accordance with at least one embodiment of the invention;
[0063] FIG. 13 is an illustrative fluid flow illustration of an exemplary electrolysis system in accordance with at least one embodiment of the invention;
[0064] FIG. 14 is an illustrative exemplary decanter module in accordance with at least one embodiment of the invention;
[0065] FIG. 15 is an illustrative exemplary decanter module in accordance with at least one embodiment of the invention; and
[0066] FIG. 16 is an illustrative exemplary decanter module in accordance with at least one embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0067] A preferred embodiment of the present invention is described bellow with reference to the drawings.
[0068] An exemplary electrocoagulation module 10 is illustrated in FIG. 1 with a section view allowing a better view of its construction. The electrocoagulation module 10 comprises an anode module 14 and a cathode module 18 adapted to interact in an electrolytic process producing electrocoagulation of undesirable colloidal particles. The electrocoagulation module 10 of the present embodiment includes an inlet 22 and an outlet 26 configured to respectively receive and extract the fluid to and from the electrocoagulation module 10 . The fluid, once introduced in the electrocoagulation module 10 , follows a path or a fluidic circuit configured to put the fluid in communication with the electrolytic process that is produced in the electrocoagulation module 10 . In the present example, the fluid follows a path identified by a series of arrows 30 defined by internal walls 34 . A pump, which is not illustrated in FIG. 1 , pushes the fluid through the electrocoagulation module 10 . An opening 38 disposed on a bottom portion 42 of the electrocoagulation module 10 is normally closed with a plug (not illustrated) to prevent the fluid to exit the electrocoagulation module 10 . The opening 38 can be opened to remove the fluid from the electrocoagulation module 10 to purge the electrocoagulation module 10 for maintenance purposes, for instance. The electrocoagulation module 10 can also be purged to remove particles and debris. A larger closure member 46 is used to close the bottom portion of the electrocoagulation module 10 lower body 50 . The closure member 46 can be optionally removed to provide a larger access in the electrocoagulation module 10 . The lower body 50 can threadedly engage the upper body 54 and be removed from the upper body 54 , if desirable.
[0069] Still referring to FIG. 1 , the closure member 46 is located at the lower portion of the electrocoagulation module 10 to receive particles therein. The cathode module 18 is bottomless and allows the particles to drop in the closure member 46 acting as a particles-receiving member 46 . The removable particles-receiving member 46 is preferably disposed in the center of the cathode module 18 as illustrated in the present embodiment and is used for removing decanted particles from the cathode module 18 . The opening 38 in the closure member 46 can alternatively be used to inject gas, like air, or liquids for further conditioning the liquid in the electrocoagulation module 10 and/or influence the electrocoagulation process inside the cathode module 18 .
[0070] The electrocoagulation module 10 further includes body portions 50 , 54 that can optionally include insulating material to prevent heat transfer with the environment. Conversely, the electrocoagulation module 10 might be equipped with heating/cooling elements 58 to keep the electrocoagulation apparatus 10 at a predetermined operating temperature. The upper body 54 of an embodiment can be made of an insulating material preventing heat transfer between the inside of the electrocoagulation module 10 and the outside of the electrocoagulation module 10 . The lower body 50 of the embodiment illustrated in FIG. 1 is made of a material that is less insulating the electrocoagulation module 10 . Heating or cooling elements 58 are disposed, for example, in a spiral around the lower body 54 to either heat or cool the lower body 50 . The heating or cooling elements 58 can use a fluid circulating in a tubular system or electric elements in contact with, or nearby, the lower body 50 . Another embodiment is using the upper body 54 to transfer heat to/from the electrocoagulation module 10 in cooperation or not with the lower body 50 .
[0071] Still referring to the embodiment of FIG. 1 , the anode module 14 is secured to the upper body 54 and extends above the upper body 54 to allow electrical connection 62 thereto. The cathode module 18 of the present embodiment is also secured to the upper body 54 and extends therefrom 66 to allow electrical connection thereto. A power supply (not illustrated) is connected to the cathode module 18 to provide negative power thereof. Electrical polarity reversal is provided when desired to avoid passivation of the anode module 14 and the anodes 16 secured thereon. Insulators may be placed between two adjacent electrodes to prevent short circuits thereof. The cathode 18 and the anodes 16 are subjected to DC current. One skilled in the art can also appreciate that the upper body 54 is made of an insulating material to prevent establishing an electrical connection between the cathode 18 and the anode 14 modules.
[0072] The anode module 14 can be made of soluble or inert materials. The cathode module 18 can be made of steel, aluminum, stainless steel, galvanized steel, brass or other materials that can be of the same nature as the anode module 14 material or having an electrolytic potential close to the electrolytic potential of the anode 16 . The cathode module 18 of the present embodiment has a hollowed cylindrical shape, fabricated of sheet material, and can be equipped with an optional lower frustoconical portion (not illustrated in FIG. 1 ). The inter electrode distance of an embodiment of the invention is about between 8-25 mm and preferably 10 mm for electro floatation and 20 mm for electrocoagulation. The interior of the cathode module 18 electrically interacts with the outside of the anode module 14 . The electrocoagulation module 10 internal wall includes non-conductive material, like polymer, in an embodiment of the invention. The cathode module 18 could alternatively serve as a reservoir, or reactor, at the same time thus holding the liquid to treat therein in other embodiments. The cathode module 18 can be made of a material different from the anode material 16 or can alternatively be made of the same material, like, for instance, magnesium.
[0073] The size and the available active surface area of the cathode module 18 can be adapted to various conditions without departing from the scope of the present invention. The surface ration of the cathode/anode can be identical or vary to about 1.5. The cathode module 18 of other embodiments can alternatively be oval or conical; its diameter expending upward or downward. The electrocoagulation module 10 can include therein an optional fluid agitator module 66 adapted to apply kinetic energy to the fluid contained in the electrocoagulation module 10 by moving or vibrating the fluid in the electrocoagulation module 10 as it is illustrated in the embodiment depicted in FIG. 2 .
[0074] As mentioned above, the movement of the fluid increases the kinetic energy contained therein to destabilize the colloidal solution. This can be achieved by turbulently injecting the fluid in the electrolytic module (the speed and tangential injection of the fluid are possible ways to create turbulences in the fluid). The electrocoagulation module 10 embodied in FIG. 2 is substantially similar to the electrocoagulation module 10 embodied in FIG. 1 with the difference that the electrocoagulation module 10 in FIG. 1 is equipped with a fluid agitator module 66 . The fluid agitator module 66 in this embodiment is a spiral shaped protrusion member 70 that is secured to the anode module 14 . The movement of the fluid between the anode module 14 and the cathode module 18 is intensified by the protrusion member 70 , which influences the electrolytic process. The anode module 14 of an alternate embodiment that is not illustrated in FIG. 1 and FIG. 2 could be rotatably secured to the upper body 54 of the electrocoagulation module 10 and be rotated by an external motor to rotate the anode and the protrusion members secured thereon to apply additional kinetic energy to the fluid as it will be discussed below. As it is illustrated in FIG. 1 and FIG. 2 , the anode module 14 is preferably centered inside the electrocoagulation module 10 and preferably located at equal distance from the cathode module 18 .
[0075] The electrocoagulation module 10 of FIG. 1 and FIG. 2 further comprises a pair of electrocoagulation module connectors 74 adapted to operatively install the electrocoagulation module 10 in a larger fluid treatment process, as it will be discussed in mode details below. The electrocoagulation module 10 can removably be mounted in series, or in parallel, in the fluid treatment process. This way, the electrocoagulation module 10 can easily be added, maintained, replaced and/or removed from the fluid treatment process.
[0076] FIG. 3 and FIG. 4 illustrates additional views of the electrocoagulation module 10 equipped with a spiral protrusion member 70 . One can appreciate from FIG. 3 and FIG. 4 that a fluid distributor 72 can be installed inside the electrocoagulation module 10 to channel the entering fluid downward between the cathode module 18 and the lower body 50 to make the fluid raise back between the anode module 14 and the cathode module 18 before it exits the electrocoagulation module 10 through the opening defined therein. One can appreciate from FIG. 3 that the spiral protrusion member 70 is substantially perpendicular to the anode module 14 and is used to add kinetic energy to the fluid passing along by adding turbulences. In an embodiment of the invention, the fluid is pushed in the electrocoagulation module 10 and the sole movement of the fluid in respect with the static spiral protrusion member 70 increases the energy in the fluid that augment the number of shocks that can lead to a more rapid agglomeration of particles therein.
[0077] Moving now to FIG. 5 illustrating another embodiment of a simplified electrocoagulation module 10 having a rod-type anode module 14 disposed in an hollowed cathode module 18 also used as a lower body 50 in which flows the fluid to be treated. Small protrusion members 70 are disposed on the anode module 14 to agitate the fluid passing nearby in the electrocoagulation module 10 according to the fluid path identified by arrows 30 .
[0078] As best seen in FIG. 6 , a typical series of steps are illustrated for using electrocoagulation to flocculate particles in accordance with an embodiment of the invention. Firstly there is insertion of a fluid 80 in the electrocoagulation module 10 and agitation of the fluid 84 with the anodes 16 movements increases the electrocoagulation speed. The fluid electrolysis 88 with an exemplary magnesium anode 16 begins. It has to be noted that a magnesium anode is used in the present illustrative embodiment although other anodic materials could be used as explained above. The fluid is subjected to an electric current and electrolysis is made between the cathode module 18 and the anodes 16 to increase the size of the particles contained in the fluid. The particles are then decanted 92 and/or filtered and the treated fluid is extracted from the electrocoagulation module 10 .
[0079] Referring to FIG. 7 , the electrocoagulation module 14 might contains an optional fluid agitator module 110 to further agitate the fluid in the cathode module 14 and thus increase the kinetic energy of the fluid. The fluid agitator module 110 can be mechanical and adapted to mechanically agitate the fluid. The fluid agitator module 110 can alternatively be electrically actuated with a specific frequency in a form of ultra sounds.
[0080] The upper body 54 of the electrocoagulation module 10 embodied in FIG. 7 includes an anode module-receiving portion 84 adapted to receive therein a rotatable anode module 14 . The anode module receiving portion 84 of the illustrated embodiment is provided with a bearing member 88 adapted to allow a rotation or a pivotal motion of the anode module 14 inside the electrocoagulation module 10 about an anode module vertical axis 92 and in respect with the cathode module 18 to add kinetic energy to the fluid in the electrocoagulation module 10 . A motor 96 , operatively connected to the anode module 18 , provides the rotation and/or the pivotal of the anode module 18 . As it can be appreciated, the anode module receiving-portion 84 is provided with seals (e.g. “O”-rings, not illustrated) and a fastening mechanism (not illustrated) to properly seal and secure the anode module 14 in the electrocoagulation module 10 .
[0081] The cathode module 18 can include one or many anodes 16 , as it can be appreciated in the embodiment of FIG. 8 , which can be individually or collectively be made of Mg, Al, Fe, Ca, or any other suitable material. The anode module 14 is operatively connected to an anode agitation module 24 adapted to rotate, or apply a reciprocal angular motion, the anodes 16 inside the electrocoagulation module 10 in respect with the cathode module 18 . It can be appreciated by a skilled reader that consumable and inert (non-consumable) anodes 16 can be collectively used to simultaneously produce electrocoagulation and electroflotation. Also, it can be appreciated that a continuous flow of fluid is desirable for a continuous treatment of the fluid in the electrocoagulation module 10 . The rotative motion of the anodes 16 creates a circular and preferably turbulent movement of the fluid in the anode module 14 hence increasing the number of particle collisions in the fluid and thus the kinetic energy contained in the fluid.
[0082] An anode module 14 can accommodate a plurality of anodes 16 as embodied in FIGS. 8 a ) through 8 c ). The plurality of anodes 16 can serve in different ways the electrocoagulation process. They can be moved to further add kinetic energy to the fluid. They can have different sizes and shapes to provide a better balance between the anode module 14 and the cathode module 18 . Also, the anodes 16 can be made of different materials depending of the type of contaminants contained in the fluid to clean because different anodic materials will interact differently with different contaminants and provide further advantages. The distance between the anodes 16 and the cathode module 18 can also be adjusted if desirable.
[0083] FIGS. 8 a ) through 8 c ) referred above illustrate a general anode module 14 embodiment where two opposed anodes holders 100 provided with a plurality of anode-receiving portions 104 adapted to receive therein an anode's extremity. The two opposed anodes holders 100 are held together by a junction member 106 to form a unitary structure. The junction member 106 , to retain the anodes 16 in their respective and opposed anodes holders 100 , provides a longitudinal tension. The opposed anodes holders 100 can be disassembled from the junction member to insert the anodes 16 in their respective opposed anode-receiving portions 104 . Plastic or other non-conductive materials can be used to manufacture the junction member 106 to prevent electric current to be conducted by the junction member 106 between the anodes holders 100 . The non-conductive junction member 106 is unlikely to interfere in the electrolysis process that is occurring only with the anodes 16 in relation with the cathode module 18 . An optional conductor, like an electrically conductive wire 108 , can be integrated into the junction member 106 to electrically connect the two opposed anodes holders 100 to ensure proper current distribution within the anodes 16 in an embodiment of the invention.
[0084] Alternatively, the opposed anodes holders 100 could be made of a non-conductive material in another embodiment. In the later embodiment the conductive wire 108 , or any other electrically conductive element would electrically connect the anodes 16 . A conductive junction member 106 can be used in embodiments using non-conductive anodes holders 100 . The conductive junction member 106 could be used as another cathode providing an electrolytic surface to the anodes 16 on the opposite side of the cathode module 18 to perform a more even electrolysis of the anodes 16 .
[0085] The anode module 14 having a plurality of anodes 16 thereof can be embodied like the anode module 14 illustrated in FIGS. 9 a ), b ) and c ). The anode module 14 includes two opposed conductive anodes holders 100 adapted to secure therebetween six anodes 16 (a different number of anodes 16 can be used if desirable). The anode module assembly thus created can be used to rotate, or angularly reciprocate, in the electrocoagulation module 10 to add kinetic energy to the fluid in the electrocoagulation module 10 . The anodes holders 100 are sized and designed to easily replace anodes 16 thereon. The anodes holders 100 are also adapted to receive anodes of different shapes, materials and are furthermore adapted to leave some anode-receiving portions 104 empty, as it will be discussed in greater details below.
[0086] FIG. 10 a) through FIG. 10 I) illustrates a plurality of anode modules 14 with different configurations of anodes 16 thereon. There are many possible variations and some are illustrated with different number of anodes 16 , anode sizes (e.g. small, medium, large, thin, thick) and with different shapes. These different anodes holders 100 configurations are presented for illustrative purpose and do not intend to limit the possibilities to the illustrated anode module 14 configurations.
[0087] The particularity of the anode module 14 of the illustrated embodiment is that it is designed like a multi-headed anode module 14 with anodes 16 thereon. A different number of anodes 16 and the position of the anodes 16 on the anode module 14 illustrated herein can vary to adjust to the fluid to be treated without departing from the scope of the present invention. The position of the anodes 16 in respect with the cathode module 18 is optionally ensured by insulating supports (not illustrated) in order to avoid uneven wear of the anodes 16 . The cathode module's 18 surface area can be larger than the combined surface areas of the anodes 16 to improve electrolytic performance. The cathode 18 surface area might be equal or smaller than the surface area of the anodes 16 by making a reduction of the cathodes' 18 surface area. The design of the cathode module 18 and the anodes 16 included in the anode module 14 depends, inter alia, of the amount of contaminants contained in the fluid and the flow of fluid to be electrocoagulated.
[0088] The cathode module 14 , or the body 30 , includes at least two electrocoagulation module connectors 74 serving as fluid inlets and outlets. The electrocoagulation module connectors 74 can be associated with optional filters 114 adapted to filter particles of filterable sizes as it is illustrated in FIG. 11 . The electrocoagulation module 10 connectors 74 can be disposed anywhere on the electrocoagulation module 10 . Preferably, the electrocoagulation module connectors 74 are disposed on opposite sides to help prevent direct fluid communication thereof.
[0089] The aforementioned electrocoagulation module 10 herein refers to uses consumable electrodes to electrocoagulated colloidal solutions. The same electrocoagulation module 10 can accommodate non-consumable electrodes, passive electrodes (i.e. non-conductive electrode), therein to be transformed into an electroflotation module 12 . The electroflotation module 12 produces microbubles in the fluid therein that helps lifting the particles in the fluid. The electrocoagulation module 10 and the electroflotation module 12 can be used separately or in combination in a process. Moreover, electrocoagulation and electroflotation can be obtained in a single reactor by combining consumable and inert anodes 16 . The present description used above a single electrocoagulation module 10 for explanation purposes. The text below refers to a process using either a single electrocoagulation module 10 as illustrated in FIG. 11 , a single electroflotation module 12 , a combination of a plurality of electrocoagulation modules 10 , a combination of a plurality of electroflotation modules 12 and a combination of electrocoagulation module(s) 10 and electroflotation module(s) 14 . Alternatively a plurality of electrocoagulation modules 10 can be connected in series or parallel depending on the type of liquid and its impurities to be treated. The multiplication of electrocoagulation modules 10 can significantly increase the performance, speed and quality of the treatment. Each module 10 , 12 can be associated with a conditioning module 144 and/or a decantation module 150 .
[0090] Turning now to FIG. 12 depicting some possible embodiments using an electrocoagulation module 10 in accordance with the present invention directed, inter alia, to the removal of organic particles and inorganic particles, like phosphor. The fluid is pumped 120 into an agitated conditioning reservoir 124 provided with an agitator 128 to remove air from solid particles in a form of micro-bubbles (or to remove gas molecules from solid particles) and then passes through a primary filter 114 prior to be injected into the electrocoagulation module 10 . The agitated conditioning reservoir 124 is further equipped with an agitator 128 using blades 132 secured to an end of a rotating shaft 136 rotated by a motor 140 . After the fluid is pumped with an optionally adjustable flow pump 114 in the electrocoagulation module 10 . The fluid is “energized” by the protrusion members 70 secured to the anode module 14 disposed in the electrocoagulation module 10 as explained in details earlier. Once the fluid has passed through the electrocoagulation module 10 it goes to a conditioning module 144 also provided with an optional agitator 128 using blades 132 secured to an end of a rotating shaft 136 rotated by a motor 140 . The conditioning module 144 is used to condition the fluid prior to entering a process phase by homogenising, changing the pH, changing the chemistry of the fluid to improve the reactiveness of the fluid flowing through the electrocoagulation module 10 and/or the electro-flotation module 12 . Its volume can illustratively be of about 500-1000 liters per hour and can be provided with a means for homogenize the fluid, a conductivity regulator module (not illustrated) and/or a pH regulator module (not illustrated). The fluid treated thereof is then ready to be used. A fluid analysis module (not illustrated) is alternatively provided at a position along the fluid path in the treatment system to determine the chemical oxygen demand contaminants level contained in the fluid, at that position, treated by the electrolysis system, the fluid analysis module being adapted to include one of an infra-red detector and a turbidity probe.
[0091] FIG. 12 illustrate an embodiment directed to the removal of COD particles, suspended solid matter and soluble organic matter. The principle is quite similar to the embodiment illustrated in FIG. 11 with some differences. Namely, there is a plurality of electrocoagulation modules 10 and homogenisation modules 144 operatively disposed in series. The fluid passes through a primary filter (not illustrated) and then reaches a conditioning reservoir 124 and conditioning module 144 prior to be injected into a first electrocoagulation module 10 . The fluid is electrocoagulated a first time in the first electrocoagulation module 10 and is released into a first decantation module 150 further equipped with an agitator 140 equipped with blades 132 secured to an end of a rotating shaft 136 rotated by a motor 128 . The fluid is optionally precisely pumped with an adjustable flow pump (not illustrated) disposed along the process. A second electrocoagulation module 10 is followed by a second decantation module 150 to remove COD residual particles. The fluid is mixed with rotatable anodes 16 disposed in the electrocoagulation module 10 as explained in details earlier.
[0092] The fluid can be transferred from an electrocoagulation module 10 , or an electroflotation module 12 , to a decantation module 150 in at least another embodiment as it is illustrated in FIG. 13 . The decantation module 150 is preferably equipped with internal routings adapted to help separate particles from the fluid that will be discussed in details below.
[0093] FIG. 13 illustrates a series of electrocoagulation modules 10 , and/or electroflotation modules 12 , and decantation modules 150 . One can appreciate that the connectors 74 are vertically at the same height to ensure efficient fluid transfer between the modules 10 , 12 , 150 . It can also be appreciated that the anode module 14 is vertically adjustable to set the length of the anodes 16 in the fluid and adjacent to a corresponding cathode module 18 . The same vertical adjustment principle is used in the decantation modules 150 to set the height of the internal routings for proper fluid routing. Once the fluid has passed through an electrocoagulation module 10 it goes to a decanter module 150 to further separate remaining particles. The fluid treated thereof is then extracted from the system.
[0094] Finally, FIG. 13 can illustrate an embodiment directed to pre-thickening. The principle still resembles to the embodiment illustrated in FIG. 12 with at least the difference that there is no electro-flotation module 14 and no conditioning modules 144 . The last stage of the process with this embodiment consists in removing fluid on a dripping table to separate the particles contained therein, which is not illustrated in FIG. 13 .
[0095] FIG. 14 through FIG. 16 depicts three different embodiments of decanter modules 150 . The decanter module 150 is generally used to help separate particles from the fluid. It achieves that by slowing down the fluid, preferably in a laminar flow, to let gravity attract heavier particles to the bottom of the module 150 to be later drained out. More precisely, in respect with FIG. 13 , the fluid enters the connector 74 above a punctured separator 160 adapted to let the particles fall through to the bottom of the decanter 150 and also prevent the inbound fluid to carry the particles at the bottom of the decanter 150 aspirated by the flow. The fluid then move up slowly given the larger diameter of the decanter module 150 to pass between two separating plates 164 , 168 , forming a channel at about 35 degree angle. Separating plate 168 includes a series of holes 172 sized and designed to let the fluid pass through to reach the exit connector 74 without creating turbulence in the fluid lower in the decanter module 150 .
[0096] A cylindrical centrifugal decanter (not illustrated) of an embodiment of the invention can rotate at about 300 RPM. Such a centrifugal decanter could be provided with internal radial fins secured to a rotatable vertical motor-driven shaft to apply desirable movement to the fluid in the decanter.
[0097] The embodiment illustrated in FIG. 15 uses a different internal structure to help separate the particles from the fluid. The fluid enters the decanter module 150 and as to move upward 30 to get downward into a first funnel-like separator 176 to change direction again upward to enter a second funnel-like separator 180 to finally reach the exit connector 74 above. One can appreciate from that design that the first separator 176 has a hole in its center connected to a tubular portion 184 extending down lower than the entering connector 74 to prevent the entering fluid to bypass the first separator 176 and to allow particles to fall through the first separator 176 to the bottom of the decanter module 150 .
[0098] A third decanter 150 embodiment is illustrated in FIG. 16 . This embodiment also slows down the flow of fluid to allow heavier particles to fall down in the decanter 150 . A number of channels 188 are defined inside the decanter 150 , with holes 192 at specific locations, to direct the fluid. It can be appreciated that the entering connector 74 faces a channel's wall and forces the fluid to move upwardly thus allowing the heavier particles to fall at the bottom of the decanter 150 . The fluid passes through the holes 192 to get to the second layer of channels 188 to finally move downward to reach exit connector 74 . It can also be appreciated that openings 192 are defined in the lower portion of the channels 188 to let particles fall to the bottom of the decanter 150 to later be drained.
[0099] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments and elements, but, to the contrary, is intended to cover various modifications, combinations of features, equivalent arrangements, and equivalent elements included within the spirit and scope of the appended claims. Furthermore, the dimensions of features of various components that may appear on the drawings are not meant to be limiting, and the size of the components therein can vary from the size that may be portrayed in the figures herein. Thus, it is intended that the present invention covers the modifications and variations of the invention, provided they come within the scope of the appended claims and their equivalents. | A method, a system and a kit for removing colloid contaminants from a fluid by destabilization thereof with addition of kinetic energy thereto is provided, the method to overcome the energetic barrier preventing an efficient fluid-solid separation comprises injecting the colloidal fluid containing contaminants in an electrolytic system including an electrocoagulation module comprising an anode and a cathode, the anode and the cathode being adapted to be electrically connected to perform electrolysis of the fluid, providing an electric current, between the anode and the cathode, to form electro-coagulated contaminants flocs in the agitated fluid, separating the electro-coagulated flocs from the fluid, and extracting the fluid from the electrolytic system. | 2 |
BACKGROUND
The present disclosure relates to an information processing apparatus.
In recent years, the importance of design is growing in information processing apparatuses such as a personal computer, a mobile terminal, and an electronic book apparatus. For example, regarding a casing, a high-quality texture can be given thereto, in addition to the shape thereof, by painting an inner side of a top plate formed of an acrylic transparent resin to cause a color to stand out and providing a pattern for irregular reflection to a front surface thereof.
Further, there is also known a structure in which a panel constituting a part of a casing emits light. For example, a light guide body is used as the panel. In the structure, a light source such as an LED (light emitting diode) is provided inside a device and the light from the light source is propagated to the panel of the light guide body. On a rear surface of the panel, patterns such as logos are printed in white color, and light propagated along the panel of the light guide body is partially reflected on the printed portion so as to be output to the front side of the panel. As a result, there is obtained such an illumination effect that the patterns such as logos are profiled on the front surface of the panel, and the improvement in aesthetic appearance of the device can be expected (see, for example, Japanese Patent Application Laid-open No. 2004-326901 (paragraph [0029], FIG. 3; hereinafter, referred to as Patent Document 1)).
SUMMARY
Various conditions to bring out the appearance of an information processing apparatus include color, light, a texture of a front surface, and so on. When the structure in which light is effectively used is adopted, the number of manufacturing steps therefor such as painting and surface processing is increased and costs are increased at the same time. For example, in the case where a light guide plate is adopted as seen in Patent Document 1 or the like, it is necessary to provide a light source in an information processing apparatus, which increases the number of components and power consumption and is inadequate particularly for an apparatus that operates using a battery.
In view of the circumstances as described above, it is desirable to provide an information processing apparatus capable of improving designability with use of light without increasing the number of steps in manufacturing or the number of components.
According to an embodiment of the present disclosure, there is provided an information processing apparatus including a display panel unit and a top plate. The display panel unit has a first surface with a display screen and a second surface opposed to the first surface. The top plate has a third surface in contact with the second surface, a fourth surface opposed to the third surface, and a fifth surface connecting an end portion of the third surface and an end portion of the fourth surface, the top plate containing a fluorescent dye to collect light toward the fifth surface.
In the information processing apparatus, since the top plate contains the fluorescent dye to collect light, natural light or artificial light is collected on the fourth surface and induced to the fifth surface while undergoing the total reflection to be output in a condensed state, with the result that the fifth surface is seen as if to emit light. Therefore, by using a material obtained by containing the fluorescent dye to collect light in the top plate of the information processing apparatus, it is possible to improve designability with use of light without increasing the number of steps in manufacturing or the number of components.
In the information processing apparatus, the top plate may include a first concave portion representing a first mark on the third surface.
With this structure, in the information processing apparatus, as in the case of the fifth surface, it is possible to effectively make the first mark stand out while saving costs for attachment of a seal or printing for representing the first mark by inducing the light to the first concave portion. The first concave portion may be integrally formed by a mold at a time of molding of the top plate, or formed by engraving. Here, the mark refers to a character, figure, symbol, or combination thereof, and is typically a trademark used for the information processing apparatus.
Further, the top plate may include a second concave portion representing a second mark on the fourth surface.
With this structure, in the information processing apparatus, by forming the concave portions on the third surface and the fourth surface of the top plate, it is possible to differentiate between the third surface and the fourth surface in visual performance of the mark, thus enhancing user's interests in design more. Here, the second mark may be identical to the first mark or may be different therefrom.
According to another embodiment of the present disclosure, there is provided an information processing apparatus including a main body unit and a plate. The main body unit has a first surface provided with a keyboard. The plate has a second surface in contact with the first surface, a third surface opposed to the second surface, a fourth surface connecting an end portion of the second surface and an end portion of the third surface, and a hole that passes through the second surface and the third surface and exposes the keyboard, the plate containing a fluorescent dye to collect light.
The information processing apparatus may further include a touchpad set to be in contact with the second surface.
In the information processing apparatus, the plate may include a groove indicating a setting position of the touchpad on the second surface.
In the information processing apparatus, the plate may have a thickness that is gradually reduced as a distance from the fourth surface becomes larger.
As described above, according to the embodiments of the present disclosure, it is possible to improve designability with use of light without increasing the number of steps in manufacturing or the number of components.
These and other objects, features and advantages of the present disclosure will become more apparent in light of the following detailed description of best mode embodiments thereof, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view showing an opened state of a display unit of a PC according to an embodiment of the present disclosure;
FIG. 2 is a perspective view showing a closed state of the display unit of the PC according to the embodiment of the present disclosure;
FIG. 3 is a plan view showing the opened state of the display unit of the PC according to the embodiment of the present disclosure;
FIG. 4 is a back view showing the closed state of the display unit of the PC according to the embodiment of the present disclosure;
FIG. 5 is a front view showing the closed state of the display unit of the PC according to the embodiment of the present disclosure;
FIG. 6 is a right side view showing the closed state of the display unit of the PC according to the embodiment of the present disclosure;
FIG. 7 is a left side view showing the closed state of the display unit of the PC according to the embodiment of the present disclosure;
FIG. 8 is a plan view showing the closed state of the display unit of the PC according to the embodiment of the present disclosure;
FIG. 9 is a bottom view showing the closed state of the display unit of the PC according to the embodiment of the present disclosure;
FIG. 10 is a schematic cross-sectional view taken along the line A-A in FIG. 8 ;
FIG. 11 is a schematic cross-sectional view taken along the line B-B in FIG. 8 ;
FIG. 12 is a bottom view showing a top plate of the PC according to the embodiment of the present disclosure;
FIG. 13 is a plan view showing the top plate of the PC according to the embodiment of the present disclosure;
FIG. 14 is a plan view showing a middle plate of the PC according to the embodiment of the present disclosure;
FIG. 15 is a perspective view of the opened state of the display unit of the PC according to the embodiment of the present disclosure, which is obliquely taken from a right direction;
FIG. 16 is a perspective view of the closed state of the display unit of the PC according to the embodiment of the present disclosure, which is obliquely taken from a right direction;
FIG. 17 is a side view of the opened state of the display unit of the PC according to the embodiment of the present disclosure, which is taken from a left side direction; and
FIG. 18 is a perspective view of logo marks and the vicinity thereof on the top plate of the PC according to the embodiment of the present disclosure.
DETAILED DESCRIPTION OF EMBODIMENTS
Hereinafter, an embodiment of the present disclosure will be described with reference to the drawings. In this embodiment, a laptop personal computer (hereinafter, referred to simply as PC) is exemplified as an information processing apparatus.
[Structure of PC]
FIG. 1 is a perspective view showing an opened state of a display unit of a PC according to an embodiment of the present disclosure. FIG. 2 is a perspective view showing a closed state of the display unit of the PC shown in FIG. 1 . FIG. 3 is a plan view showing the opened state of the display unit of the PC. FIG. 3 shows the display unit and a main body unit in a state separated from each other. Further, FIGS. 4 , 5 , 6 , 7 , 8 , and 9 are a back view, a front view, a right side view, a left side view, a plan view, and a bottom view, respectively, showing the closed state of the display unit of the PC.
As shown in those figures, a PC 1 includes a main body unit 2 and a display unit 3 . The main body unit 2 and the display unit 3 are coupled to each other so as to be relatively rotatable by hinges 4 .
On an upper surface of the main body unit 2 , a keyboard 5 , a touchpad 6 , a power switch, other various types of switches, a status display unit, and the like are arranged. The keyboard 5 is a keyboard having a standard QWRTY key layout. The touchpad 6 is a user interface using a capacitive touch panel, for example. In the vicinity of the touchpad 6 , two click buttons to which functions as a left button and a right button of a mouse are assigned are provided.
As shown in FIGS. 1 , 2 , 6 , and 7 , on side surfaces of the main body unit 2 , various types of external connection terminals 2 a , a disc slot 2 b of a disc drive, a slot for a memory card/memory stick, and the like are provided. Examples of the external connection terminals 2 a include a USB (Universal Serial Bus), an iLINK, a LAN (Local Area Network), an external display output, a video input, an audio input, an HDMI (High-Definition Multimedia Interface) output, a microphone input, and a headphone output.
As shown in FIGS. 4 and 9 , the main body unit 2 includes a battery 7 at an end portion of the bottom surface on the back side. The battery 7 is detachable from the main body unit 2 . Inside the main body unit 2 , various types of devices such as a mother board, an optical disc drive, a hard disc drive, a wireless communication device, an audio function, and a speaker/amplifier are provided. On the mother board, a main memory, a CPU, a graphics chip, a chip set, other electronic components such as a control circuit are mounted. The chip set is a chip for managing exchange of data among the devices inside the PC 1 . The chip set includes a built-in graphics chip or the like. Further, the chip set includes an interface for connection with peripheral devices such as a nonvolatile memory and an EC (Embedded Controller).
The display unit 3 includes a display panel unit 8 constituted of an LCD (Liquid Crystal Display), for example. The display panel unit 8 includes a display module having a display screen. The display module is incorporated into the display unit 3 such that the display screen thereof is opposed to the upper surface of the main body unit 2 in the closed state of the display unit 3 of the PC 1 and faces to the front in the opened state of the display unit 3 of the PC 1 . Further, in the closed state of the display unit 3 of the PC 1 , the display unit 3 is used as a lid body of the upper surface of the main body unit 2 . Therefore, on a surface of the display unit 3 that is opposite to the display screen (opposed surface), a top plate 9 as a decorative exterior unit is arranged. The top plate 9 is provided with logo marks M of a product name of the PC 1 , a manufacturer name, and the like. The structure of the decorative exterior unit of the display unit 3 will be described later. The logo mark M is also provided to the upper surface of the main body unit 2 .
[Structure of Display Unit]
Next, the structure of the display unit 3 will be described. FIG. 10 is a schematic cross-sectional view taken along the line A-A in FIG. 8 , and FIG. 11 is a schematic cross-sectional view taken along the line B-B in FIG. 8 . Further, FIG. 12 is a bottom view showing the top plate 9 taken apart from the display unit 3 , and FIG. 13 is a plan view showing the top plate 9 taken apart from the display unit 3 .
As shown in FIGS. 4 to 7 , 10 , and 11 , the display unit 3 includes the display panel unit 8 and the top plate 9 . Into one surface of the display panel unit 8 (front surface), a display module 14 having a display screen is incorporated. To the other surface of the display panel unit 8 that is opposite to the display screen (rear surface), a protective sheet 13 for protecting the display panel unit 8 is attached.
To the rear surface of the display panel unit 8 , via the protective sheet 13 , one surface of the top plate 9 (rear surface) is attached fixedly. As shown in FIGS. 10 and 11 , a concave portion 9 a is provided to the rear surface of the top plate 9 , and at least a part of the display panel unit 8 is accommodated in the concave portion 9 a . Specifically, end portions of the top plate 9 on four sides are bent in the same direction so that the concave portion 9 a described above is formed at a portion surrounded by those end portions. The thickness of an area corresponding to the concave portion 9 a of the top plate 9 is substantially equal and front and rear surfaces thereof are flat surfaces. Further, the thickness of at least the left and right end portions of the top plate 9 is set so as to be gradually increased from the thickness of the area corresponding to the concave portion 9 a.
Further, as shown in FIGS. 2 , 8 , 12 , and 13 , the top plate 9 is provided with logo marks M of, for example, a product name of this apparatus and a manufacturer name. Those logo marks M are formed as concave portions on the rear surface of the top plate 9 . Here, a cross section of the concave portion representing the logo mark M is formed to be a right angle, for example, but it may have a semicircular, semielliptical, or other arciform cross-sectional configuration.
A film is attached to the front surface of the top plate 9 . The film enhances the strength of the front surface of the top plate 9 and also has a decorative function. Specifically, a gradation pattern is printed on the film, in which, for example, a central part that occupies a great part of the film is transparent, and a certain width portion from the ends of the top plate 9 on the four sides is gradually changed to be semi-transparent and then opaque.
Further, on the protective sheet 13 interposed between the display panel unit 8 and the top plate 9 , a color or decorative pattern to hide the rear surface of the display panel unit 8 and to be seen through the transparent portion of the top plate 9 is printed. As the decorative pattern, a 3D pattern to allow the top plate 9 to be sterically seen may be adopted. Specifically, the protective sheet 13 may be formed as a 3D sheet. It may be possible to prepare color variations and decorative pattern variations for the protective sheet 13 such that the protective sheet 13 can be exchanged with one corresponding to a user's preference.
(Material of Top Plate)
Next, the material of the top plate 9 will be described.
The top plate 9 is formed of a plastic light-collecting plate having transparency. The light-collecting plate contains a fluorescent dye having light-condensing property. As the plastic, for example, poly methyl methacrylate, polycarbonate, or polystyrene is used. Due to the fluorescent dye, the top plate 9 collects natural light or artificial light on the surface thereof. Due to excitation light such as ultraviolet rays included in the collected light, the fluorescent dye within the top plate 9 emits light, and major part of the emitted light is induced to end surfaces of the top plate 9 (side surfaces connecting the end portions of the front surface and the end portions of the rear surface) while undergoing total reflection within the top plate 9 , and then output from the end surfaces in a condensed state. Accordingly, the end surfaces (side surfaces) of the top plate 9 on the four sides emit bright light. Further, an edge portion of the logo mark M provided as a concave portion on the rear surface of the top plate 9 also emits bright light by the induced light within the top plate 9 densely gathering at that concave portion, similarly to the end surfaces described above. Accordingly, a decoration effect is obtained in which a silhouette of the top plate 9 and the logo marks M are profiled by the bright light.
The top plate 9 is manufactured by, for example, insert molding (IMF), including the concave portions as the logo marks M described above. Specifically, the film is formed in advance in vacuum in accordance with the shape of the top plate 9 . By setting the film in a mold for injection molding having the shapes of the top plate 9 and logo marks M, injecting a molten resin serving as a material of the top plate 9 into the mold, welding the film to the molten resin, and solidifying them, a top plate 9 integrally formed with the film is thus manufactured. Therefore, as compared to a seal or a printed logo mark in related art, it is possible to save costs for attachment of a seal or printing and effectively make the logo mark stand out due to the above-mentioned effect of the light by forming the logo mark as a concave portion.
In this manner, since a film is welded on the front surface of the top plate 9 , the front surface has to be extremely flat. As described above, in this embodiment, the logo marks M are provided on the rear surface of the top plate 9 so as to cope with the problem.
[Structure of Main Body Unit]
Next, the structure of the exterior of the main body unit 2 will be described. As shown in FIGS. 1 and 3 , the upper surface of the main body unit 2 (surface provided with the keyboard 5 ) is mainly covered with a deep-side plate 11 , a near-side plate 12 , a middle plate 10 , and the like.
The deep-side plate 11 is an exterior unit including notch portions for securing movable areas for the hinges 4 and corresponding to an area where various types of switches such as a power switch are arranged. The near-side plate 12 is an exterior unit corresponding to a near portion where left and right click buttons attached to the touchpad 6 are arranged in the main body unit 2 . The middle plate 10 is an exterior unit corresponding to a middle portion where the keyboard 5 and the touchpad 6 are arranged in the main body unit 2 . Of those exterior plates, the middle plate 10 is formed of a plastic light-collecting plate having transparency as in the case of the top plate 9 described above. Therefore, as shown in FIGS. 1 , 2 , 6 , and 7 , end surfaces of the middle plate 10 that are exposed from the side surfaces of the PC 1 (side surfaces connecting the end portions of the front surface and the end portions of the rear surface) also emit bright light by the effect of light described above. Intending to obtain such an effect of light, the side surfaces of the middle plate 10 are designed to be exposed from the side surfaces of the main body unit 2 . Further, the middle plate 10 is formed by injection molding, for example, including the logo marks M, as in the case of the top plate 9 described above.
The deep-side plate 11 and the near-side plate 12 are formed of a synthetic resin such as an AS resin or an ABS resin, as in the case of the bottom surface of the main body unit 2 and the exterior units of the respective side surfaces. The top plate 9 of the display unit 3 and the exterior units of the main body unit 2 have a common color.
FIG. 14 is a plan view showing the middle plate 10 formed of a plastic light-collecting plate. As shown in FIG. 14 , the middle plate 10 has a rectangular hole 10 c that passes through the front surface and rear surface of the middle plate 10 and exposes the keyboard 5 .
As shown in FIG. 10 , the thickness of the left and right end portions of the middle plate 10 are set so as to be gradually increased with respect to the thickness at the center thereof as in the case of the top plate 9 of the display unit 3 . Specifically, the thickness of the middle plate 10 is set to be smaller as a distance from the end surface (side surface) becomes larger. With this structure, it is possible to improve design with use of light while securing setting positions of components located below the middle plate 10 within the main body unit 2 .
As shown in FIG. 11 , the thickness of an area between the left and right end portions of the middle plate 10 is substantially equal. It should be noted that an edge circumference of the hole 10 c from which the keyboard 5 is exposed in the middle plate 10 is bent in a direction of the bottom surface of the main body unit 2 and uplifted. With this structure, the strength of the middle plate 10 particularly in the circumference of the hole 10 c is improved. Further, the uplifted portion of the edge circumference of the hole 10 c , that is, an inner surface of the hole 10 c is to be an end surface that emit bright light by the induced light within the top plate 9 being condensed.
As shown in FIGS. 10 and 11 , the rear surface of the middle plate 10 is provided with the touchpad 6 attached thereto using, for example, a double-sided tape or the like. As shown in FIGS. 10 and 14 , the rear surface of the middle plate 10 is provided with a V-shaped groove 10 a as a positioning mark of the touchpad 6 . Specifically, the touchpad 6 is attached to the middle plate 10 while being aligned with a position of the V-shaped groove 10 a of the middle plate 10 as a reference. Accordingly, since light is induced to end surfaces of the touchpad 6 and the V-shaped groove 10 a described above and condensed, it is possible to achieve an effect in terms of decoration that causes the periphery of the touchpad 6 to emit bright light and an effect of improving operability by casing a user to visually identifying the position of the touchpad 6 immediately.
Further, as shown in FIGS. 10 and 14 , a slightly concave portion 10 b is formed on the front surface of the middle plate 10 in an area positioned slightly inner side of the position corresponding to the V-shaped groove 10 a . The concave portion 10 b is formed and accordingly the thickness of the middle plate 10 is adjusted so as to be a thickness at which the touchpad 6 can detect a capacitance. Further, at the periphery of the concave portion 10 b , end surfaces are slightly formed in a direction substantially perpendicular to the direction in which light is induced within the middle plate 10 . Therefore, it is possible for the user to visually identify the position of the touchpad 6 by the end surfaces in the periphery of the concave portion 10 b emitting bright light.
[Visual Effect of Exterior]
FIG. 15 illutrates a perspective view of an opened state of the display unit 3 of the PC 1 , which is obliquely taken from a right direction. FIG. 16 illutrates a perspective view of a closed state of the display unit 3 of the PC 1 , which is obliquely taken from the right direction. FIG. 17 illutrates a side view of the opened state of the display unit 3 of the PC 1 , which is taken from a left side direction, and FIG. 18 illutrates a perspective view of logo marks M and the vicinity thereof on the top plate 9 of the PC 1 .
As shown in those figures, by adopting a plastic plate containing a fluorescent dye having light-condensing property as the top plate 9 and the middle plate 10 , the end surfaces of the top plate 9 and the middle plate 10 emit bright light, and by forming a logo mark M as a concave portion on the top plate 9 and attaching the touchpad 6 to the rear surface of the middle plate 10 , the periphery of the logo mark M and touchpad 6 emit bright light, which contributes to the improvement of the design of the PC 1 .
[Conclusion]
According to the embodiment described above, a plastic plate containing a fluorescent dye having light-condensing property is used as the exterior members of the main body unit 2 and the display unit 3 of the PC 1 , with the result that the designability of the PC 1 can be improved using light without increasing the number of steps in manufacturing or the number of components.
Further, in the display unit 3 , the concave portions indicating the logo marks M are formed on the rear surface of top plate 9 containing a fluorescent dye having light-condensing property, with the result that the logo marks can be made to stand out while reducing costs, as compared to a logo mark obtained by attachment of a seal or printing in related art.
Further, in the main body unit 2 , the touchpad 6 is attached to the rear surface of the middle plate 10 containing the fluorescent dye having light-condensing property, with the result that it is possible not only to improve designability, but also for user to visually identify the position of the touchpad 6 immediately.
Further, in this embodiment, the light-collecting plate is adopted in equipment having a relatively large shape on a top plate or an arrangement surface of a keyboard, such as a laptop PC, with the result that it is possible to ensure a sufficient amount of light induced to end surfaces thereof and effectively cause the end surfaces to emit light.
[Modified Example]
In the embodiment described above, the logo marks M as concave portions of the top plate 9 are provided by injection molding, but may be provided by other methods such as engraving. Further, although the logo marks M are provided on the rear surface of the top plate 9 , instead of or in addition to this, the logo marks M may be provided on the front surface of the top plate 9 . Further, instead of the logo marks M, various character strings or decorative patterns may be provided as concave portions. By providing a logo mark or other designs as concave portions on both the front surface and rear surface of the top plate 9 , it is possible to differentiate between the front surface and the rear surface in visual performance, thus providing a more complicated and attractive design.
In the embodiment described above, a laptop PC is exemplified as the information processing apparatus. However, the present disclosure is applicable to, for example, a tablet PC, a portable information terminal, a mobile phone, a smartphone, a portable game console, an electronic dictionary, and an electronic book terminal, a portable audio/video player, a car navigation apparatus, and other information processing apparatuses. In this case, the information processing apparatus may not be provided with a keyboard.
The present disclosure contains subject matter related to that disclosed in Japanese Priority Patent Application JP 2010-170113 filed in the Japan Patent Office on Jul. 29, 2010, the entire content of which is hereby incorporated by reference.
It should be understood by those skilled in the art that various modifications, combinations, sub-combinations and alterations may occur depending on design requirements and other factors insofar as they are within the scope of the appended claims or the equivalents thereof. | An information processing apparatus includes a display panel unit and a top plate. The display panel unit has a first surface with a display screen and a second surface opposed to the first surface. The top plate has a third surface in contact with the second surface, a fourth surface opposed to the third surface, and a fifth surface connecting an end portion of the third surface and an end portion of the fourth surface, the top plate containing a fluorescent dye to collect light toward the fifth surface. | 6 |
TECHNICAL FIELD
[0001] The present invention relates to a method for deactivating a transition metal complex used as a catalyst for producing a reduction reaction product by a reduction reaction, without loss in optical purity of the target product.
BACKGROUND ART
[0002] Hydrogenation and hydrogen transfer reactions using transition metal complexes are important methods for producing optically active compounds. It is known that prochiral ketones are reacted in the presence of a transition metal catalyst by using a secondary alcohol, formic acid, hydrogen, or the like as a hydrogen source, in general.
[0000]
[0003] Since a transition metal catalyst having a reducing function also has an oxidizing function, oxidation of the produced secondary alcohol occurs in some cases, causing decrease in optical purity of the product.
[0000]
[0004] Since these reactions proceed under a neutral or basic condition, a method in which an acid such as hydrochloric acid is added or the like is employed for stopping these reactions.
SUMMARY OF INVENTION
Technical Problem
[0005] However, when the product is distilled in the presence of hydrochloric acid, the inside of a distillation apparatus is exposed to a high temperature and an acidic atmosphere, and hence the apparatus is more likely to be damaged. Hence, limitations are imposed on the reaction apparatus used and the operation method employed.
Solution to Problem
[0006] The present inventors have found that when a nitrogen-containing compound is added to a reaction solution of a reduction reaction, (i) the nitrogen-containing compound selectively reacts with a transition metal catalyst, and (ii) the reducing function and the oxidizing function of the transition metal complex are eliminated, so that the decrease in optical purity of a reduction reaction product is suppressed. This finding has led to the completion of the present invention.
[0007] The present invention includes the following contents [1] to [8].
[0000] [1] A method for producing a reduction reaction product, comprising:
[0008] adding a nitrogen-containing compound to a reaction solution in which a reduction reaction has been conducted by using a transition metal complex; and then
[0009] performing reaction solvent recovery and/or distillation.
[0000] [2] The production method according to the above-described [1], wherein the reduction reaction is an asymmetric hydrogenation, asymmetric hydrogen transfer, or ester reduction reaction.
[3] The production method according to the above-described [1] or [2], wherein the transition metal complex is a ruthenium complex, a rhodium complex, or an iridium complex.
[4] The production method according to the above-described [3], wherein one equivalent or more of the nitrogen-containing compound is added relative to the transition metal complex.
[5] The production method according to the above-described [4], wherein the number of nitrogen atoms in the nitrogen-containing compound is two or more.
[6] The production method according to the above-described [5], wherein the nitrogen-containing compound is an imidazole.
[7] The production method according to the above-described [1] to [6], wherein the addition of the nitrogen-containing compound is intended to suppress the decrease in optical purity of the reduction reaction product during the reaction solvent recovery and/or the distillation.
[8] The production method according to the above-described [7], wherein the addition of the nitrogen-containing compound results in a reaction of the nitrogen-containing compound with the transition metal complex to form a complex containing the nitrogen-containing compound, and thus suppresses the decrease in optical purity of the reduction reaction product.
Advantageous Effects of Invention
[0010] The present invention makes it possible to efficiently produce an optically active compound without causing decrease in optical purity during purification of the product conducted after a reduction reaction such as an asymmetric hydrogenation, asymmetric hydrogen transfer, or ester reduction reaction is conducted.
DESCRIPTION OF EMBODIMENTS
[0011] Hereinafter, the present invention will be described specifically.
[0012] Transition metals in the transition metal complex used in the present invention include metals of group 8 to 10 in the periodic table. Of these metals, rhodium, ruthenium, and iridium are preferable, and ruthenium is particularly preferable.
[0013] Preferred transition metal complexes include complexes in which a diamine, a diphosphine, a lower alkyl group (for example, a linear or branched alkyl groups having 1 to 10 carbon atoms, and specifically, a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, a s-butyl group, an isobutyl group, a t-butyl group, or the like; a linear or branched alkyl group having 1 to 6 carbon atoms is preferable), a substituted benzene, a halogen atom, pentamethylcylcopentadiene, or the like is coordinated as a ligand. The diamine and the diphosphine as the ligand is more preferably optically active.
[0014] Examples of the diamine include diamines represented by general formula (A):
[0000]
[0000] wherein * represents an asymmetric carbon atom; R N1 and R N2 each independently represent an optionally substituted C 1 to C 20 alkyl group, an optionally substituted C 3 to C 8 cycloalkyl group, an optionally substituted C 7 to C 20 aralkyl group, an optionally substituted C 6 to C 20 aryl group, or an optionally substituted C 3 to C 20 heterocyclic group, or R N1 and R N2 may together form an alkylene group or an alkylenedioxy group; R N3 represents a hydrogen atom or an optionally substituted C 1 to C 20 alkyl group; and R N4 represents an alkyl group having 1 to 10 carbon atoms, a halogenated alkyl group having 1 to 10 carbon atoms, or a C 5 to C 20 aryl group which may be substituted with an alkyl group (s) having 1 to 10 carbon atoms, a halogenated alkyl group (s) having 1 to 10 carbon atoms, or a halogen atom(s).
[0015] Substituents which may be possessed by the C 1 to C 20 alkyl group, the C 3 to C 8 cycloalkyl group, the C 7 to C 20 aralkyl group, the aryl group, or the heterocyclic group represented by R N1 or R N2 and substituents which may be possessed by the C 1 to C 20 alkyl group represented by R N3 include methyl groups, ethyl groups, cyclopropyl groups, cyclobutyl groups, cyclopentyl groups, cyclohexyl groups, benzyl, 1-phenylethyl groups, phenyl groups, o-toluoyl groups, p-toluoyl groups, thienyl groups, furyl groups, pyridyl groups, piperidinyl groups, piperidino groups, and the like.
[0016] Specific examples of the optically active diamine include N-(p-toluenesulfonyl)-1,2-diphenylethylenediamine, N-methanesulfonyl-1,2-diphenylethylenediamine, N-trifluoromethanesulfonyl-1,2-diphenylethylenediamine, N-(p-fluorobenzenesulfonyl)-1,2-diphenylethylenediamine, N-pentafluorobenzenesulfonyl-1,2-diphenylethylenediamine, N-(p-methoxybenzenesulfonyl)-1,2-diphenylethylenediamine, N-(3,5-xylylsulfonyl)-1,2-diphenylethylenediamine, N-(2,4,6-trimethylbenzenesulfonyl)-1,2-diphenylethylenediamine, N-((1R)-camphorsulfonyl)-1,2-diphenylethylenediamine, N-(naphthylsulfonyl)-1,2-diphenylethylenediamine, N-(p-toluenesulfonyl)-1,2-cyclohexanediamine, N-methanesulfonyl-1,2-cyclohexanediamine, and N-trifluoromethanesulfonyl-1,2-cyclohexanediamine.
[0017] Examples of the diphosphine include diphosphines represented by general formula (B):
[0000] R P1 R P2 P-Q-PR P3 R P4 (B)
[0000] wherein R P1 , R P2 , R P3 , and R P4 each independently represent an optionally substituted aryl group, an optionally substituted cycloalkyl group, or an optionally substituted alkyl group, or R P1 and R P2 and/or R P3 and R P4 may together form a ring(s); and Q represents an optionally substituted divalent arylene group or a ferrocenediyl group.
[0018] In the above formula, examples of the optionally substituted aryl group represented by R P1 , R P2 , R P3 or R P4 include aryl groups having 6 to 14 carbon atoms, and specifically include a phenyl group, a naphthyl group, an anthryl group, a phenanthryl group, a biphenyl group, and the like. These aryl groups may have one or two or more substituents, and the substituents include alkyl groups, alkoxy groups, aryl groups, heterocyclic groups, and the like.
[0019] The alkyl groups as the substituents in the aryl group include linear or branched alkyl groups having, for example, 1 to 15 carbon atoms, preferably 1 to 10 carbon atoms, and more preferably 1 to 6 carbon atoms, and specific examples thereof include methyl groups, ethyl groups, n-propyl groups, isopropyl groups, n-butyl groups, s-butyl groups, isobutyl groups, t-butyl groups, and the like.
[0020] The alkoxy groups as the substituents in the aryl group include linear or branched alkoxy groups having, for example, 1 to 6 carbon atoms, and specifically include methoxy groups, ethoxy groups, n-propoxy groups, isopropoxy groups, n-butoxy groups, s-butoxy groups, isobutoxy groups, t-butoxy groups, and the like.
[0021] The aryl groups as the substituents in the aryl group include aryl groups having, for example, 6 to 14 carbon atoms, and specifically include phenyl groups, naphthyl groups, anthryl groups, phenanthryl groups, biphenyl groups, and the like.
[0022] The heterocyclic groups as the substituents of the aryl group include aliphatic heterocyclic groups and aromatic heterocyclic groups. Examples of the aliphatic heterocyclic groups include 5 to 8-membered, preferably 5 or 6-membered monocyclic aliphatic heterocyclic groups having 2 to 14 carbon atoms and containing at least one, preferably 1 to 3 hetero atoms such as nitrogen atoms, oxygen atoms, and sulfur atoms; and polycyclic or condensed-cyclic aliphatic heterocyclic groups constituted of any of these monocyclic aliphatic heterocyclic groups. Specific examples of the aliphatic heterocyclic groups include 2-oxopyrrolidyl groups, piperidino groups, piperazinyl groups, morpholino groups, tetrahydrofuryl groups, tetrahydropyranyl groups, tetrahydrothienyl groups, and the like. Meanwhile, examples of the aromatic heterocyclic groups include 5 to 8-membered, preferably 5 or 6-membered monocyclic heteroaryl groups having 2 to 15 carbon atoms and containing at least one, preferably 1 to 3 hetero atoms such as nitrogen atoms, oxygen atoms, and sulfur atoms; and polycyclic or condensed-cyclic heteroaryl groups constituted of any of these monocyclic heteroaryl groups. Specifically, the aromatic heterocyclic groups include furyl groups, thienyl groups, pyridyl groups, pyrimidinyl groups, pyrazinyl groups, pyridazinyl groups, pyrazolyl groups, imidazolyl groups, oxazolyl groups, thiazolyl groups, benzofuryl groups, benzothienyl groups, quinolyl groups, isoquinolyl groups, quinoxalyl groups, phthalazinyl groups, quinazolinyl groups, naphthyridinyl groups, cinnolinyl groups, benzoimidazolyl groups, benzoxazolyl groups, benzothiazolyl groups, and the like.
[0023] Meanwhile, the optionally substituted cycloalkyl group represented by R P1 , R P2 , R P3 , or R P4 includes 5-membered or 6-membered cycloalkyl groups, and preferred cycloalkyl groups include a cyclopentyl group, a cyclohexyl group, and the like. One or two or more substituents such as alkyl groups or alkoxy groups as listed as the substituents of the aryl group may be introduced onto the ring of the cycloalkyl group.
[0024] Moreover, the optionally substituted alkyl group represented by R P1 , R P2 , R P3 , or R P4 include linear or branched alkyl groups having, for example, 1 to 15 carbon atoms, preferably 1 to 10 carbon atoms, and more preferably 1 to 6 carbon atoms. Specific examples thereof include a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, a s-butyl group, an isobutyl group, a t-butyl group, a pentyl group, a hexyl group, and the like. These alkyl groups may have one or two or more substituents, and examples of the substituents include alkoxy groups, halogen atoms, and the like. The alkoxy groups include the alkoxy groups listed as the substituents of the aryl group.
[0025] In addition, the ring which may be formed by R P1 and R P2 and/or R P3 and R P4 includes four-membered rings, five-membered rings, and six-membered rings including the phosphorus atom to which R P1 and R P2 or R P3 and R P4 are bound. Specifically, the rings include phosphetane rings, phospholane rings, phosphane rings, 2,4-dimethylphosphetane rings, 2,4-diethylphosphetane rings, 2,5-dimethylphospholane rings, 2,5-diethylphospholane rings, 2,6-dimethyl phosphane rings, 2,6-diethyl phosphane rings, and the like. These rings may be optically active.
[0026] In addition, the optionally substituted divalent arylene group represented by Q includes arylene groups having 6 to 20 carbon atoms such as phenylene groups, biphenyldiyl groups, and binaphthalenediyl groups. The phenylene groups include o- and m-phenylene groups, and the phenylene groups may be substituted with any ones of alkyl groups having 1 to 4 carbon atoms such as methyl groups, ethyl groups, n-propyl groups, isopropyl groups, n-butyl groups, s-butyl groups, isobutyl groups, and t-butyl groups; alkoxy groups having 1 to 4 carbon atoms such as methoxy groups, ethoxy groups, n-propoxy groups, isopropoxy groups, n-butoxy groups, s-butoxy groups, isobutoxy groups, and t-butoxy groups; hydroxy groups; amino groups; substituted amino groups (substituents of the substituted amino groups include alkyl groups having 1 to 4 carbon atoms); and the like. The biphenyldiyl groups and the binaphthalenediyl groups preferably have a structure of the 1,1′-biaryl-2,2′-diyl type, and the biphenyldiyl groups and the binaphthalenediyl groups may be substituted with any ones of the alkyl groups and the alkoxy group described above, alkylenedioxy groups such as methylenedioxy groups, ethylenedioxy groups, and trimethylenedioxy groups, hydroxy groups, amino groups, substituted amino groups, and the like. In addition, the ferrocenediyl group may also have substituents, and the substituents include the alkyl groups, alkoxy groups, alkylenedioxy groups, hydroxy groups, amino groups, substituted amino groups, which are described above, and the like.
[0027] Specific examples of the diphosphines represented by general formula (B) include known diphosphines, and one of the known diphosphines is a compound represented by the following general formula (C):
[0000]
[0000] wherein R 1 and R 2 each independently represent a phenyl group which may be substituted with a substituent(s) selected from halogen atoms, alkyl groups, and alkoxy groups, a cyclopentyl group, or a cyclohexyl group.
[0028] Examples of the alkyl groups as the substituents in the phenyl group represented by the above-described R 1 or R 2 include linear or branched alkyl groups having 1 to 6 carbon atoms such as methyl groups and t-butyl groups. Examples of the alkoxy groups as the substituents in the phenyl group include linear or branched alkoxy groups having 1 to 6 carbon atoms such as methoxy groups and t-butoxy groups. Examples of the halogen atoms as the substituents in the phenyl group include chlorine atoms, bromine atoms, fluorine atoms, and the like. A plurality of these substituents may be introduced onto the phenyl group.
[0029] Specific examples of R 1 and R 2 include phenyl groups, p-tolyl groups, m-tolyl groups, o-tolyl groups, 3,5-xylyl groups, 3,5-di-t-butylphenyl groups, p-t-butylphenyl groups, p-methoxyphenyl groups, 3,5-di-t-butyl-4-methoxyphenyl groups, p-chlorophenyl groups, m-chlorophenyl groups, p-fluorophenyl groups, m-fluorophenyl groups, cyclobutane groups, cyclopentyl groups, cyclohexyl groups, isopropyl groups, and the like.
[0030] In addition, the binaphthyl ring, which is a basic skeleton of the compound represented by general formula (C), may be substituted with a substituent(s), and examples of the substituents include C 1 to C 20 alkyl groups such as methyl groups and t-butyl group; C 1 to C 20 alkoxy groups such as methoxy groups and t-butoxy groups; tri(C 1 to C 20 )alkylsilyl groups such as trimethylsilyl groups, triisopropylsilyl groups, and t-butyldimethylsilyl groups; and tri(C 1 to C 20 ) arylsilyl groups such as triphenylsilyl groups.
[0031] In addition, another specific example of the diphosphines represented by general formula (B) is a compound represented by the following general formula (D):
[0000]
[0000] wherein R 3 and R 4 each independently represent a phenyl group which may be substituted with a substituent(s) selected from halogen atoms, alkyl groups, and alkoxy groups, a cyclopentyl group, or a cyclohexyl group; R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 , which may be the same or different, each represent a hydrogen atom, an alkyl group, an alkoxy group, an acyloxy group, a halogen atom, a haloalkyl group, or a dialkylamino group; two of R 5 , R 6 , and R 7 may form an optionally substituted methylene chain or an optionally substituted (poly)methylenedioxy group; two of R 8 , R 9 , and R 10 may form an optionally substituted methylene chain or an optionally substituted (poly) methylenedioxy group; and R 7 and R 10 may form an optionally substituted methylene chain or an optionally substituted (poly) methylenedioxy group, provided that neither R 7 nor R 10 is a hydrogen atom.
[0032] Examples of the alkyl groups as the substituents in the phenyl group represented by the above-described R 3 or R 4 include linear or branched alkyl groups having 1 to 6 carbon atoms such as methyl groups and t-butyl groups. Examples of the alkoxy groups as the substituents in the phenyl group include linear or branched alkoxy groups having 1 to 6 carbon atoms such as methoxy groups and t-butoxy group. Examples of the halogen atoms as the substituents in the phenyl group include chlorine atoms, bromine atoms, fluorine atoms, and the like. A plurality of these substituents may be introduced onto the phenyl group. Specific examples of R 3 and R 4 include phenyl groups, p-tolyl groups, m-tolyl groups, o-tolyl groups, 3,5-xylyl groups, 3,5-di-t-butylphenyl groups, p-t-butylphenyl groups, p-methoxyphenyl groups, 3,5-di-t-butyl-4-methoxyphenyl groups, p-chlorophenyl groups, m-chlorophenyl groups, p-fluorophenyl groups, m-fluorophenyl groups, cyclobutane groups, cyclopentyl groups, cyclohexyl groups, isopropyl groups, and the like.
[0033] In addition, examples of the alkyl group represented by R 5 to R 10 include linear or branched alkyl groups having 1 to 6 carbon atoms such as a methyl group or a t-butyl group; examples of the alkoxy group represented by R 5 to R 10 include linear or branched alkoxy groups having 1 to 6 carbon atoms such as a methoxy group or a t-butoxy group; and examples of the acyloxy group represented by R 5 to R 10 include acyloxy groups having 2 to 10 carbon atoms such as an acetoxy group, a propanoyloxy group, a trifluoroacetoxy group, or a benzoyloxy group; examples of the halogen atom represented by R 5 to R 10 include a chlorine atom, a bromine atom, a fluorine atom, and the like; examples of the haloalkyl group represented by R 5 to R 10 include haloalkyl groups having 1 to 4 carbon atoms such as a trifluoromethyl group; and examples of the dialkylamino group represented by R 5 to R 10 include di(C 1 to C 20 )alkylamino groups such as a dimethylamino group and a diethylamino group.
[0034] When an optionally substituted methylene chain is formed by two of R 5 , R 6 , and R 7 , or an optionally substituted methylene chain is formed by two of R 8 , R 9 , and R 10 , the methylene chain is preferably, for example, a methylene chain having 3 to 5 carbon atoms, and specifically includes a trimethylene group, a tetramethylene group, a pentamethylene group, and the like. In addition, the substituent (s) in the optionally substituted methylene chain include alkyl groups, halogen atoms, and the like, and specific examples thereof include the above-described alkyl groups having 1 to 6 carbon atoms, fluorine atoms, and the like.
[0035] In addition, when an optionally substituted methylene chain is formed by two of R 5 , R 6 , and R 7 , when an optionally substituted methylene chain is formed by two of R 8 , R 9 , and R 10 , or when an optionally substituted methylene chain is formed by R 7 and R 10 , specific examples of the methylene chain include methylene chains having 1 to 4 carbon atoms such as a methylene group, an ethylene group, a trimethylene group, and a propylene group. In addition, the substituent (s) introduced onto the methylene chain include alkyl groups, halogen atoms, and the like, and specific examples thereof include the above-described alkyl groups having 1 to 6 carbon atoms, fluorine atoms, and the like.
[0036] Meanwhile, when an optionally substituted (poly)methylenedioxy group is formed by two of R 5 , R 6 , and R 7 , when an optionally substituted (poly)methylenedioxy group is formed by two of R 8 , R 9 , and R 10 , or when an optionally substituted (poly)methylenedioxy group is formed by R 7 and R 10 , specific examples of the (poly)methylenedioxy group include (poly)methylenedioxy groups having 1 to 4 carbon atoms such as a methylenedioxy group, an ethylenedioxy group, and a trimethylenedioxy group. In addition, the substituent(s) introduced onto the (poly)methylenedioxy group include alkyl groups, halogen atoms, and the like, and specific examples thereof include the above-described alkyl groups having 1 to 6 carbon atoms, fluorine atoms, and the like.
[0037] Specific examples of the optically active diphosphine include 2,2′-bis(diphenylphosphino)-1,1′-binaphthyl, 2,2′-bis[di(p-tolyl)phosphino]-1,1′-binaphthyl(tolbinap), 2,2′-bis[di(m-tolyl)phosphino]-1,1′-binaphthyl, 2,2′-bis[di(3,5-xylyl)phosphino]-1,1′-binaphthyl(xylbinap), 2,2′-bis[di(p-t-butylphenyl)phosphino]-1,1′-binaphthyl, 2,2′-bis[di(p-methoxyphenyl)phosphino]-1,1′-binaphthyl, 2,2′-bis[di(3,5-di-t-butyl-4-methoxyphenyl)phosphino]-1,1′-binaphthyl, 2,2′-bis[di(cyclopentyl)phosphino]-1,1′-binaphthyl, 2,2′-bis[di(cyclohexyl)phosphino]-1,1′-binaphthyl, 2,2′-bis(diphenylphosphino)-5,5′,6,6′,7,7′,8,8′-octahydro-1,1′-binaphthyl, 2,2′-bis(di-p-tolylphosphino)-5,5′,6,6′,7,7′,8,8′-octahydro-1,1′-binaphthyl, 2,2′-bis(di-m-tolylphosphino)-5,5′,6,6′,7,7′,8,8′-octahydro-1,1′-binaphthyl(xylyl-H8-binap), 2,2′-bis(di-3,5-xylylphosphino)-5,5′,6,6′,7,7′,8,8′-octahyd ro-1,1′-binaphthyl, 2,2′-bis(di-p-t-butylphenylphosphino)-5,5′,6,6′,7,7′,8,8′-o ctahydro-1,1′-binaphthyl, 2,2′-bis(di-p-methoxyphenylphosphino)-5,5′,6,6′,7,7′,8,8′-o ctahydro-1,1′-binaphthyl, 2,2′-bis(di-p-chlorophenylphosphino)-5,5′,6,6′,7,7′,8,8′-octahydro-1,1′-binaphthyl, 2,2′-bis(dicyclopentylphosphino)-5,5′,6,6′,7,7′,8,8′-octahy dro-1,1′-binaphthyl, 2,2′-bis(dicyclohexylphosphino)-5,5′,6,6′,7,7′,8,8′-octahyd ro-1,1′-binaphthyl, ((4,4′-bi-1,3-benzodioxole)-5,5′-diyl)bis(diphenylphosphine) (segphos), (4,4′-bi-1,3-benzodioxole)-5,5′-diyl)bis(di(3,5-xylyl)phosphine) (dm-segphos), ((4,4′-bi-1,3-benzodioxole)-5,5′-diyl)bis(di(3,5-di-t-butyl-4-methoxyphenyl)phosphine), ((4,4′-bi-1,3-benzodioxole)-5,5′-diyl)bis(di(4-methoxyphenyl) 1)phosphine), ((4,4′-bi-1,3-benzodioxole)-5,5′-diyl)bis(dicyclohexylphosphine), ((4,4′-bi-1,3-benzodioxole)-5,5′-diyl)bis(bis(3,5-di-t-buty 1-phenyl)phosphine), 2,2′-bis(di-3,5-xylylphosphino)-6,6′-dimethoxy-1,1′-bipheny (xylyl-MeO-biphep), 2,2′-bis(diphenylphosphino)-6,6′-dimethyl-1,1-biphenyl, 2,2′-bis(di-p-tolylphosphino)-6,6′-dimethyl-1,1′-biphenyl, 2,2′-bis(di-o-tolylphosphino)-6,6′-dimethyl-1,1′-biphenyl, 2,2′-bis(di-m-fluorophenylphosphino)-6,6′-dimethyl-1,1′-biphenyl, 2,2′-bis(diphenylphosphino)-6,6′-dimethoxy-1,1′-biphenyl, 2,2′-bis(di-p-tolylphosphino)-6,6′-dimethoxy-1,1′-biphenyl, 2,2′,6,6′-tetramethoxy-4,4′-bis(di-3,5-xylylphosphino)-3,3′-bipyridine (xylyl-p-phos), 2,2′,6,6′-tetramethoxy-4,4′-bis(diphenylphosphino)-3,3′-bip yridine, 2,2′,6,6′-tetramethoxy-4,4′-bis(di-p-tolylphosphino)-3,3′-bipyridine, 2,2′,6,6′-tetramethoxy-4,4′-bis(di-o-tolylphosphino)-3,3′-bipyridine, 4,12-bis(di-3,5-xylylphosphino)-[2.2]-paracyclophane, 4,12-bis(diphenylphosphino)-[2.2]-paracyclophane, 4,12-bis(di-p-tolylphosphino)-[2.2]-paracyclophane, 4,12-bis(di-o-tolylphosphino)-[2.2]-paracyclophane, 1,1′-bis(2,4-diethylphosphotano)ferrocene, 1,13-bis(diphenylphosphino)-7,8-dihydro-6H-dibenzo[f,h][1,5]dioxonin, 1,13-bis(bis(3,5-dimethylphenyl)phosphino)-7,8-dihydro-6H-dibenzo[f,h][1,5]dioxonin (xylyl-C3-tunephos), 6,6′-bis(bis(3,5-dimethylphenyl)phosphino)-2,2′,3,3′-tetrahydro-5,5′-bi-1,4-benzodioxin (xylyl-synphos), and the like.
[0038] Besides the above-described diphosphines, specific examples of the diphosphines usable in the present invention include
[0000] N,N-dimethyl-1-[1′,2-bis(diphenylphosphino)ferrocenyl]ethyl amine, 2,3-bis(diphenylphosphino)butane, 1-cyclohexyl-1,2-bis(diphenylphosphino)ethane, 2,3-O-isopropylidene-2,3-dihydroxy-1,4-bis(diphenylphosphino) butane, 1,2-bis[(o-methoxyphenyl)phenylphosphino]ethane, 1,2-bis(2,5-dimethylphospholano)ethane, N,N′-bis(diphenylphosphino)-N,N′-bis(1-phenylethyl)ethylene diamine, 1,2-bis(diphenylphosphino)propane, 2,4-bis(diphenylphosphino)pentane, cyclohexylanisylmethylphosphine, 2,3-bis(diphenylphosphino)-5-norbornene, 3,4-bis(diphenylphosphino)-1-benzylpyrrolidine, 1-[1′,2-bis(diphenylphosphino)ferrocenyl]ethyl alcohol, 2,2′-bis(diphenylphosphino)-1,1′-dicyclopentane, 2,2′-bis(diphenylphosphino)-1,1-binaphthyl-5,5′-disulfonic acid sodium salt, 2,2′-bis(di(3,5-xylyl)phosphino)-1,1-binaphthyl-5,5′-disulfonic acid sodium salt, 1,1-(2,2′-bis(diphenylphosphino)-1,1′-binaphthyl-6,6′-diyl)bis(methylene)guanidine, 1,1-(2,2′-bis(di(3,5-xylyl)phosphino)-1,1′-binaphthyl-6,6′-diyl)bis(methylene)guanidine, (6,6′-bis(tris(3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluorooctyl)silyl)-1,1′-binaphthyl-2,2′-diyl)bis(diphenylphosphine), (6,6′-bis(tris(3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluorooctyl)silyl)-1,1′-binaphthyl-2,2′-diyl)bis(di(3,5-xylyl)phosphine), (2,2′-bis(diphenylphosphino)-1,1′-binaphthyl-4,4′-diyl)dime thanamine•hydrobromide, (2,2′-bis(di(3,5-xylyl)phosphino)-1,1′-binaphthyl-4,4′-diyl)dimethanamine•hydrobromide, (4,4′-bis(trimethylsilyl)-1,1′-binaphthyl-2,2′-diyl)bis(diphenylphosphine), (4,4′-bis(trimethylsilyl)-1,1′-binaphthyl-2,2′-diyl)bis(di(3,5-xylyl)phosphine), (4,4′-bis(triisopropylsilyl)-1,1′-binaphthyl-2,2′-diyl)bis(diphenylphosphine), (4,4′-bis(triisopropylsilyl)-1,1′-binaphthyl-2,2′-diyl)bis(di(3,5-xylyl)phosphine), 2,2′-bis(diphenylphosphino)-1,1′-binaphthyl-4,4′-diyldiphosphonic acid, 2,2′-bis(di(3,5-xylyl)phosphino)-1,1′-binaphthyl-4,4′-diyldiphosphonic acid, tetraethyl 2,2′-bis(diphenylphosphino)-1,1′-binaphthyl-4,4′-diyldiphosphonate, tetraethyl 2,2′-bis(di(3,5-xylyl)phosphino)-1,1′-binaphthyl-4,4′-diyldiphosphonate, (4,4′-diphenyl-1,1′-binaphthyl-2,2′-diyl)bis(diphenylphosphine), (4,4′-diphenyl-1,1′-binaphthyl-2,2′-diyl)bis(di(3,5-xylyl)phosphine), (4,4′-dichloro-1,1′-binaphthyl-2,2′-diyl)bis(diphenylphosphine), (4,4′-dichloro-1,1′-binaphthyl-2,2′-diyl)bis(di(3,5-xylyl)phosphine), (4,4′-dibromo-1,1′-binaphthyl-2,2′-diyl)bis(diphenylphosphine), (4,4′-dibromo-1,1′-binaphthyl-2,2′-diyl)bis(di(3,5-xylyl)phosphine), (4,4′-dimethyl-1,1′-binaphthyl-2,2′-diyl)bis(diphenylphosphine), (4,4′-dimethyl-1,1′-binaphthyl-2,2′-diyl)bis(di(3,5-xylyl)phosphine), (2,2′-bis(diphenylphosphino)-1,1′-binaphthyl-4,4′-diyl)bis(diphenylmethanol), (2,2′-bis(di(3,5-xylyl)phosphino)-1,1′-binaphthyl-4,4′-diyl) bis(diphenylmethanol), (4,4′-bis(1,1,1,2,2,3,3,4,4,5,5,6,6,8,8,9,9,10,10,11,11,12,12,13,13,13-hexacosafluoro-7-(perfluorohexyl)tridecan-7-yl)-1,1′-binaphthyl-2,2′-diyl)bis(diphenylphosphine), (4,4′-bis(1,1,1,2,2,3,3,4,4,5,5,6,6,8,8,9,9,10,10,11,11,12,12,13,13,13-hexacosafluoro-7-(perfluorohexyl)tridecan-7-yl)-1,1′-binaphthyl-2,2′-diyl)bis(di(3,5-xylyl)phosphine), (7,7′-dimethoxy-1,1′-binaphthyl-2,2′-diyl)bis(diphenylphosphine), (7,7′-dimethoxy-1,1′-binaphthyl-2,2′-diyl)bis(di(3,5-xylyl) phosphine), 4,4′-di-tert-butyl-4,4′,5,5′-tetrahydro-3H,3′H-3,3′-bidinaphtho[2,1-c:1′,2′-e]phosphapine, 1,2-bis(3H-dinaphtho[2,1-c:1′,2′-e]phosphapin-4(5H)-yl)benz ene, 3,3′-bis(diphenylphosphino)-4,4′-biphenanthrene, 3,3′-bis(di(3,5-xylyl)phosphino)-4,4′-biphenanthrene, (3,3′-diphenyl-1,1′-binaphthyl-2,2′-diyl)bis(methylene)bis(diphenylphosphine), (3,3′-diphenyl-1,1′-binaphthyl-2,2′-diyl)bis(methylene)bis(di(3,5-xylyl)phosphine), 2,2′-bis(diphenylphosphinoxy)-1,1′-binaphthyl, 2,2′-bis(di(3,5-xylyl)phosphinoxy)-1,1′-binaphthyl, (3,3′-dimethyl-1,1′-binaphthyl-2,2′-diyl)bis(oxy)bis(diphenylphosphine), (3,3′-dimethyl-1,1′-binaphthyl-2,2′-diyl)bis(oxy)bis(di(3,5-xylyl)phosphine), (3,3′-diphenyl-1,1′-binaphthyl-2,2′-diyl)bis(oxy)bis(diphenylphosphine), (3,3′-diphenyl-1,1′-binaphthyl-2,2′-diyl)bis(oxy)bis(di(3,5-xylyl)phosphine), (3,3′-bis(3,5-dimethylphenyl)-1,1′-binaphthyl-2,2′-diyl)bis(oxy)bis(diphenylphosphine), (3,3′-bis(3,5-dimethylphenyl)-1,1′-binaphthyl-2,2′-diyl)bis(oxy)bis(di(3,5-xylyl)phosphine), (3,3′-diphenyl-1,1′-binaphthyl-2,2′-diyl)bis(oxy)bis(bis(3,5-dimethylphenyl)phosphine), N2,N2′-bis(diphenylphosphino)-1,1′-binaphthyl-2,2′-diamine, N2,N2′-bis(di(3,5-xylyl)phosphino)-1,1′-binaphthyl-2,2′-diamine, (SP)-1-[(S)-α-(dimethylamino)-2-(diphenylphosphino)benzyl]-2-diphenylphosphinoferrocene, (RP)-1-[(R)-α-(dimethylamino)-2-(diphenylphosphino)benzyl]-2-diphenylphosphinoferrocene, (R)-1-{(RP)-2-[2-(diphenylphosphino)phenyl]ferrocenyl}ethyl diphenylphosphine, (S)-1-{(SP)-2-[2-(diphenylphosphino)phenyl]ferrocenyl}ethyl diphenylphosphine, (R)-1-{(RP)-2-[2-(diphenylphosphino)phenyl]ferrocenyl}ethyl dicyclophosphine, (S)-1-{(SP)-2-[2-(diphenylphosphino)phenyl]ferrocenyl}ethyl dicyclophosphine, (R)-1-{(RP)-2-[2-(diphenylphosphino)phenyl]ferrocenyl}ethyl di(2-norbonyl)phosphine, (S)-1-{SP)-2-[2-(diphenylphosphino)phenyl]ferrocenyl}ethyl di(2-norbonyl) phosphine, (R)-1-{(RP)-2-[2-(diphenylphosphino)phenyl]ferrocenyl}ethyl di(3,5-xylyl)phosphine, (S)-1-{(SP)-2-[2-(diphenylphosphino)phenyl]ferrocenyl}ethyl di(3,5-xylyl)phosphine, (R)-1-{(RP)-2-[2-[di(3,5-xylyl)phosphino] phenyl]ferrocenyl}ethyldi(3,5-xylyl)phosphine, (S)-1-{(SP)-2-[2-[di(3,5-xylyl)phosphino]phenyl]ferrocenyl}ethyldi(3,5-xylyl)phosphine, (R)-1-{(RP)-2-[2-(diphenylphosphino)phenyl]ferrocenyl}ethyl bis[3,5-bis-(trifluoromethyl)phenyl]phosphine, (S)-1-{(SP)-2-[2-(diphenylphosphino)phenyl]ferrocenyl}ethyl bis[3,5-bis-(trifluoromethyl)phenyl]phosphine, (R)-1-{(RP)-2-[2-[bis(4-methoxy-3,5-dimethylphenyl)phosphino]phenyl]ferrocenyl}ethylbis[3,5-bis(trifluoromethyl)phenyl]phosphine, (S)-1-{(SP)-2-[2-[bis(4-methoxy-3,5-dimethylphenyl)phosphino]phenyl]ferrocenyl}ethylbis[3,5-bis(trifluoromethyl)phenyl]phosphine, 3,3′,4,4′-tetramethyl-1,1′-diphenyl-2,2′,5,5′-tetrahydro-1H,1′H-2,2′-biphosphole, 1,1′-di-tert-butyl-2,2′-biphospholane, 2,2′-di-tert-butyl-2,2′,3,3′-tetrahydro-1H,1′H-1,1′-bisisophosphindole, 1,2-bis(2,4-dimethylphosphetan-1-yl)ethane, 1,2-bis(2,5-dimethylphospholan-1-yl)ethane, 1,2-bis(2,4-dimethylphosphetan-1-yl)benzene, 1,2-bis(2,5-dimethylphospholan-1-yl)benzene, 3,4-bis(2,5-dimethylphospholan-1-yl)furan-2,5-dione, 3,4-bis(2,5-diethylphospholan-1-yl)furan-2,5-dione, 3,4-bis(2,5-dimethylphospholan-1-yl)-1-phenyl-1H-pyrrole-2,5-dione, 1-(3,5-bis(trifluoromethyl)phenyl)-3,4-bis(2,5-dimethylphospholan-1-yl)-1H-pyrrole-2,5-dione, 1-((1R,2S,4R,5S)-2,5-dimethyl-7-phosphabicyclo[2.2.1]heptan-7-yl)-2-H2R,5S)-2,5-dimethyl-7-phosphabicyclo[2.2.1]hepta ne-7-yl)benzene, 1,1′-(benzo[b]thiophene-2,3-diyl)bis(2,5-dimethylphospholan e), (2,2′,4,4′-tetramethyl-3,3′,4,4′-tetrahydro-2H,2′H-6,6′-bibenzo[b][1,4]dioxepin-7,7′-diyl)bis(diphenylphosphine), (2,2′,4,4′-tetramethyl-3,3′,4,4′-tetrahydro-2H,2′H-6,6′-bibenzo[b][1,4]dioxepin-7,7′-diyl)bis(di(3,5-xylyl)phosphine), ((6R)-6,7-dimethyl-6,7-dihydrodibenzo[e,g][1,4]dioxocin-1,12-diyl)bis(diphenylphosphine), ((6R)-6,7-dimethyl-6,7-dihydrodibenzo[e,g][1,4]dioxocin-1,12-diyl)bis(di(3,5-xylyl)phosphine), (4,4′,5,5′,6,6′-hexamethylbiphenyl-2,2′-diyl)bis(diphenylphosphine), (4,4′,5,5′,6,6′-hexamethylbiphenyl-2,2′-diyl)bis(di(3,5-xyl yl)phosphine), (4,4′,5,5′,6,6′-hexamethoxybiphenyl-2,2′-diyl)bis(diphenylphosphine), (4,4′,5,5′,6,6′-hexamethoxybiphenyl-2,2′-diyl)bis(di(3,5-xy lyl)phosphine), (5,5′-dichloro-4,4′,6,6′-tetramethylbiphenyl-2,2′-diyl)bis(diphenylphosphine), (5,5′-dichloro-4,4′,6,6′-tetramethylbiphenyl-2,2′-diyl)bis(di(3,5-xylyl)phosphine), (5,5′-dimethoxy-4,4′,6,6′-tetramethylbiphenyl-2,2′-diyl)bis(diphenylphosphine), (5,5′-dimethoxy-4,4′,6,6′-tetramethylbiphenyl-2,2′-diyl)bis(di(3,5-xylyl)phosphine), 2,2′-bis(diphenylphosphino)-6,6′-dimethoxybiphenyl-3,3′-dio 1,2,2′-bis(di(3,5-xylyl)phosphino)-6,6′-dimethoxybiphenyl-3,3′-diol, (3,3′,6,6′-tetramethoxybiphenyl-2,2′-diyl)bis(diphenylphosphine), (3,3′,6,6′-tetramethoxybiphenyl-2,2′-diyl)bis(di(3,5-xylyl) phosphine), (3,3′-diisopropyl-6,6′-dimethoxybiphenyl-2,2′-diyl)bis(diphenylphosphine), (3,3′-diisopropyl-6,6′-dimethoxybiphenyl-2,2′-diyl)bis(di(3,5-xylyl)phosphine), (6,6′-dimethoxy-3,3′-bis(p-tolyloxy)biphenyl-2,2′-diyl)bis(diphenylphosphine), (6,6′-dimethoxy-3,3′-bis(p-tolyloxy)biphenyl-2,2′-diyl)bis(di(3,5-xylyl)phosphine), 2,2′-bis(diphenylphosphino)-6,6′-dimethoxybiphenyl-3,3′-diylbis(2,2-dimethylpropanoate), 2,2′-bis(di(3,5-xylyl)phosphino)-6,6′-dimethoxybiphenyl-3,3′-diylbis(2,2-dimethylpropanoate), (5,5′-dichloro-6,6′-dimethoxybiphenyl-2,2′-diyl)bis(diphenylphosphine), (5,5′-dichloro-6,6′-dimethoxybiphenyl-2,2′-diyl)bis(di(3,5-xylyl)phosphine), 6,6′-bis(diphenylphosphino)biphenyl-2,2′-diyl diacetate, 6,6′-bis(di(3,5-xylyl)phosphino)biphenyl-2,2′-diyl diacetate, 6,6′-bis(diphenylphosphino)biphenyl-2,2′-diylbis(2,2-dimethylpropanoate), 6,6′-bis(di(3,5-xylyl)phosphino)biphenyl-2,2′-diylbis(2,2-dimethylpropanoate), 6,6′-bis(diphenylphosphino)biphenyl-2,2′-diylbis(2-methylpropanoate), 6,6′-bis(di(3,5-xylyl)phosphino)biphenyl-2,2′-diylbis(2-methylpropanoate), 6,6′-bis(diphenylphosphino)biphenyl-2,2′-diyldicyclohexanecarboxylate, 6,6′-bis(di(3,5-xylyl)phosphino)biphenyl-2,2′-diyldicyclohexanecarboxylate, (4,4′,6,6′-tetrakis(trifluoromethyl)biphenyl-2,2′-diyl)bis(diphenylphosphine), (4,4′,6,6′-tetrakis(trifluoromethyl)biphenyl-2,2′-diyl)bis(di(3,5-xylyl)phosphine), (5-methoxy-4,6-dimethyl-4′,6′-bis(trifluoromethyl)biphenyl-2,2′-diyl)bis(diphenylphosphine), (5-methoxy-4,6-dimethyl-4′,6′-bis(trifluoromethyl)biphenyl-2,2′-diyl)bis(di(3,5-xylyl)phosphine), (2,2,2′,2′-tetramethyl-4,4′-bibenzo[d][1,3]dioxole-5,5′-diyl)bis(diphenylphosphine), (2,2,2′,2′-tetramethyl-4,4′-bibenzo[d][1,3]dioxole-5,5′-diyl)bis(di(3,5-xylyl)phosphine), 6,6′-bis(diphenylphosphino)-2,2′,3,3′-tetrahydro-7,7′-bibenzofuran, 6,6′-bis(di(3,5-xylyl)phosphino)-2,2′,3,3′-tetrahydro-7,7′-bibenzofuran, (2,2,2′,2′-tetrafluoro-4,4′-bibenzo[d][1,3]dioxole-5,5′-diy 1)bis(diphenylphosphine), (2,2,2′,2′-tetrafluoro-4,4′-bibenzo[d][1,3]dioxole-5,5′-diyl)bis(di(3,5-xylyl)phosphine), 2-(naphthyl)-8-diphenylphosphino-1-[3,5-dioxa-4-phospha-cyclohepta[2,1-a; 3,4-a′]dinaphthalene-4-yl]-1,2-dihydroquinoline, 4,12-bis(di(3,5-xylyl)phosphino)-[2.2]-paracyclophane, 7,7′-bis(di(3,5-xylyl)phosphino)-2,2′,3,3′-tetrahydro-1,1′-spirobiindane (Xyl-SDP), 7,7′-bis(diphenylphosphino)-2,2′,3,3′-tetrahydro-1,1′-spirobiindane (SDP), bis(2-diphenylphosphinophenyl)ether (DPEphos), 4,5-bis(diphenylphosphinomethyl)-2,2-dimethyl-1,3-dioxolane (DIOP), 1,2-bis(diphenylphosphino)propane (PROPHOS), 2,3-bis(diphenylphosphino)butane (CHIRAPHOS), 1,2-bis[(2-methoxyphenyl)(phenyl)phosphinolethane (DIPAMP), 3,4-bis(diphenylphosphino)-1-benzylpyrrolidine (DEGUPHOS), 2,3-bis(diphenylphosphino)-bicyclo[2.2.1]hept-5-ene (NORPHOS), 1-tertiary-butoxycarbonyl-4-diphenylphosphino-2-(diphenylphosphinomethyl)pyrrolidine (BPPM), (2,2′-bis-(dibenzofuran-3,3-diyl)-bis-diphenylphosphine (BIBFUP), 2,2′-bis(diphenylphosphino)-3,3-binaphtho[b]furan (BINAPFu), 2,2′-bis(diphenylphosphino)-3,3′-bi[benzo[b]thiophene] (BITIANP), N,N′-dimethyl-7,7′-bis(di(3,5-xylyl)phosphino)-3,3′,4,4′-tetrahydro-8,8′-bi-2H-1,4-benzoxazine (Xyl-Solphos), 2,3-bis(tertiary-butylmethylphosphino)quinoxaline (QuinoxP*), 2,4-bis(diphenylphosphino)pentane (SKEWPHOS), 2,4-bis(di(3,5-xylyl)phosphino)pentane (XylSKEWPHOS), 4,4′-bis(diphenylphosphino)-2,2′,5,5′-tetramethyl-3,3′-bithiophene (TMBTP), 3,3′-bis(diphenylphosphonyl)-1,1′-2,2′-biindole (N-Me-2-BINPO), (2,2′,5,5′-tetramethyl-3,3′-bithiophene-4,4′-diyl)bis(diphenylphosphine) (BITIANP), (4,4′,6,6′-tetramethyl-3,3′-bibenzo[b]thiophene-2,2′-diyl)bis(diphenylphosphine) (tetraMe-BITIANP), 1,1′-bis(diphenylphosphino)-3,3′-dimethyl-1H,1′H-2,2′-biindole (BISCAP), 2,2′-bis(diphenylphosphino)-3,3′-bibenzofuran (BICUMP), 2,2′-bis(diphenylphosphino)-1,1′-bibenzo[d]imidazole (BIMIP), 1,3-bis(diphenylphosphino)propane, 1,4-bis(diphenylphosphino)butane, bis(2-(diphenylphosphino)ethyl)amine,
2-(diphenylphosphino)ethaneamine, and the like.
[0040] The following are specific examples of the transition metal complex:
[0000]
[0041] The nitrogen-containing compound added in the present invention includes aliphatic amines, aromatic amines, and nitrogen-containing heterocyclic compounds. Of these, nitrogen-containing compounds having two or more nitrogen atoms are preferable.
[0042] An aliphatic amine means a compound in which a hydrogen atom(s) of ammonia (NH 3 ) is(are) replaced by an aliphatic group(s). The aliphatic groups include linear or branched alkyl groups having 1 to 10 carbon atoms and alicyclic groups. Linear or branched alkyl groups having 1 to 6 carbon atoms and alicyclic groups are preferable. Specifically, examples of the aliphatic amines include methylamine, ethylamine, propylamine, butylamine, isopropylamine, 2-ethylhexylamine, tert-butylamine, diethylamine, diisopropylamine, triethylamine, tributylamine, diethylenetriamine, triethylenetetramine, tris(2,2′,2″-aminoethyl)amine, N,N′-bis(2-aminoethyl)-1,3-propanediamine, N,N′-bis(3-aminopropyl)ethylenediamine, bis(3-aminopropyl)amine, 1,2-bis(3-aminopropylamino)ethane, 1,4-bis(3-aminopropyl)piperidine, cyclopropylamine, cyclohexylamine, and the like. The aliphatic amine is preferably diethylenetriamine, triethylenetetramine, tris(2,2′,2″-aminoethyl)amine, N,N′-bis(2-aminoethyl)-1,3-propanediamine, N,N′-bis(3-aminopropyl)ethylenediamine, bis(3-aminopropyl)amine, 1,2-bis(3-aminopropylamino)ethane, 1,4-bis(3-aminopropyl)piperidine, or the like, and more preferably diethylenetriamine or triethylenetetramine.
[0043] An aromatic amine means a compound in which a hydrogen atom(s) of ammonia is(are) replaced by an aromatic group(s). The aromatic groups include monocyclic or polycyclic (condensed cyclic) aromatic groups having aromaticity. Specific examples of the aromatic amines include aniline, toluidine, xylidine, anisidine, naphthylamine, diphenylamine, triphenylamine, benzidine, 1,2-phenylenediamine, 4-fluoro-1,2-phenylenediamine, 2,3-diaminopyridine, 3,4-diaminopyridine, 2,3-diaminotoluene, 3,4-diaminotoluene, 3,3′-diaminobenzene, 3,4-diaminobenzophenone, 2,5-diamino-5-bromopyridine, 6,6′-diamino-2,2′-dipyridyl, 4,5-dichloro-1,2-phenylenediamine, 3,4-diaminobenzoic acid, 2,2′-dipyridyl, 2,2′-bi-4-picoline, 6,6′-bi-3-picoline, phthalocyanine, 2,2′-bisquinoline, and the like. Preferred aromatic amines include 1,2-phenylenediamine, 4-fluoro-1,2-phenylenediamine, 2,3-diaminopyridine, 3,4-diaminopyridine, 2,3-diaminotoluene, 3,4-diaminotoluene, 3,3′-diaminobenzene, 3,4-diaminobenzophenone, 2,5-diamino-5-bromopyridine, 6,6′-diamino-2,2′-dipyridyl, 4,5-dichloro-1,2-phenylenediamine, 3,4-diaminobenzoic acid, 2,2′-dipyridyl, 2,2′-bi-4-picoline, 6,6′-bi-3-picoline, phthalocyanine, 2,2′-biquinoline, and the like. 1,2-Phenylenediamine and 3,4-diaminobenzoic acid are more preferable.
[0044] The nitrogen-containing heterocyclic compounds include aromatic compounds such as pyrrole, pyridine, imidazole, 2-methylimidazole, 1-methylimidazole, 1,3-thiazole, oxazole, pyrazole, 1,2,4-triazole, pyrazine, pyrimidine, pyridazine, indole, quinoline, and purine; and endocyclic aliphatic amines such as diazabicycloundecane (DBU), piperidine, diazabicyclooctane (DABCO), and sparteine. Preferred nitrogen-containing heterocyclic compounds include imidazole, 2-methylimidazole, 1-methylimidazole, 1,3-thiazole, 1,3-oxazole, pyrazole, 1,2,4-triazole, and the like. Imidazoles such as 2-methylimidazole, 1-methylimidazole, and imidazole are more preferable.
[0045] The amount of the nitrogen-containing compound added is not less than one, preferably two, and more preferably three times the number of moles of the transition metal complex, when the nitrogen-containing compound has one nitrogen atom, or is not less than 1 and preferably 1.5 times the number of moles of the transition metal complex, when the nitrogen-containing compound has two or more nitrogen atoms.
[0046] Especially after an asymmetric reduction reaction using an optically active transition metal complex as a catalyst, the present invention makes it possible to avoid the decrease in optical purity of the product without separating the catalyst.
[0047] Asymmetric reduction methods conducted in the production method of the present invention includes asymmetric hydrogenation reactions, asymmetric hydrogen transfer reactions, and the like.
[0048] The asymmetric hydrogenation reactions are not particularly limited, and include a method for producing an optically active alcohol by asymmetric hydrogenation of a carbonyl group (for example, Documents (5th ed., Jikken Kagaku Kouza 19, organic compound synthesis VII, Maruzen Company, Limited, p. 122) etc.), and a method for producing an optically active compound by asymmetric hydrogenation of a carbon-carbon double bond, an imino group, or the like (for example, Documents (Asymmetric Catalysis In Organic Synthesis, p. 16 to p. 94) etc.).
[0049] The asymmetric hydrogen transfer reactions are not particularly limited, and examples thereof include a method for producing an optically active alcohol by asymmetric reduction of a carbonyl group as described in Documents (J. Am. Chem. Soc., 1997, 119, 8378, J. Am. Chem. Soc. 1996, 118, 2521, etc.), and the like.
[0050] In the production method of the present invention, after the nitrogen-containing compound is added to a reaction solution in which the reduction reaction has been conducted by using the transition metal complex, reaction solvent recovery and/or distillation are/is performed.
EXAMPLES
[0051] Hereinafter, the present invention will be described in detail based on Examples. However, the present invention is not limited to these examples. Note that, in the following Examples and Comparative Examples, the MS spectrum was measured with an LCMS-IT-TOF apparatus manufactured by SHIMADZU. In addition, the GC analysis was conducted with GC: Chirasil Dex-CB (0.25 mm×25 m, DF=0.25).
Example 1
[0052] To a 200 ml reaction vessel, 0.5 g (4.15 mmol) of acetophenone, 250 mg (0.415 mmol) of [Ru (R,R)-Tsdpen (p-cymene)], and 42 mg of 2-propanol were added, followed by purging with nitrogen. In this solution, a reaction was allowed to proceed at room temperature for 2 hours.
[0053] The conversion to (R)-phenylethanol was 86%, and the optical purity was 91% ee.
[0054] Moreover, 67.3 mg (0.622 mmol) of α-phenylenediamine was added to the reaction solution, and the reaction solution was stirred. As a result, the color of the solution changed from reddish brown to purple. The solvent was removed by distillation under reduced pressure, and reslurring in heptane was conducted to remove acetophenone and phenylethanol. After, drying, mass spectrometry was conducted. The mass was 679.1438. From the mass spectrometry, the obtained compound was assumed to be Ru[(R,R)-Tsdpen](phenylenediamine) 2 .
((R)-Phenethyl Alcohol Racemization Experiment)
[0055] The reaction shown below was conducted in the presence of Ru[(R,R)-Tsdpen](phenylenediamine) 2 in an amount of 0.5 equivalents to a substrate (phenylethanol having an optical purity of (R)-phenylethanol of 94.5% ee). In addition, the reaction shown below was conducted in the same manner in the presence of [Ru(R,R)-Tsdpen(p-cymene)] instead of Ru[(R,R)-Tsdpen](phenylenediamine) 2 . Moreover, the reaction shown below was conducted in the same manner while 1.5 equivalents of α-phenylenediamine was added in addition to [Ru(R,R)-Tsdpen(p-cymene)].
[0000]
[0056] Table 1 shows the obtained results. From Table 1, it can be seen that no racemization proceeds in the presence of Ru[(R,R)-Tsdpen](phenylenediamine) 2 or in the presence of [Ru(R,R)-Tsdpen(p-cymene)] and α-phenylenediamine.
[0000]
TABLE 1
Optical Purity
Ru[(R,R)-Tsdpen](phenylenediamine) 2
94.5% ee
[Ru(R,R)-Tsdpen(p-cymene)]
75.3% ee
[Ru(R,R)-Tsdpen(p-cymene)]
93.2% ee
and α-phenylenediamine
Reference Example 1
Asymmetric Hydrogen Transfer Reaction of Acetophenone
[0057] To a 200 ml reaction vessel, 10 g (8.32 mmol) of acetophenone, 1.06 g (1.6646 mmol) of [RuCl (S,S)-Tsdpen (p-cymene)], and 41.5 ml of formic acid/triethylamine (5/2 (volume ratio)) were added, followed by purging with nitrogen. This solution was stirred at 30° C. for 17 hours. Then, 45 ml of methylene chloride and 40 ml of water were added thereto, and the organic layer was separated. From the organic layer, methylene chloride was removed by distillation to obtain 13.5 g of an (S)-phenylethanol concentrate. This concentrate was stored at 5° C. for 4 days. The change in optical purity from the completion of the reaction was as follows.
[0000]
TABLE 2
Completion of reaction
Concentrate
5° C., 4 days
97.1% ee
96.6% ee
79.5% ee
Comparative Example 1
[0058] One gram of the (S)-phenylethanol concentrate having an optical purity of 79.5% ee, obtained in Reference Example 1, and stored at 5° C. for 4 days was heated at 80° C. for 16 hours. As a result, the optical purity decreased to 13.6% ee.
Examples 2 to 5
[0059] Nitrogen-containing compounds were each added to 1 g (Ru: 0.123 mmol) of the (S)-phenylethanol concentrate having an optical purity of 79.5% ee, obtained in Reference Example 1, and stored at 5° C. for 4 days, and the mixtures were heated at 80° C. for 16 hours. The results were as shown in the following table.
[0000]
TABLE 3
Example
Additive
Equivalents
Optical purity
2
Triethylenetetramine
3
79.5% ee
3
3,4-Diaminobenzoic acid
2
79.5% ee
4
Imidazole
2
79.5% ee
5
Bipyridine
2
71.4% ee
Example 6
Synthesis of (R)-4-(1-Hydroxyethyl)benzonitrile
[0060] To a 200 mL four-necked flask, 15.0 g (103.3 mmol) of 4-acetylbenzonitrile, 30 ml of MeOH, and 126 mg (0.2 mmol) of [RuCl(R,R)-Tsdpen(p-cymene)] were added. While the temperature was kept at 15° C., 75 ml of formic acid/triethylamine (5/2 (volume ratio)) was added dropwise at 20° C. or below over 30 minutes. After the temperature was raised to 25° C., the mixture was stirred for 64 hours. After completion of the reaction, the mixture was cooled to 15° C. Then, 30 ml of water was added, and extraction was conducted with 90 ml of ethyl acetate, followed by washing with 30 ml of water twice. Subsequently, 75.5 mg (0.5 mmol) of triethylenetetramine was weighed in a 300 ml recovery flask, and the ethyl acetate extract solution was added to the recovery flask. Under reduced pressure, ethyl acetate was removed by distillation. The obtained liquid concentrate (14.4 g (95.9% ee)) was purified by distillation under reduced pressure (118 to 120° C./1 torr) to obtain 11.7 g of the desired (R)-4-(1-hydroxyethyl)benzonitrile (yield 76.9%).
[0061] The optical purity was 95.6% ee.
Comparative Example 2
[0062] The same procedures as in Example 6 were conducted, except that no triethylenetetramine was added. The optical purity of the distillate was 86.2% ee.
Reference Example 2
Asymmetric Hydrogen Transfer Reaction of Acetophenone
[0063] To a 200 ml reaction vessel, 10 g (8.30 mmol) of acetophenone, 1.00 g (1.5712 mmol) of [RuCl (S,S)-Tsdpen (p-cymene)], 300 ml of 2-propanol, and 300 mg (7.500 mmol) of sodium hydroxide were added, followed by purging with nitrogen. This solution was stirred at 40° C. for 22 hours, and then the solvent was removed by distillation to obtain 11.3 g of (S)-phenylethanol concentrate. The change in optical purity from the completion of the reaction was as follows.
[0000]
TABLE 4
Completion of reaction
Concentrate
84.2% ee
83.9% ee
Comparative Example 2
[0064] One gram of the (S)-phenylethanol concentrate having an optical purity of 83.9% ee obtained in Reference Example 2 was heated at 80° C. for 17 hours. As a result, the optical purity decreased to 78.2% ee.
Examples 7 to 9
[0065] Nitrogen-containing compounds were each added to 1 g (Ru: 0.138 mmol) of a (S)-phenylethanol concentrate having an optical purity of 83.9% ee and obtained by the same procedures as in Reference Example 2, and the mixtures were heated at 80° C. for 17 hours. The results were as shown in the following Table.
[0000]
TABLE 5
Example
Additive
Equivalents
Optical purity
7
Diethylenetriamine
2
83.6% ee
8
Imidazole
2
83.8% ee
9
Bipyridine
2
83.8% ee
Reference Example 3
Racemization of Optically Active (R)-Phenylethanol
[0066] To a 200 ml reaction vessel, 100 mg (0.819 mmol) of (R)-phenylethanol (94.5% ee), 24.6 mg (0.041 mmol) of [Ru(R,R)-Tsdpen(p-cymene)], and 2 ml of formic acid/triethylamine (5/2 (volume ratio)) were added, followed by purging with nitrogen. This solution was stirred at 80° C. for 17 hours. As a result, the optical purity was 55.4% ee.
Examples 10 to 15
[0067] The same procedures as in Reference Example 3 were conducted, except that nitrogen-containing compounds were added to reaction vessels. The results were as shown in the following Table.
[0000]
TABLE 6
Example
Additive
Equivalents
Optical purity
10
2-Methylimidazole
1.5
90.1% ee
11
2-Methylimidazole
3
93.7% ee
12
1-Methylimidazole
1.5
91.4% ee
13
1,2,4-Thiazole
1.5
93.3% ee
14
2-Pyridinol
1.5
92.0% ee
15
Pyrazole
1.5
89.1% ee | The present invention provides a method for producing a reduction reaction product, wherein recovery of the reaction solvent and/or distillation is carried out after adding a nitrogen-containing compound into a reaction liquid of a reduction reaction that has been conducted using a transition metal complex. The present invention is capable of suppressing decrease in the optical purity of the reduction reaction product due to the transition metal complex used as a catalyst. | 2 |
RELATED APPLICATIONS
The present application is based on, and claims priority from, French Application Number 07 07336, filed Oct. 19, 2007 the disclosure of which is hereby incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The present invention relates to an absolute target system intended to be incorporated in observation satellites.
BACKGROUND OF THE INVENTION
Currently, in many space missions, and notably those requiring the flight in formation of several satellites, the required absolute pointing accuracy is very high. To carry out the absolute pointing of observation instruments on board satellites, star sensors, also called stellar sensors, are currently used. These conventional star sensors have catalogues of stars whose absolute position is known with great accuracy. However, the star sensors make it possible to point towards a known bright star only approximately, with an accuracy of the order of several seconds of arc.
Thus, for absolute target systems of the state of the art, even the most recent, it is impossible to achieve the absolute pointing accuracies required for the missions currently envisaged, for which the required accuracies are of the order of a tenth of a second of arc.
Furthermore, it is particularly difficult to accurately calibrate this type of instrument: the mechanical and thermoelastic biases induced by the incorporation and launch, and the thermal environment, being virtually impossible to calibrate.
Consequently, the commonly-sought solutions consist:
either in developing new star sensors with the requisite accuracy, that is, less than a second of arc, but this involves heavy investments; furthermore, if such a solution did result in the development of a star sensor with the desired absolute accuracy, this would lead to a major extra cost and weight, which is not desirable, particularly for space applications, or in seeking to accurately measure the induced biases, but this is very difficult and the residues are in any case generally estimated at several seconds of arc.
One aim of the invention is notably to overcome the abovementioned drawbacks. Thus, to create an absolute target system provided with a maximum accuracy, the present invention proposes coupling a star sensor to an optical metrological sensor. Since these two items of equipment are normally already on board the satellites, in particular for formation flight missions, this solution adds no extra weight or cost.
SUMMARY OF THE INVENTION
To this end, the subject of the invention is an absolute target system comprising a star sensor having a catalogue of stars listing a set of known bright stars, that is, stars whose absolute position is known, with a catalogue accuracy, characterized in that it further comprises an optical metrological sensor making it possible to accurately determine relative positions, with a measurement accuracy with which is associated a frame of reference, said optical metrological sensor moreover having no knowledge of the absolute stellar environment, said star sensor and said optical metrological sensor cooperating so that the star sensor can be used to roughly point the optical metrological sensor in a target direction corresponding to a known bright star in the star catalogue, the optical metrological sensor then accurately determining the direction of said known bright star in its own frame of reference, so making it possible to know the target direction with optimized absolute accuracy, corresponding approximately to the measurement accuracy of the optical metrological sensor, within the tolerance of the catalogue accuracy.
Advantageously, the known bright star presents a magnitude that can be 3, 4, 5 or 6.
Advantageously, the optical metrological sensor comprises a set of CCD, CMOS or APS type detectors.
Advantageously, the optical metrological sensor presents an accuracy enabling it to determine a relative position of a target object at 20 meters to within approximately 10 microns, so making it possible to achieve a target angular accuracy less than or equal to approximately 0.1 second of arc.
Advantageously, the calibration of the optical metrological sensor can all be performed on the ground, using an incoherent fibre-connected optical source with a power of the order of a milliwatt.
Advantageously, a satellite can incorporate the absolute target system according to the invention, enabling it to accurately point the observation instrument to a celestial body.
Advantageously, an absolute pointing method can use the absolute target system according to the invention, said star sensor presenting a wide field of view and the optical metrological sensor presenting a detection field and a target axis, characterized in that:
initially, the star sensor brings the known bright star, chosen as target direction, into the detection field of the optical metrological sensor via any displacement control and application means of said absolute target system, or even, the wide field of view of the star sensor and the detection field of the optical metrological sensor overlap, by appropriate accommodation of said star sensor and optical metrological sensor, then, the optical metrological sensor measures the target direction in its own frame of reference,
the accurate knowledge of the target direction corresponding to the known bright star in the frame of reference of the optical metrological sensor and of the absolute position of said known bright star thanks to the star catalogue making it possible to ultimately deduce the absolute target direction accurately.
Advantageously, having a star catalogue on the ground, with an accuracy greater than the catalogue accuracy of the star catalogue incorporated in said previously described absolute target system, it is possible to implement an absolute pointing method, in which said star catalogue on the ground is referred to in order to increase the absolute accuracy concerning the knowledge of the coordinates of said known bright star, so as to increase the accuracy of the absolute target direction.
Still other objects and advantages of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein the preferred embodiments of the invention are shown and described, simply by way of illustration of the best mode contemplated of carrying out the invention. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious aspects, all without departing from the invention. Accordingly, the drawings and description thereof are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example, and not by limitation, in the figures of the accompanying drawings, wherein elements having the same reference numeral designations represent like elements throughout and wherein:
FIG. 1 : the illustration of a first example of absolute pointing of a satellite towards a bright star using the device according to the invention;
FIG. 2 : the theoretical diagram of a second example of absolute target system according to the invention, making it possible to detail the method of implementing the device according to the present patent application;
FIG. 3 : the diagrammatic representation of an example of optical metrological sensor in the device according to the invention, enabling the application of the present patent application.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a simple diagram illustrating the absolute pointing of any space instrument 6 a onboard a satellite 1 a in the direction 7 of a bright star S. This satellite 1 a comprises a service module 3 a and a solar panel 2 a intended to supply all the energy needed for the mission.
Thus, the star sensor, or stellar sensor, comprising in this diagram four “heads” 4 , creates a map of a part of the celestial arch using a digital sensor, of CCD or CMOS type, and focussing optics of short focal length and relatively wide field, approximately 20°, which corresponds approximately to a constellation in the celestial arch.
Following this mapping, the stellar sensor stores and digitizes all the stars that it has detected, then an integrated computer determines the target axis of said stellar sensor by calculating its three coordinates using a recognition algorithm and a star catalogue listing the absolute positions of the bright stars in the celestial arch. It is also possible to use an even more accurate ground catalogue if necessary.
Generally, the stars used are of magnitudes 2 to 5 and three or four stars are more often than not sufficient for the algorithm to converge. Moreover, the algorithm generally includes processing operations for minimizing noise and eliminating “false stars”. The determination accuracy is of the order of 10 to 20 seconds of arc, these values being average values that vary according to the manufacturers and the technologies employed.
However, the accuracy achieved by the current star sensors, even the most refined, does not reach the accuracy required for certain space missions that are currently envisaged. Consequently, the present invention proposes coupling the previously described stellar sensor with an optical metrological sensor 5 N making it possible to accurately determine relative positions.
This optical metrological sensor 5 N is backed up by an identical sensor 5 R. The specific operation of an accurate optical metrological sensor will be described using FIG. 3 which represents an example of such a sensor.
FIG. 2 represents an example of absolute target system according to the invention, mounted on a satellite 1 b comprising a service module 3 b and a payload 6 b . The principle is therefore to couple a conventional star sensor with its four “heads” 4 , to an accurate optical metrological sensor 5 N backed up by the sensor 5 R. In this example, the fields of view of the four stellar sensors 4 are represented by cones 8 , the angle at the summit of which measures approximately 20°. These wide fields of view 8 make it possible to detect numerous known bright stars, whose absolute coordinates appear in the star catalogue to which the star sensor can refer.
The accurate optical metrological sensor 5 N is invoked when the star sensor has brought a known bright star S into its detection cone, corresponding to the field of view 9 N ( 9 R for the sensor 5 R). The optical metrological sensor 5 N can then locate the known bright star S in its focal plane with a maximum accuracy. Thus, initially, a bright star S is identified thanks to the star sensors 4 ; it is known and its coordinates appear in the star catalogue. Through the intermediary of the star sensors 4 , it is located absolutely with an average accuracy due to the imperfections of the star sensor, typically at best a few seconds of arc.
Then, said bright star S is located accurately and relatively in the frame of reference of the instrument 6 b using the optical metrological sensor 5 N. Consequently, the coupling of the star sensor 4 and of the optical metrological sensor 5 N makes it possible to bring to the satellite a maximum absolute pointing accuracy, typically 0.1 second of arc. The error is limited to the sum of the error on the relative location of the bright star S targeted by the optical metrological sensor 5 N in the frame of reference of the satellite and of the error on the absolute coordinates of the targeted bright star S appearing in the star catalogue.
The star catalogues, and more particularly the bright star catalogues, have very high accuracies, so the absolute accuracy of the system is approximately equal to the relative accuracy of the optical metrological sensor 5 N, conventionally at least ten times better than the absolute accuracy of the standard star sensors, such as the stellar sensors 4 .
In an example of preferred implementation of the absolute target system according to the invention, it is thus possible to use as optical metrological sensor a device of the type of that described in the French patent application No. FR2902894. This patent application describes a metrology system for the formation flight of satellites making it possible to relatively locate satellites in space.
Generally, in the context of flight of satellites in formation, a measurement of the relative positions of the satellites is required, just like a measurement of the absolute pointing of the satellites to inertial directions, such as the stars. For the relative inter-satellite position measurements, an optical metrological sensor is used. For the absolute pointing measurements, a star sensor is used. The accuracy of the measurement of the relative position metrological sensor is generally far better than the absolute measurement of the star sensor. On the other hand, the metrological sensor has no knowledge of the absolute stellar environment. The object of the invention is to combine these two measurements and the information from the two types of sensor to provide an absolute measurement accuracy of the order of the inter-satellite relative measurement accuracy, and this without adding any extra sensor on board.
FIG. 3 is a highly simplified representation of the operation of such an optical metrological sensor 5 N. In the abovementioned patent application, an optical source on board a primary satellite emits a light beam towards a second satellite which reflects the light beam towards the primary satellite. The primary satellite comprises a set of detectors on which is focussed the reflected light beam. It is the measurement of the position of the light spot obtained on the set of detectors that makes it possible to know the relative position of the secondary satellite in relation to the primary satellite. For use in the context of the present invention, the bright star S replaces the optical source reflected by a mirror. The light obtained from said bright star S is focussed using lenses L and mirrors M at a point P on the set of CCD detectors of the optical metrological sensor 5 N. Thus, the distance from the point P to the centre R of the CCD detector matrix is measured accurately, and the direction in which the bright star S lies is deduced therefrom relative to the target axis X-X′ of the optical metrological sensor 5 N in the specific frame of reference of said sensor 5 N, therefore in that of the satellite, or of the set of satellites, on which it is mounted. With such an optical metrological sensor 5 N, the absolute pointing accuracy of the system according to the invention can reach approximately 0.1 second of arc.
Moreover, such an optical metrological sensor 5 N can be fully calibrated on the ground. In practice, an optical source can be used, which will replace the star S in order to perform on the ground the calibration of the optical metrological sensor 5 N. This calibration on the ground of such a sensor makes it possible to achieve an accuracy on the position of the optical source of the order of ten or so microns at 20 meters, which well corresponds to an accuracy on the target axis of the order of a tenth of a second of arc.
To sum up, the main advantage of the invention is to make it possible to implement an absolute target system presenting a maximum accuracy, compatible with the accuracies required for the current and future space observation missions. Furthermore, to achieve this result, the invention requires only one star sensor, normally systematically incorporated in the observation satellites, and an optical metrology system, essential to any formation flight mission. The solution proposed in the present patent application is therefore easy to incorporate, and potentially cost-free in terms of equipment weight and cost.
It will be readily seen by one of oridinary skill in the art that the present invention fulfils all of the objects set forth above. After reading the foregoing specification, one of oridinary skill in the art will be able to affect various changes, substitutions of equivalents and various aspects of the invention as broadly disclosed herein. It is therefore intended that the protection granted hereon be limited only be definition contained in the appended claims and equivalents thereof. | The present invention relates to an absolute target system intended to be incorporated in observation satellites. To establish an absolute target system provided with maximum accuracy, the present invention proposes coupling a star sensor ( 4 ) to an optical metrological system ( 5 N, 5 R). Since these two items of equipment are normally already on board the satellites, in particular for formation flight missions, this solution adds no extra weight or cost. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of treating the anode slimes which are generated during electrolytic copper refining, and more particularly to a method of treating the anode slimes so as to recover the gold content therein.
2. Description of the Prior Art
Anode slimes which are generated when crude copper is electrolytically refined consist mostly of those impurities originally contained in the copper anode which are insoluble in the electrolyte. Such anode slimes, which will either remain on the copper anode or settle to the bottom of the electrolytic tank, normally contains not only numerous valuable metals, including gold, silver, selenium, tellurium, lead, and metals of the platinum group but copper accompanied.
Various methods for recovering the valuable metals from such slimes are known. These methods utilize the steps of copper and selenium removal, smelting, volatilization, cupellation, silver electrolysis and gold electrolysis in noted order. Since the gold recovery step is usually preceded by other metal recovery steps, each of which needs to take one to five days to complete, the gold recovery step may not be commenced for two to three weeks. And because the gold will have been contained in the matte and slag during the prior smelting step, and also into the litharge of the cupellation step, repeated treatments of these products will be required to recover the gold therefrom, thus lengthening the time period needed to recover all the gold from the initial anode slimes.
It is thus an object of the present invention to eliminate the noted drawbacks of the prior art and to provide a simple, quick and effective method for the recovery of the gold from anode slimes generated during electrolytic copper refining.
SUMMARY OF THE INVENTION
According to the present invention the anode slimes generated during electrolytic copper refining is first treated to remove the copper and selenium therefrom, then the slimes are dispersed in water to form an aqueous slurry, chlorine gas is subsequently blown into the aqueous slurry so as to dissolve the gold, and finally the dissolved gold is separated from the residue. These method steps, accomplished in sequence, enable the gold in the anode slimes to be recovered simply, quickly and effectively.
DETAILED DESCRIPTION OF THE INVENTION
The first step of the inventive method is to remove the copper and selenium from the anode slimes. Such methods are in themselves well known. (Refer to, for example, page 40 of the literature "Flow Charts and Capacity of Copper Refining Operation", October 1978 published by Japan Mining & Industry Association.)
One technique for removing these metals from the anode slimes is to react the slimes with dilute sulfuric acid, and air or oxygen, or to react the slimes with concentrated sulfuric acid, then extracting the reacted slimes with water. The reaction is carried out in a vessel either under atmospheric pressure or else under an elevated pressure and temperature. Thus the copper is dissolved from the slimes. Next, the residue is oxidized by roasting at temperatures of 600° C. to 800° C. so as to volatilize the selenium therein as selenium dioxide.
Another technique is to react the anode slimes with either an acid or an alkali and with air or oxygen in an autoclave at a high temperature and under elevated pressure. If an acid is used, the reaction is carried out at a higher temperature than is used when the sulfuric acid treatment techniques (discussed above) are used, and copper and selenium can be simultaneously dissolved from the slimes. If an alkali is used, selenium is dissolved in the alkaline solution while copper is extracted from the residue with dilute sulfuric acid.
A further technique is to oxidize the anode slimes by roasting (either in the presence or absence of concentrated sulfuric acid) to volatilize the selenium as selenium oxide and then to extract the copper from the roasted slimes with water or dilute sulfuric acid.
A still further technique which can be used is disclosed in the applicants' Japanese Patent Application No. 148506/1980, filed Oct. 23, 1980. In this technique free sulfuric acid is removed from the slimes to the greatest possible extent and thereafter an aqueous slurry containing the slimes is treated with air or oxygen at a high temperature and under a high pressure in a vessel so as to convert the copper and selenium to an acid-soluble substances. The copper and selenium are then extracted with sulfuric acid.
In any event, according to the present invention the initial removal of the copper and selenium from the anode slimes is performed in order to prevent simultaneous dissolution of these metals when the gold is subsequently dissolved from the slimes. Their removal also facilitates the separation of the other remaining metals from the slimes at a later time.
Moreover, the noted treatments of the anode slimes for the removal of copper and selenium therefrom also performs the removal of any organic additives which may be present in the anode slimes, these organic additives, e.g., glue, pulp waste or casein, being initially present in the electrolyte. In this regard, it is desirable to remove these additives from the anode slimes prior to the treatment of the aqueous slurry of anode slimes with chlorine gas according to the present invention because, if present, the chlorine gas will be reduced by the organic additives (the organic additives being likewise oxidized) to form chloride ions, and these chloride ions will react by the following reactions with silver chloride which has been formed by chlorination, so that the silver chloride will be dissolved in the form of complex ions:
AgCl+Cl.sup.- →[AgCl.sub.2 ].sup.-
AgCl+2Cl.sup.- →[AgCl.sub.3 ].sup.--
Similar reactions will dissolve any lead in the form of lead ions or lead ion complexes, the lead being initially present in the form of lead sulfate prior to the chlorination.
On the other hand, if the aqueous slurry of anode slimes has contained no organic additives when chlorine gas is added thereto according to the present invention, the formation of chloride ions will be limited to the amount required to react with the gold metal present. Accordingly, the aqueous slurry of anode slimes after chlorination will be acidic in pH order, and only a very small quantity of silver and lead present will be dissolved.
Of the various noted techniques for removing copper and selenium from anode slimes, these which involve the dry oxidation of the slimes by roasting and the wet oxidation techniques using autoclaves, the former are preferred in the capacity for removing the organic additives. This is due to the formation of less chloride ions when the aqueous slurry of slimes is treated with chlorine gas and to a smaller dissolution of silver or lead. But even by the wet oxidation techniques using autoclaves, the purposes of the present invention can be sufficiently achieved. According to the next step of the inventive method the anode slimes which have been treated to remove the copper and selenium therein (as well as any organic additives) are dispersed in water to form an aqueous slurry and then chlorine gas is blown therein. The aqueous slurry will be put in a vessel which may be either open or closed, and the aqueous slurry will be usually stirred while the chlorine gas is added. The slimes concentration in the slurry should not be too high because if it is, its pH value will be too low and the added chlorine gas will cause an unpreferable dissolution of silver, lead and like metals.
Chlorine gas is supplied to the aqueous slurry of anode slimes until unreacted chlorine gas appears in bubbles on the surface of the aqueous slurry, or until the chlorine gas pressure in a closed vessel stop dropping. Since the gold in the slimes are in the form of fine particles and thus will be highly reactive with the chlorine, after not more than three hours of treatment with the chlorine at least 99.5% of the gold will have been dissolved from the slimes.
The gold-containing extraction solution is thereafter separated from the residue, and treated with a reducing agent to recover the gold. Suitable reducing agents include a well-known hydrogen peroxide, oxalates, ferrous salts or the like. Using these reducing agents, the gold can be directly recovered in a highly purified state. The solution from which the gold has been recovered can then be passed to another process stage for recovery of the metals of the platinum group. The residue from which the gold-containing extraction solution has been separated will have a very low gold content, e.g., no more than several tens of grams per ton. It can be smelted and the silver can be therefrom. The silver can be concentrated to form a silver anode, which may be later subjected to electrolysis to produce high purity silver.
The present invention will now be described in further detail by reference to the following examples.
EXAMPLE 1
Anode slimes resulting from electrolytic copper refining, containing 18.8% by weight of Cu, 6.2% by weight of Se, 6.8% by weight of Pb, 24% by weight of H 2 O, 3,430 g/t of Au, and 107,000 g/t of Ag, was dried. Particles having a particle size of 4 to 20 mesh were separated from the slimes, and oxidized by roasting at 700° C. for at least one hour in a rotary kiln. Six kilograms of the roasted slimes were crushed, and treated at 80° C. for one hour with 30 liters of dilute sulfuric acid having a concentration of 250 grams per liter. The acid extraction residue had a dry weight of 1.82 kg.
An aqueous slurry was formed from 1.3 kg of the acid extraction residue and 3.9 liters of water. Chlorine gas was blown into the slurry at a rate of 390 ml/min so that the residue would react with chlorine for three hours at 80° C. No neutralizing agent was added to adjust the pH of the slurry. The solution obtained by the reaction showed a pH value of 1.06. The quantities and chemical analyses of the residue, etc., and the extraction ratio are shown in TABLE 1 below.
TABLE 1______________________________________CompositionQuan-tity Cu Se Pb Ag Au______________________________________Acid 1.3 kg 0.97% 0.11% 31.5% 166,000 11,100extraction g/t g/tresidueSolution 3.51 0.51 g/ 0.19 g/ 0.03 g/ Less 4.1 g/after liters liter liter liter than literacid 0.001 g/extraction literChlorina- 1.15 kg 0.94% 0.06% 35.6% 187,000 31 g/ttion g/tresidueExtraction -- 14.2% 46.9% 0.03% 0.00% 99.7%ratio______________________________________
EXAMPLE 2
The procedures of EXAMPLE 1 were repeated, except that slimes containing 14.8% by weight of Cu, 6.0% by weight of Se, 13.9% by weight of Pb, 18% by weight of H 2 O, 5,010 g/t of Au, and 101,000 g/t of Ag was used, an aqueous slurry was formed from 0.65 kg of the acid extraction residue and 2.0 liters of water, and chlorine gas was blown into the slurry at a rate of 200 ml/min. The solution obtained by the reaction showed a pH value of 1.19. The results are shown in TABLE 2 below.
TABLE 2______________________________________CompositionQuantity Cu Se Pb Ag Au______________________________________Acid 0.65 kg 1.93% 0.02% 41.2% 114,000 11,800extraction g/t g/tresidueSolution 1.90 0.23 Less 0.026 Less 4.04 g/after liters g/liter than g/ than literacid 0.01 g/ liter 0.001extraction liter g/literChorination 0.605 2.00% Less 44.2% 122,000 2 g/tresidue kg than g/t 0.01%Extraction -- 3.5% 0.00% 0.019% 0.00% Moreratio than 99.9%______________________________________
A mixture of the gold-containing extraction solution obtained in EXAMPLES 1 and 2 was reacted directly with an aqueous solution of hydrogen peroxide to yield a reduced gold precipitate containing 99.98% by weight of Au, 1 ppm of Ag, 3 ppm of Pb, 7 ppm of Cu and 130 ppm of Sb. The precipitate was boiled in nitric acid, and the product obtained by solid-liquid separation was melted in a crucible. And then high purity gold containing at least 99.99% by weight of Au, not more than 1 ppm of Ag, not more than 1 ppm of Pb, 1 ppm of Cu, and 2 ppm of Sb was recovered.
EXAMPLE 3
A slurry was formed from 1.6 kg of anode slimes resulting from electrolytic copper refining, containing 13.7% by weight of Cu, 5.3% by weight of Se, 9.6% by weight of Pb, 20% by weight of H 2 O, 5,000 g/t of Au, and 95,000 g/t of Ag, and four liters of water. The slurry was put in an autoclave and oxidized for one hour at a temperature of 220° C. and an oxygen partial pressure of 10 kg/cm 2 . The slurry thus oxidized was taken out from the autoclave, and extracted by adding 1.6 kg of 98% concentrated sulfuric acid for one hour at 80° C. There was obtained 418 g (dry) of extraction residue containing 0.43% by weight of Cu, 0.20% by weight of Se, 193,000 g/t of Ag, and 19,300 g/t of Au.
An aqueous slurry was formed from 209 g of the acid extraction residue and 630 ml of water. Chlorine gas was blown therein at a rate of 63 ml/min so that the residue would react with chlorine at 80° C. for three hours. The pH was not adjusted. The gold-containing extraction solution showed a pH value of 0.31. Although it had slightly higher silver and lead concentrations, i.e., 0.004 and 0.30 gram per liter, respectively, the solution contained 5 g of gold per liter, and the residue contained 5 g of gold per ton. This meant a gold extraction ratio of at least 99.5%.
The remaining 209 g of the acid extraction residue was likewise treated except the adjustment of its pH value to about 1 with sodium hydroxide during the reaction of gold with chlorine. The solution showed silver and lead concentrations of 0.004 and 0.09 grams, respectively, per liter, and a gold extraction of at least 99.5% was obtained.
COMPARATIVE EXAMPLE 1
The same slimes as employed in EXAMPLE 3 was directly treated with chlorine without removal of copper and selenium. A slurry was formed from 600 g of the slimes and 2.0 liters of water, and chlorine gas was blown into the slurry at a rate of 210 ml/min so that the slimes would react with chlorine at 80° C. for three hours. The solution showed a pH value of 0 or below. The results are shown in TABLE 3.
TABLE 3______________________________________ Composition Quantity Cu Se Pb Ag Au______________________________________Solution 2.33 28.2 10.7 0.83 0.004 1.02 liters g/liter g/liter g/liter g/liter g/literResidue 0.191 0.03% 0.27% 23.1% 238,000 105 g/t kg g/tExtraction -- 99.8% 98.0% 4.19% 0.02% 99.5%ratio______________________________________
As is obvious from the results hereinabove shown, this invention provides an industrially excellent method which can recover gold at a high yield quickly in one or two days, as opposed to two to three weeks required in prior art processes, and achieves a separation of the gold from the other valuable metals effectively using only a hydrometallurgical method which needs a small and simple apparatus. | A method of recovering gold from anode slimes resulting from electrolytic copper refining comprises treating the anode slimes to remove copper and selenium, forming an aqueous slurry from the treated slimes, blowing chlorine gas into the aqueous slurry to dissolve the gold therein, and separating the so-dissolved gold from the residue. | 8 |
FIELD OF THE INVENTION
The present invention relates to a vehicle seating system. More particularly, the present invention relates to a fold and tumble vehicle seat that pivots about a cantilever extending from a center console of a vehicle.
BACKGROUND OF THE INVENTION
In vehicles such as automobiles, sport utility vehicles, and mini-vans, fold and tumble seating is used to aid in occupant ingress and egress from the vehicle, and provide easier access to storage space behind a row of seats. Typically the rear end of a fold and tumble seat is releasably attached to the floor of the vehicle by a pair of legs. A release mechanism allows the seatback to be folded forward. A second mechanism releases the rear legs such that the folded seat can be tumbled forward toward the front of the vehicle. The fold and tumble operation creates a larger opening into the vehicle.
When the seat is in the tumbled position, the rear legs jut outward toward the rear of the vehicle, presenting a hazard for the occupants of the vehicle, particularly with respect to the rear leg on the outside portion of the seat. To solve this problem, the rear legs of conventional fold and tumble seats have been designed to collapse or fold into the seat frame when the seat is in the tumbled position. The collapsing leg removes the safety hazard.
Conventional fold and tumble seats typically have a frame that is supported at the front and by a pair of brackets or legs that are further supported by the floor of the vehicle. The seat pivots about the points at which it is supported by the front legs. The front legs take up space that could otherwise be used as storage space below the vehicle seat. Two front legs are required because the outside front leg not only supports the seat but resists the bending moment from the load of the occupant and the seat, as well as downward forces during a vehicle crash. If the vehicle crashes while moving in a forward direction, the seatbelt retains the occupant in the seat, resulting in a submarining-type force wherein the front portion of the seat cushion is driven downward toward the floor as the seatback attempts to rotate toward the front of the vehicle.
The space taken up by the front support legs is greater with newer vehicle seats that have taller seatbacks and headrests. Because of the taller seatback and headrest, the points about which the seat pivots as it tumbles forward must be at a greater distance above the floor than in previous designs to prevent the headrest from crashing into the floor in the final fold and tumble configuration. Therefore, the front legs or brackets must be taller as well.
Conventional fold and tumble seats do not typically have a substantial support member that runs orthogonal to the side of the vehicle. This is because the seats are supported by structural members rising from the floor of the vehicle, and therefore substantial cross support members are not required to resist bending moments. A disadvantage of the conventional design is that the seat frame does not afford a great amount of side impact protection in the event of a vehicle crash.
Accordingly, it would be advantageous to have a fold and tumble seat that does not require a rear outside leg that can present a safety hazard to vehicle occupants. Further, it would be advantageous to have a fold and tumble seat that does not have front legs extending to the floor of the vehicle. Further still, it would be advantageous to have a fold and tumble seat that has a substantial structural support running orthogonal to the side of the vehicle to provide side impact protection.
SUMMARY OF THE INVENTION
An exemplary embodiment relates to a vehicle seat having a seat frame with a front portion and a rear portion. A seatback is pivotally coupled to the rear portion, and a cantilever is pivotally coupled to and supports the front portion.
Another embodiment relates to a vehicle having a floor and a plurality of side doors. A cantilever extends in a direction orthogonal to the side doors and is supported by a center console. A seat is pivotally supported on the cantilever.
Still another embodiment relates to a vehicle seat having a seat frame coupled to a vehicle floor. A cushion is coupled to the frame and a seatback is coupled to the cushion or the seat frame. A maximum of one support leg extends between the seat frame and the floor.
BRIEF DESCRIPTION OF THE DRAWINGS
An exemplary embodiment will hereinafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
FIG. 1 is a perspective view of a conventional fold and tumble seating system;
FIG. 2 is a perspective view of an improved fold and tumble seating system; and
FIG. 3 is a sectional view taken generally along line 3 — 3 of FIG. 2;
FIG. 4 is a perspective view from the rearward direction of the frame of the improved fold and tumble seating system;
FIG. 5A is a side view of an improved fold and tumble seating system in an upright position;
FIG. 5B is a side view of an improved fold and tumble seating system in a folded position;
FIG. 5C is a side view of an improved fold and tumble seating system in a folded and tumbled position;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a seat 10 has a cushion 12 , a seatback 14 , a headrest 16 , and a frame 18 . The cushion 12 can have a cushion frame (not shown). The seatback 14 can be pivotally coupled to the cushion frame or directly to the frame 18 by a pair of brackets 15 . The frame 18 is supported by two pairs of legs 20 , 22 .
Further shown in FIG. 1, in a vehicle there can be a floor 32 , a number of seats 10 , and a center console 34 . The center console 34 can include a middle seat (not shown). The seat 10 and center console 34 can be located in any row of the vehicle. The vehicle body has cut-outs 38 to accommodate side doors (not shown).
A conventional seat frame 18 has a pair of side rails 40 coupled to the legs 20 , 22 . A front end 42 of each of the side rails 40 is pivotally coupled to the pair of front legs 20 . The front legs 20 are secured to the floor 32 . Rear ends 44 of the rails 40 are coupled to the pair of rear legs 22 . The rear legs 22 are releasably secured to the floor 32 . The rear legs 22 are releasably coupled to the floor 32 so that the seat 10 may be tumbled forward, pivoting about a pair of front pivot points 46 .
The seat 10 is designed to fold and tumble forward to aid in occupant ingress and egress. The seatback 14 is first folded forward onto the seat cushion 12 . The rear legs 22 are then released from the floor 32 to allow the folded seat 10 to be tumbled forward about the front pivot points 46 . The fold and tumble operation results in a collapsed configuration of the seat 10 wherein the headrest 16 is positioned proximal the floor 32 , and the rear legs 22 face rearward.
Referring to FIG. 2, an improved seat 110 is shown. The improved seat 110 has a cushion 112 , a seatback 114 , and a headrest 116 in the same configuration as the seat 10 depicted in FIG. 1. A pair of brackets 115 pivotally couple the seatback 114 to a cushion frame or the seat frame 118 .
The frame 118 has a front portion 150 that is pivotally coupled to a cantilever, shown as a pivot tube 154 . The pivot tube 154 extends into the frame 118 from a center console 134 . Thus, the front portion 150 of the frame 118 is supported by a portion of the pivot tube 154 that is cantilevered off the center console 134 . Alternatives to the pivot tube 154 can include any cantilever structure, such as a beam.
The center console 134 has an associated frame 136 designed to support the pivot tube 154 . Also attached to the center console frame 136 can be a storage system, an armrest, or a middle seat.
Referring to FIG. 3, the frame 118 is supported by the pivot tube 154 . A frame bearing surface 156 can be provided at multiple points, or continuously across the frame 118 to support the mass of the seat 110 . Thus, the frame 118 can pivot about a plurality of bearing surfaces 156 or about an axis stabilized by the pivot tube 154 . As an alternative embodiment to having the frame 118 bearing directly on the pivot tube 154 , the pivot tube 154 can have attached brackets that pivotally support the frame 118 . This alternative embodiment is useful when the cantilever 154 is not a cylindrical member.
Referring to FIG. 4, a rear portion 152 of the frame 118 can be supported by a support member, shown as a rear leg 122 . A support bracket, shown as a structural latch 160 , may be used to provide additional structural support, for example, to carry a seatbelt. The structural latch 160 aids in stabilizing the seat 110 with respect to torsional forces. The rear leg 122 can be supported by the floor 32 . A release mechanism 162 permits the detachment of the rear leg 122 to tumble the seat 110 . The structural latch 160 is attached to the center console frame 136 , and also selectively releases from the center console frame 136 .
Referring to FIGS. 5A, 5 B, and 5 C, the improved seat 110 folds and tumbles in a similar fashion to the conventional seat shown in FIG. 1 . FIG. 5A shows the seat 110 in a standard operative position. The seatback 114 can be folded forward onto the seat cushion 112 in the direction shown by the arrow in FIG. 5B. A release mechanism (not shown) can be operated to release the seatback 114 from the operative position to effect the folding motion.
Referring to FIG. 5C, the seat 110 is shown in the tumbled position. The seat 110 is placed into the tumbled position by first operating the rear leg 122 release mechanism 162 (FIG. 4 ). The rear leg 122 releases from the floor 32 , and the structural latch 160 (FIG. 4) releases the rear portion 152 to allow the frame 118 to pivot about the pivot tube 154 in a forward direction (shown by the arrow in FIG. 5 C). A handle 164 can be used to aid in tumbling the seat.
The improved seat 110 permits more storage room below the seat 110 because the conventional front legs 20 have been removed (compare FIG. 1 to FIG. 2 ).
The pivot tube 154 has a large diameter to withstand the bending moment on the tube due to the removal of the front legs 20 . The pivot tube 154 must maintain the integrity of the frame 118 both during normal vehicle operations as well as during a vehicle crash.
Referring to FIG. 4, it can be seen that the two conventional rear legs 22 have been removed in the improved design and replaced with a single rear leg 122 , which is positioned adjacent the center console 134 rather than toward the outside of the vehicle. Therefore, when the seat 110 is in the tumbled configuration, there is no longer a rear outside leg 22 to interfere with occupants entering or exiting the vehicle. The remaining rear leg 122 is positioned proximate the center console 134 such that it does not interfere with occupants. If desired, the rear leg 122 can be designed to collapse or fold into the frame 118 when the seat 110 is in the tumbled position.
The improved seat 110 can be used in the front row of the vehicle, or rearward rows in vehicles with more than two rows of seats.
Thus, the improved seat 110 solves the disadvantages of conventional fold and tumble seats discussed in the Background of the Invention section. One of the rear legs 22 has been removed, and the remaining rear leg 122 is disposed toward the interior of the vehicle, removing the obstruction and safety hazard of a rear leg 22 jutting outward in the path of travel when the conventional seat 10 is in the tumbled configuration. Further, the improved fold and tumble seat 110 does not have front legs 20 , increasing the amount of storage space below the seat 110 . Further, the pivot tube 154 enhances the structural integrity of the seat 110 , particularly with respect to side impact vehicle crashes.
While several embodiments of the invention have been described, it should be apparent to those skilled in the art that what has been described is considered at present to be the preferred embodiments of a fold and tumble seating system. However, changes can be made in the design without departing from the true spirit and scope of the invention. The following claims are intended to cover all such changes and modifications that fall within the true spirit and scope of the invention. | A fold and tumble vehicle seat has a cushion, seatback, and a frame. The frame is supported at the front end by a cantilever that extends perpendicular to the direction that the seat faces. The seat frame is pivotally coupled to the cantilever, allowing the removal of the customary front legs that would otherwise support the seat. A single rear leg is releasably attached to the floor of the vehicle, and a structural latch may be used to attach the frame to a center console. The vehicle seat is pivoted out of the way by folding the seatback forward, and releasing the rear leg to allow the seat to pivot forward about the pivot tube. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a plasma display panel and a method of forming a fluorescent screen of a plasma display panel.
There is generally known a DC (direct current) or an AC (alternating current) type plasma display panel or unit in which front and rear plates are arranged parallel to each other and a cell barrier constituting a plurality of display element cells is disposed between the front and rear plates.
The fluorescent screen or surface of the DC or AC type plasma display panel having the structure described above, is formed by the steps of coating a photosensitive slurry containing a phosphor to the rear surface of the front plate, exposing the coated surface by utilizing a photomask corresponding to the pattern of the fluorescent screen to be formed, and finally developing and calcinating the exposed surface.
Utilized as the photosensitive slurry is a mixture containing a phosphor, PVA(poly vinyl alcohol), or diazonium salt, for example, and a defoaming agent or surfactant may be added as occasion demands.
In the case when light is observed by the eyes of an operator after transmission through this formed fluorescent screen itself, the amount of the light is reduced during the passage through the fluorescent screen. For this reason, in the conventional technology, there has been developed a plasma display panel in which a fluorescent screen is formed on the wall surface of the cell barrier for increasing the luminance of the light, and the reflected light of the light emitted from the fluorescent screen is observed.
The plasma display panel of the type described above utilizes a spacer provided with holes each having a trapezoidal cross section as a cell barrier, and a slurry solution containing a phosphor is fed into the hole from a widened opening side thereof. The slurry solution containing a phosphor is coated on the wall surface of the spacer hole by sucking the slurry solution from the other side of the hole to thereby form the fluorescent screen on the spacer wall surface.
With the conventional fluorescent screen forming method of the character described above, it is necessary to coat and suck the slurry solution containing a phosphor to form the fluorescent screen on the wall surface of the spacer, and accordingly, the front plate and the rear plate are assembled with the spacer after the formation of the fluorescent screen on the wall surface of the spacer. This assembling working makes it difficult to precisely adjust the positions of the front and rear plates and the spacer, which requires high-precision work for the preparation of the spacer member. The spacer member is prepared by providing holes in a photosensitive glass material with hydrofluoric acid. However, in the present technique, it is difficult to provide a photosensitive glass having a size of more than about 30×30 cm 2 . Accordingly, it is not applicable to utilize the photosensitive glass to the large sized plasma display panels which are required for the recent industrial use. In addition, the recent plasma display panel mainly requires a discharging space having a thickness of about 100 to 200 μm and hence it is difficult to assemble the spacer in such discharging space and handle such a thin glass.
Furthermore, the conventional DC or AC type plasma display panel has a structure in which the cell barrier is attached to either the front plate or the rear plate and a cathode (cathode and anode in the AC type plasma display panel) is formed on the rear plate so that it is impossible to apply the conventional fluorescent screen forming technique as it is.
SUMMARY OF THE INVENTION
An object of this invention is to eliminate the defects or drawbacks encountered in the prior art described above and to provide a method of easily and precisely forming a fluorescent screen or surface on a wall surface of a cell barrier of a plasma display panel.
Another object of this invention is to provide a plasma display panel formed by the method according to this invention and provided with a fluorescent screen having excellent characteristics.
These and other objects can be achieved according to this invention, in one aspect, by providing a method of forming a fluorescent screen for a plasma display panel provided with a front plate and a rear plate disposed parallel to each other and a cell barrier mounted on the front or rear plate, and constituting a plurality of cells as display elements, the method characterized in that the cell barrier is located on the surface of the front or rear plate, a slurry solution containing a phosphor is filled in a portion defined by a cell wall of the cell barrier on the front or rear plate, only the wall surface of the cell barrier is exposed, and so a photosensitive layer containing a phosphor is formed at a portion inside the cell barrier.
In another aspect, according to this invention, there is provided a method of forming a fluorescent screen for a plasma display panel provided with a front plate and a rear plate disposed parallel to each other and a cell barrier mounted on the front or rear plate and constituting a plurality of cells as display elements, the method being characterized in that a slurry solution containing a phosphor is filled inside the cell of the cell barrier on the front or rear plate, the cell barrier mounted plate is inclined immediately thereafter with an inclination of about 90° or more degrees with respect to a horizontal plane, the plate in an inclining state is settled till the phosphor in the slurry solution precipitates on the cell wall of the cell barrier, and the cell wall is dried and hardened after the precipitating process.
In a further aspect, according to this invention, there is provided a plasma display panel comprising a front plate having a rear surface, a rear plate as a substrate having a front surface which opposes the rear surface of the front plate and in which a cell barrier provided with a plurality of cells is mounted, the rear plate being arranged parallel to the front plate, and a fluorescent screen formed on a wall surface of the cell and the rear surface of the front plate.
In a still further aspect according to this invention, there is provided a plasma display panel comprising a front plate having a rear surface, a rear plate as a substrate having a front surface opposing the rear surface of the front plate and on which a cell barrier is mounted, the rear plate being arranged parallel to the front plate, a fluorescent screen formed on a wall surface of the cell, and a color filter means formed on the rear surface of the front plate.
The preferred embodiments according to this invention will be described in further detail hereunder with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a cross sectional view of a conventional DC type plasma display panel;
FIG. 2 is a cross sectional view of a conventional AC type plasma display panel;
FIG. 3 shows a cross section of a conventional spacer for a plasma display panel;
FIGS. 4 through 9 represent the first embodiment according to this invention, in which FIG. 4 is a vertical section of a substrate on which a cell barrier is formed; FIG. 5 is a view similar to that shown in FIG. 4, but a slurry solution containing a phosphor is applied to a cell of the cell barrier; FIG. 6 shows a view similar to that shown in FIG. 5 for showing an exposure process; FIG. 7 is a perspective view of the cell barrier provided with circular cells; FIG. 8 is a perspective view of the cell barrier provided with rectangular cells; and FIG. 9 is a vertical section of the plasma display panel which is exposed by utilizing a mask;
FIGS. 10 through 15 represent the second embodiment according to this invention, in which FIG. 10 is a vertical section of a substrate on which a cell barrier is formed; FIGS. 11 and 15 are views showing the state where a photosensitive coating agent containing a phosphor is applied to the plasma display panels, respectively; FIG. 12 is a sectional view showing the state where light is irradiated by utilizing a mask; FIG. 13 is a sectional view showing the state where the photosensitive coating agent containing the phosphor remains only on the wall surface of the cell barrier; and FIG. 14 is a sectional view showing a plasma display unit utilizing the base plate formed by the method represented by FIG. 10 through 13;
FIGS. 16 through 23 represent the third embodiment according to this invention, in which FIG. 16 is a vertical sectional view of a substrate on which a cell barrier is formed; FIG. 17 is a view similar to that shown in FIG. 16 for representing a fluorescent screen formation process; FIG. 18 is a view representing the exposure status; FIG. 19 shows a chart showing the formation processes according to the third embodiment; FIG. 20 is a perspective view of the cell barrier provided with circular cells; FIG. 21 is a perspective view of the cell barrier provided with rectangular cells; FIG. 22 is a vertical section of the plasma display panel exposed by utilizing a mask member; and FIG. 23 is a vertical section of the DC type plasma display panel provided with a cell barrier in a linear arrangement; and
FIGS. 24 and 25 represent the fourth embodiment according to this invention, which are sectional views of the plasma display panels in the course of the formation of the fluorescent screen.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For a better understanding of this invention, a conventional DC type plasma display panel, an AC type plasma display unit, and a spacer utilized for a cell barrier provided with holes in each trapezoidal cross section will be first described hereunder with reference to FIGS. 1, 2 and 3, respectively.
FIG. 1 shows a conventional DC type plasma display panel, in which flat front and rear plates 11 and 12 both made of glass are arranged parallel to each other in an opposing fashion. A cell barrier 13 is secured to the front (upper as viewed) surface of the rear plate 12 thereto and to define cells 14 therein, and a space having a proper volume is maintained between the front and rear plates 11 and 12 by the location of the cell barrier 13. Anodes 15 are formed on the rear (lower as viewed) surface of the front plate 11, and a cathode 16 is formed on the front surface of the rear plate 12 so as to be normal, in plan view, to the anodes 15. Fluorescent screens 17 are formed adjacent to both sides of the anodes 15.
According to the conventional DC type plasma display panel shown in FIG. 1, discharge is caused in the respective cells 14 defined between the front and rear plates 11 and 12 and the cell barrier 13 by applying an electric field between the anodes 15 and the cathode 16. The discharge creates ultraviolet rays which illuminate the fluorescent screens 17 and the light through the front plate 11 is observed by a viewer 18.
FIG. 2 shows a conventional AC type plasma display unit, in which flat front and rear plate 21 and 22 both made of glass are arranged parallel to each other in opposing fashion. A cell barrier 23 is secured to the front (upper as viewed) surface of the rear plate 22 thereto and to define cells therein. A space having a proper volume is maintained between the front and rear plates 21 and 22 by the location of the cell barrier 23. Two electrodes 24 and 25 arranged normal to each other in plane view, are formed on the front surface of the rear plate 22 through a layer 26 of an electrically dielectric layer. A second electrically dielectric layer 27 and a protective layer 28 are laminated on the dielectric layer 26. A fluorescent screen 29 is formed on the rear (lower as viewed) surface of the front plate 21.
According to the conventional AC type plasma display unit shown in FIG. 2, discharge is caused in the respective cells 14 defined between the front and rear plates 21 and 22 and the cell barrier 23 by applying an electric field between the two electrodes 24 and 25. The discharge creates ultraviolet rays which illuminate the fluorescent screen 29 and the light through the front plate 21 is observed by a viewer 30.
FIG. 3 shows a conventional spacer means 32 to be disposed between the front and rear plates and provided with holes 31 each having a trapezoidal cross section.
A slurry solution containing a phosphor is supplied into the spacer 32 through widely opened sides (upper side as viewed) of the holes 31 by a screen printing technique or by means of a spray, and the slurry solution is sucked from the other opening sides of the holes 31 to spread the slurry solution over the wall surface of the hole 31 of the spacer 32.
However, these conventional plasma display panels involve the various problems described hereinbefore.
Preferred embodiments according to this invention for overcoming the problems of the prior art will be described hereunder with reference to FIGS. 4 to 25.
FIRST EMBODIMENT
1-1 Basic Structure
FIGS. 4 through 9 represent the first embodiment for forming a fluorescent screen or surface according to this invention, and the first embodiment represents a case in which a fluorescent screen is formed on a cell wall surface of a cell barrier secured to a rear plate of a DC type plasma display panel. A rear plate 2 made of a flat glass substrate is provided with a front (upper as viewed) surface to which a cell barrier 3 is secured to be normal to the front surface of the rear plate 2 so as to define a proper space between the rear plate and a front plate, not shown. Cathodes 5 are formed on the front surface of the rear plate 2. As shown in FIG. 4, the inner dimension of an opening of the cell is provided as "a" and the height of the cell barrier is provided as "b" for convenience's sake.
In the next step shown in FIG. 5, a liquid of a photosensitive material 10 containing a phosphor is coated on the inner portion of the cell barrier 3. The coating is carried out by various methods, such as, by means of a spray utilizing a mask, by a screen printing technique, or by a method in which the photosensitive liquid 10 is first coated on the entire surface of the substrate and the front end portion of the cell barrier 3 is scraped by a scraper made of rubber, for example, to thereby coat the liquid 10 to only the inner portion of the cell barrier 3.
According to this embodiment, the photosensitive liquid containing a phosphor 10 is uniformly and adequately adhered to the cell wall surface of the cell barrier 3 by rotating the rear plate 2, inclining the same or reversing it to the extent that the liquid 10 is not dropped, after the photosensitive liquid has been coated. In this embodiment, a photosensitive liquid, i.e., negative type, which is hardened (not dissolved) by the exposure is used.
After the photosensitive liquid 10 has dried, light is irradiated so that the shadow of the cell barrier 3 causes oblique light to not be irradiated onto the front surface of the rear plate. The inclination angle of the irradiation is expressed as follows.
θ=arctan (b/a)
When the light having an inclination as defined by the above equation is irradiated, the light 41 only irradiates the wall surface 3a of the cell barrier 3 and, hence, only the photosensitive liquid 10 coating the wall surface 3a of the cell barrier 3 is exposed and hardened. Such an exposure process is carried out for the respective cell walls (four in case of a matrix cell arrangement such as shown in FIG. 8), whereby all fluorescent layers on the wall surfaces of the cell barrier 3 are exposed and hardened. The fluorescent layer on the bottom surface of the substrate is thereafter removed by developing treatment and the fluorescent layer remains only on the wall surfaces 3a.
In a case where the cell enclosed by the cell barrier 3 has a circular shape as shown in FIG. 7, the phosphor will adhere only to the wall surface 3a of the cell barrier 3 by rotating the rear plate 2 and exposing the surface 3a to the light 41 while maintaining the irradiation inclination θ. In the case where the cell enclosed by the cell barrier 3 has a rectangular shape as shown in FIG. 8, the light cannot uniformly expose the phosphor coated on the wall surface 3a of the cell barrier 3 with the irradiation inclination θ maintained because of the difference between the inner dimensions of the long and short sides of the rectangular cell. Accordingly, the irradiation of the light will have to be carried out by changing the inclination with respect to the respective sides of the cell by rotating the rear plate 2 by 90°.
When it is required to adhere multiple-colored (for example, red, blue and green) phosphor to the respective cells, a mask 43 having an opening 42 at predetermined portions of the mask 43 will be disposed above the rear plate 2 so that only the desired wall surface of the cell barrier 3 can be exposed to the light through the opening 42. This operation is repeated with respect to the respective colors to form a multiple-colored fluorescent screen. Alternatively, it may be possible to preliminarily coat the inner surface of the cell with the photosensitive liquids containing a phosphor of multiple kinds in accordance with the desired pattern and to then simultaneously expose the cell walls of the respective colors.
In the final step, a calcinating process is carried out for substantially removing the photosensitive material and remaining only the phosphor on the wall surface of the cell barrier 3.
The following are the phosphors utilized for this embodiment for the respective colors of red, blue and green.
For red; Y 2 O 3 :Eu, Y 2 SiO 5 :Eu, Y 3 Al 5 O 12 :Eu, Zn 3 (PO 4 ) 2 :Mn, YBO 3 :Eu, (Y,Gd)BO 3 :Eu, GdBO 3 :Eu, ScBO 3 :Eu, LuBO 3 :Eu. For blue; Y 2 SiO 5 :Ce, CaWO 4 :Pb, BaMgAl 14 O 23 :Eu. For green; Zn 2 SiO 4 :Mn, BaAl 12 O 19 :Mn, SrAl 13 O 19 : Mn, CaAl 12 O 19 :Mn, YBO 3 :Tb, BaMgAl 14 O 23 :Mn, LuBO 3 :Tb, GdBO 3 :Tb, ScBO 3 :Tb, Sr 6 Si 3 O 8 Cl 4 :Eu.
As a photoresist for scattering the phosphor, a PVA-ADC, PVA-diazonium salt or the like may be utilized, and as a solvent of slurry liquid state, water, alcohol or both mixture or the like may be used. The concentration of the phosphor of the slurry liquid state is 10 to 60 weight % for the slushing method, or 30 to 80 weight % for the screen printing method, and the concentration of the vehicle is 0.5 to 8 weight %.
In the foregoing, only the DC type flat substrate is referred to, but substantially the same processes are carried out for the AC type flat substrate according to this invention.
1-2 Actual Example
According to the screen printing method, a nickel electrode was formed on the glass substrate with the width of 200 μm, and a cell barrier of a square matrix structure having a height (b) of 200 μm, a width of 200 μm, a pitch of 1 mm and an inner dimension (a) of 800 μm is also formed on the glass substrate.
A photosensitive liquid containing a phosphor was prepared by adding Zn 2 SiO 4 :Mn (green color) of 60 wt % as a phosphor and a PVA-diazonium salt of 8 wt % into water. The thus prepared liquid was coated on the respective wall surfaces of the cell barrier on the glass substrate by the screen printing method, and then dried. After the drying process, the cell barrier 3 was exposed to the light irradiated with an inclination of 14° (arctan (200 μm/800 μm)). Since the cell has a square inner shape, the substrate was rotated by 90° to perform exposure four times once for each of the respective cell walls. After the exposing process, the substrate is developed with hot water and then calcinated at a temperature of about 440° C. for 15 minutes, whereby a plasma display panel provided with a cell barrier only on which the fluorescent screen having a thickness of 10 μm was formed can be obtained.
1-3 Effects
According to the first embodiment of this invention, the fluorescent screen can be easily and precisely formed on the wall surfaces of the cell barrier and it is possible to provide a plasma display panel having an effective luminance by observation of the light reflected from the fluorescent screen.
SECOND EMBODIMENT
2-1 Basic Structure
FIGS. 10 to 15 represent the second embodiment according to this invention, in which a cell barrier 3 is secured to the front (upper as viewed) surface of a rear plate 2 made of a flat glass substrate. The cell barrier 3 serves to define the distance between the rear plate 2 and a front plate, not shown, and is provided with cell openings widening upwardly. Cathodes 5 are formed on the front surface of the rear plate 2.
Referring to FIG. 11, a photosensitive liquid containing a phosphor is coated on the front side of the cell barrier 3 to form a photosensitive layer 10. In this embodiment, a negative type photosensitive material which is hardened by the irradiation of light is utilized. Although the photosensitive liquid may be coated by means of a spray or splash-flow method, it is preferred to carry out the coating in accordance with the spraying method by which a uniform coating can be effected. With the splash-flow method, the photosensitive liquid may be spread uniformly in the case where the photosensitive liquid has a low viscosity, but in such a case, the photosensitive liquid is liable to stay in the bottom portion of the rear plate 2, and accordingly, it may be necessary to rotate, incline, or reverse the substrate after the coating of the photosensitive liquid in order to uniformly coat the same to the front side of the rear plate 2.
Referring to FIG. 12, a mask 43 is disposed above the cell barrier 3 and the mask 43 is provided with openings 42 so that the light irradiated from the upper portion of the cell barrier 3 can irradiate only the cell wall surfaces 3a and the light towards the upper flat surface of the cell barrier and the front surface of the rear plate is shut out. After the location of the mask 43, the light is irradiated from the upper portion of the cell barrier 3 to irradiate only the cell wall surfaces 3a through the openings 42 of the mask 43, whereby only photosensitive layer 10 including the phosphor coated on the cell wall surfaces 3a is exposed and hardened. The substrate is thereafter developed, and only the photosensitive layers 10 including the phosphor on the cell wall surfaces 3a remain.
The following are the phosphors utilized for this embodiment for the respective colors of red, blue and green.
For red; Y 2 O 3 :Eu, Y 2 SiO 5 :Eu, Y 3 Al 5 O 12 :Eu, Zn 3 (PO 4 ) 2 :Mn, YBO 3 :Eu, (Y,Gd)BO 3 :Eu, GdBO 3 :Eu, ScBO 3 :Eu, LuBO 3 :Eu. For blue; Y 2 SiO 5 :Ce, CaWO 4 :Pb, BaMgAl 14 O 23 :Eu. For green; Zn 2 SiO 4 :Mn, BaAl 12 O 19 :Mn, SrAl 13 O 19 :Mn, CaAl 12 O 19 :Mn, YBO 3 :Tb, BaMgAl 14 O 23 :Mn, LuBO 3 :Tb, GdBO 3 :Tb, ScBO 3 :Tb, Sr 6 Si 3 O 8 Cl 4 :Eu.
As a photoresist for scattering the phosphor, a PVA-ADC, PVA-diazonium salt or the like may be utilized, and as a solvent of slurry liquid state, water, alcohol or both mixture or the like may be used. The concentration of the phosphor of the slurry liquid state is 10 to 60 weight % for the slushing method, or 30 to 80 weight % for the screen printing method, and the concentration of the vehicle is 0.5 to 8 weight %.
The formation of the multiple color fluorescent screen is carried out by the following two methods, one in which a mask (photomask) provided with openings formed at portions corresponding to the fluorescent screens of the respective colors is utilized and the exposure process carried out in a repeated manner with respect to the respective colors, and the other in which the photosensitive liquid containing the phosphor is coated on the respective cell surfaces by means of a spray through a mask provided with predetermined openings for coating the phosphor of the desired color such as red, blue or green and thereafter substantially the same processes as those referred to the slushing method are carried out in a repeated manner.
Finally, as shown in FIG. 13, the substrate is calcinated for substantially removing the photosensitive material and leaving only the phosphor on the wall surfaces of the cell barrier 3.
Referring to FIG. 14, a front plate 1 provided with a rear (lower as viewed) surface on which are arranged anodes 4 so as to oppose to the front surface of the cell barrier 3, whereby a plasma display panel provided with a fluorescent screen 6 on the wall surface 3a of the cell barrier 3 can be formed.
Alternatively, referring to FIG. 15, it may be possible to coat the photosensitive liquid containing the phosphor on only the inner cell surface of the cell barrier 3. Utilized in such a case is a screen printing method or a method in which the photosensitive liquid containing the phosphor is once coated over the entire surface of the cell barrier and the coating applied to the front flat surface of the cell barrier 3 is thereafter scraped by a scraper made of rubber, for example, whereby the coating on the inner cell surface of the cell barrier can remain. In the next step, as described hereinbefore with reference to FIG. 12, the mask 43 is arranged over the rear plate 2 and the light irradiated from the upper portion of the mask plate 43 through the openings provided in the mask 43.
With the second embodiment described above, the photosensitive liquid containing the phosphor is utilized, but, in a modification, it may be possible to utilize a phototacky agent which is made adhesive when exposed in place of the photosensitive liquid containing a phosphor. In such case, the phototacky agent coated on the wall surface of the cell barrier is only exposed to the light to be made adhesive, and thereafter, the powders of the phosphor are adhered thereon, whereby the fluorescent screen can be also formed on the wall surface of the cell barrier in this modification.
The DC type flat substrate is referred to hereinabove with reference to the second embodiment of this invention, but substantially the same processes may be effected to the AC type flat substrate to provide the plasma display panel.
2-2 Actual Example
According to the screen printing method, a nickel electrode was formed on the glass substrate to the width of 200 μm, and a cell barrier having a lower width of 300 μm, an upper width of 100 μm, and a height of 200 μm, was prepared by an overlapped coating manner.
A photosensitive liquid containing a phosphor was prepared by adding Zn 2 SiO 4 :Mn (green color) of 30 weight % as a phosphor and a PVA-diazonium salt of 4 weight % into water. The thus prepared coating agent was coated on the respective cell surfaces of the cell barrier on the glass substrate by the spraying method, and then dried. After the drying process, the cell barrier 3 is exposed to the light irradiated from the upper portion of the cell barrier through openings formed in the mask located above the front end of the cell barrier only to expose the wall surfaces of the cell barrier. After the exposing process, the substrate is developed with hot water and then calcinated at a temperature of about 440° C. for 15 minutes, whereby a plasma display panel provided with a cell barrier having the cell wall only on which the fluorescent screen having a thickness of 10 μm was formed, could be obtained.
2-3 Effects
According to the second embodiment of this invention, the fluorescent screen can be easily and precisely formed on the wall surfaces of the cell barrier and it is possible to provide a plasma display panel having an effective luminance by the observation of the light reflected from the fluorescent screen.
THIRD EMBODIMENT
3-1 Basic Structure
FIGS. 16 to 23 represent the third embodiment according to this invention, in which FIGS. 16 to 18 show the structures of the embodiments for forming a fluorescent screen or surface in a plasma display panel according to this invention, the structures being applied to cases wherein the fluorescent screens are formed on the wall surfaces of the cell barrier secured to the front or rear plate of a DC type plasma display panel.
Referring to FIG. 16, a cell barrier 3 is secured to the front (upper as viewed) surface of a rear plate 2 made of a flat glass substrate to define a space between the rear plate and a front plate, not shown. The cell barrier has a lattice structure. Cathode 5 is formed on the front surface of the rear plate 2. In the illustration, the inner dimension of an opening of the cell of the cell barrier 3 is referred to as "a" and the height thereof is referred to as "b".
A slurry liquid containing a phosphor is filled in the openings of the cell barrier 3 as shown in FIG. 17a, the rear plate 2 is raised in a vertical fashion as shown in FIG. 17b immediately after the filling of the slurry in the openings. The rear plate 2 is maintained as it is until the time when the phosphor 20a contained in the slurry liquid is moved and precipitated to the wall surface of the cell barrier 3 as shown in FIG. 17c. After the adequate drying process, the phosphor 20a is adhered on the wall surface of the cell barrier 3 as shown in FIG. 17d.
The fluorescent slurry liquid containing a phosphor 20 is filled in the interior of the openings of the cell barrier 3 by means of a spray, a screen printing method, or a method in which the slurry is coated on the entire surface of the substrate and the front end portion of the cell barrier is thereafter scraped by a scraper made of rubber for example. In these methods, it is preferred to preliminarily wet the substrate for the smooth and uniform filling of the slurry.
It will be understood that the fluorescent screen is formed on the four surfaces of the inner wall of the cell barrier 3 by repeating the processes described above four times, and in a modification, the fluorescent screen can be formed on the four wall surfaces of the cell barrier 3 by drying the wall surfaces while rotating the rear plate 2 in the standing position, after filling of the fluorescent slurry liquid. In this modified method, however, the thickness of the thus formed fluorescent screen is about 1/4 of the thickness thereof formed in the former method.
As the photosensitive liquid, a negative type photosensitive liquid which is hardened (undissolved) by the exposure, was utilized.
After the drying of the fluorescent slurry liquid, the light 41 is irradiated, as shown in FIG. 18, from an oblique direction so that the light is not irradiated to the inner bottom portion of the cell barrier of the rear plate 2 by shutting the light with the side wall portion of the cell barrier 3. In this irradiation, the inclination θ of the light is determined as follows.
θ=arctan (b/a)
When the light 41 is irradiated with the irradiation inclination θ obtained by the above equation, the light is irradiated only to the wall surface 3a of the cell barrier 3, whereby the phosphor 20a precipitated only on the wall surface 3a of the cell barrier 3 can be exposed and then hardened.
When the thus described exposure process is carried out for the wall surfaces of the respective cells after the process represented by FIG. 17 has been performed, all the phosphor layer on the wall surfaces 3a of the cells has been hardened. The phosphor adhered on the bottom surface of the substrate without being precipitated during the precipitation process will be removed by performing the developing operation for every exposure and hence, the phosphor layer can be formed only on the wall surface 3a of the cell barrier 3.
In a modification, the phosphor may be hardened by thermal treatment. However, it will be understood as a matter of course that it is necessary to fill the phosphor in the cell and then harden the same in a selective manner when a multicolor phosphor is utilized.
The processes described above will be represented by a chart shown in FIG. 19.
In a case where the cell surrounded by the cell wall of the cell barrier has a circular configuration, as shown in FIG. 20, the rear plate 2 is rotated in a standing position, to precipitate the phosphor. Thereafter, the rear plate 2 is exposed to the light at the inclination described hereinbefore while rotating the same, whereby it is possible to form the fluorescent screen on only the wall surface 3a of the circular cell.
FIG. 21 represents a case in which the cell has a rectangular shape having a long side and a short side, that is, the length "a" in FIG. 16 is different in the long and short sides of the cell. In this case, it is impossible to uniformly expose the phosphor layers adhered on the long and short side surfaces of the cell by the manner described with respect to the cell having the circular shape. Accordingly, in this case, the exposures are performed respectively for the long side surface and the short side surface of the cell by changing the irradiation inclinations while rotating the rear plate 2 by 90°.
Furthermore, in the case where it is required to form a multiple colored, for example, with red, blue and green colors, fluorescent screen on each of the cells, the formation method is carried out by a method represented by FIG. 22, in which a mask 43 provided with openings 42 at predetermined pattern portions is disposed above the rear plate 2 so as to expose only the wall surfaces 3a of the desired cells and this exposure process is repeated with respect to the respective colors by the manner represented by FIG. 19, whereby a fluorescent screen having multiple colors can be formed on the cell wall surface 3a of the cell barrier 3. Alternatively, it may be possible to preliminarily precipitate the phosphor only at a desired portion by a screen printing method, for example, and to then simultaneously expose the cell walls of the respective colors.
In the final process, the exposed cell surfaces are calcinated to substantially remove the photosensitive material and leave only the phosphor on the wall surface 3a of the cell barrier.
In the described embodiment, the following substances may be used for the phosphors of the respective colors. As a red color phosphor: Y 2 O 3 :Eu, Y 2 SiO 5 :Eu, Y 3 Al 5 O 12 :Eu, Zn 3 (PO 4 ) 2 :Mn, YBO 3 :Eu, (Y,Gd)BO 3 :Eu, GdBO 3 :Eu, ScBO 3 :Eu, LuBO 3 :Eu; as a blue color phosphor; Y 2 SiO 5 :Ce, CaWO 4 :Pb, BaMgAl 14 O 23 :Eu; and as a green color phosphor; Zn 2 SiO 4 :Mn, BaAl 12 O 19 :Mn, SrAl 13 O 19 :Mn, CaAl 12 O 19 :Mn, YBO 3 :Tb, BaMgAl 14 O 23 :Mn, LuBO 3 :Tb, GdBO 3 :Tb, ScBO 3 :Tb, Sr 6 Si 3 O 8 Cl 4 :Eu.
Utilized as a photoresist for dispersing the phosphor is utilized a PVA-ADC, PVA-diazonium salt or the like, while water, alcohol or both mixture may be utilized for a solvent of slurry solution state. The phosphor in the slurry solution occupies 20 to 60 weight % and a vehicle occupies 0.5 to 15 weight %.
In the foregoing description of the third embodiment, the flat substrate of the DC type plasma display panel is only described, but it is a matter of course that this embodiment may be applicable to the AC type plasma display panel in the like manner.
3-2-1 Embodiment 1
An Ni electrode having a width of 300 μm was formed on the glass substrate by a screen printing method and a cell barrier formed on the substrate, the cell barrier having a square structure having a height of 200 μm, a width of 150 μm, a pitch of 500 μm and an inner cell dimension of 350 μm.
A photosensitive coating material was prepared as a phosphor by adding a Zn 2 SiO 4 :Mn (green) of 40 weight % and PVA-diazonium salt of 10 weight % into water.
The thus prepared coating material was poured in the respective cells of the cell barrier on the substrate by utilizing a squeegee, and the substrate was stood vertically to precipitate the phosphor. After drying the same, the predetermined portions of the cell walls were exposed to light at an inclination of about 30° (=arctan (200 μm/350 μm)) by utilizing the mask. The substrate was developed with hot water at a temperature about 40° C. and then dried at a temperature of about 150° C. for about 10 minutes. These processes were repeated four times with respect to the respective cells and three times with respect to the respective colors of red, blue and green. That is, a total of twelve processes were performed. Obtained as the result of these processes, was a plasma display panel including a cell barrier provided with cells each having a cell wall on which only a fluorescent screen having a thickness of about 20 μm has been formed selectively.
3-2-2 Embodiment 2
Transparent electrodes 65 each having a width of 200 μm and a pitch of 300 μm were formed on the glass substrate 61 by a deposition method and a cell barrier having linear wall portions 63 between the adjacent electrodes 65 was formed on the substrate as shown in FIG. 23, each of the wall portions 63 having a width of 150 μm and the height of 140 μm.
A photosensitive coating material was prepared as a phosphor by adding Zn 2 SiO 4 :Mn (green) of 40 weight % and PVA-diazonium salt of 10 weight % into water.
The thus prepared coating material was poured in the respective linear wall cells of the cell barrier on the substrate 61 by utilizing a rubber squeegee, and the substrate was stood vertically so that the linear cell wall portions are made horizontal and the phosphor was precipitated. After drying the same, the predetermined linear wall portions of the cell barrier were exposed to light at an inclination of about 45° (=arctan (140 μm/150 μm)) by utilizing the mask. The substrate was developed with hot water of a temperature about 40° C. and then dried at a temperature of about 150° C. for about 10 minutes. These processes were repeated twice with respect to both sides of the respective linear cell wall portions. These processes were performed six times with respect to the respective colors of red, blue and green. As the result of these processes, was obtained a plasma display panel in combination of the glass substrate 61 as the front plate and the rear plate 6 provided with a cathode 66, the plasma display panel being provided with a fluorescent screen only on the linear cell wall portions having a thickness of about 20 μm.
3-3 Effects
As described above, according to this embodiment, it is possible to easily form a fluorescent screen on the wall surface of the cell barrier with high precision and a plasma display panel having an excellent luminance can be prepared by observing the light reflected by the fluorescent screen.
With the embodiments described hereinbefore, there are proposed plasma display panels in which the cells are arranged in a matrix shape, but this invention may be applied to a plasma display panel in which the cells are arranged linearly by substantially the same manner as those described with respect to the described embodiments.
FOURTH EMBODIMENT
4-1 Basic Structure (No. 1)
FIG. 24 represents the first basic structure of a plasma display panel of the fourth embodiment according to this invention.
Referring to FIG. 24, a DC type plasma display panel is composed of a front plate 1 made of a glass substrate and a rear plate 2 arranged in parallel to the front plate 1. The rear plate 2 is provided with a front (upper as viewed) surface on which a lattice shaped cell barrier 3 is mounted for defining the space between the rear plate 2 and the front plate 1, and a cathode 5 is further formed on the front surface of the rear plate 2. Anodes 4 are formed on the rear (lower as viewed) surface of the front plate 1, and fluorescent screens 6 are closely formed on both sides of the respective anodes 4. The fluorescent screens 6 are also formed on the wall surfaces of the respective cells of the cell barrier 3.
The fluorescent screen 6 on the front plate 1 is formed in the manner that the photosensitive slurry containing a phosphor is coated on the upper surface of the rear plate 2, the coated slurry is then exposed by using a photomask having a shape corresponding to the pattern of the fluorescent screen, and then developed and calcinated.
The fluorescent screen 6 on the wall surface of the cell barrier 3 is formed in substantially the same manner as that described hereinbefore with respect to the third embodiment in which the slurry solution containing the phosphor is filled in the cells of the cell barrier, the rear plate is stood vertically to precipitate the phosphor, and the phosphor on the cell wall is then exposed.
The fluorescent screen may be formed on a portion of the rear plate 2 except for the location of the cathode 5. In this modification, the slurry solution containing the phosphor is filled in the cell of the cell barrier by the method described with reference to the third embodiment. The phosphor is thereafter precipitated with a suitable time interval on the rear plate 2, which is then inclined to expose the wall portion to the light irradiated from an oblique direction to thereby form the fluorescent screen on the wall surface of the cell barrier 3. Finally, the screen surface is formed by exposing the rear plate 2 to the light from the upward direction by locating the mask so as to cover the cathode 5 and by developing.
4-2 Basic Structure No. 2
FIG. 25 represents the second basic structure of the plasma display panel of the fourth embodiment according to this invention.
Referring to FIG. 25, a DC type plasma display panel is composed of a front plate 1 made of a glass substrate and a rear plate 2 arranged in parallel to the front plate 1. The rear plate 2 is provided with a front (upper as viewed) surface on which a lattice shaped cell barrier 3 is mounted for defining the space between the rear plate 2 and the front plate 1, and a cathode 5 is further formed on the front surface of the rear plate 2. Anodes 4 are formed on the rear (lower as viewed) surface of the front plate 1, and color filters 8 corresponding to the colors of the fluorescent substance are closely formed on both sides of the respective anodes 4. The fluorescent screens 6 are also formed on the wall surfaces of the respective cells of the cell barrier 3.
The fluorescent screens 6 on the cell walls are formed by substantially the same manner as that described hereinbefore with respect to the third embodiment.
The color filters 8 are formed on the rear surface of the front plate 1 in accordance with the following manner.
A solution prepared by dispersing a pigment and a frit glass in a PVA-diazonium salt is uniformly coated on the surface of the front plate 1, and the coated surface is then exposed so as to expose only the predetermined portions by locating the mask and to harden the coated solution with ultraviolet light. The pigment coated on portions except for the front plate is thereafter removed by developing. Finally the substrate is calcinated for securing the pigment to the substrate.
These processes are performed in substantially the same manner as that described with respect to the respective colors to form the multiple-colored fluorescent screen.
The solution to be coated on the front plate having the following composition was utilized for the fourth embodiment.
______________________________________Pigment (Blue: Co--Al--Cr oxide; 30% Green: Co--Ni--Ti--Zr oxide)Vanish (ethyl-cellurous and 65% butyl-carbitol acetate)Frit Glass (low melting point glass) 5%______________________________________ | A method of forming a fluorescent screen for a plasma display panel provided with a front plate and a rear plate disposed parallel to each other and a cell barrier mounted on the front or rear plate and constituting a plurality of cells as display elements is characterized in that the cell barrier is located on a surface of the front or rear plate facing the other plate, a slurry solution containing a phosphor is filled in a portion defined by a cell wall of the cell barrier on the front or rear plate, only the wall surface of the cell barrier is exposed, and so a photosensitive layer containing a phosphor is formed at a portion inside the cell barrier. The fluorescent screen forming method is further characterized in another aspect in that a slurry solution containing a phosphor fills inside the cell of the cell barrier disposed on the plate, the plate is inclined immediately thereafter with an inclination of about 90° or more degrees with respect to a horizontal plane, the rear plate in an inclining state is settled till the phosphor in the slurry solution is precipitated on the cell wall of the cell barrier, and the cell wall after the precipitating process is dried and hardened. | 7 |
SPECIFICATION
[0001] This Application claims the benefit of U.S. Provisional Application No. 62/024,126, filed Jul. 14, 2014.
FIELD OF THE INVENTION
[0002] The present invention relates generally to indoor plumbing and gravity-operated flush toilets. More particularly, the present invention relates to flapper valves that are used in such toilets and to an improved flapper valve and assembly of the type that has variably adjustable mounts such that the flapper valve is attachable to a variety of flush valve housings. Further, the two-way adjustment of the rotatable leg clips allows for use of the same flapper valve with a variety of makes and models of flush valves, and flush valves having pegs that may be spaced apart so as to adjust for pegs that may have different diameters or that may be separated from one another by different distances, depending on the flush valve used in the toilet.
BACKGROUND OF THE INVENTION
[0003] Conventional gravity-operated flush toilets have several basic components. The porcelain or china components include a bowl and a water tank mounted on top of a rear portion of the bowl. The bowl and tank can be separate pieces bolted together to form a two-piece toilet. Other gravity-operated flush toilets are made as a one-piece toilet in which the bowl and tank are made as one continuous integral piece of china.
[0004] More importantly, the plumbing components of a gravity-operated flush toilet include a fill valve in the tank which is connected to a water supply line, a flush valve surrounding a drain hole in the bottom of the tank that communicates with the bowl, and a flapper valve that normally closes and seals the flush valve or, more precisely, the main flush valve orifice.
[0005] Toilet flapper valves are typically formed as a single structure having a rim for sealing the main flush valve orifice with the flapper valve rim following flushing. The flapper valve is often formed of a soft elastomeric material and is hinged to allow the valve to be pivotally moved upwardly and away from the main flush valve orifice by means of a chain that is connected to the flush handle on the outside of the tank. Once the tank empties, the flapper valve then returns to a position where it seals the main flush valve orifice, the rim of soft elastomeric material forming a sealing area about that main flush valve orifice.
[0006] The hinged toilet flapper valve mentioned above is typically secured to the flush valve by virtue of a pair of spaced apart parallel mounting arms. The mounting arms also typically include apertures, the apertures being used to rotatably connect the flapper valve to pegs that form part of the flush valve. Depending on the make and model of toilet tank, the size of its flush valve determines how far apart the mounting arms must be in order to accommodate a specific size of flapper valve for that flush valve. That is, the two-way adjustment of the rotatable leg clips of the present invention allows for use of the same flapper valve with a variety of makes and models of flush valves, and flush valves having pegs that may be spaced apart so as to adjust for pegs that may have different diameters or that may be separated from one another by different distances depending on the flush valve used in the toilet.
[0007] Located forwardly of the flapper valve mounting arms is also a ballast structure which controls the buoyancy of the flapper valve. The buoyancy of a flapper valve is an important function because it determines how much or how little water is used to empty the water tank upon flushing, thus creating water conservancy issues. The buoyancy of the flapper valve is determined by how quickly air is allowed to escape from the ballast. One way that the buoyancy of the flapper valve ballast can be controlled is by controlling the rate at which air within the ballast can flow out of the ballast. This can be done by creating and/or adjusting the size of an aperture at a point within the flapper valve ballast.
[0008] In the experience of this inventor, flapper valves of current manufacture do not provide an easy-to-use and adjustable flapper valve which combines both functionalities into a single structure.
SUMMARY OF THE INVENTION
[0009] Accordingly, a primary objective of the device of the present invention is to provide a new, useful and non-obvious improved toilet flapper valve that can be used to cover and seal the main flush valve orifice, which flapper valve comprises a pair of rotatable legs and leg clips having two-way adjustment capabilities and which serve to function as the “mounting arms” described above. Significantly, the two-way adjustment of the rotatable leg clips allows for use of the same flapper valve with a variety of makes and models of flush valves, and flush valves having pegs that may be spaced apart so as to adjust for pegs that may have different diameters or that may be separated from one another by different distances depending on the flush valve used in the toilet. The flapper valve of the present invention also includes a variably-adjustable air outlet capability.
[0010] The foregoing and other features of the improved flapper valve of the present invention will be apparent from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a top, front and left side perspective view of one embodiment of an improved flapper valve that is constructed in accordance with the present invention.
[0012] FIG. 2 is a bottom, rear and right side perspective view of the flapper valve shown in FIG. 1 .
[0013] FIG. 3 is a top plan view of the flapper valve illustrated in FIG. 1 and showing the mounting legs in a “narrow setting” position.
[0014] FIG. 4 is a view similar to that illustrated in FIG. 3 and showing the mounting legs in a “wide setting” position.
[0015] FIG. 5 is a cross-sectioned left side elevational view of the flapper valve shown in FIG. 1 taken along line A-A of FIG. 3 .
[0016] FIG. 6 is a rear elevational view of the flapper valve shown in FIG. 1 .
[0017] FIG. 7 is a front elevational view of the flapper valve shown in FIG. 1 .
[0018] FIG. 8 is an enlarged top and partially sectioned view of the leg clip mounting structure in accordance with the present invention.
[0019] FIG. 9 is an enlarged side and partially sectioned view of the captive portions that are built into the flapper body of the flapper valve of the present invention and showing how an edge of the cone is captured and how an edge of the rotatable vent ring is captured as well.
DETAILED DESCRIPTION
[0020] Referring now to the drawings in detail, wherein like-numbered elements refer to like elements throughout, FIGS. 1 and 2 generally illustrate a preferred embodiment of an improved flapper valve, generally identified 10 , that is constructed in accordance with the present invention. The improved flapper valve 10 is the type that is intended to be used with a toilet flush valve and main flush valve orifice (not shown). As illustrated, the improved flapper valve 10 is comprised of four primary elements: a flapper body 20 ; a pair of mounting legs 30 disposed rearwardly of the flapper body 20 ; a cone 40 disposed below the flapper body 20 ; and a rotating vent band 50 disposed below the flapper body 20 and about the cone 40 .
[0021] The flapper body 20 is typically made of an elastomeric material such as real or synthetic rubber having a suitable durometer or softness. In the preferred embodiment, the flapper body 20 is comprised of a real rubber material for suitable sealing with chemical resistance by virtue of CHLORAZONE® additive (CHLORAZONE is a registered trademark of Lavelle Industries, Inc. The flapper body 20 has a top surface 21 , a bottom surface 23 and a circumferential peripheral lip 22 .
[0022] Forwardly of the top surface 21 of the flapper body 20 and extending upwardly from that top surface 21 is a connection structure 25 . The connection structure 25 typically includes an aperture (not shown) to receive a hook and chain-like structure (also not shown) for lifting the flapper valve 10 upwardly during the initiation of the flush cycle of the toilet. The peripheral lip 22 is configured to mate with the valve seat (also not shown) of the main flush valve orifice to close off water flow through that orifice.
[0023] Extending rearwardly of the flapper body 20 and also disposed on the top surface 21 thereof is a pair of spaced-apart parallel leg clip mounting structures 24 . Each mounting structure 24 comprises a rearward flat 26 and a frustroconical retainer 28 extending rearwardly from the flat 26 . See FIGS. 3 and 8 . The retainer 28 comprises a peripheral groove 29 that is disposed immediately adjacent the rearward-facing surface 126 of the rearward flat 26 . Extending forwardly of the rearward flat 26 is a plurality of support ribs 27 . The mounting structures 24 and all of their respective component structures are integrally formed as part of the flapper body 20 .
[0024] Attachable to each flat 26 of the leg clip mounting structures 24 is a mounting leg 30 . The mounting leg 30 is a substantially L-shaped structure having a forward facing flat 36 , which flat 36 has a hole 39 defined in it. The hole 39 is configured to receive the retainer 28 of the flapper body 20 , the hole 39 capturing the retainer 28 via the peripheral groove 29 . The retainer 28 , like the remainder of the flapper body 20 , is made of rubber which allows the retainer 28 to collapse when pulled on to pass through the hole 39 in the flat 36 of the leg 30 . Once captured, the mounting leg 30 is rotatable about the axis of the retainer 28 such that the mounting legs 30 can be rotated inwardly and set in a “narrow setting” position, as is shown in FIG. 3 , or rotated outwardly and set in a “wide setting” position, as is shown in FIG. 4 .
[0025] Extending rearwardly from the flat 36 is a clip portion 32 , the clip portion 32 being disposed substantially perpendicular to the flat 36 . The clip portion 32 comprises a first clip member 31 and a second clip member 33 which, together, provide a pincer action such that the mounting legs 30 can “capture” the pegs (not shown) of a flush valve (also not shown) of conventional manufacture within an opening 34 formed between the clip members 31 , 33 to rotatably connect the flapper valve 10 to the flush valve. See FIG. 5 . This allows the mounting legs 30 to rotate the flapper valve 10 when the flush valve is actuated. It should also be appreciated that the size of the mounting legs 30 can be altered to accommodate flush valve pegs of different diameters. That is, a mounting leg 30 having a wider or narrower opening 34 is intended to be included within the scope of this invention.
[0026] Extending upwardly from the bottom surface 23 of the flapper body 20 is a round and circumferential captive portion 127 . This captive portion 127 of the flapper body 20 is configured to receive a portion of the cone 40 within a first groove 128 and a portion of the vent band 50 within a second groove 129 . The cone 40 comprises a hollow cup-like structure defining a cone cavity 42 . The cone 40 further comprises a substantially horizontal upper cone edge 44 . The upper cone edge 44 is captured within and held in place by the first groove 128 of the flapper body 20 . The cone 40 further comprises an upper cone wall 43 having an outer surface 41 and a cone bottom 45 having an opening 46 defined in it. The upper cone wall 43 likewise has a plurality of openings 47 defined in it, the openings 47 facing forwardly of the flapper body 20 . These openings 47 work with the vent ring 50 to control air outflow from the cone cavity 42 . Further, the cone 40 comprises a polarizing tab (not shown) to ensure proper positioning of the cone 40 relative to the flapper body 20 . In other words, the cone 40 is attached and polarized in one position so that the holes or openings 47 in the cone 40 can only be positioned one way, which is forward. In short, the cone 40 is integral with the flapper body 20 and does not rotate. Lastly, the cone 40 comprises a plurality of snap tabs 48 extending outwardly from the outer surface 41 of the upper cone wall 43 . The snap tabs 48 are used to maintain the vent band 50 in a position such that the band 50 is rotatable about the upper cup wall 43 but is not able to move vertically relative to that wall 43 . The upper cup wall 43 further comprises indicia 140 to indicate to the user that the rotatable band 50 is functionally disposed about the cone 40 in several positions. See FIG. 6 .
[0027] The rotating vent band 50 comprises a flat ring-like structure comprising a cylindrical band body 52 having an inner surface 51 , an outer surface 53 , an upper band body lip 58 and a plurality of support ribs 54 . As shown in FIG. 9 , the upper band body lip 58 is receivable within the second groove 129 of the captive portion 127 of the flapper body 20 , the band body 52 further being rotationally-movable about the outer surface 41 of the upper cone wall 43 of the cone 40 . The vent band body 52 further comprises a substantially plurality of circular apertures 56 . The vent band body 52 is rotatable to place the apertures 56 in several different positions to achieve desired air flow out of the cone cavity 42 . In short, the vent band 50 is a locking device that captures the flapper body 20 and the cone 40 . That is, it is a metering device that rides on the edge of the cone 40 which prevents binding during rotation. The vent band 50 further provides detents (not shown) which allow the band 50 to be positioned in specific settings.
[0028] The present invention also contemplates use of the flapper valve 10 in combination with a flush valve as described at the beginning of this disclosure. This use would be an assembly of the type that could be installed within the tank of a conventional toilet. | An improved toilet flapper valve is used to cover and seal a main flush valve orifice, which flapper valve comprises a pair of rotatable legs and leg clips having two-way adjustment capabilities and which serve to function as mounting arms. The two-way adjustment of the rotatable leg clips allows for use of the same flapper valve with a variety of makes and models of flush valves, and flush valves having pegs that may be spaced apart so as to adjust for pegs that may have different diameters or that may be separated from one another by different distances depending on the flush valve used in the toilet. The flapper valve of the present invention also includes a variably-adjustable air outlet capability. | 4 |
RELATED APPLICATIONS
[0001] This application claims priority of provisional patent application 60/388,976, filed on Jun. 14, 2002, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention pertains fasteners, and more particularly fasteners which have expandable legs and which attach one object to another object. It also pertains combinations of one or more objects with said fastener(s), assemblies of fasteners with a part, parts or objects connected with the fastener(s), as well as vehicles comprising parts connected with said fastener(s).
BACKGROUND OF THE INVENTION
[0003] In the original conventional technology of fasteners employed to securely attach one object to another, such as for example one part to another in the case of an automobile or an appliance, has utilized a nut on one of the two objects, usually welded or glued to the back of said object, and a bolt passing through a hole on the second object in a manner to be engaged by the nut, thereby securing the two objects together.
[0004] This arrangement presents many problems, among which, one of the most important is that in the case that one object is hollow, the nut has to be in place at the back of the hollow object before assembling the two objects together. If for any reason the nut is misplaced, and/or if it becomes desirable to introduce a new fastening connection between the two objects, the task of achieving such connection becomes very difficult, if not impossible, for all practical purposes.
[0005] The so-called “quick nuts” have also been used to connect two objects. In addition, vibration during the operation of a device, such as an automobile or appliance for example, containing the two objects results very often in loosening of the bolt or “quick nut” and in either full disassembling of the objects from each other, or in a vibration noise which is most annoying and often of unacceptable levels. Further, such connections are not water-resistant and water may be easily penetrate the connection point and be transferred from one side of one or both objects to the other side.
[0006] Fasteners of the type described in U.S. Pat. No. 4,500,238 (Vassiliou) have been utilized to reduce considerably the potential of bolt or screw loosening and vibration. They have also eliminated the problem of having to place one member of the fastener at the back portion of the hollow object. These fasteners are placed through a slot from the front part of the hollow object. The second part of the fastener, being usually a bolt or a screw, supports the second object by forcing the legs of the fastener (as described for example in U.S. Pat. No. 4,500,238) to open or expand, thereby securing the two objects together. The fasteners of this type have greatly improved the prevailing torque (torque required to render a screw loose), as well as the pulling force (pulling force applied on a screw to the point of failure) of the system.
[0007] The fasteners of the type described in U.S. Pat. No. 4,500,238 have a funnel portion into which an expanding is driven for expanding the legs of the fastener. This funnel has a bucket-like shape which has been impressed on the legs during the manufacture of the fastener. This impression derived funnel is rather inflexible and in some occasions has a tendency to drive the expanding member in undesired direction.
[0008] An example of fasteners having oblong funnels is described in U.S. Pat. No. 6,280,129 B1 (Lowry et al.), which is incorporated herein by reference. U.S. Pat. No. 6,409,443 B1, which is also incorporated herein by reference, discloses a spring fastener having a Y-shaped cut funnel, and which may eliminate, if so desired, barbs which are used to support the fastener in one of the parts to be connected together by said fastener.
[0009] The fasteners of the type used in industrial applications, wherein the fastener is first inserted into the slot of a sheet, usually a metal sheet, such as the frame of an automobile for example, have barbs which secure initially the fastener on the sheet. After the fastener has been secured on the sheet, the fastener cannot be extracted from the slot without destruction of either the slot or the fastener, since the barbs are disposed against the lower surface of the sheet without the feasibility of springing back when the fastener is pulled from the region of the upper surface of said sheet.
[0010] A large number of advantages are derived from the critical configuration of the barbs of the present invention, which allow the extraction of the fastener without destruction of the slot and/or the fastener, as well as the retention of the fastener in slots of various widths preventing rattling noises, as described in detail hereinbelow.
SUMMARY OF THE INVENTION
[0011] In the text presented below, the following comments and definitions are appropriate:
[0012] The expanding member is preferably a screw having threads and a root on which the threads are supported.
[0013] Engageable hole or region is an at least partial hole or region which can be engaged with a screw, or similar element.
[0014] At least partial hole may be a part of a hole, such as an arc for example. However, the hole does not have to be round.
[0015] Curved portion is defined as a portion having a non-linear configuration, even if it comprises smaller non-aligned linear sections, such as saw tooth for example.
[0016] This invention is related to a fastener comprising:
[0017] (a) a substantially flat head portion comprising a first hole, the flat head comprising at least a lower side;
[0018] (b) a neck having an opening and two side neck portions, the neck extending from the lower side of the substantially flat head portion at a substantially right angle with respect to the substantially flat head portion;
[0019] (c) two substantially flat legs extending from the neck, each leg having an inner surface, the two inner surfaces of the two legs being at an initial proximity with each other, the legs being expandable in opposite directions upon inserting through the first hole an expansion member, thus bringing the expansion member to a contact region of the legs, each leg also having side leg portions;
[0020] (d) a funnel configuration in the vicinity of the contact region; and
[0021] (e) barbs having an origin at a region selected from the side neck portion, and the side leg portion, the barbs also having a front point which front point substantially reaches or exceeds the lower side, the barbs directed outwardly away from the legs.
[0022] This invention also pertains an assembly comprising a first part and a fastener, the first part having an upper surface and a lower surface, a slot commensurate to the fastener, the slot having a length, a width, lower edges, upper edges, and side edges, along its length;
[0023] (a) a substantially flat head portion comprising a first hole, the flat head comprising at least a lower side;
[0024] (b) a neck having an opening and two side neck portions, the neck extending from the lower side of the substantially flat head portion at a substantially right angle with respect to the substantially flat head portion;
[0025] (c) two substantially flat legs extending from the neck, each leg having an inner surface, the two inner surfaces of the two legs being at an initial proximity with each other, the legs being expandable in opposite directions upon inserting through the first hole an expansion member, thus bringing the expansion member to a contact region of the legs, each leg also having side leg portions;
[0026] (d) a funnel configuration in the vicinity of the contact region; and
[0027] (e) barbs having an origin at a region selected from the side neck portion, and the side leg portion, the barbs directed outwardly away from the legs, the barbs also having a front point which front point is substantially disposed above the lower surface of the first part and above the lower edges of the slot.
[0028] Further, this invention is related to a fastener comprising:
[0029] (a) a substantially flat head portion comprising a first hole, the flat head comprising at least a lower side;
[0030] (b) a neck having an opening and two side neck portions, the neck extending from the lower side of the substantially flat head portion at a substantially right angle with respect to the substantially flat head portion;
[0031] (c) two substantially flat legs extending from the neck, each leg having an inner surface, the two inner surfaces of the two legs being at an initial proximity with each other, the legs being expandable in opposite directions upon inserting through the first hole an expansion member, thus bringing the expansion member to a contact region of the legs, each leg also having side leg portions;
[0032] (d) a funnel configuration in the vicinity of the contact region; and
[0033] (e) barbs having a front point and an origin at a region selected from the lower head side, the side neck portion, and the side leg portion, the barbs being directed outwardly away from the legs and then inwardly toward the legs.
[0034] This invention also pertains an assembly comprising a first part and a fastener,
[0035] the first part having an upper surface and a lower surface, a slot commensurate to the fastener, the slot having a length, a width, lower edges, upper edges and side edges, along its length;
[0036] the fastener being inserted into the slot and comprising:
[0037] (a) a substantially flat head portion comprising a first hole, the flat head comprising at least a lower side;
[0038] (b) a neck having an opening and two side neck portions, the neck extending from the lower side of the substantially flat head portion at a substantially right angle with respect to the substantially flat head portion;
[0039] (c) two substantially flat legs extending from the neck, each leg having an inner surface, the two inner surfaces of the two legs being at an initial proximity with each other, the legs being expandable in opposite directions upon inserting through the first hole an expansion member, thus bringing the expansion member to a contact region of the legs, each leg also having side leg portions;
[0040] (d) a funnel configuration in the vicinity of the contact region; and
[0041] (e) barbs having a front point and an origin at a region selected from the lower side of the head portion, the side neck portion, and the side leg portion, the barbs being directed outwardly away from the legs and then inwardly toward the legs, the barbs also having sliding portions in contact with at least one of the lower, upper, and side edges of the slot.
[0042] The present invention is also related to a fastener comprising:
[0043] (a) a substantially flat head portion comprising a first hole, the flat head comprising at least a lower side;
[0044] (b) a neck having an opening and two side neck portions, the neck extending from the lower side of the substantially flat head portion at a substantially right angle with respect to the substantially flat head portion;
[0045] (c) two substantially flat legs extending from the neck, each leg having an inner surface, the two inner surfaces of the two legs being at an initial proximity with each other, the legs being expandable in opposite directions upon inserting through the first hole an expansion member, thus bringing the expansion member to a contact region of the legs, each leg also having side leg portions;
[0046] (d) a funnel configuration in the vicinity of the contact region;
[0047] (e) at least one high barb having an origin at a region selected from the side neck portion, and the side leg portion, the at least one high barb also having a front point which front point substantially reaches or exceeds the lower side, the at least one high barb directed outwardly away from the legs; and
[0048] f) at least one low barb having an origin at a region selected from the side neck portion, and the side leg portion, the at least one low barb also having a front point which front point reaches lower than the lower side, the at least one low barb directed outwardly away from the legs.
[0049] The head portion of the fastener may comprise an upper side and a lower side, or it may have a single side corresponding to the lower side, as described for example in U.S. Pat. No. 6,250,864 B1, which is incorporated herein by reference.
[0050] The hole may be substantially round or it may be in the form of an oblong opening, as disclosed for example in U.S. Pat. Nos. 6,270,129 B1 and 6,409,443 B1, both of which are incorporated herein by reference.
[0051] The fastener may further comprise an elastic body molded at least under the at least lower side of the head of the fastener, as described for example in U.S. Pat. Nos. 5,725,343 and 6,379,092, both of which are incorporated herein by reference.
[0052] The first hole is preferably engageable to the expansion member.
[0053] The fastener may comprise at least one region under the at least lower side, which region is engageable to the expansion member, as described for example in non-provisional application Ser. No. 09/699,760. which is incorporated herein by reference.
[0054] In the case that the head of the fastener has an upper side and a lower side, at least one region under the upper side of the head, may be engageable to the expansion member.
[0055] The outwardly and inwardly portions of the barbs should preferably have an angle which is adequately large to allow the fastener to be removed from the first part without destruction of said fastener or said first part, when the removal takes place solely from the side of the first part, wherein the head of the fastener is positioned.
[0056] The present invention further pertains parts connected with the above described spring fasteners and/or combinations, as well as vehicles comprising parts connected with the above described spring fasteners.
BRIEF DESCRIPTION OF THE DRAWING
[0057] The reader's understanding of this invention will be enhanced by reference to the following detailed description taken in combination with the drawing figures, wherein:
[0058] [0058]FIG. 1 is a perspective view of fastener and a first part according to a preferred embodiment of the present invention, wherein the front points of the barbs reach or exceed the lower side of the head of the fastener.
[0059] [0059]FIG. 1A is a perspective view of fastener having conventional barbs, and a first part having a slot.
[0060] [0060]FIG. 2 is a cross section illustrating the barbs with relation to the first part of FIG. 1, after the fastener has been inserted into a slot of the first part, wherein the front points of the barbs substantially reach the lower side of the head of the fastener.
[0061] [0061]FIG. 2A is a cross section illustrating the barbs with relation to the first part of FIG. 1A, after the fastener has been inserted into a slot of the first part, wherein the front points of the barbs are engaged to the lower surface of the first part.
[0062] [0062]FIG. 3 is a cross section according to another preferred embodiment of the present invention illustrating the barbs in relation to the first part, in the case of an assembly of a fastener and the first part, wherein the distance of the front points of the barbs from the lower side of the head of the fastener is smaller than the thickness of the first part.
[0063] [0063]FIG. 4 is a cross section of a combination of a second part attached to the assembly of the fastener and the first part by an expansion member, after said fastener has been inserted to a slot of said first part.
[0064] [0064]FIG. 5 is a perspective view of fastener and a first part according to another preferred embodiment of the present invention, wherein the barbs are initially directed outwardly and then inwardly.
[0065] [0065]FIG. 6 is a cross section illustrating the barbs with relation to the first part of FIG. 5, after the fastener has been inserted into a slot of the first part, wherein inwardly directed portions of the barbs are engaged to the lower edges of the slot of the first part.
[0066] [0066]FIG. 7 is a cross section illustrating an example of the barbs with relation to the first part of FIG. 5, after the legs of the fastener have been expanded by an expansion member.
[0067] [0067]FIG. 8 is a perspective view of fastener and a first part having identical barbs as the barbs of FIG. 5, but wherein the fastener comprises an oblong hole and an oblong funnel.
[0068] [0068]FIG. 9 is a perspective view of fastener and a first part according to another preferred embodiment of the present invention, wherein the barbs originate from the lower side of the head of the fastener, are initially outwardly directed, and then inwardly directed.
[0069] [0069]FIG. 10 is a cross section illustrating the barbs with relation to the first part of FIG. 9, after the fastener has been inserted into a slot of the first part, wherein outwardly directed portions of the barbs are engaged to the lower edges of the slot of the first part.
[0070] [0070]FIG. 11 is a cross section illustrating the barbs with relation to the first part of FIG. 9, after the fastener has been inserted into a slot of the first part, wherein outwardly directed portions of the barbs are engaged to the upper edges of the slot of the first part, provided that the slot has appropriate partial conical shape to allow this type of engagement.
DETAILED DESCRIPTION OF THE INVENTION
[0071] The fasteners of the type disclosed in U.S. Pat. No. 4,500,238 are intended for use mainly in hollow walls. Fasteners of the same type, which are used in industrial applications, wherein the fastener is first inserted into the slot of a sheet, usually a metal sheet, such as the frame of an automobile for example, have barbs which secure initially the fastener on the sheet. After the fastener has been secured on the sheet, the fastener cannot be extracted from the slot without destruction of either the slot or the fastener, since the barbs are disposed against the lower surface of the sheet without the feasibility of springing back when the fastener is pulled from the region of the upper surface of said sheet.
[0072] The fasteners of the present invention pertain the critical configuration of the barbs, which allow the extraction of the fastener without destruction of the slot and/or the fastener, as described in detail hereinbelow.
[0073] Referring now to FIGS. 1, 2, and 4 there is depicted a fastener 10 , which comprises a substantially flat head portion 12 having a hole 11 . The hole 11 may be substantially round, oblong, or have any other desirable shape.
[0074] In this particular illustration, the flat portion 12 comprises an upper side 14 and a lower side 16 . However, in other instances, the flat head 12 my comprise only a lower side (single side), as described for example in U.S. Pat. No. 6,250,864 B1, which is incorporated herein by reference.
[0075] The fastener 10 , further comprises a neck 18 which has an opening 20 and two side neck portions 22 . The neck 18 extends from the lower side 16 of the substantially flat head portion 12 at a substantially right angle with respect to the substantially flat head portion 12 .
[0076] The fastener 10 , also comprises two substantially flat legs extending from the neck 18 . Each leg 24 has an inner surface 26 (see FIG. 4). The two inner surfaces 26 of the two legs 24 are at an initial proximity with each other, as shown in FIG. 1, but the legs expand in opposite directions upon inserting through the first hole 11 an expansion member 28 , and bringing said expansion member 28 to a contact region 30 of the legs 24 . Each leg also has side leg portions 32 .
[0077] Examples of expansion members are screws, bolts, nails, etc. The hole 11 is preferably but not necessarily engageable to the expansion member 28 .
[0078] Engagement, if desired, may be achieved in one or more of the miscellaneous regions of the fastener as disclosed in patent application Ser. No. 09/699,760, for example, which patent application is incorporated herein by reference.
[0079] The fastener 10 , further comprises a funnel configuration 34 in the vicinity of the contact region. The funnel 34 may be conical-like as shown in FIG. 1, or have other shapes, such as for example the funnels disclosed in U.S. Pat. No. 6,280,129 B1, and the funnel shown in FIG. 8.
[0080] In addition, the fastener comprises barbs 36 . The barbs 36 are directed outwardly away from the legs, and have an origin 38 . The origin 38 may preferably be either on the side neck portion 22 , or the side leg portion 32 . The barbs also have a front point 32 , which front point 32 substantially reaches or exceeds (goes over) the lower side 16 , as better illustrated in FIG. 1.
[0081] In operation, the fastener 10 is inserted into a slot 42 of a first part 44 , such as a metal sheet for example. The slot 42 has a length L, a width W, an upper edge 46 , a side edge 48 , and a lower edge 50 .
[0082] The metal sheet has a thickness T, an upper surface 42 , and a lower surface 54 . No matter what the value of the thickness T is, the barbs 36 push against at least one of the edges of the slot 42 , thus holding the fastener in the slot 42 . The fastener can also be easily pulled away from the slot, since the barbs 36 will slide right out when the fastener 10 is pulled from the side of the head 12 of said fastener 10 . Since the barbs 36 reach or exceed the lower side 16 , there is no way that they can move under the first part 44 , and permanently engage on the lower surface 54 of said first part 44 , such as a metal sheet for example.
[0083] After the fastener 10 has been inserted into the slot 42 of the first part 44 , a second part 56 , having a hole 58 is positioned on top of the fastener 10 , and the hole 58 is aligned with the hole 11 of the head 12 of the fastener 10 . In sequence, the expansion member 28 , such a screw for example in inserted and initially engaged on the hole 11 , and then proceeds to the contact region there by causing the legs 24 to expand and firmly secure the first part 44 on the second part 56 through the fastener 10 , as better shown in FIG. 4.
[0084] When it becomes desirable, all parts can be readily disassembled, including the easy separation of the fastener 10 from the first part 44 , thanks to the special configuration of the barbs 36 with respect to other elements of the fastener 10 .
[0085] [0085]FIG. 2 illustrates barbs 36 , the front points 40 of which substantially reach the lower side 16 (not shown) of the head 12 , thus reaching substantially the level of the upper surface 52 of the first part 44 . This is because the upper surface 44 is substantially in contact with the lower side 16 of the head 12 , during operation, as better shown in FIG. 4.
[0086] In contrast, the prior art barbs 36 A, better shown in FIGS. 1A and 2A, are designed to be disposed under the first part 44 A, after the fastener 10 A has been inserted into the slot 42 A, and permanently engage on the lower surface 54 A. Thus, after the fastener 10 A has been inserted into the slot 42 A, it cannot be removed without damage to either the fastener 10 A or to the part 44 A.
[0087] A different embodiment of the present invention, is concerned with an assembly of a fastener 10 and a first part 44 , wherein the fastener is disposed into a slot 42 of said first part 44 . The fastener 10 and the first part are similar to the respective fastener 10 and first part 44 described in the previous embodiment, with the difference that the front point 40 of the barbs 36 of this embodiment is at a distance T1 from the lower side 16 (not shown) of the fastener 10 smaller than the thickness T of the first part. In such a case, as better illustrated in FIG. 3, the front points 40 of the barbs 36 remain necessarily within the slot 42 , pushing against the side edges 48 of the slot 42 in a manner to hold the fastener 10 within the slot 42 . In different words, in this case, the barbs 36 are also directed outwardly away from the legs 24 , and are substantially disposed above the lower surface 54 of the first part 44 and above the lower edges 54 of the slot 42 . Therefore, upon disassembling the assembly, the fastener 10 may be easily removed from the slot.
[0088] The operation of this embodiment is for all practical purposes identical to the operation of the previous embodiment of the present invention.
[0089] In still a different embodiment, better illustrated in FIGS. 5 and 6, the barbs 36 have an origin 38 at the side neck portion 22 or the side leg portion 32 . The barbs 36 are initially directed outwardly away from the legs 24 , and then inwardly toward the legs 24 and the neck 18 .
[0090] The operation of this embodiment is similar to the operation of the previous embodiments with the difference that when the fastener 10 is being inserted into the slot 42 , the outwardly directed portions of the barb 36 are initially squeezed, and finally the inwardly directed portions of the barbs 36 find themselves pushing against the lower edges 50 of the slot 42 , thus engaging the fastener 10 on the first part 44 through the slot 42 .
[0091] When the second part 56 (see FIG. 4) is secured on the fastener 10 and the first part 44 , as already described in the earlier embodiments, the barbs 36 are tilted and assume a position as illustrated in FIG. 7, and further support the attachment of the second object onto the first object. Of course the degree of tilting, may vary, and what is shown in FIG. 7 is just an example.
[0092] The angle A (FIG. 6) is preferably larger than 90 degrees. In any event, it should preferably be such that the fastener can be removed from the first object without destruction of said fastener, when the removal takes place solely from the side of the first object, wherein the head of the fastener is positioned.
[0093] When it is desired to disassemble the miscellaneous components, the expanding member 28 is removed, which frees the second part 56 from the assembly of the fastener 10 with the first part 44 . The legs, assume their initial non-expanded position, and the barbs 36 resume the un-tilted position illustrated in FIG. 6. By pulling the fastener 10 away from the first part 44 (from the side of the upper surface 52 ) the barbs 36 slide initially on the lower edges 50 toward each other, then over the side edges 48 , and finally liberate the fastener 10 from the slot 42 and the first part 44 , without any damage to the fastener and/or the first part 44 .
[0094] [0094]FIG. 8 illustrates an example of the same type of barbs 36 as the ones described in the above embodiment, on a fastener 10 , the head 12 of which fastener 10 has an oblong hole 11 , and an oblong Y-shaped funnel 34 .
[0095] In still another embodiment of this invention, better illustrated in FIGS. 9, 10, and 11 , the origin 38 of the barbs 36 is disposed at the lower side 16 of the fastener 10 . Again, the barbs are initially directed outwardly away from the legs 24 and the neck 18 , and then inwardly toward the legs 24 and the neck 18 .
[0096] The operation of this embodiment is similar to the operation of the previous embodiment with the difference that when the fastener 10 is being inserted into the slot 42 , the inwardly directed portions of the barb 36 are initially squeezed, and finally the outwardly directed portions of the barbs 36 find themselves pushing against the lower edges 50 of the slot 42 , thus engaging the fastener 10 on the first part 44 through the slot 42 , as better illustrated in FIG. 10.
[0097] [0097]FIG. 11 illustrates a case that the slot 42 has a partial conical shape, in which case the barbs 36 may be pushed against the upper edges 46 of the slot 42 . As a matter of fact, the conical shape may be such that the barbs 36 are pushed (not shown) against all three edges 46 , 48 , and 50 .
[0098] In another embodiment of this invention, better shown in FIG. 12, 20 the fastener 10 has a front leg 24 a and a back leg 24 b . The front leg 24 comprises a first front barb 36 a and a second front barb 36 a ′. The back leg 24 b comprises a first back barb 36 b opposite the respective front first barb 36 a , and a second back barb 36 b ′ opposite the respective front barb 36 a ′. The characteristics of the particular barbs and their functionality have already been 25 described hereinabove, and they do not need any further clarification.
[0099] It is highly preferable that the barbs 36 a an 36 b ′ have the characteristics of barbs 36 A illustrated in FIGS. 1A and 2A, while the barbs 36 a ′ and 36 b have the characteristics of the barbs illustrated in FIGS. 1 , and/or 2 , or 3 . However, this invention includes the case that at least one of the barbs has the characteristics of 36 A illustrated in FIGS. 1A and 2A, while the rest of the barbs have the characteristics of the barbs illustrated in FIGS. 1 , and/or 2 , or 3 .
[0100] The barbs which have the characteristics of the barbs illustrated in FIGS. 1 , and/or 2 , or 3 are collectively named high barbs, while the barbs which have the characteristics of barbs 36 A illustrated in FIGS. 1A and 2A are collectively named low barbs.
[0101] In operation of this embodiment, the fastener 10 of FIG. 10 is inserted into the slot 42 of the first part 44 , such as metal sheet for example, illustrated in FIG. 1. The barb(s) having the characteristics of the barbs illustrated in FIGS. 1 , and/or 2 , or 3 (high barbs) prevent rattling of the fastener in the slot 42 for various widths W (see FIG. 1) of the slot 42 and/or various thicknesses of the first part 44 , while the barb(s) having the characteristics of barbs 36 A illustrated in FIGS. 1A and 2A (low barbs) secure the fastener 10 , and prevent it from falling off the slot 24 of the part 44 .
[0102] As aforementioned, the head of the fastener may have an upper side and a lower side or it may have a single side corresponding to the lower side. Examples of fasteners having single sided heads are described in U.S. Pat. No. 6,250,864 B1, which is incorporated herein by reference.
[0103] When water-proofing, and/or gas-proofing are desired for a particular application, and/or vibration noises are to be prevented, an elastic body is preferably integrally molded at least at the lower side of the substantially flat head portion. Such elastic bodies are for example disclosed in U.S. Pat. No. 5,725,343 (Smith), and U.S. Pat. No. 6,379,092 (Patel et al.) both of which are incorporated herein by reference.
[0104] As also aforementioned, the fastener may comprise at least one region under the at least lower side, which region is engageable to the expansion member, as described for example in non-provisional application Ser. No. 09/699,760. which is incorporated herein by reference.
[0105] It should be noted that the barbs 36 may be disposed as a mirror image against each other as shown in the Figures, but they may also be positioned sideways so that one barb can cross its respective barb, thus forming inner and outer barbs, as disclosed in non-provisional patent application Ser. No. 10/164,963, filed Jun. 7, 2002, which is incorporated herein by reference. Their width may be uniform along their length or non-uniform, as also disclosed in the same application Ser. No. 10/164,963.
[0106] This invention pertains fasteners alone, assemblies of fasteners with a first part, assemblies of fasteners with a first part wherein a second part has been attached to said assemblies, and vehicles comprising any of the 5 above.
[0107] Indiscriminately, each of the first and the second parts may be for example a plastic panel or a metal sheet or a handle, or a different type of an object.
[0108] It is evident that the embodiments of the above applications may have to be adjusted to fit the requirements of the instant invention.
[0109] The embodiments described hereinabove serve illustration purposes only regarding this invention, which should only be bound by the claims.
[0110] Any explanations given are speculative and should not restrict the scope of the claims.
[0111] A large number of advantages are derived from the critical configuration of the barbs of the present invention, which allow the extraction of the fastener without destruction of the slot and/or the fastener, as well as the retention of the fastener in slots of various widths preventing rattling noises, as described in detail hereinabove. | The present invention pertains fasteners with critical configuration of the barbs, which allow the extraction of the fastener without destruction of the slot and/or the fastener. Further, this critical configuration of the barbs allows the fasteners to be used in slots of various widths and prevents rattling, which would take place in the case of fasteners of the present state of the art. The critical configuration is based on the special dimensions and special shape of the barbs with regard to the parts and the slots involved in assemblies of the fasteners and the parts. The present invention also pertains assemblies of miscellaneous parts connected together by means of the fasteners, as well as vehicles comprising such assemblies. In addition, the present invention comprises fasteners providing a combination of low and high barbs, which combination prevents rattling of the fastener and allows secure attachment on a part, such as a sheet metal, for example. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to novel amphoteric starch derivatives and their application as wet-end additives for improving both wet and dry strength of paper.
2. Description of the Prior Art
Commercial wet-strength paper additives, which include polyamide-polyamine-epichlorohydrin (PAE), urea-formaldehyde (UF), malamine-formaldehyde (MF), polyethylenimine (PEI), modified polyacrylamide, and similar resins, are derived from diminishing reserves of petroleum and natural gas products and/or high energy processes. They are thereby rapidly becoming economically impractical. Moreover, these resins generally cause difficulty in paper repulping processes and are not readily biodegradable, thereby being ecologically undesirable.
In some cases, neutral to alkaline pH papermaking systems are required to improve properties such as interfiber bonding, stability of paper on aging, retention of alkaline fillers, and paper softness. However, except for PAE, the above-mentioned commercial wet-strength resins function marginally unless the pH of the paper-making systems are in the range of about 4.5-5.5. These acidic conditions of course contribute to equipment corrosion and increased maintenance costs.
The principal industrial wet-end dry-strength paper additives are the cationic starches. Exemplary of these are the starch ethers containing tertiary and quaternary amines as taught in U.S. Pat. Nos. 2,813,093 (Caldwell et al.) and 2,876,217 (Paschall), and also sulfonium and phosphonium starch derivatives as described in U.S. Pat. Nos. 2,989,520 (Rutenberg et al.) and 3,077,469 (Aszalos), respectively. Cationic starches do not improve paper wet strength, and frequently their effectiveness is significantly reduced when furnish pH is appreciably above 5.5, particularly for the tertiary amines.
When both wet- and dry-strength additives are required in commercial paper, it is often necessary to use a dry-strength agent, such as a cationic starch, and a wet-strength resin. As a consequence of interaction between the resin and the cationic starch, the efficiency of both additives is significantly reduced.
In U.S. Pat. No. 3,763,060 (Hamerstrand et al.) is disclosed the wet-end addition to paper of interpolymers such as starch xanthate crosslinked with PAE resin, and U.S. Pat. No. 3,436,305 (Maher) teaches starch xanthate crosslinked with PEI. though these compositions are somewhat effective for the purpose of strengthening paper, they suffer from the disadvantages characteristic of the resinous components as described above.
Other additives have been designed which have bi- or mult-functional activity, such as dry-strength improvement and pigment or filler retention. Predominant in this field are the amphoteric strengthening agents such as the polysalt coacervates of U.S. Pat. No. 3,790,514 (Economou) and the polysaccharides having both cationic and anionic substituents. This latter group is the subject of U.S. Pat. Nos. 3,467,647 (Benninga), 3,459,632 (Caldwell et al.), 3,649,624 (Powers et al.), 3,793,310 (Elizer), and 3,562,103 (Moser et al.). Starch is the most commonly used backbone of these substituted polysaccharide compositions. The cationic groups are usually the tertiary and quaternary amines, and others such as sulfonium and phosphonium groups have also been used. Typical of the anionic substituents are phosphates, phosphonates, carboxylates, sulfates, and sulfonates. Though all of these amphoteric compositions have at least some degree of paper dry-strength properties, they have not been observed to impart to paper significant wet strength.
Certain polysaccharide xanthates, such as the ammonium cellulose xanthates of Bridgeford et al., U.S. Pat. No. 3,336,144, are known to impart wet strength to paper. Such additives have not been widely accepted in the paper industry because they operate in a relatively narrow pH range and have no effect on dry strength. When starch is substituted for cellulose as within the scope of Bridgeford and the resultant composition is used as a wet-end additive, no increase in wet strength is observed.
SUMMARY OF THE INVENTION
The primary objective of the present invention is to derive novel amphoteric starch-based wet-end additives, which can simply be admixed with papermaking furnish, and which will improve both wet and dry strength of paper on a cost/performance basis competitive with commercial systems.
Another important object of the invention is to provide wet-strength agents for paper that permit unusual ease of repulping.
It is also an object of the invention to prepare novel paper additives that are highly substantive to the pulp fibers, ecologically acceptable, and biodegradable.
A further object of the invention is to tailor the novel paper additives to be equally effective in acidic, neutral, and alkaline papermaking systems.
Other objects associated with the instant paper additives include their use as effective fiber flocculants for improving furnish freeness (drainage) and as pigment filler retention agents.
These and other advantages are accomplished by the provision of a novel class of amphoteric starch derivatives; namely, xanthated starch amines (XSA) characterized by the following general structure: ##STR1## wherein R 1 is a C 1 -C 6 alkylene or hydroxy-substituted alkylene; and R 2 , R 3 , and R 4 are each selected from the group consisting of hydrogen, C 1 -C 12 straight or branched alkyl, cyclohexyl, phenyl, and benzyl;
wherein D.S.-A represents the degree of substitution of the amine group; and
wherein D.S.-X represents the degree of substitution of the xanthate group.
As represented in the above formula, the XSA have the cationic amine groups and the anionic xanthate groups attached to the same starch backbone. These amphoteric starch derivatives can easily be tailored to a variety of conditions of use, particularly to the furnish pH, by varying the degrees of substitution of both the anionic and cationic substituents, by varying the cationic/anionic molar ratio, and by proper selection of the level of addition.
In view of the prior art discussed above, it is surprising that these xanthated starch amines improve dry strength of paper more than do the nonxanthated starch amines, and it is completely unexpected that they could also effect an increase in the wet strength of up to about 1000%.
DETAILED DESCRIPTION OF THE INVENTION
The amphoteric starch derivative paper additives of the instant invention are xanthated starch amines (XSA) having the following general structure: ##STR2## wherein R 1 is a C 1 -C 6 alkylene or hydroxy-substituted alkylene; and R 2 , R 3 , and R 4 are each selected from the group consisting of hydrogen, C 1 -C 12 straight or branched alkyl, cyclohexyl, phenyl, and benzyl;
wherein D.S.-A represents the degree of substitution of the amine group; and
wherein D.S.-X represents the degree of substitution of the xanthate group.
In the preparation of the XSA, any starch material can be used whether it be granular, gelatinized, modified, or unmodified, provided that it has available reactive sites for etherification and xanthation of the starch backbone as described below. Exemplary starches are corn, wheat, rice, potato, tapioca, maize, and others as known to the skilled artisan. Alternatively, commercial cationic starches may be employed as the starting material wherein the cationic substituent corresponds to the substituent A as defined in the above structural formula.
The amine group A may be selected from primary, secondary, tertiary, and quaternary amines. The quaternary amines, of course, always carry a positive charge. The primary, secondary, and tertiary amines are neutral or positively charged as dependent upon the pH of the medium in which they are placed. The primary and secondary amines are less preferred for use in the invention. In the subsequent xanthation step as described below, primary and secondary amines are susceptible to a side reaction in which the amine hydrogens are displaced by the xanthate radicals, resulting in the dithiocarbamic acid salt. Tertiary and quaternary amines, which do not have free amine hydrogens available for this side reaction, are therefore preferred for use in the invention.
The amine is attached to the starch backbone through an ether linkage formed with a starch hydroxyl oxygen and the R 1 substituent. Though R 1 , R 2 , R 3 , and R 4 may vary within the limits defined above, the shorter substituents are preferred. As the chain lengths increase, the solubility of the substituted starch decreases. Thus at high degrees of amine substitution onto the starch backbone, long-chained amines could reduce the operability of the XSA as a wet-end additive. Most preferred as cationic substitutents of XSA are diethylaminoethyl [--CH 2 CH 2 N(C 2 H 5 ) 2 ] and 2-hydroxypropyltrimethylammonium [--CH 2 CHOHCH 2 N.sup.⊕ (CH 3 ) 3 ] because of the commercial availability of the reagents from which they are provided and the ease of XSA preparation therewith. Examples 1A and 2A below illustrate the preferred method of preparing the cationic starch amines (SA). However, novelty of the invention does not lie in the method of preparing the SA. It is to be understood that SA in commercial use and those prepared by other methods known and described in the prior art are equivalent to those of Examples 1A and 2A for purposes of use within the instant invention.
The SA are converted to the XSA by reaction with carbon disulfide (CS 2 ). The ordinary procedures and conditions for xanthation of unmodified starch as known in the art are applicable for preparing the instant XSA compositions from SA, and are taught, for example, in Lancaster et al., "Xanthation of Starch in Low-Concentration Pastes," I+EC Prod. Res. Develop. 5:354 (December 1966), which is hereby incorporated by reference. Examples 1B and 2B below further illustrate the procedure, and it is understood that other equivalent methods of xanthation as known in the art could be used. The XSA may be stored either as a dispersion or as a dry solid.
The effectiveness of the instant XSA as paper strengthening agents is a function of the degree of substitution of the amine (D.S.-A) as well as the degree of substitution of the xanthate (D.S.-X). The following ranges pertain to both wet and dry strength, though wet strength is most sensitive to changes in D.S. The operable range of D.S.-A is from about 0.01 to about 0.35, beyond which little improvement of wet strength is observed. The preferred D.S.-A is from about 0.02 to about 0.11 with optimum results being obtained at about 0.06 for tertiary amines and about 0.07 for quaternary amines. The D.S.-X may vary from about 0.002 to about 0.35, with a preferred range of about 0.004 to about 0.11. As with the D.S.-A, optimum results in wet strength are with a D.S.-X of about 0.06 for tertiary amines and about 0.07 for quaternary amines.
The isoelectric points of the XSA are a function of the ratio of D.S.-A/D.S.-X (A/X). At a given A/X ratio, varying the degrees of substitution within the operable limits does not significantly raise the isoelectric point. Also, at a given A/X ratio, XSA with quaternary groups exhibited higher isoelectric point values than XSA with the tertiary amine groups. Thus, it would be advantageous to use XSA with quaternary groups in forming insoluble complexes under alkaline conditions. At optimum D.S.-A (0.06-0.07), optimum wet strengths are obtained when the isoelectric points of the XSA additives approach pH 7.0, which is when A/X is about 1:1. However, at the upper limit of D.S.-A (0.35), this ratio for optimum wet strength is about 3:1. Generally, XSA additives havin A/X ratios ranging from about 1:2.5 to about 5:1 and having isoelectric pH values in the range of about 4.5-10.5 have been found to result in improved paper wet strengths. At a given furnish pH value within the normal papermaking pH range of 4.5-8.0, the instant XSA additives in the isoelectric pH range of 4.5-10.5 all function substantially equally with respect to increasing wet strength. They perform best at a furnish pH of about 7. By proper tailoring of the D.S.-A and D.S.-X, the XSA additives can increase furnish paper strength at furnish pH's s as low as 4 and as high as 9. At pH's lower than 4, the xanthate moiety decomposes and releases CS 2 .
The XSA additives of the instant invention are mixed with the pulp furnish in the same manner as commercial wet-end additives. For example, XSA in alkaline solution may be mixed into an unbleached, kraft, pulp furnish, and the pH of the treated furnish is then adjusted to near the XSA isoelectric point. Fiber flocculation, which is general, can be disrupted by high shear agitation without loss of XSA retention, thereby enhancing its effectiveness.
The level of XSA addition to the paper furnish for increasing both wet and dry strength is in the range of about 0.1 to about 10% (oven-dry pulp-weight basis). The preferred level is in the range of about 1 to about 2%, after which the point of diminishing returns is rapidly reached. At a given level of addition, the effectiveness of the XSA is a function of the specific amine substituent. For example, XSA with the quaternary amine substituent are slightly more effective than those with the tertiary amine.
Another factor influencing the XSA effectiveness on wet strength at a given level of addition is the method of drying. For example, it was found that XSA-treated handsheets oven dried at 105° C. for 30 minutes have wet strength values of approximately 20% greater than those that have been air dried for 24-48 hours at TAPPI Standard conditions (Tappi Standards and Provisional Methods, Technical Association of Pulp and Paper Industry). A similar increase is observed when XSA-treated papers are either cured at 105° C. for 30 minutes following air drying or stored about 1 year at TAPPI Standard conditions.
By proper selection of cationic amine substituent D.S.-A, D.S.-X, level of addition and pulp furnish pH improvements in paper wet strength of up to about 1000% can be obtained, as compared to paper without strengthening additives. Similarly, dry strength can be increased to unusual extents up to about 75%, and the burst factor about 100% over the untreated control paper strength. Actual values as compared to commercial and other prior art values are set forth in Table II below.
Under optimum conditions for wet strength development as defined above, XSA additives with D.S.-A from 0.035 to 0.11 are equally retained. These retentions, expressed as percent of XSA added, range from about 76 to 44% for addition levels from 1 to 5%, respectively. Corresponding values for cationic SA as taught in the prior art range from only 65 to 30%.
The instant XSA additives have been found to exhibit a combination of wet-strength permanency properties superior to the commercial wet-strength resins. As shown in Table I below, the wet-strength permanence is comparable to the commercial resins with respect to distilled or tap water. However, for purposes of repulpability, paper treated with 2% XSA lost wet strength under alkaline conditions much more readily than papers treated with 1% of urea-formaldehyde resin, 1% melamine-formaldehyde resin, or 0.5% polyamide-polyamine-epichlorohydrin. Only the urea-formaldehyde resin lost wet strength as readily as XSA but under corrosive acidic conditions.
While not desiring to be bound to any particular theory, it is proposed that XSA contribute to the strength of paper as a result of crosslinking between cationic nitrogen groups and anionic xanthate groups, ##STR3## of the XSA complex, intimately sorbed into and around interfiber bonding areas. However, previous studies have revealed that when xanthates per se, such as sodium ethyl xanthate and sodium starch xanthate, are heated at 100° C. or above, carbonyl sulfide (COS) as well as CS 2 is released. The evolution of COS from xanthates under paper drying conditions suggests that secondary rearrangement reactions could contribute to wet strength of XSA-treated paper. Evidence of superior enhancement of interfiber bonding as well as higher retention of XSA accounts for superior dry-strength improvement imparted by XSA over SA.
Other conventionally used paper additives may be employed in combination with the XSA additives of the present invention. Included in the group are binders, pigments, fillers, dispersants, preservatives, defoamers, coating agents, sizing agents, and the like.
The XSA are effective as pigment filler retention agents and also as fiber flocculants for improving furnish freeness (drainage).
The following examples are intended only to further illustrate the invention and are not intended to limit the scope of the invention which is defined by the claims.
EXAMPLE 1
A. Preparation of tertiary starch amine (diethylaminoethyl derivative)
To 32.0 g. (oven-dried basis) of unmodified pearl corn starch in a 3-necked round-bottomed flask equipped with stirrer, condenser, and thermometer was admixed (1) 46 ml. distilled H 2 O, (2) 12 g. Na 2 SO 4 , (3) 5 ml. 10% NaOH, and (4) 0.69 g. 2-chlorotriethylamine hydrochloride dissolved in 10 ml. H 2 O. The mixture was heated at 55° C. for 6 hours, cooled to 25° C., and allowed to stand overnight before isolation of the product. By centrifugation-decantation procedures, the product was washed four times (each with 200 ml. H 2 O), filtered, and washed successively with ethanol, hexane, and ether. The product contained 0.20% nitrogen, corresponding to an amine D.S. of 0.023.
Starch amines having different D.S.-A as used in the Examples below were similarly prepared by appropriately altering the proportion of materials in the reaction mixture. The exemplified procedure was followed throughout, except that for D.S.-A greater than about 0.07, the SA were too swollen to be washed by centrifugation-decantation or by filtration procedures, and were therefore dialyzed and then precipitated in ethanol.
B. Preparation of tertiary XSA
The tertiary SA (2.5 g. oven-dried basis) of Example 1A was (1) slurried in 28 ml. H 2 O plus 5 ml. 5% NaOH, (2) heated to 50° C. for 10 minutes, (3) cooled to 25°-35° C., and (4) xanthated by pipetting CS 2 (ranging in amounts from 0.01 ml. to 0.2 ml. for xanthate D.S. from 0.006 to 0.092) beneath the surface of the SA dispersion. After 1 hour, the XSA dispersion was diluted to 5% concentration and stored 16 hours at 34° C. before analyses and evaluation of XSA as a paper-handsheet additive. The UV monitoring of portions of the XSA dispersion (diluted in 0.1N NaOH) showed that xanthation was 90% or more complete within 1hour after CS 2 addition.
EXAMPLE 2
A. Preparation of quaternary starch amine (2-hydroxypropyltrimethylammonium derivative)
To 32.0 g. (oven-dried basis) of unmodified pearl corn starch in a 3-necked round-bottomed flask equipped with stirrer, condenser, and thermometer was admixed (1) 37 ml. distilled H 2 O, (2) 12 g. Na 2 SO 4 , (3) 14 ml. 10% NaOH, and (4) 4.1 g. 3-chloro-2-hydroxypropyltrimethylammonium chloride dissolved in 10 ml. H 2 O. The mixture was heated at 55° C. for 6 hours, cooled to 25° C., and allowed to stand overnight before isolation of the product. The product was then dialyzed and precipitated in ethanol. The product contained 0.60% nitrogen, corresponding to an amine D.S. of 0.072.
B. Preparation of quaternary XSA
The quaternary SA of Example 2A was xanthated according to the procedure of Example 1B.
EXAMPLES 3-54
In Examples 3-54, paper handsheets were prepared containing various paper additives according to the following procedure: To a 1750 g. pulp slurry (15.0 g., oven-dried basis, of unbleached kraft pulp in tap water--560 ml. Canadian Standard freeness), under good agitation, was added 45 ml. of 1.0% additive dispersion in about 1 minute. After 2 additional minutes of mixing, pH of the treated furnish was adjusted to near the product's isoelectric point with H 2 SO 4 (10% v/v). Then, the furnish was diluted with tap water to 0.24% consistency, and 1.2-g. (60 g./m. 2 ) handsheets were prepared and tested according to TAPPI Standard Methods--except that wet-tensile test strips were soaked 30 minutes (distilled H 2 O). A description of the additives and the strength properties of the resultant handsheets are set forth in Table II below.
It is to be understood that the foregoing detailed description is given by way of illustration and that modification and variations may be made therein without departing from the spirit and scope of the invention.
Table I.__________________________________________________________________________Wet-Strength Permanency of Paper Treated with XanthatedStarch Amine (XSA) and Commercial ResinsAddition levelbased on Wet breaking length of paperoven-dry pulp Temperature soaked for 30 min., m.basis, % of solution, °C. Distilled H.sub.2 O 0.025N NaOH 0.025N H.sub.2 SO.sub.4__________________________________________________________________________XSA.sup.12.0 23 1880 -- 18502.0 60 1850 540 18502.0 60 1850 540 18502.0 83 1750 250 16102.0 93 1670 250 --Urea-Formaldehyde Resin.sup.21.0 23 2200 2150 12701.0 83 2170 710 2501.0 93 1650 530 250Melamine-Formaldehyde Resin.sup.21.0 23 1570 1550 14401.0 93 1260 1330 610Polyamide-Polyamine-Epichlorohydrin Resin.sup.20.5 23 2120 1710 21500.5 93 2000 1520 1980__________________________________________________________________________ .sup.1 D.S. 0.072 quaternary ammonium, 0.065 xanthate. Paper was dried at TAPPI Standard conditions. Tensile values were essentially unchanged when soaked from 5 min. to 48 hr. in tap water. .sup.2 Resin-treated papers were oven cured aat 105° C. for 30 min.
Table II__________________________________________________________________________ Degree of pH Tensile strength substitution Isoelectric Pulp Burst factor breaking length (m.)ExampleAdditive.sup.1 % Addition Cation Anion point furnish (g./cm..sup.2)/(g./m..sup.2) Wet Dry__________________________________________________________________________Controls: 3 None -- -- -- -- 5.5 45 200 6870 4 None -- -- -- -- 7.0 44 200 6800Commercial wet strength agents: 5 MF resin 0.5 -- -- -- -- 50 940 7710 6 PAE 0.5 -- -- -- -- 55 2120 8340Prior art starch amines: 7 Tert. SA 1 0.023 -- -- 5.5 62 221 8737 8 Tert. SA 3 0.023 -- -- 7.0 66 200 9300 9 Tert. SA 5 0.023 -- -- 5.5 73 250 992210 Tert. SA 1 0.078 -- -- 5.5 61 219 853011 Tert. SA 5 0.078 -- -- 5.5 74 254 984612 Tert. SA 3 0.037 -- -- 7.0 70 200 960013 Tert. SA 3 0.06 -- -- 7.0 68 200 930014 Tert. SA 3 0.11 -- -- 7.0 68 225 912015 Quat. SA 2 0.072 -- -- 7.0 67 220 949016 Quat. SA 3 0.072 -- -- 7.0 70 225 9632Commercial wet-strength agentsplus prior art starch amines:17 MF resin + quat. SA 0.5, 2.0 0.072 -- -- -- 71 990 967018 PAE + quat. SA 0.5, 2.0 0.072 -- -- -- 64 1969 9090Prior art starch xanthates:19 Starch xanthate 3 -- 0.05 -- 7.0 44 158 744820 Starch xanthate 3 -- 0.05 -- 5.0 44 131 7262Prior art amphoteric starch derivatives:21 Quat. SA sulfate 3 0.030 0.027 6.6 7.0 57 150 829922 Quat. SA sulfate 3 0.071 0.064 9.3 7.0 62 221 849823 Quat. SA carboxylate 3 0.07 0.065 10.5 7.0 62 157 889124 Quat. SA carboxylate 3 0.07 0.094 3.9 7.0 53 134 815925 Quat. SA carboxylate 3 0.07 0.128 3.6 7.0 48 140 770226 Quat. SA carboxylate 3 0.039 0.029 10.4 7.0 67 174 916027 Quat. SA carboxylate 3 0.039 0.037 7.5 7.0 63 167 880028 Quat. SA carboxylate 3 0.039 0.041 4.5 7.0 62 161 806829 Quat. SA carboxylate 0.5 0.032 0.029 10.4 7.0 50 166 772430 Quat. SA carboxylate 3.0 0.032 0.029 10.4 7.0 63 176 877931 Quat. SA phosphate 0.5 0.074 0.042 7.5 7.0 48 165 756732 Quat. SA phosphate 3.0 0.074 0.042 7.5 7.0 66 196 9497Xanthated starch amines:33 Tert. XSA 1 0.023 0.010 8.3 5.5 69 395 955134 Tert. XSA 1 0.023 0.020 5.1 5.5 66 486 906535 Tert. XSA 3 0.023 0.020 5.1 7.0 78 700 1015036 Tert. XSA 3 0.023 0.055 <3.5 7.0 61 280 855537 Tert. XSA 5 0.023 0.020 5.1 5.5 80 735 1044438 Tert. XSA 2 0.037 0.020 6.4 7.0 77 1074 1041939 Tert. XSA 3 0.037 0.006 9.5 7.0 79 657 1075940 Tert. XSA 3 0.037 0.020 6.4 7.0 79 1100 1089541 Tert. XSA 3 0.037 0.060 <4 7.0 70 720 990342 Tert. XSA 2 0.06 0.032 9.6 7.0 79 1057 1077643 Tert. XSA 2 0.06 0.092 <4 7.0 70 770 957744 Tert. XSA 3 0.06 0.060 5.6 7.0 82 1258 1003145 Tert. XSA 2 0.11 0.054 7.7 7.0 86 1166 1058846 Tert. XSA 3 0.11 0.054 7.7 7.0 79 1323 1040347 Tert. XSA 5 0.11 0.054 7.7 7.0 89 1453 1184948 Quat. XSA 2 0.072 0.065 5.3 7.0 78 1610 1053149 Quat. XSA 3 0.072 0.046 10.0 7.0 83 1450 1088150 Quat. XSA 3 0.072 0.065 5.3 7.0 85 1940 1097051 Quat. XSA 3 0.072 0.082 <4.5 7.0 80 1433 1073752 Quat. XSA 5 0.072 0.065 5.3 7.0 89 2268 1142953 Tert. XSA.sup.2 3 0.11 trace none 7.0 70 285 952554 Tert. XSA.sup.3 3 0.11 0.057 7.1 7.0 76 1331 10758__________________________________________________________________________ .sup.1 MF = melamine-formaldehyde; PAE = polyamide-polyamine-epichlorohydrin resin; quat. = quaternary ammonium [--CH.sub.2 CHOHCH.sub.2 N.sup.⊕ (CH.sub.3).sub.3 ]; Tert. = tertiary amino [--CH.sub.2 CH.sub.2 N(C.sub.2 H.sub.2).sub.2 ]; SA = starch amine; XSA = xanthated starch amine. .sup.2 Acid-treated (pH 2) freeze-dried XSA. .sup.3 Freeze-dried XSA stored 49 days at 1° C. | Novel amphoteric starch derivatives, xanthated starch amines, have been employed as wet-end paper additives for improving both wet and dry strength. They are easily repulpable, readily biodegradable, effective in a broad range of furnish pH's, and are competitive on a cost/performance basis with commercial systems. | 3 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. application Ser. No. 13/400,016, filed Feb. 17, 2012, which is a continuation-in-part of U.S. application Ser. No. 13/010,763, filed Jan. 20, 2011, both of which are incorporated by reference in their entirety.
[0002] This application also incorporates by reference the concurrently filed and commonly owned U.S. application entitled “Herb Grinder” (VIOLI-90073) by the same inventors.
BACKGROUND
[0003] This invention relates generally to a grinder, and more particularly has reference to a lighter-shaped grinder especially adapted for cigarettes and other smoking material.
[0004] There are two types of cigarettes. The first is an already finished cigarette, and the second needs to be manually assembled by the smoker using leaves and cigarette paper. To make the cigarette, the user needs to have a grinder or a pair of scissors to grind or cut the leaf into fine pieces, which is often inconvenient.
[0005] A need exists for a new type of grinder which can solve the issue of inconvenience. The present invention fulfills that need.
SUMMARY OF THE INVENTION
[0006] Briefly, and in general terms, the present invention relates to a new type of grinder embodying a shell in the shape of a lighter body with special groove patterns forming a grinding area on the shell.
[0007] The grooves can be in the shape of rectangles, squares, circles, ovals, hearts, or other polygonal shapes. Aligned and/or staggered arrangements of grooves can be used. The grooves also can be in the shape of concentric rings, and distributed at specific radial intervals. They can have a curved shape or be in a straight line, and can be distributed in parallel at specified intervals.
[0008] The grinder shell is generally in the form of a hollow elongated tubular or cylindrical structure with a cross-sectional shape that may be circular, oval or square with rounded or sharp corners. The grinder shell material may be plastic, metal, or wood. The grinder may feature multiple grinding areas on the outer surface of the shell.
[0009] The grinder may be provided with a plurality of through holes distributed both in the grooves and/or on the surface of the shell. The bottom end of the grinder may be either open or closed.
[0010] A grinder made in accordance with the present invention has a lighter-shaped body or shell which features a plurality of grooves or notches on the shell forming grinding areas, making it easier and more convenient to grind. The sidewalls of the grooves can be used as a grinding edge which can grind leaves and other kinds of materials.
[0011] Safety is a concern since the grinder needs to be able to be carried anywhere and used anytime like a conventional lighter. A grinder made in accordance with the present invention is safer to use because it does not require cutting blades or any sharp edges or parts sticking out from the surface of the grinder that could cut a user's fingers during use or cause personal injury. The grinding area is formed by the special grooved shell which makes grinding safe and easy. The grinder is particularly suitable for grinding softer herbs, spices, fruits, nuts, and tobacco, etc.
[0012] These and other features and advantages of the invention will become more apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the features of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of a lighter-shaped grinder embodying novel features of the present invention;
[0014] FIG. 2 is a side elevational view of the grinder shown in FIG. 1 ;
[0015] FIG. 3 is a perspective view of another embodiment of the invention;
[0016] FIG. 4 is a front elevational view of the grinder shown in FIG. 3 ;
[0017] FIG. 5 is a front elevational view of yet another embodiment of the invention;
[0018] FIG. 6 is a front elevational view of still another embodiment of the invention;
[0019] FIG. 7 is a front elevational view of another embodiment of the invention;
[0020] FIG. 8 is a front elevational view of yet another embodiment of the invention;
[0021] FIG. 9 is a front elevational view of still another embodiment of the invention;
[0022] FIG. 10 is a perspective view of another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Referring now to the drawings, and in particular to FIGS. 1 and 2 , the invention is embodied in grinder having a lighter-shaped body or shell with a plurality of notches or grooves 2 on the grinder shell 1 . In accordance with the present invention, the grooves 2 and grinder shell 1 form a grinding area. In this embodiment, as best shown in FIG. 1 , the cross-sectional shape of the shell is rectangular, with rounded corners. The grooves 2 in this particular embodiment, have an elongated rectangular shape and are arranged in straight lines, or strips, spaced apart and extending horizontally in parallel across a portion of a face of the shell. There are a plurality of grooves, and they are distributed in parallel at specified intervals across the exterior surface of the shell.
[0024] FIG. 2 shows the profile of the grinder of FIG. 1 , illustrating the difference between the grooves and the surface of the grinder. The plurality of grooves 2 make it easy and convenient to grind. The sidewalls of the grooves 2 can be used as a grinding edge which can grind leaves, and other types of materials.
[0025] Safety is a concern since the grinder needs to be able to be carried anywhere and used anytime like a conventional lighter. Therefore, it is desirable to avoid any sharp edges or parts sticking out of the grinder surface. Otherwise, personal injury could occur. The benefit of using a grinder made in accordance with the present invention is that it is safer to use because it does not need any cutting blades on the surface that could cut a user's fingers during use. The grinding area is formed by the grinder shell 1 and the grooves 2 , which makes the grinding safe and easy. The grinder is particularly suitable for use in grinding softer herbs, spices, fruits, nuts, and tobacco, etc.
[0026] While the grinder shell shown in FIG. 1 has a generally rectangular cross-sectional shape, it will be appreciated that the cross-sectional shape of the shell 1 can be circular, oval or any other shape.
[0027] FIGS. 3 and 4 show an alternative embodiment of the invention. Compared to the first embodiment, the difference in this embodiment is that in addition to the grooves 2 , there are a plurality of through holes 3 on grinder shell 1 . These through holes 3 are distributed in the grooves or recessed areas, and on the surface of grinder shell 1 itself in the spaces between the grooves. These holes 3 perform both a grinding and cutting function. The holes add additional cutting edges to the grinder which makes it more efficient than the previous embodiment. The holes 3 can vary in size, location, concentration and spacing. In order to better illustrate the difference between the grooves and the adjacent surface of the sheet, the grooves have been illustrated with a hatching pattern in FIG. 4 (and in subsequent Figs.) to distinguish between the grooves and the adjacent spaces on the shell.
[0028] The bottom end of the grinder shell 1 can be either open or closed. When the bottom is open, the holes 3 have the added feature of expelling waste bits of ground material from the grinder preventing waste accumulation in the grooves 2 which could adversely affect the grinding. When the bottom of the shell is closed, the groove bits can be collected in the shell and then emptied out at a desired location.
[0029] FIG. 5 shows an alternative embodiment in which each of the grooves 2 a has a square shape, and the grooves are arranged with alternating spaces in a checkerboard pattern. This checkerboard pattern forms a grinding area. Compared with the first embodiment, the grinding resistance is less, and results in a smoother and more delicate grind.
[0030] FIG. 6 shows another embodiment. In this embodiment, the shape of the grooved areas 2 b is circular, and there are spaces between the circular grooves 2 b. The grooved areas and grinder shell 1 form the grinding area.
[0031] In each of the above embodiments, the shape of grooved areas can be different from those illustrated, and can be triangles, rectangles, stars, polygons, ovals, hearts, gems or other irregular shapes, and combinations thereof. The shape and size of the grooved areas 2 also can be different, and can also be aligned unevenly.
[0032] FIG. 7 shows another embodiment in which the grooved areas 2 c form an angled, inverted V, or arrowhead, shape distributed in parallel at spaced interval on the shell 1 forming a grinding area. Because the grooves are bent at an angle, the sidewall segments provide an inward pushing effect on the material being ground, resulting in easier crushing and grinding of the material.
[0033] FIG. 8 shows another embodiment in which the grooved sections form a 2 d series of concentric rings arranged at specified radial intervals on the shell 1 forming the grinding area. Because the grooves 2 d are not straight lines in the grinding area, but are arcuate in shape, this also has the effect of pushing material inward when grinding, making it easier to crush and grind the material, and more efficient to use.
[0034] In the embodiment shown in FIG. 8 , there are two separate grinding areas on the body or shell, and these two grinding areas are of two different sizes. These two areas can be used for different functions, as one can be used as a rough grinding area while the other can be used as a fine grinding area. This provides different selections of grinding areas within the same grinder.
[0035] FIG. 9 shows another embodiment which uses two different grinding options within the same grinding area. The grinding area is similar to the one in FIG. 5 , but includes through holes in both the grooves 2 a and on the shell 1 in half of the grinding area, divided lengthwise. The portion of the grinding area without the through holes serves as a normal grinding area, while the portion with the through holes serve as a more high-efficient grinding zone.
[0036] FIG. 10 shows an alternative embodiment in which the shell is in the shape of a cylinder with a circular cross section, and the grooves 2 e are provided by recessed sections of the shell having a smaller diameter in cross section. It also includes a plurality of through holes on both the surface of the shell and within the recessed sections.
[0037] In all of the embodiments described above, the notches or grooves are generally but not necessarily rectangular in cross section with sidewalls that are preferably but not necessarily perpendicular to the surface of the sheet. The angle between the sidewall and the surface of the shell can be either acute or obtuse. When the angle is acute, the grinding edge protrudes more. The cutting effect is enhanced, and the grinding effect is reduced. When the angle is obtuse, the cutting edge is blunt. The grinding effect is enhanced, while the cutting effect is reduced.
[0038] In all of the foregoing embodiments, the grinder shell can be made out of plastic, metal, wood or glass, and combinations thereof. The thickness of the shell is preferably between about 0.15 mm and 5 mm. The depth of the notches or grooves is preferably between about 0.005-2 mm. When the depth of the notch or groove is relatively small, it can grind to a more fine texture.
[0039] In all of the foregoing embodiments, there are many ways of forming the notches or grooves. For example, the notches or grooves can be formed using a CNC machine, mold stamping, laser cutting, or water jetting to process the shells. Another option is to use mask chemical corrosion which when processing, causes the bottom of the notches or grooves to be corroded and rough, which can enhance the grinding efficiency. The surface of the shell can be either smooth or rough, as desired.
[0040] The grooves and holes can be formed on a flat sheet of material, which is then rolled to form a tube. Alternatively, the grooves and holes can be formed directly on a finished tube or cylinder. The holes can be formed by stamping or punching or by any other suitable means.
[0041] It will be appreciated that each of the grinder shells described above can be used as a case or sleeve for holding a conventional lighter, or it can be integrated as part of the lighter body.
[0042] The invention may be embodied in other forms without departure from the spirit and essential characteristics thereof. The embodiments described therefore are to be considered in all respects as illustrative and not restrictive. Although the present invention has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art are also within the scope of the invention. Accordingly, the scope of the invention is intended to be defined only by reference to the appended claims. | A grinder in the form of a lighter where the grinding is performed on the outer shell. The grinder has unique groove patterns on the shell that form the grinding area. This lighter shaped grinder can grind herbs as well as other materials | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. patent application Ser. No. 11/203,645 filed on Aug. 11, 2005, which is a continuation of the U.S. patent application Ser. No. 10/448,202 filed on May 28, 2003.
BACKGROUND
1. Field
Invention relates to electronic media devices and processing methods, particularly to networked reconfigurable media appliance.
2. Related Art
Conventional digital video media appliances rely on external computing resources for post-processing of recorded audio or video signals, since limited on-appliance editing and filtering capabilities may render such tasks impractical. Furthermore, limited on-appliance software extensibility and limited communication with external resources leave conventional digital media appliances as standalone audio or video recording tools limited by factory-loaded on-appliance processing capacity.
Accordingly, there is need for network-extensible and easily reconfigurable media appliance capable of communicating over networks and allowing for extension of on-appliance audio or video processing software and tagging of recorded audio or video signals.
SUMMARY
Network-extensible reconfigurable media appliance senses incoming audio and/or video, and encodes and stores in media appliance memory or alternatively relays over network to recipient. On-appliance digital audio and/or video effects and filters process audio and/or video data stored in memory, as well as incoming audio and/or video stream on-the-fly. Media appliance dynamically stores, modifies, updates and deletes on-appliance set of digital effects and filters, providing mobile extensible reconfigurable effects studio. Media appliance communicates wirelessly and/or over-wire with other media appliances, computers, security systems, video storage, Global Positioning System (GPS) services, Internet, cellular services and/or personal digital assistants (PDA) providing seamless integration of captured audio and/or video stream with off-appliance resources and/or services. Audio and/or video, wireless, biometric and GPS input and/or output as well as on-appliance acceleration detector render media appliance suitable for security applications. Extensible reconfigurable on-appliance effects and filters studio render media appliance for entertainment and video production or editing applications.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 a is an architectural diagram illustrating network-extensible reconfigurable media appliance according to an embodiment of the present invention.
FIG. 1 b is an architectural diagram illustrating network-extensible reconfigurable media appliance according to an embodiment of the present invention.
FIG. 2 is a diagram illustrating memory element of network-extensible reconfigurable media appliance according to an embodiment of the present invention.
FIG. 3 a is a diagram illustrating network-extensible reconfigurable media appliance communicating with other networked services and devices, according to an embodiment of the present invention.
FIG. 3 b is a diagram illustrating network-extensible reconfigurable media appliances communicating over a network with a server, according to an embodiment of the present invention.
FIG. 4 is a flow diagram illustrating a method for sensing according to an embodiment of the present invention.
FIG. 5 is a flow diagram illustrating a method for filling in a template according to an embodiment of the present invention.
FIG. 6 is a flow diagram illustrating a method for tagging audio and/or video representation with location and/or direction information.
FIG. 7 is a flow diagram illustrating a method for transferring data and/or instructions from off-appliance source to on-appliance memory.
DETAILED DESCRIPTION
FIG. 1 a is an architectural diagram illustrating network-extensible reconfigurable media appliance 100 according to an embodiment of the present invention. Media appliance 100 comprises media unit 101 , controller 108 , communication unit 103 , and power module 116 .
Media unit 101 comprises audio and/or video (A/V) sensor 120 for sensing incoming audio and/or video. Sensed video is stored in memory 110 using video format such as Digital Video Disc (DVD), PAL Digital Video Cassette (PAL DVC), PAL or NTSC Laserdisc, 24P HD, ¾-inch, MPEG-2, MPEG-4 (DV-25, DV-50, IMIX, ISMA, etc.), H.264, AVI, DV, DVCAM, DVCPRO, DVCPRO-25/50/100, VHS, D-VHS, W-VHS, Digital-8, Digital-S, D1, D2, D5 HD, Betacam SX, Digital Betacam, other digital ENG format, Motion JPEG, any other HDTV format, NTSC, PAL, HDD/RAID/Disk Arrays, and/or other format for encoding video (specifications for describing these formats are herein incorporated by reference).
Media unit 101 optionally comprises biometric module 106 . Biometric module 106 comprises finger-print scanner, retinal scanner, and/or other element for collecting a biometric sample, and stores scanned biometric data and/or result of biometric identification process in memory 110 . For example, a data structure is stored comprising a digital representation of collected biometric sample for authorization based on comparison with previously-stored biometric identifier. Biometric module 106 optionally couples with a micro-array chip for genetically-based identification.
Media unit 106 optionally comprises reconfigurable logic and/or software 122 for performing programmable audio and/or video sensing, or for conversion to or from audio and/or video formats.
Controller 108 comprises microprocessor 123 (such as one from the Intel Centrino processor family, the specification of which is herein incorporated by reference), and optionally comprises co-processor 124 , Digital Signal Processing (DSP) unit 125 , array processor 126 , and/or reconfigurable logic 127 . Controller 108 performs audio and/or video processing on audio and/or video data residing in memory 110 . Optionally in real-time manner, controller 108 performs on-the-fly audio processing and/or on-the-fly video processing on incoming encoded audio data and/or incoming encoded video data prior to storage of resulting processed audio data and/or resulting processed video data in memory 110 .
Controller 108 is implemented in Application Specific Integrated Circuit (ASIC) blocks, synthesizable intellectual-property cores, cell processors, reconfigurable logic blocks, Field Programmable Gate Arrays (FPGAs), Tensilica's XTensa chip architecture and/or instruction set, Single or Multiple Instruction Single or Multiple Data (S/MIS/MD) architecture signal processing chips, Sony “Cell” chip, and/or other architecture for performing audio and/or video processing.
Controller 108 and/or A/V sensor 120 may perform color-space conversion, brightness, white-balance, backlight compensation, gain control, activity detection, motion detection, motion tracking, gamma correction, sharpening, multi-frame noise reduction, depth estimation, 2-D bad-pixel correction, video compression, video stabilization, digital pan, digital tilt, digital zoom, and/or mosaicing for building panoramic images from successive frames.
Communication unit 103 comprises radio-frequency (RF) transceiver 128 for communicating via radio waves (e.g. over cellular or other wireless network), and/or network controller 129 for communicating via a wired and/or wireless network (e.g. local area network (LAN), wide area network (WAN), wireless fidelity (WiFi) network, etc.).
Communication unit 103 optionally comprises subscriber information module (SIM) unit 130 and/or smart card unit for storage and/or retrieval of information about a user (such as user preference, subscribed service, permission, account information, etc.), and/or for allowing usage of media appliance 100 by one or more users.
Communication unit 103 optionally comprises GPS module 112 for receiving GPS data over satellite. Optionally, GPS module 112 is a micro GPS transponder implemented in single chip or chipset.
Communication unit 103 optionally comprises acceleration detector 113 (such as a gyroscope, a single-chip accelerometer or other element for detecting acceleration) for determining orientation and/or acceleration of media appliance 100 .
Communication unit 103 optionally comprises reconfigurable logic or software 131 for performing programmable protocol translation, format conversion, network packet processing, network packet compression and/or decompression, communication encryption and/or decryption, and/or other communication processing.
Power module 116 provides power for media appliance 100 , and comprises AC and/or DC source, portable rechargeable battery, fuel cell (e.g. direct methanol fuel cell, etc.), and/or other source for providing electrical power. Optionally, media appliance 100 employs MICA microsensor platform for low-power wireless sensor networks, herein incorporated by reference.
Optionally, media appliance 100 architecture conforms to Advanced Telecommunication Computing Architecture (AdvancedTCA), herein incorporated by reference.
FIG. 1 b is a diagram illustrating network-extensible reconfigurable media appliance 100 according to one embodiment of the present invention. Light or video sensor 102 senses incoming image stream and stores digital representation in memory 110 . Preferably, sensor 102 is a complementary metal oxide semiconductor (CMOS) image sensor. Optionally, sensor 102 is integrated with an image preprocessor. Optionally, sensor 102 comprises integrated two-chip set such as Pixim D1000 or D2000 Video Imaging System chip sets. Sensor 102 optionally comprises a partition for post image processing steps. Alternatively, sensor 102 is a charge-coupled device (CCD) or an Active Pixel Sensor (APS) imager. Audio sensor 104 senses incoming sound and stores digital representation of incoming sound in memory 110 using audio format such as Audio Interchange File Format (AIFF), MPEG Layer 3 (MP3), and/or other format for encoding audio information.
I/O module 111 preferably has audio and video outputs. I/O module 111 preferably communicates with on-appliance display or screen unit 114 and on-appliance speaker 115 for displaying video and generating audio. Optionally, display unit 114 comprises a teleprompter for displaying visual prompts (such as text and/or pictures).
Optionally, I/O module 111 communicates wirelessly, wired, over cellular network, over LAN and/or over WAN (such as Internet), to send and/or receive GPS data, Digital Rights Management (DRM) meta-data, audio and/or video plugins, and/or other instructions and/or data for processing and/or tagging of audio and/or video data. Optionally, I/O module 111 has video and audio inputs for receiving audio and video signals from external audio and/or video source such as a camera, a PDA, a media repository, a satellite, a security service, a DRM service, a biometric service, a GPS service, a PC or workstation, a cellular service or cellular device, or other device or service communicating with media appliance 100 . Media appliance 100 optionally has network controller 117 for communicating with other devices and/or services over a network.
FIG. 2 shows memory 110 according to a preferred embodiment of the present invention. Memory 110 comprises Dynamic Random-Access Memory (DRAM), Static Random-Access Memory (SRAM), high-speed Flash memory, and/or removable memory (e.g. removable flash memory card such as MultiMediaCard). Memory 110 stores audio and video data 201 .
Optionally, memory 110 stores software instructions and data implementing billing 202 and/or business methods, such as a time-based pay-per-view and/or micro-billing feature. For example, memory 110 stores a data structure comprising a field describing a viewing (such as a home-viewing of a video clip of video stream) and/or a field indicating an amount to be charged for the viewing and/or a field identifying a party to be charged.
Optionally, memory 110 stores meta-data and/or instructions for implementing DRM 203 (e.g. Disney Media Asset Management (MAM) format), Resource Definition Framework (RDF) implementation such as Adobe's XMP (eXtensible Metadata Framework), or other scheme for managing meta-data. For example, an XMP packet data structure comprising a header, an XML meta-data, a trailer, and a padding field is employed. Optionally, memory 110 stores data and/or instructions for implementing DRM according to a Right Expression Language Data Model, for example employing Extensible Rights Markup Language (XrML). Optionally, memory 110 stores meta-data and/or instructions for implementing proposed Global Release Identifier Syntax (GRID), for example employing a data structure having an Identifier Scheme, an Issuer Code, a Release Number, and a Checksum.
Optionally, memory 110 stores instructions and/or data 204 for performing digital authentication, encryption, decryption, key generation, digital signing, digital watermarking, and/or other instructions for performing security and/or privacy related computation on audio and/or video data, DRM data, billing data and/or conditions, sensitive personal data, or other data residing in media appliance 100 and/or communicated to or from media appliance 100 . For example, memory 110 stores a data structure comprising a field describing an encryption (and/or decryption) key, and further stores instructions for encrypting a video stream using the encryption (and/or decryption) key.
Optionally, memory 110 stores instructions and/or data 205 for performing identity recognition (such as facial recognition, emotion recognition, voice recognition, and/or other pattern or identity recognition) on video data 201 and/or on incoming video signal. For example, memory 110 stores a data structure comprising an identifier for a database against which image recognition is to be performed, for example a database of faces for recognizing faces in a crowd. The database may be stored (partially or completely) internally on media appliance 100 or reside externally on a server. As another example, memory 110 stores a data structure comprising a feature extracted from a video stream and/or video clip (using image extraction instructions stored in memory 110 ), and the extracted feature is used for a data base query or is sent to a server for further handling.
Optionally, memory 110 stores instructions and/or data for performing authoring 206 and/or digital video editing (e.g. linear or non-linear editing), compositing, and/or special effects, such as Apple's Final Cut Pro software. For example, memory 110 stores a data structure comprising a bit rate associated with the encoding of a video clip and/or video stream. As another example, memory 110 stores a data structure comprising author information, genre information, title, characters, actors, genre, story, activities, viewer demographics, locations, scenes, backgrounds, props, objects, set pieces, or other information pertaining to a video clip and/or video stream.
Optionally, memory 110 stores instructions and/or data for tagging 207 the digital representation of a sensed scene (video stream and/or video clip) with meta-data. For example, memory 110 stores a data structure comprising time, media appliance location (such as provided by GPS module 112 ), media appliance orientation and/or media appliance acceleration (such as provided by acceleration detector 113 ), multi-lingual features (allowing for translation, subtitles, voice-over, etc.), cues to a theater automation system (such as instructions for house lights to go up, half-way up, or down, or instructions to open or close curtains, etc.), instructions for allowing or disallowing content (such as trailers or promotional clips) to play next to other similar content, information indicating suitability of content for different audiences such as children, information indicating any promotional offers, products and/or services (such as advertisements, product catalogs and/or coupons for products and/or services), information allowing for organizing and/or managing meta-data available to advertisers and/or service providers, and/or other information describing, identifying and/or relating to content.
DRM meta-data and/or instructions optionally comprise flags for implementing rights and/or limitations of reproduction, rights and/or limitations of public performance, rights and/or limitations of display, rights and/or limitations of distribution, rights and/or limitations of importation, rights and/or limitations of transmission or access, rights and/or provisions under Digital Millennium Copyright Act (DMCA), rights and/or limitations of caching, rights and/or limitations of browsing, rights and/or limitations of storage, rights and/or limitations of transfer such as burning to Compact Disk (CD) or DVD, rights and/or limitations of referring or linking or framing, rights and/or limitations of streaming or downloading, rights and/or limitations of advertising, or other rights and/or limitations and/or provisions. For example, memory 110 stores a data structure comprising a field identifying a video clip or video stream, and a field for indicating whether a reproduction right is granted for the identified video clip of video stream. In another example, memory 110 stores a data structure comprising a field identifying a video clip or video stream, and a field for indicating whether a public performance (and/or display) right is granted for the identified video clip of video stream. Other digital rights can be implemented analogously. DRM meta-data and/or instructions optionally support secure promotion, sale, delivery, distribution, and/or usage tracking of digital content. Optionally, execution environment is partitioned into kernel versus user space and/or into standard versus trusted partitions according to Microsoft's Next-Generation Secure Computing Base (NGSCB).
Media appliance 100 optionally inserts, deletes, and/or modifies a label in an RDF (e.g. XMP) tag describing a media segment.
Media appliance 100 optionally implements content authenticity, device authentication, and/or user authentication. Content authenticity comprises digital watermarking, digital fingerprinting, and/or other technique for content authentication. For example, memory 110 stores instructions for reading an identifier describing a source of a video clip and/or video stream, wherein the identifier is embedded in a digital watermark within the video clip and/or video stream. As another example, memory 110 stores a data structure comprising a field identifying one or more authorized sources for downloading video clips and/or video streams. Device authentication comprises smartcards, public key certificates, and/or device for performing authentication. User authentication comprises biometrics using biometric module 106 , passwords, and/or other technique for performing user authentication.
Media appliance 100 optionally implements, in software (e.g. residing in memory 110 ) and/or hardware, an abstraction layer between application and display, such as DVB (Digital Video Broadcast) and/or MHP (Multimedia Home Platform) abstraction layers. Specifications for incorporating the DVB and MHP formats are herein incorporated by reference.
FIG. 3 a shows networked media appliance 100 communicating with other device and/or service, according to a preferred embodiment of the present invention. Communication with other device and/or service proceeds via direct network connection, Internet, WiFi, IEEE 802.11, IEEE 802.16, IEEE 802.15.4, ZigBee specification, cellular, Bluetooth, Universal Serial Bus (USB), Apple's FireWire, and/or other communication channel or protocol. Communication is optionally encrypted, authenticated and/or digitally signed, preferably with encryption engine 204 implemented in memory 110 , or alternatively with encryption engine 204 implemented in controller 108 .
Media appliance 100 optionally communicates with media repository 307 for downloading and/or uploading video and/or audio clips, video and/or audio meta-data such as author information, genre information, title, characters, actors, genre, story, activities, demographics, locations, scenes, backgrounds, props, objects, set pieces, etc.
Media appliance 100 optionally communicates with DRM service 308 for downloading and/or uploading DRM meta-data. Optionally, media appliance 100 generates a message indicating an infringement and/or other violation of digital rights, according to a set of DRM rules, such as copying without permission, broadcasting without permission, etc. For example, memory stores a data structure comprising a field identifying a video clip and/or video stream, and an indicator of a violation of a DRM rule, such as an act of broadcasting the video clip and/or video stream without permission.
Media appliance 100 optionally communicates with security service 309 to upload security information such as video and/or audio record of scene, identity recognition data as computed by identity recognition instructions 203 , GPS data as provided by GPS module 112 , directional data as provided by acceleration detector 113 , and/or to download security information such as location to watch, identity data to store for matching against images, and/or voice audio signature to store for matching against audio clips. For example, media appliance 100 sends a data structure to security service 309 , wherein the data structure comprises a field identifying a person, and a field identifying the location of the media appliance 100 at the time the person is sensed by media appliance 100 . Optionally, media appliance 100 couples to police authority for providing live and/or recorded footage and/or triggering alarm and calling police according to built-in media appliance intelligence for identifying potential dangerous and/or suspicious conditions.
Media appliance 100 optionally communicates with biometric service 301 to upload biometric information obtained by biometric module 106 , and/or to download biometric signature for matching against incoming biometric data.
Media appliance 100 optionally communicates with GPS service 302 , such as GPS satellites, to receive GPS information. For example, if media appliance 100 moves into a restricted area, as indicated by GPS service 302 and/or by information residing on media appliance 100 and/or obtained remotely, GPS unit 112 activates an alert. For example, memory 110 stores a data structure comprising a field identifying a restricted geographical area, and media appliance 100 generates an alarm when location of media appliance 100 , as indicated by GPS service 302 , falls within the restricted geographic area.
Media appliance 100 optionally communicates with news service 310 and/or other objective information service. In one embodiment, media appliance 100 receives a data structure from news service 310 , the data structure representing a digital template and comprising a field identifying a location, and one or more fields identifying elements to be covered by reporter (such as a person to interview, a particular place to point out to viewers, other news reporters covering the same news story, etc.).
Media appliance 100 optionally communicates with sports broadcasting network, game-show broadcasting network, and/or other gaming or competition-related network 311 . In one embodiment, media appliance 100 receives a data structure from sports broadcasting network 310 , the data structure comprising a field identifying one or more competing parties, a field identifying a location of the competition, and a field indicating the competition schedule.
Media appliance 100 optionally communicates with private service 312 . In one embodiment, media appliance 100 receives a data structure from movie production source or network 310 , the data structure comprising a field identifying one or more movie or media production, a field identifying a location of the production, a field indicating the production schedule, a field indicating one or more scenes, and a field indicating one or more cast or staff members.
Media appliance 100 optionally communicates with renderer 313 to display video data. Renderer 313 comprises a cinema or movie theater, television receiver, computer display, IMAX display, a Digital Audio Broadcast (DAB) broadcaster, a satellite broadcaster, a digital TV, a High Definition TV (HDTV), a PDA and/or cellular phone (or other mobile device display).
Media appliance 100 optionally communicates with a personal computer (PC) and/or workstation 303 and/or other computing device for synchronization of data residing on media appliance 100 with computer 303 (optionally interfacing with media repository manager and/or program manager residing on computer 303 ). For example, memory 110 stores a data structure comprising a field indicating the time of last synchronization of media appliance 100 with computer 303 (or media repository manager or program manager residing on computer 303 ). Communication proceeds wirelessly and/or via a cradle (coupled to computer 303 ) into which media appliance 100 is placed for synchronization. In one embodiment, media appliance 100 comprises a user interface offering a synchronization button (hard button on media appliance 100 and/or soft button displayed in media appliance's 100 graphical display), activation of which causes described data synchronization.
Media appliance 100 optionally communicates with PDA 304 , cellular service and/or device 305 , and/or other mobile service and/or device for displaying video and/or audio data.
Media appliance 100 optionally communicates with other networked media appliance 306 for exchanging video and/or audio clips and/or for collaborating in the production of a media project, wherein a media appliance is assigned a token (number, string, etc.), statically or dynamically, for identifying the media appliance. Media appliance 100 optionally communicates with other networked media appliance 306 to enable video-conferencing and/or multi-way collaboration, for example, in business meetings, real estate transactions, distance learning, sports, fashion shows, surveillance, training, games, tourism, etc. For example, memory 110 stores a data structure comprising a field for describing a group of collaborating media appliances 100 , and a field identifying media appliance 100 itself among the group of collaborating media appliances.
FIG. 3 b is a diagram illustrating network-extensible reconfigurable media appliances communicating over a network with a server, according to an embodiment of the present invention. One or more client media appliances 330 communicate over a network 331 with server 332 . Network 331 is a combination of one or more wired and/or wireless networks such as the Internet, a LAN, a WAN, a satellite network, or other network for communication. In one embodiment, server 332 is a news server, having a script or digital template for producing a news program. Server 332 delegates the recording or streaming of various predetermined pieces of audio and/or video footage to the various media appliance clients 330 , wherein the recorded or streamed pieces will serve to fill-in the server 332 script or digital template for producing the news program. In another embodiment, server 332 is a server for sports or other competition, having a script or digital template for producing a sports program or a program for other competitive activity. Server 332 delegates the recording or streaming of various predetermined pieces of audio and/or video footage to the various media appliance clients 330 , wherein the recorded or streamed pieces serve to fill-in the server 332 script or digital template for producing the sports (or other competition) program.
In one embodiment, I/O module 111 presents a user interface (UI), comprising a combination of hard (physical) buttons and/or soft (graphical) buttons for accessing and using billing functions, DRM functions, authentication, identity recognition, digital editing of media, and/or other services as shown in FIG. 3 a and described above. For example, a view (for example comprising a button) is presented via display 114 to allow approval of a billing associated with the viewing of video data. As another example, a view is presented via display 114 , allowing selection of one or more audio and/or video data for submission or transmission to a server 332 , such as a news server or a sports server, as described above. Selection of a presented audio and/or video data designates the selected data for submission or transmission to the server. Optionally, interfaces and media appliances are physically separate, wherein through an interface a user can tap into a pool or one or more media appliances to view available audio and/or video data, and/or select one or more available audio and/or video for submission or transmission to a server 332 , as described above. As another example, a view is presented at server 332 for approving the inclusion of a submitted or transmitted audio and/or video data into a script or a digital template for a news or sports program, wherein the audio and/or video data is submitted by a media appliance client 330 to server 332 , as described above.
FIG. 4 is a flow diagram illustrating a method for sensing according to one embodiment of the present invention. The method begins with pre-production 401 . Pre-production comprises employing 402 a script and/or storyboard flowchart, or employing 403 a digital template 403 . A portion of this front-end may be implemented automatically or manually in software, comprising analysis, design, development, production, implementation or evaluation of script, storyboard, and/or digital template. Optionally, frames and/or scenes are labeled (via meta-data) according to script, storyboard, or digital template in use.
A script or storyboard is downloaded over a wired and/or wireless network, made available via removable storage (e.g. memory card and/or disk), or is alternatively created on media appliance. A digital template describes how to construct a video and/or multimedia document by sensing (i.e. “shooting” or recording) and assembling individual scenes and/or segments in particular order, and is downloaded over a wired and/or wireless network or created on media appliance. Alternatively, user of media appliance 100 may decide not to consult a script, storyboard, or digital template, and proceed directly to sensing 404 .
One example of a template is a template for insurance inspection of vehicle accidents, wherein the template indicates “slots” for video clips, taken from various angles, of the vehicles involved in the accident, as prescribed by an insurance company.
Optionally, media appliance 100 adaptively guides media appliance operator in making discretionary decisions to take alternate script paths and/or alter flow of script (or storyboard or digital template) or generally deviate from the script, for example when dealing with emergency conditions and/or events which do not occur according to script. Such guidance may employ non-deterministic scripts, according to logic specified using Bayesian modeling, neural networks, fuzzy logic, and/or other technique for making decisions under complex conditions and/or under incomplete information. For example, in one embodiment a cast member in a script is described by fuzzy attributes, such as “a female actor with at least five years drama experience” in leading role (instead of or in addition of identifying the lead role actor by name). Then, in case the lead actor canceling her engagement, instructions employing fuzzy logic perform a search for actors matching the fuzzy attributes to dynamically recommend one or more candidates to fill the role.
Optionally, digital template or script is non-linear, allowing for one or more branching points. A branching point allows the script and/or template to flow in more than one path. For example, scene (or clip or stream) A can be followed by scene B or scene C, depending on which branch of the branching point following A is taken. For a viewer, a media presentation prepared according to such non-linear template or script allows for a multiplicity of presentations comprising different scene (or clip or stream) orderings. For a viewer, the decision of which of the alternate paths to follow in a branching point can be viewer selected, randomly chosen, based on external variable (such as a combination of one or more of: weather, temperature, stock quotes, time of day or year, viewing location, amount of money left in viewer's account, or any other external variables), based on biometric sensing of viewer, based on the result of an identity or emotion recognition procedure on viewer (such as distinguishing between happiness, sadness, excitement, apathy, interest in a particular aspect of the presentation and/or other emotions or indications of interest exhibited by viewer), based on real-time input from viewer or from larger audience (such as deliberate viewer decision of which script or template path to take next, provided via an input device or detected by the presentation module), or based on other variables. Such non-linear template or script allows for example for the production and presentation of a PG-rated, R-rated, or X-rated version of a given movie depending on the audience (for example a parent may elect to view the R-rated version of the movie while electing a PG-rated presentation for the children). As another example, a wedding template or script may allow for different presentations based on whether the bride's family or the groom's family is viewing. As another example, a mystery presentation may offer alternate endings, based on viewer input or external variables as described above.
Media appliance 100 senses 404 video and/or audio and stores a digital representation in memory 110 . Optionally, multiple audio and/or video streams are sensed, either by the same media appliance or by collaborating media appliances, wherein synchronization is provided for the multiple streams, in the form of meta-data tags describing related scenes and/or streams and/or frames, and/or in the form of meta-data describing time stamps relating different scenes and/or streams. For example, memory 110 stores a data structure comprising one or more fields identifying one or more related video scenes and/or streams and/or frames, and a field indicating the nature of the relation (for example indicating that the video scenes and/or streams and/or frames represented different viewing angles of the same sensed object).
Media appliance 100 then post-produces the stored digital representation, using controller 108 and/or audio or video plugin stored in memory 110 .
The post-produced digital representation is then stored 406 in memory 110 (or in other storage medium such as optional on-appliance hard-disk or storage tape for storing data), displayed 407 on on-appliance display unit 114 , and/or sent for off-appliance display and/or exhibition (e.g. for IMAX display according to IMAX 15/70 format, or for Texas Instruments DLP (Digital Light Processing) format), or for digital remastering according to IMAX's DMR (Digital Remastering) format, or for satellite distribution (e.g. to Digital Audio Broadcast (DAB) distribution scheme to DAB enabled devices such as PDAs, cellular phones, personal audio and/or video players, or other devices for presenting audio and/or video). Optionally, communication of media appliance 100 with other devices and/or services complies with ATSC DASE (Advanced Television Systems Committee Digital TV Application Software Environment) architecture, incorporated herein by reference.
FIG. 5 is a flow diagram illustrating a method for optionally filling-in a template according to a preferred embodiment of the present invention. Starting 501 with a template, sense 502 a first scene according to the template, and fill-in 503 sensed scene in template. If no additional scene is desired 505 , finish 506 , else 504 proceed to step 502 and repeat until done. Template is stored in memory 110 comprising suitable format such as the Advanced Authoring Format (AAF).
FIG. 6 is a flow diagram illustrating a method for optionally tagging audio and/or video representation with information contained in a meta-data structure. Upon sensing 601 a scene, the digital representation of the sensed scene is tagged 602 with meta-data. Meta-data comprises time, media appliance location (such as provided by GPS module 112 ), media appliance orientation and/or media appliance acceleration (such as provided by acceleration detector 113 ), multi-lingual features (allowing for translation, subtitles, voice-over, etc.), cues to a theater automation system (such as instructions for house lights to go up, half-way up, or down, or instructions to open or close curtains, etc.), instructions for allowing or disallowing content (such as trailers or promotional clips) to play next to other similar content, information indicating suitability of content for different audiences such as children, information indicating any promotional offers, products and/or services (such as advertisements, product catalogs and/or coupons for products and/or services), information allowing for organizing and/or managing meta-data available to advertisers and/or service providers, and/or other information describing, identifying and/or relating to content. Tagging may be done per scene, per frame, per audio and/or video stream (e.g. when multiple streams are present), or per other defined segment of audio and/or video. For example, a video scene is tagged with meta-data comprising a field identifying the language used in the video scene. As another example, a video stream is tagged with meta-data comprising a field indicating a warning against viewing by children.
FIG. 7 is a flow diagram illustrating a method for transferring data and/or instructions from off-appliance source to on-appliance memory. After determining 701 off-appliance source, such as external repository (for templates, plugins, DRM data, encryption keys, media clips, security data, biometric data, GPS data, etc.), proceed by transferring 702 data and/or instructions from determined off-appliance source to on-appliance memory 110 .
In one embodiment, media appliance 100 is a member of a distributed group of media appliances 100 , for example in a distributed network of media appliances 100 and/or in a peer-to-peer configuration of media appliances 100 . A media appliance 100 dynamically joins and/or leaves a distributed group of media appliances 100 , in parallel and/or serially with other media appliances 100 . Alternatively, media appliance 100 initiates a distributed group of media appliances 100 , allowing for other media appliance's 100 to dynamically join and/or leave the group. In one embodiment, the group of media appliances 100 collaborates to cover an event, such as a sporting event, a public political event (e.g. a rally), a family event (e.g. a wedding), or other event. Media appliances 100 tag sensed audio and/or video data as described above (e.g. with GPS information, time stamps, DRM meta-data, or other information previously described), allowing reconstruction of covered event from the audio and/or video data collected by distributed media appliances 100 . Memory 110 stores instructions and/or data for initiating, joining, leaving and/or querying the status of or information about such a distributed group of media appliances 100 .
Foregoing described embodiments of the invention are provided as illustrations and descriptions. They are not intended to limit the invention to precise form described. In particular, it is contemplated that functional implementation of invention described herein may be implemented equivalently in hardware, software, firmware, and/or other available functional components or building blocks, and that networks may be wired, wireless, or a combination of wired and wireless. Other variations and embodiments are possible in light of above teachings, and it is thus intended that the scope of invention not be limited by this Detailed Description, but rather by Claims following. | Extensible reconfigurable media appliance for security and entertainment captures images digitally for storage. Digital effects and filters are applied to incoming video stream on-the-fly or to video data stored in memory. Digital effects and filters are dynamically stored, modified, updated or deleted, providing extensible reconfigurable effects studio. Digital media appliance communicates wirelessly with other media appliances, computers, security systems, video storage, email, chat, cellular services or PDAs to provide seamless integration of captured video stream. | 6 |
[0001] Pursuant to 35 U.S.C. § 119(a), this application claims the benefit of earlier filing date and right of priority to Korean Patent Application No. 57739/2004, filed on Jul. 23, 2004, the content of which is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a coding of a mobile communications terminal, and particularly, to a voice coding apparatus and method using a Perceptual Linear Prediction (PLP).
[0004] 2. Background of the Related Art
[0005] As mobile communication techniques are developed, mobile communications terminals have provided data communications using numbers, characters, symbols, and the like, and multimedia communications including various image signals as well as voice communications. A plurality of terminal users receive radio channels allocated thereto from a system and transmit and receive required data using radio resources. However, the radio channels have limited bandwidths in order for the plurality of users to use the radio channels at the same time, and accordingly a data bit rate of each user is deservedly limited.
[0006] Therefore, a coding technique has been proposed for transmitting a greater amount of data using above limited data bit rate. Various methods exist as the related art voice coding technique, each of which has several advantages at a certain bit rate.
[0007] For instance, a speech coding using a generic audio coding, a Pulse Code Modulation (PCM), and an Adaptive Delta Pulse Code Modulation (ADPCM) are effectively used at a high-bit rate over 16 Kbps, and a Code Excited Linear Prediction (CELP) and other various variations are effectively used at a medium-bit rate at a range of 2.4 Kbps to 16 Kbps. In particular, a coding method using LD-CELP, CS-ACELP, VSELP and MELP and a wideband speech coding can be used at the medium-bit rate. Also, a Linear Predictive Coding (LPC), Residual Excited Linear Predictive (RELP), formants vocoder and Cepstral vocoder have many advantages at a low-bit rate at a range of 75 bps to 2.4 Kbps.
[0008] Thus, in the related art and the present invention, a method for improving the LPC among coding methods used at the low-bit rate will now be explained.
[0009] FIG. 1 illustrates a structure of the related art LPC encoder.
[0010] As illustrated in the drawing, the related art LPC encoder includes: a correlator 10 for calculating an autocorrelation value r x [n] of an input signal x[n]; an LP coefficient calculator 11 for calculating an LP coefficient a L and a gain G by processing the autocorrelation value r x [n]; a V/UV determining unit 12 for determining whether the input signal x[n] is a voiced V signal or a unvoiced UV signal; a pitch calculator 13 for calculating a pitch P of the corresponding signal when the input signal x[n] is the voice V signal; a parameter coding unit 14 for outputting a bit stream by coding the LP coefficient a n , the gain G and the pitch P received from the LP coefficient calculator 11 and the pitch calculator 13 according to a V/UV indication bit outputted from the V/UV determining unit 12 .
[0011] An operation of the related art LPC encoder having such construction will now be explained.
[0012] First, the correlator 10 autocorrelates an input signal x[n]. The LP coefficient calculator 11 processes an autocorrelation value r x [n] calculated by the correlator 10 so as to calculate a n LP coefficient an and a gain G. At this time, the V/UV determining unit 12 determines whether the input signal x[n] is a voiced V signal or a unvoiced UV signal to output a V/UV indication bit, and then outputs only the voiced V signal. The pitch calculator 13 calculates a pitch P of the voiced V signal which is outputted from the V/UV determining unit 12 .
[0013] Accordingly, when the V/UV indication bit indicates the voiced V signal, the parameter coding unit 14 outputs a bit stream by coding (encoding by a low-bit rate) the LP coefficient a n , the gain G, and the pitch P received from the LP coefficient calculator 11 and the pitch calculator 13 . Afterwards, a controller (not shown) processes the bit stream to thusly output it to a radio (wireless) unit (not shown). The radio unit converts the signal outputted from the control unit into a radio (wireless) signal and transmits the converted radio signal.
[0014] Thus, in the related art, a mobile communications terminal performs the LPC coding to transmit an audio signal by a low-bit rate. However, in the related art LPC coding, a linear predication coefficient is generally used, which does not consider human auditory sensing features. Therefore, for the related art LPC coding operated using the low-bit rate, a compression efficiency is not very high (i.e., 1200 Kbps to 2400 Kbps) and good sound quality can not be obtained.
SUMMARY OF THE INVENTION
[0015] Therefore, an object of the present invention is to provide a voice coding apparatus and method of a mobile communications terminal capable of improving compression efficiency and sound quality by performing an LPC coding using a PLP coefficient.
[0016] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, there is provided a Linear Predictive Coding (LPC) encoder of a mobile communications terminal comprising: a Perceptual Linear Prediction (PLP) coefficient calculator for calculating a PLP coefficient and a gain by processing an input signal; a V/UV determining unit for determining whether the input signal is a voiced signal or a unvoiced signal, and thusly outputting the determination signal and the voiced signal when the input signal is the voiced signal; a pitch calculator for calculating a pitch of the input signal outputted from the V/UV determining unit; and a parameter coding unit for performing a low-bit rate coding using the PLP coefficient, the gain, and the pitch on the basis of the determination signal.
[0017] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, there is provided a low-bit rate voice coding method of a mobile communications terminal comprising: calculating a Perceptual Linear Prediction (PLP) coefficient and a gain by processing an input signal; determining whether the input signal is a voiced signal and a unvoiced signal, and thereby outputting a determination bit value and the voiced signal when the input signal is determined as the voiced signal; calculating a pitch of the input signal outputted from a V/UV determining unit; and performing a low-bit rate coding using the PLP coefficient, the gain and the pitch on the basis of the determination bit value.
[0018] Preferably, the voiced signal is a speech signal.
[0019] Preferably, the PLP coefficient has about a 7 th degree for a 8 kHz sampling rate.
[0020] The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
[0022] In the drawings:
[0023] FIG. 1 illustrates a structure of a related art LPC encoder using an LP coefficient;
[0024] FIG. 2 illustrates an LPC encoder using a PLP coefficient according to the present invention; and
[0025] FIG. 3 illustrates sequential steps, in detail, of calculating a PLP coefficient in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0026] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0027] The present invention provides a low-bit rate voice coding using a Perceptual Linear Prediction (PLP) capable of performing a coding of a degree (an order) lower than that of a Linear Predictive Coding (LPC) in order to perform a voice coding having high compressibility.
[0028] First, a difference between the PLP and the LP will now be explained.
[0029] The LP is classically well-known, so that a detailed derived formula therefor will not be described. The LP basically refers to obtaining a LP coefficient a k so that a Mean Squared Error (MSE), namely, a value of e[n] can be a minimum value according to Formula (1) as follows.
e _ [ n ] = x _ [ n ] - x _ ^ [ n ] = ∑ k = 0 N pred a k x _ [ n - k ] Formula ( 1 )
[0030] The obtained LP coefficient a k has about 8 th to 12 th degrees (orders) for a 8 kHz sampling rate. Therefore, the obtained LP coefficient a k is used for various coding methods (e.g., LPC, CELP, MELP, RELP, etc) using a Linear Prediction (LP), which is disclosed in more detail in Speech coding and synthesis, Amsterdam, the Netherlands: Elsevier, 1995.
[0031] The PLP was introduced on a paper of Hermansky in 1990 for the first time. The PLP uses human auditory sensing features similar to the existing Mel-Frequency Cepstral Coefficient (MFCC). Therefore, the present invention performs a low-bit rate voice coding using the PLP coefficient in stead of using the LP coefficient upon performing the LPC for a low-bit rate.
[0032] That is, the present invention obtains spectrum using the PLP coefficient. The PLP coefficient reflects a human auditory effect. Accordingly, in aspect of the MSE, a greater error may occur in the spectrum using the PLP coefficient than using the LP. However, the spectrum using the PLP coefficient may have a less error when considering the auditory effect. Also, for coefficient transmissions, in case of LPC, for a typical 8 kHz sampling rate, transmissions of about a 10 th degree (order) are used, but for PLP, transmissions of about a 7 th degree (order) are used, thus the bit rate can be lowered.
[0033] FIG. 2 illustrates a construction of an LPC encoder using the PLP coefficient according to the present invention.
[0034] Referring to the FIG. 2 , an LPC encoder using the PLP coefficient is constructed as same as the related art LPC encoder shown in FIG. 1 , except of which the correlator 10 is not included and a PLP coefficient calculator 20 replaces the LP coefficient calculator 11 .
[0035] The PLP coefficient calculator 20 processes a speech signal S[n] to calculate a PLP coefficient a P and a gain G in which the auditory effect is considered.
[0036] An operation of the LPC encoder using the PLP coefficient having such construction according to the present invention will now be explained with reference to the accompanying drawing.
[0037] First, the PLP coefficient calculator 20 receives the speech signal S[n], so as to calculate the PLP coefficient ap and the gain G by sequentially performing operations shown in FIG. 3 .
[0038] That is, the PLP coefficient calculator 20 performs a fast Fourier transform (FFT) of the input signal, namely, the speech signal S[n]. A critical-bank integration and resampling processing is performed for the Fourier-transformed speech signal to thusly remove noise components from the speech signal S[n] by a frequency unit.
[0039] Once removing the noise components, the PLP coefficient calculator 20 performs equalizing and loudness processing of the Fourier-transformed speech signal into sound components having magnitudes appropriate for human auditory sensing, and then the speech signal is matched with an output power to allow listening by humans.
[0040] When the power matching is completed, the PLP coefficient calculator 20 performs an inverse discrete Fourier transform of the corresponding speech signal to thereafter obtain a set of Linear equations from the corresponding speech signal. Therefore, the PLP coefficient calculator 20 performs a Cepstral Recursion processing for the set of Linear equations, and thus outputs Cepstral Coefficients of a PLP model, namely, the PLP coefficients ap. In other words, the PLP coefficient calculator 20 outputs to the parameter coding unit 23 a low degree (order) of the PLP coefficients ap and a gain G reflecting the human auditory sensing features as parameter values.
[0041] At this time, the V/UV determining unit 21 outputs a V/UV Indication bit and transfers the speech signal S[n] to the pitch calculator 22 . The pitch calculator 22 calculates a pitch P of the speech signal S[n].
[0042] Accordingly, the parameter coding unit 23 outputs a bit stream by coding (encoding by a low-bit rate) the V/UV Indication bit value, the PLP coefficient a P , the gain G and the pitch P received from the PLP coefficient calculator 20 and the pitch calculator 22 . Preferably, a degree of the transmitted PLP coefficient a P is about a 7 th degree for a 8 kHz sampling rate. Afterwards, a controller (not shown) processes the bit stream and then outputs the processed bit stream to a radio (wireless) unit (not shown). The radio unit converts the signal outputted from the controller into a radio signal (wireless signal) and transmits it.
[0043] As described above, in the present invention, the LPC is performed by using the PLP coefficient, and thus a compressibility can be improved and voice-grade signal can be transmitted by a more efficient low-bit rate.
[0044] In addition, in the present invention, a higher compressibility can be realized and a quality of signal with high sound quality can be expected by using the PLP coefficient as a parameter rather than using the existing LP coefficient.
[0045] Therefore, the voice coding apparatus and method according to the present invention can be used for coding and decoding voice using a low-bit rate, or be used for a device which takes up a small area and performs a voice synthesis using PLP parameters.
[0046] Furthermore, the voice coding apparatus and method according to the present invention can be used for a speech coding for an application as much as a voice itself is not very important but enough to hear. Also, an effective voice conversation can be performed on the Internet which stores data by a high compressibility or requires a low-bit rate in an embedded system with a limited memory.
[0047] As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalence of such metes and bounds are therefore intended to be embraced by the appended claims. | A voice coding apparatus and method of a mobile communications terminal can embody higher compressibility and ensure high sound quality, compared with the case of using a Linear Prediction (LP) coefficient, by performing a Linear Predictive Coding (LPC) using a Perceptual Linear Prediction (PLP) coefficient. | 6 |
FIELD OF THE INVENTION
[0001] This invention relates to securing wire mesh panels to each other, securing wire mesh to other materials and or structures and joining concrete reinforcement bars.
BACKGROUND OF THE INVENTION
[0002] Wire mesh panels and rods are presently joined by the use of wire, cable ties or staples, all of which are destroyed when disconnected. Furthermore none of these connectors are strong and if panels are joined end to end they allow the panels to hinge in respect to each other.
[0003] Wire structures are expensive to transport and it would be better if such structures could be readily assembled on site using reusable connectors that are easily assembled and disassembled.
[0004] Welding is another means that is presently used to connect mesh panels and rods however this requires that the person doing the assembly is skilled in this art and the act of welding also destroys the coating on galvanized wire mesh.
[0005] For joining bars end to end in concrete reinforcement a number of techniques are used and all have inadequacies.
[0006] It would be advantageous if there was a means of joining mesh panels and rods using connectors that resolved the said issues and were also cost effective. Methods currently available are represented by reference to prior art and inadequacies of each is noted:
[0007] Burbidge. U.S. Pat. No. 3,840,947 discloses an open metal ring which is clamped around strands of wire to hold the said wires together. This allows the wire mesh panels to hinge and does not prevent lateral movement of the wires.
[0008] Baker. U.S. Pat. No. 4,982,932 discloses a fence clip assembly to hold and guide wire however these clips do not prevent lateral movement of the wire furthermore these clips need to be nailed to posts or a supporting structure.
[0009] Tetzlaff. U.S. Pat. No. 2,515,615 discloses a fence post which addresses the said issue of lateral movement by distorting the wire at the connection point by use of a nail however the invention is limited to fenced posts.
[0010] Burk. U.S. Pat. No. 5,350,155 discloses a wire holding fence post attachment assembly requiring connection to a fence post however the assembly does not address the said issue of lateral movement.
[0011] Svend. U.S. Pat. No. 2,238,523 discloses a highway guard which uses a wedge to secure the wire and in doing so prevents lateral movement however this device is specific for connection to a post.
[0012] McFarland. U.S. Pat. No. 1,117,214 discloses a fence post which has a plurality of connectors built in however the design does not prevent the issue of lateral movement.
[0013] Bartlett. U.S. Pat. No. 3,776,522 discloses a fence post construction method which does not prevent the issue of lateral movement.
[0014] Holdsworth U.S. Pat. No. 5,664,902 discloses a tubular coupler for concrete reinforcing bars. This connector is expensive to produce, and difficult to apply as the rods need to be inserted in the connector from each end and when used in concrete for reinforcement, the sealed connector prevents concrete from entering the connector to further strengthen the connection.
[0015] Young. U.S. Pat. No. 5,046,878 discloses a reinforcing bar coupling system which is similar to the Holdsworth invention and just as difficult to use. The hole in the connector is cylindrical and easier to produce however there is added a second part to prevent the metal rods from sliding in the connector and furthermore similar to the Holdsworth invention, it is an enclosed unit and does not permit concrete to enter the connector to further strengthen the connection.
[0016] Lancelot. U.S. Pat. No. 5,152,118 discloses a couplings for concrete reinforcement bars which has similar shortcomings to the Holsworth invention and furthermore the metal rods need to be shredded and carefully lined up before the coupling can be screwed on.
[0017] Lancelot. U.S. Pat. No. 5,383,740 discloses a combination mechanical/grout sleeve coupling for concrete reinforcement bars which is expensive to produce and has all the disadvantage of the aforementioned end to end metal rod connections.
[0018] Antosh. U.S. Pat. No. 4,143,986 discloses a rebar splice connector which allows the metal rod to be introduced side ways as it is made in two parts, however, it is impossible to make the inner surface conform to different manufactures rods requiring that different connectors be made to suit each manufactures rod sizes.
SUMMARY OF THE INVENTION
[0019] An object of the present invention is to provide a connector for slender metal components which is strong.
[0020] Another object of the present invention is to provide a connector which is reusable.
[0021] Yet another object of the present invention is to provide a connector which will prevent lateral movement of slender metal components.
[0022] Yet another object of the present invention is to provide a connector which provides a means of joining slender metal components without welding.
[0023] Yet another object of the present invention is to provide a connector which can be simply produced from sheet metal.
[0024] Yet another object of the present invention is to provide a connector which can be quickly assembled and disassembled with a standard tool by an unskilled person.
[0025] Yet another object of the present invention is to provide a connector which can be produced to suit various sizes of slender metal components.
[0026] Yet another object of the present invention is to provide a connector which can connect slender metal components at right angles.
[0027] Yet another object of the present invention is to provide a connector for joining wire structure at a set distance apart.
[0028] Yet another object of the present invention is to provide a connector for wire meshes.
[0029] Yet another object of the present invention is to provide a connector for joining wire mesh to other structures.
[0030] Yet another object of the present invention is to provide a connector which can be welded to other structures.
[0031] Yet another object of the present invention is to provide a connector for joining wire mesh to fence posts.
[0032] Yet another object of the present invention is to provide a connector for joining wire mesh to scaffolding.
[0033] Yet another object of the present invention is to provide a connector for concrete reinforcement bars.
[0034] Yet another object of the present invention is to provide an improved connector for joining concrete reinforcement bars end to end.
[0035] Yet another object of the present invention is to provide a connector which can be used for on-site erection.
[0036] Yet another object of the present invention is to provide a connector which singularly can be used to join wire structures.
[0037] Yet another object of the present invention to provide a connector which singularly can be used to join wire structures positively at right angles.
[0038] In the further description of the workings and functions of the invention, wire mesh and reinforcement bars will be referred to as wire.
[0039] With these objectives in mind is provided a channel shaped body which has an aperture in the bottom of said channel for accommodating the wire to be connected and a means to secure said wire and or wires in said aperture, which could be in the form of a parallel or tapered pin, wedge and or screw. There is further provided a device for joining metal reinforcement rods end to end and also provided is a simple singular connector for joining wires.
[0040] Further benefits and advantages of the invention will become apparent from a consideration of the following detailed description given with reference to the accompanying drawings, which specify and show preferred embodiments of the invention:
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 is a perspective view of a connector device ( 30 ) comprising a channel shaped part ( 31 ) with a tapered aperture ( 32 ) having edges ( 29 ) in the bottom of said channel shaped part ( 31 ).
[0042] FIG. 2 is a perspective view of a wedge ( 33 ) made from sheet metal for securing wire and or wires in said tapered aperture ( 32 ) of FIG. 1 .
[0043] FIG. 3 is a perspective view showing connector device ( 30 ) of FIG. 1 with wires ( 34 a ) and ( 34 b ) secured in the said tapered aperture ( 32 ) and prevented from lateral movement by said wedge ( 33 ) of FIG. 2 .
[0044] FIG. 4 is a perspective view of a connector device for securing wire to other structures designated ( 40 ).
[0045] FIG. 5 is a plan view of connector device ( 40 ) of FIG. 4 screwed to a piece of wood ( 46 ).
[0046] FIG. 6 is a perspective view of a right angle connector device ( 50 ).
[0047] FIG. 7 is a plan view of right angle connector device ( 50 ) of FIG. 6 with wires ( 54 a ) and ( 54 b ) secured at right angles to each other.
[0048] FIG. 8 is a perspective view of a one part right angle connector device ( 60 ).
[0049] FIG. 9 is a perspective view of a connector device ( 100 ) for joining wire structures parallel to each other at a set distance apart.
[0050] FIG. 10 is a perspective view of a one part right angle wire connector device ( 70 ).
[0051] FIG. 11 is a perspective view of connector device ( 80 ) designed for welding to other components.
[0052] FIG. 12 is a perspective view of connector device ( 90 ) designed for connecting wire to a round post.
[0053] FIG. 13 is a plan view of connector device ( 90 ) of FIG. 12 showing a wire ( 95 ) secured to a post ( 94 ).
[0054] FIG. 14 is a perspective view of a connector device ( 110 ) designed for joining wires end to end.
[0055] FIG. 15 is a plan view of connector device ( 110 ) of FIG. 14 with wire ( 113 a ) clamped in the neck of said channel shaped part ( 111 ) by a wedge ( 33 ).
[0056] FIG. 16 is a plan view of connector device ( 110 ) of FIG. 14 ) with wire ( 113 a ) clamped in the neck of said channel shaped part ( 111 ) by a self tapping screw ( 115 ).
[0057] FIG. 17 is a perspective view of a one part connector device ( 120 ) for joining wire structures parallel to each other and a set distant apart.
DETAILED DESCRIPTION OF INVENTION
[0058] In more detail, referring to FIG. 1 , is shown a connector device ( 30 ) which is designed to join two or more wires and is made of sheet metal bent to form a channel shaped part ( 31 ) comprising a tapered cavity ( 32 ) in the bottom of the said channel shaped part of a size determined by the number and diameter of wires it is made to accommodate. The cavity comprises two edges ( 29 ) (only one shown) at an angle to the said channel shaped part ( 31 ) to correspond with the tapered sheet metal wedge ( 33 ) of FIG. 2 . The purpose for the angle of the said cavity ( 32 ) is so that when two or more wires are clamped into the said cavity ( 32 ) with the aid of the said wedge ( 33 ) all said wires ( 34 a ) and ( 34 b ) are clamped simultaneous.
[0059] FIG. 3 shows the said connector device ( 30 ) with wires ( 34 a ) and ( 34 b ) clamped in the said angled cavity ( 32 ) by the said wedge ( 33 ) forced in to the neck of the said channel shaped part ( 31 ) with the aid of either a pair of pliers or hammer thereby securely and strongly joining the said wires ( 34 a ) and ( 34 b ).
[0060] A second embodiment is shown in FIGS. 4 and 5 of the connector device ( 40 ) made from sheet metal comprising of two channel shaped parts ( 41 a ) and ( 41 b ) and apertures ( 42 a ) and ( 42 b ) in the bottom of the said channel shaped parts. These said channel shaped parts are joined together by a flange ( 43 ). Each said channel shaped part ( 41 a ) and ( 41 b ) are clamps for securing wire and or wires in the same manner and using the same principles as in the aforementioned. This said connector device ( 40 ) is designed for connecting wire and or wires to other materials or structures by riveting or screwing using mounting aperture ( 44 ) in the said flange ( 43 ).
[0061] FIG. 5 shows the said connector device ( 40 ) screwed to a piece of wood ( 46 ) with the aid of a wood screw ( 47 ) and a wire ( 48 ) is clamped in the said cavities ( 42 a ) and ( 42 b ) and secured by wedges ( 33 ).
[0062] A third embodiment is shown in FIGS. 6 and 7 of the connector device ( 50 ) made from sheet metal and is designed to join wires at right angles comprising channel shaped parts ( 52 a ) and ( 52 b ) and apertures ( 53 a ) and ( 53 b ) in the bottom of the said channel shaped parts. Note that the said apertures ( 53 a ) and ( 53 b ) are rounded at each end as they are designed to accommodate only one wire. It will be appreciated that the said apertures ( 53 a ) and 53 b ) could be of the same configuration as those in FIGS. 1 , 3 , 4 , and 5 . Further included are flanges ( 55 ) (only one shown) to strengthen the said connector device. It should be understood that flanges may be added to all connector devices described herein.
[0063] FIG. 7 is a plan view of the connector device ( 50 ) of FIG. 6 with wires ( 54 a ) and ( 54 b ) clamped in the said apertures ( 53 a ) and ( 53 b ) at right angles to each other and secured by wedges ( 33 ).
[0064] FIG. 8 shows a fourth embodiment of a connector device made from sheet metal ( 60 ) which has the same function as the said connector device ( 50 ) of FIGS. 6 and 7 and is comprised of two channel shaped parts ( 61 a ) and ( 61 b ) each having an aperture ( 62 a ) and ( 62 b ) respectively in the bottom of the said channel shaped parts. These said apertures also form lips ( 63 a ) and ( 63 b ) for securing wires. As an example, a wire ( 64 ) is secured in the said cavity ( 62 a ) by deforming lip ( 63 a ).
[0065] FIG. 9 is a perspective view of a fifth embodiment of a connector device ( 100 ) made from sheet metal comprised of one channel shaped part ( 101 ) having two apertures ( 102 a ) and ( 102 b ) for accommodating wires parallel to each other and a set distance apart. As an example wire ( 103 ) is secured in the said aperture ( 102 a ) by a wedge ( 33 ).
[0066] FIG. 10 is a perspective view of a sixth embodiment of a connector device made from sheet metal ( 70 ) comprised of a channel shaped part ( 71 ) which is similar to the channel shaped part in FIG. 9 except for having apertures ( 72 a ) at 45 degree angles to the said channel shaped part and aperture ( 72 b ) at a reversed 45 degrees angle to the said channel shaped part for accommodating wire at right angles to each other and thereby forming a right angled connector device.
[0067] FIG. 11 is a perspective view of a seventh embodiment of a connector device ( 80 ) made from sheet metal comprised of a channel shaped part ( 81 ) and aperture ( 82 ) in the bottom of the said channel shaped part with the addition of extension ( 83 ) for welding the said connector device ( 80 ) to other components and or posts.
[0068] FIG. 12 is a perspective view showing a eighth embodiment of a connector device made from sheet metal ( 90 ) designed for connecting wire to posts comprised of a channel shaped parts ( 91 a ) and ( 91 b ) joined together by a semi circular part ( 93 ) and each having an aperture in the bottom of the said channel shaped parts ( 92 a ) and ( 92 b ) respectively. Note the said apertures are larger towards the inside of the said semicircular part ( 93 ). The reason for this will become clearer when describing the function of the said connector device ( 90 ) in FIG. 13 .
[0069] FIG. 13 is a plan view showing the connector device ( 90 ) of FIG. 12 securing wire ( 95 ) to a round post ( 94 ) with the aid of wedges ( 33 ). Because the said apertures ( 92 a ) and ( 92 b ) are larger adjacent to the post ( 94 ), the said wedges when inserted both clamp the said wire ( 95 ) and tighten the said semi circular part ( 93 ) around the said post ( 94 ). It will be readily understood the said connector device ( 90 ) can be made to fit any shaped post.
[0070] FIG. 14 is a perspective view showing a ninth embodiment of a connector device ( 110 ) made from sheet metal comprised of one channel shaped part ( 111 ) and a plurality of apertures ( 112 ) along the top and extending through both sides of the said channel shaped part ( 111 ) for inserting the said wedges ( 33 ) to prevent lateral movement of the metal rods ( 113 a ) and ( 133 b ) in the bottom of said channel shaped part. Also shown by way of example are two said wedges ( 33 ) inserted into the said apertures ( 112 ). The said channel shaped part may also include serrations in the base of the said channel shaped part to further help prevent the said metal rods ( 113 a ) and ( 113 b ) from sliding out of the said connector device ( 110 ). When this connector device is assembled and embedded in concrete, the concrete will flow around and into the assembled connector device and after setting further strengthen the joint.
[0071] FIG. 15 is plan view of the connector device ( 110 ) of FIG. 14 with metal rod ( 113 a ) secured in the said channel shaped part ( 111 ) by a wedge ( 33 ).
[0072] FIG. 16 is a plan view of the connector device ( 110 ) of FIG. 14 with a metal rod ( 113 a ) secured in the said channel shaped part ( 111 ) by a self tapping screw ( 115 ).
[0073] FIG. 17 a perspective view of a tenth embodiment of a connector device made from sheet metal ( 120 ) comprised of a channel shaped part ( 121 ) and lips ( 122 a ) and ( 122 b ) at each end of the said channel part for folding around and securing wires to said channel shaped part at a set distance from each other. By way of example wire ( 123 ) is secured to said channel shaped part by folded lip ( 122 a ).
[0074] These embodiments have been described by way of example only and modifications are possible within the scope of the invention. | An improved connector for joining wire mesh and or concrete reinforcement bars and for joining them to other structures comprised of a channel shaped part and wedge. Also connectors constructed from one part having the same function. All connectors preferable made from sheet metal. | 4 |
BACKGROUND
As fewer hydrocarbon resources are available and global demand continues to increase, methods and devices to produce hydrocarbons efficiently are becoming increasingly crucial.
One method of increasing efficiency and reducing the cost of producing hydrocarbons is to drill a single wellbore that intercepts many zones. Once the well is drilled it may be necessary to stimulate each zone independently. Typically the stimulation process begins nearest the lower end of the well otherwise known as the toe of the well.
In the past, the process began by drilling a well, during which, the number of formations that are to be stimulated is determined, keeping in mind the upper limit that can be run into a wellbore.
In the past, systems have been used that may have for example, 21 different stages. In turn, each stage needs a different ball size. Typically the lowermost stage will use the smallest ball size and each stage will use progressively larger ball sizes as the stimulation process moves from the toe of the well towards the surface.
When running the twenty one zone system into the formation the various sliding sleeves and zone isolation packers are assembled on the surface, starting with the smallest sliding sleeve at the bottom so that the smallest ball will activate the smallest or lowermost sleeve.
The production tubing is assembled on the surface. At the lowermost end of the tubing may be a fill shoe or it may have a pressure actuated sliding sleeve or toe sleeve. The toe sleeve is typically opened with tubing pressure alone and a ball is not necessary to actuate the sliding sleeve in the toe sleeve. At various intervals along the production assembly, zone isolation devices and corresponding sliding sleeve assemblies may be placed.
Zone isolation may be accomplished by cementing the production tubing and sliding sleeve system into place. Other devices may be used for formation zone isolation such as wellbore packers, including swellable packers, hydraulic control line packers, and mechanically actuated packers.
The zone isolation devices are located along the production assembly both above and below each sliding sleeve corresponding with each formation zone that is going to fraced or produced. Typically a ball actuated sliding sleeve is placed so that it is centrally located in a formation zone. Zone isolation devices are placed so that the production tubing is sealed to the wellbore below the formation zone and above the formation zone. Additionally it may be necessary to place anchoring devices at intervals along the length of the production tubular to prevent movement of the production tubular. Any movement of the production tubular could cause the zone isolation devices to shift so that they are no longer located above and below a formation zone or movement could cause erosion of the isolation packer's seal thereby causing the seal to fail.
Each of the sliding sleeve assemblies starting just above the toe sleeve and moving towards the surface utilizes a successively larger ball.
As the production tubular is assembled it is lowered into the wellbore. In those cases where a fill shoe is used the production tubing may be lowered at any rate that keeps the production tubing at least partially filled in order to reduce the buoyancy of the production tubular. In other instances the toe sleeve may be used to seal the lower end of the production tubular. When the lower end of the production tubular is sealed, mud or other fluid may be pumped into the production tubular from the surface. When the mud or other fluid is pumped into the production tubular from the surface the buoyancy of the production tubular may be controlled. By controlling the production tubular's buoyancy the production tubular may be floated into any relatively long horizontal sections of the wellbore.
Practical issues related to the size of the larger and smaller balls tend to limit the number of sleeves in a system. While referring generally to a ball to engage each seat in the corresponding sliding sleeve, any object such as a dart or plug, that can move through the well and engage the seat in the sliding sleeve may be used.
SUMMARY
A device and method is provided to actuate two or more sliding sleeves utilizing approximately the same sized ball. The device has a resettable seat in the upper sliding sleeve and a non-resettable seat in the lower sliding sleeve. A ball is dropped into a wellbore where it seats on the resettable seat in the upper sleeve forming a seal. Pressure is applied from the surface whereupon the resettable seat and an insert are shifted from a first position to a second position. Upon being shifted from the first position to the second position the resettable seat may release the ball. The ball then moves downward to the lower sliding sleeve where the ball may land upon the non-resettable seat to shift the insert open, sealing the wellbore and allowing the adjacent formation to be fraced. After the first ball is released from the upper sliding sleeve, a biasing device shifts the insert from the second position to a third position where the seat is reset to catch the next ball. A second but approximately same sized ball may then be dropped in to the wellbore where it lands upon the now reset first seat to shift the first insert open and to seal the wellbore whereupon the adjacent formation may be fraced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a schematic view of a well intersecting multiple formation zones.
FIG. 2A depicts an upper sliding sleeve with a ball landed in the resettable seat.
FIG. 2B depicts a fluid pressure bias device for an upper sliding sleeve having a resettable seat.
FIG. 2C depicts a gas pressure bias device for an upper sliding sleeve having a resettable seat.
FIG. 2D depicts an enlarged view of a portion of the upper sliding sleeve with a ball landed in the resettable seat as illustrated in FIG. 2A .
FIG. 3A depicts an upper sliding sleeve with the insert in position 2 and the ball released.
FIG. 3B depicts an enlarged view of a portion of the upper sliding sleeve with the insert in position 2 and the ball released.
FIG. 4A depicts a upper sliding sleeve with the insert in position 3 and the resettable seat reset.
FIG. 4B depicts an enlarged view of a portion of the upper sliding sleeve with the insert in position 3 and the resettable seat reset.
FIG. 5A depicts a lower sliding sleeve with the ball landed on the seat.
FIG. 5B depicts an enlarged view of a portion of the lower sliding sleeve with the ball landed on the seat.
FIG. 6A depicts a lower sliding sleeve with the insert in position 2 and the ball landed on the seat.
FIG. 6B depicts an enlarged view of a portion of the lower sliding sleeve with the insert in position 2 and the ball landed on the seat.
FIG. 7A depicts an upper sliding sleeve with the insert in position 3 and ball landed on the resettable seat.
FIG. 7B depicts an enlarged view of a portion of the upper sliding sleeve with the insert in position 3 and ball landed on the resettable seat.
FIG. 8A depicts an upper sliding sleeve with the insert in position 4.
FIG. 8B depicts an enlarged view of a portion of the upper sliding sleeve with the insert in position 4.
DETAILED DESCRIPTION
The description that follows includes exemplary apparatus, methods, techniques, and instruction sequences that embody techniques of the inventive subject matter. However, it is understood that the described embodiments may be practiced without these specific details.
FIG. 1 depicts a wellbore 10 that intersects several hydrocarbon formations 12 . A production tubular 20 is assembled on the surface 30 and lowered into the wellbore 10 . The production tubular 20 is assembled so that each sliding sleeve assembly 32 , 34 , 36 , 38 is placed so that it will be adjacent to a formation zone 12 . Zonal isolation is accomplished by cementing the production tubular in place or by placing a packer 24 above each formation zone 12 and a packer 26 below each formation zone 12 . Typically a toe sleeve 42 is placed at the lowermost end of the production tubular 20 .
The production tubular 20 is run into the wellbore 20 until each sliding sleeve assembly 32 , 34 , 36 , 38 is adjacent to its designated formation zone 12 . Once the production tubular is in place each packer 24 , 26 is set. Once the packers 24 , 26 are set the operator may drop the smallest ball. The smallest ball will travel down the interior of production tubular 20 until it lands on a seat in sliding sleeve 38 . The operator continues to apply pressure from the surface 30 . The pressure will act on the ball and seat in sliding sleeve 38 to shift open an insert in sliding sleeve 38 to allow fluid access from the interior of the production tubular 20 and the formation zone. The ball remains on the seat in sliding sleeve 38 blocking any further fluid flow past the production tubular 20 . With formation zone 12 adjacent to the now open sliding sleeve 38 and isolated by packers 24 and 26 , fluid flow through the interior of production tubular 20 is blocked. The operator may then begin to stimulate formation zone 12 that is adjacent to sliding sleeve 38 .
Once the formation zone 12 adjacent to sliding sleeve 38 is stimulated the operator may then begin operations to stimulate the next higher formation zone 12 adjacent to sliding sleeve 36 .
Ball actuated stimulation operations begin at the lowermost formation zone since a large ball will block access to any lower formations.
FIGS. 2A and 2D depict a sliding sleeve 100 with a resettable seat 110 and insert 120 in the first position. Ball 112 is landed on the resettable seat 110 . The resettable seat 110 is linked to insert 120 . The sliding sleeve has ports 114 that allow access from the throughbore 116 to the sliding sleeve exterior 118 . In position 1 insert 120 blocks fluid access through the port 114 between the throughbore 116 and the exterior of the sliding sleeve 118 .
A bias device 166 , in FIG. 2 a spring, is shown in its compressed position. Other bias devices known in the industry may be used as well.
FIG. 2B shows a piston 172 , such as a hydraulic piston, with a pressure chamber 170 and a pressure supply line 174 that may be used to supply bias force to move the insert 120 from the second position to the third position. Sleeve 176 contains the pressure as the attached pressure piston 172 moves downward.
FIG. 2C shows a piston 184 with a pressure chamber 182 where the pressure chamber is filled with a compressed gas to supply bias force to move the insert 120 from the second position to the third position. Sleeve 180 contains the pressure as the attached piston 184 moves downward.
The resettable seat 110 is shown in a set position where the resettable seat 110 has an interior portion 128 that is capable of retaining an appropriately sized ball such as ball 112 . The resettable seat 110 has an exterior portion 124 that is supported by the interior of the sliding sleeve housing 126 .
Typically the sliding sleeve 100 is run into the wellbore 10 in a first position with the insert 120 latched into position by a retaining device such as a shear pin 122 , a snap ring, or any other device provides sufficient resistance to retain the insert 120 .
Once the ball 112 engages the resettable seat 110 the operator may then begin to apply pressure from the surface against the ball 112 and the resettable seat 110 . When sufficient pressure is exerted against the ball 112 and the resettable seat 110 , then the insert 120 , the ball 112 , and the resettable seat 110 will all shift together to a second position.
FIGS. 3A and 3B depicts a sliding sleeve 200 having a resettable seat 210 and insert 220 in the released or second position. The ball 212 is shown just downstream of resettable seat 210 after it has been released.
Typically, insert 220 is biased so that it may only move downward. Initially retaining device 222 prevents any movement of the insert 222 while bias device 266 prevents any upward movement of the insert 220 . The retaining device 222 has been sheared and the insert 220 has moved in the only direction allowed, downward, a small amount to allow the resettable seat 210 to move outward into the recess 230 in the interior of the sliding sleeve housing 126 . With the exterior portion 224 of the resettable seat 210 in the recess 230 , the interior portion 228 of the resettable seat is no longer capable of retaining the appropriately sized ball 212 .
In the second position the insert 220 has moved downward a small amount but not enough to uncover the ports 214 . In the second position fluid access from the throughbore 216 to the sliding sleeve exterior 218 is blocked.
In the second position the insert 220 is not restrained from moving in the downward direction. The bias device 266 continues to apply force to the insert 220 causing it to continue to move to the third position. While bias device is shown as a spring any alternative device to apply pressure, such as a hydraulic piston, compressed gas, or hydrostatic pressure, could be used.
FIGS. 4A and 4B depicts a sliding sleeve 300 having a resettable seat 310 in a reset position and insert 320 in the third position.
In the third position the resettable seat 310 has been reset due to the bias device 366 applying sufficient force to move the insert 320 down to allow a second shear device 332 attached to the insert 320 to come into contact with a shoulder 334 in the interior of the sliding sleeve housing 326 . When the second shear device 332 contacts the shoulder 334 further downward movement of the insert 320 ceases.
When the insert 320 moves from the second position to the third position the resettable seat 310 is reset so that it will retain the next appropriately sized ball. As the resettable seat 310 moves downward the exterior portion 324 is forced out of the recess 330 and in towards the center of the sliding sleeve 300 so that the interior portion 328 of the resettable seat is once again capable of retaining an appropriately sized ball.
FIGS. 5A and 5B depict a lower, single shot sliding sleeve 400 with a ball 212 . The ball 212 is the same ball that previously moved the upper sliding sleeve's resettable seat from a first position to a second position before the ball 212 was released downhole and landed on seat 410 . Seat 410 is linked to insert 420 . Sliding sleeve 400 has ports 414 that allow fluid access from throughbore 416 to sliding sleeve exterior 418 . In the first position insert 420 blocks fluid access between throughbore 416 and the exterior of sliding sleeve 418 .
Typically the sliding sleeve 400 is run into the wellbore in the first position with the insert 420 latched into position by a retaining device such as a shear pin 422 , snap ring, or any other device that provides sufficient resistance to retain the insert 420 .
As soon as ball 212 engages seat 410 the operator may then begin to apply pressure from the surface against ball 212 and seat 410 . When sufficient pressure is exerted against ball 212 and seat 410 , insert 420 , ball 212 , and seat 410 will all shift together to a second position.
FIGS. 6A and 6B depicts a lower, single shot sliding sleeve 500 with a ball 212 landed on the seat 510 . As shown the insert 520 is in the second position. In the second position the ball 212 on seat 510 prevents fluid from traveling downward and diverts the fluid traveling down the throughbore out to the exterior of the sliding sleeve 518 as shown by arrows 540 . By diverting fluid flow 540 from the throughbore 516 to the exterior of the sliding sleeve 518 and blocking fluid flow through the throughbore 516 past the ball 212 and seat 510 , the adjacent formation zone may now be stimulated.
Once the formation adjacent to the lower sliding sleeve 510 has been stimulated a second ball, approximately the same size as the first ball, may be pumped down to land on the partially actuated, but with the ports still blocked, upper sliding sleeve as shown in FIG. 7 .
FIGS. 7A and 7B depict an upper sliding sleeve 700 with the insert 720 in position 3 and ball 760 landed on the resettable seat 710 . The ball 760 is approximately the same size ball that previously moved the upper resettable seat from a first position to a second position before the ball was released downhole and actuated the lower sliding sleeve. The seat 710 is linked to insert 720 . The sliding sleeve 700 has ports 714 that allow fluid access from the throughbore 716 to the sliding sleeve exterior 718 . In the third position insert 720 blocks fluid access between the throughbore 716 and the exterior of the sliding sleeve 718 .
When the ball 760 seats the operator will see an increase in pressure and may then begin to increase the pressure from the surface against the ball 760 and the seat 710 . When sufficient pressure is exerted against the ball 760 and the seat 710 then the second shear device 732 will shear allowing the insert 720 , the ball 760 , and the seat 710 to shift together into a fourth position.
FIGS. 8A and 8B depicts an upper sliding sleeve 800 with the insert 820 in a fourth position where ball 860 remains on the resettable seat 810 forming a seal with the resettable seat 810 that blocks fluid flow downward past the upper sliding sleeve 800 .
In the fourth position the ball 860 on resettable seat 810 prevents fluid from traveling downward and diverts the fluid traveling down throughbore 816 out to the exterior of the sliding sleeve 818 as shown by arrows 840 . By diverting fluid flow 840 from the throughbore 816 to the exterior of the sliding sleeve 818 and blocking fluid flow through the throughbore 816 past the ball 860 and resettable seat 810 the adjacent formation zone may now be stimulated.
The insert 810 is locked into the fourth position by lock 850 that engages with another recess 852 . The lock 850 prevents fluid flow from below the well from causing the insert 820 to move back towards the top of the well where the insert 820 might block fluid flow through ports 814 .
While the embodiments are described with reference to various implementations and exploitations, it will be understood that these embodiments are illustrative and that the scope of the inventive subject matter is not limited to them. Many variations, modifications, additions and improvements are possible. For example, the implementations and techniques used herein may be applied to any downhole tool that may be actuated by a ball or other flow blocking device.
Plural instances may be provided for components, operations or structures described herein as a single instance. In general, structures and functionality presented as separate components in the exemplary configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements may fall within the scope of the inventive subject matter. | A device comprising multiple sliding sleeves actuated using same-sized balls has a resettable seat in an upper sliding sleeve and a non-resettable seat in a lower sliding sleeve. A dropped ball seats on the resettable seat forming a seal. Pressure applied from the surface shifts the resettable seat and an insert. Upon being shifted, the resettable seat releases the ball, which then moves downward to the lower sliding sleeve where the ball lands on the non-resettable seat and shifts the insert. After the first ball is released from the upper sliding sleeve, a biasing device shifts the insert whereby the seat is reset to catch the next ball. A second same-sized ball may then be dropped and land on the now reset first seat to further shift the first insert. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to an improved process for the preparation of Bis-(1(2)H-tetrazol-5-yl)-amine monohydrate of the formula (I) by the reaction of sodium dicynamide and sodium azide, by adding a 6 molar solution of hydrochloric acid in the presence or absence of a catalytic amount of boric acid (1% to 5% by weight) into the reaction mixture for a period of 2-8 hour at 55° to 58°
[0000]
BACKGROUND OF THE INVENTION
[0002] Bis-(1(2)H-tetrazol-5-yl)-amine monohydrate of the formula also known as BTA having the structural formula (I), useful as a gas generant. According to the available literature, it is prepared by the reaction of sodium dicynamide with sodium azide in the presence of inorganic or organic acids.
[0003] In the patent U.S. 2003/0060634, described this reaction in the presence of hydrochloric acid (HCl), sulphuric acid (H2SO4), phosphoric acid (H3PO4), nitric acid (HNO3), perchloric acid (HClO4) and the mixtures thereof. Also some organic acids like trifluoro acetic acid, trifluoromethane sulfonic acid and methane sulfonic acid. But this patent preferred hydrochloric acid and the most preferred the addition of 1.6 molar hydrochloric acid solutions at refluxing temperature, over the course of 24 hours with 85.6% yield. But due to the formation of very fine amorphous product, it is difficult to filter the product during the scale up process.
[0004] In the patent U.S. 2008/0207914 mentioned the addition of concentrated hydrochloric acid at 60° C. for a period of 10-42 hour followed by reflux for another 24 hour yielded 86-92% with 99.4% purity by HPLC.
[0005] In the patent U.S. 2010/0261912 described the preparation of bis-(1(2)H-tetrazol-5-yl)-amine monohydrate by using boric acid, 63% sulphuric acid and 90% acetic acid. The addition was done for a period of 3 hour followed by maintenance of 10 to 42 hour.
SUMMARY OF THE INVENTION
[0006] In accordance with the present invention relates to an improved process for the preparation of the bis-(1(2)H-tetrazol-5-yl)-amine monohydrate. In this method sodium dicynamide reacted with sodium azide in presence of 6 molar hydrochloric acid and a catalytic amount of boric acid. The reaction carried without boric acid gave bis-(1(2)H-tetrazol-5-yl)-amine monohydrate in amorphous state with 90-93% yield, which gave a difficulty during filtration. But the use of 10% boric acid along with 6 molar hydrochloric acid gave 93-95% in yield with fine crystal instead of amorphous powder.
DETAILED DESCRIPTION OF THE INVENTION
[0007] The present invention is an improved process for the preparation of the bis-(1(2)H-tetrazol-5-yl)-amine monohydrate. Bis-(1(2)H-tetrazol-5-yl)-amine monohydrate was prepared as follows:
[0008] In this method sodium dicynamide and sodium azide was dissolved in water and then heated the mixture to 55° to 58° C. “At this temperature, the solution of boric acid (1% to 10%) and dilute hydrochloric acid was added for a period of 2 to 8 hour”. After complete addition of hydrochloric acid, heated the reaction mixture to reflux for another 25 hour.
[0009] After 25 hour maintenance, cooled the reaction mixture to 55° C. and adjusted the pH of the reaction mass to <1 using the same molar concentration of hydrochloric acid,
[0010] Cooling to 25° to 30° C. followed by filtration and washing with water gave the bis-(1(2)H-tetrazol-5-yl)-amine monohydrate.
[0011] The crystalline product was isolated with 93-95% yield and 99.2% purity in HPLC,
EXPERIMENTAL DETAILS
Example 1
[0012] Charged 100 gm of sodium dicynamide (1.123 mol) and 153 gm of sodium azide (2.35 mol) along with water (600 ml) at room temperature, into a four neck round bottom flask fitted with mechanical stirrer, condenser, thermometer and one addition funnel. Slowly heated the reaction mixture to 55° C. and at this temperature added 6 molar solution of hydrochloric acid (400 ml) was added into the reaction mixture for a period of 2 to 6 hour. Then reaction mixture was heated to reflux (98° to 100° C.) for 25 hour. After completion of the reaction, cooled the reaction mixture to 55° C. and to it was added 400 ml of 6 molar hydrochloric acid, adjusted the pH to 0.5 (<1). Stirred the reaction mixture at the same temperature for another 1 hour. Then cooled the reaction mixture to 25° to 30° C. or another 1 hour. Filtered the reaction mixture, washed with water (100 ml) to get 158 gm of bis-(1(2)H-tetrazol-5-yl)-amine monohydrate (yield: 93%) having an HPLC purity of 99% without any further crystallization.
Example 2
[0013] Charged 100 gm of sodium dicynamide (1.123 mol) and 153 gm of sodium azide (2.35 mol) along with water (600 ml) at room temperature, into a four neck round bottom flask fitted with mechanical stirrer, condenser, thermometer and one addition funnel. Slowly heated the reaction mixture to 55° C. and at this temperature added the boric acid solution (10 gm in 100 ml of water) for a period of 30 minute. After addition of the boric acid solution, 6 molar solution of hydrochloric acid (400 ml) was added into the reaction mixture for a period of 2 to 6 hour. Then reaction mixture was heated to reflux (98° to 100° C.) for 25 hour. After completion of the reaction, cooled the reaction mixture to 55° C. and to it was added 400 ml of 6 molar hydrochloric acid, adjusted the pH to 0.5 (<1). Stirred the reaction mixture at the same temperature for another 1 hour. Then cooled the reaction mixture to 25° to 30° C. or another 1 hour. Filtered the reaction mixture, washed with water (100 ml) to get 154 gm of wet bis-(1(2)H-tetrazol-5-yl)-amine monohydrate (yield; 90%) having an HPLC purity of 99% without any further crystallization. | A process for the preparation of Bis-(1(2)H-tetrazol-5-yl)-amine monohydrate.
This preparation process is carried out by the reaction between sodium dicynamide and sodium azide in presence of a dilute solution of an inorganic acid solution in aqueous medium. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to improvements in the art of producing melt-blown microfibers of plastic wherein a plurality of laterally spaced aligned hot melt strands of polymeric material or the like are extruded downwardly and immediately engaged by a pair of heated pressurized angularly colliding heated gas streams.
In typical arrangements heretofore used, the gas streams each were in a flat sheet-like configuration and on opposed sides of each of the strands. The streams functioned to break up the strands into fine filamentous structures attenuating the strands for strength. Examples of constructions of this type are shown in copending applications of Langdon, Ser. No. 463,460 and Daane, Ser. No. 463,459.
In structures such as those shown and disclosed in the above applications, and also in other contemporary developments, two flattened gas streams were employed to laterally engage the fine streams of plastic as they were extruded from the small die openings. Gas temperature, pressure, volume are controlled and maintained uniform for obtaining the optimum effect on the plastic strands. However, difficulties in production caused by nonuniform temperature gradients and problems in elongation occured in certain circumstances and various efforts have been made to correct these difficulties and to improve the quality of the strands formed and the speed of production of the mechanisms and certain improvements are disclosed in the above referred to copending patent applications.
One way of improving the quality of the product produced is to produce a better velocity component of the flow of gas in the direction of the extruded fibers produced by the die. For various reasons, physical limitations are encountered in the relative velocity of the flow of gas. It has been discovered that high velocities approaching or exceeding sonic velocities are desirable. It has also been felt that it is essential to improved product quality and speed of production to obtain a relationship between the gas and plastic flow that obtains optimum contact, both for the attenuation effect of the gas on the plastic and the heat transfer relationship therebetween.
It is accordingly an object of the present invention to provide an improved mechanism and method for producing plastic microfibers which are extruded and engaged with a high velocity flow of gas wherein the gas flow path is controlled relative to the plastic flow to obtain improved product and improved production speed.
More particularly, an object of the invention is to provide a mechanism and method for an improved attenuation effect and improved contact between the flow of gas and flow of plastic in a process embodying blown microfiber production.
A further object of the invention is to provide an improved die head construction incorporating the flow of gas for the production of blown microfibers wherein increased gas velocities can be employed.
A still further object of the invention is to provide an improved extrusion head structure for producing melt-blown microfibers wherein the heat transfer relationship and attenuation relationship between the gas and fibers is improved and wherein the flows are parallel to each other at the point in time of contact therebetween and for the duration of contact.
Other objects, advantages and features, as well as equivalent structures and methods which are intended to be covered herein, will become more apparent with the disclosure of the preferred embodiments in connection with the teachings of the principles of the invention in the specification, claims and drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical sectional view taken substantially along line I--I of FIG. 2;
FIG. 2 is a fragmentary bottom plan view taken substantially along the arrowed lines II--II;
FIGS. 2a, 2b and 2c are fragmentary bottom plan views similar to FIG. 2, but illustrating modified forms of the invention; and
FIG. 3 is a greatly enlarged perspective view illustrating the air flow relative to one of the plastic filaments.
DESCRIPTION
As shown in FIGS. 1 and 2, a melt-blown die head 10 is supplied with heated plastic under pressure through a line 11 from a heater and extruder delivery mechanism 13. The head is provided with a supply of plastic and a flow of heated air and ancillary mechanism for providing these materials is described further in the above referred to copending applications and in my copending applications, Ser. No. 427,727 filed Dec. 26, 1973 now U.S. Pat. No. 3,905,734, the drawings and descriptions of which are incorporated herein by reference.
The die head 10 is preferably formed in two mating parts, 10a and 10b which are fitted together to form a plastic flow chamber 12 therein.
It will be understood that the die head 10 can be formed as a single unit such as by being cast. In a cast construction, the various capillary tubes 15 will be cast into the material of the die head 10. Where the die head is formed of mating parts, the tubes are clamped between the parts 10a and 10b.
The plastic material flows downwardly and into a plurality of small parallel flow passages 14 which are of the same size and are uniformly spaced from each other, being aligned in a row. The chamber 12 is elongate in a direction transversely of the downward flow of plastic so that a large number of passages 14 are arranged along the bottom of the die chamber 12.
Each off the flow passages 14 has a capillary tube extension 15 through which the plastic material flows to be emitted through an opening 16 at the lower end of each of the tubes. The tubes extend into an air slot 35 to which the air supply is delivered, as will be described in further detail below. The air slot is constructed so that air flow downwardly is oriented in the direction of the flow of the plastic fibers emitting from the tubes, and so that the air flow is substantially in the fibers' axial direction. The tubes extend down with the air slot with the air delivered to the slot in such a manner that the flow essentially surrounds each of the tubes for approaching uniform circumferential distribution around each of the fibers in a manner indicated schematically in FIG. 3, with the fiber represented, and the flow velocity surrounding the fiber indicated by the arrowed vector lines 37 to represent uniform flow at all circumferential locations around the fiber 36a.
In the arrangement of FIG. 1, the side walls of the air slots 35 and 36 are planar at 38 and 39. In the alternate arrangement shown in FIGS. 2a, 2b and 2c, the surfaces of the ducts are shaped to form a plurality of air channels with the distance between the center tubes and the outer walls of the channels being somewhat uniform. This will help insure uniform air flow downwardly around the capillary tubes so that uniform air flow will be emitted around the filament as it emerges from the lower end of the tube. As illustrated in FIG. 2a, outwardly from the tubes 15 the inner surfaces 40 and 41 of the air duct walls 19 and 20 are shaped to form undulations. The undulations form grooves or recesses and are concave curved shaped. Preferably they are of a size and shape so that the flow of air around the tubes 15 will be of uniform velocity at all circumferential locations.
In the arrangement of FIG. 2b, a modified form of air flow arrangement is provided with the inner surfaces 42 and 43 being V-shaped. The grooves formed by the V-shaped surfaces are in alignment with the tubes 15 so as to form air channels or ducts around each of thee tubes.
In the arrangement of FIG. 2c, the inner surfaces 44 and 45 of the air duct walls 19 and 20 are formed in V-shaped grooves or channels. Also, the capillary tubes shown at 15' are rectangular shaped so that their outer surfaces somewhat match the V-shaped channels of the surfaces 44 and 45. This will result in the filaments being rectangular shaped and in a channel around each of the tubes which helps insure a uniform velocity and flow of air downwardly. Also, the outer surfaces of the tubes may be rectangular while the inner surfaces are circular.
Returning now to the air supply arrangement, the nose-piece for the air supply is arranged to essentially enclose the lower portion of the die head 10. The air flow is arranged to flow in downwardly in first and second ducts 17 and 18 which are immediately outwardly of both sides of the die head 10. The ducts are formed by outer air duct walls 19 and 20, and the outer surfaces 21 and 22 of the die head form the inner walls of the air ducts so that good exchange relationship will be maintained between the air and the duct as the air is flowing downwardly. Air is supplied to the two ducts through air conduits 23 and 24, controlled by balancing valves 25 and 26 supplied by a main supply conduit 27. The air is received from a heater 29 and a control valve 28 may be positioned downstream from the heater. A pressurized supply for directing air through the heater is provided by a compressor 31 which may have an output control valve 30. The flow of air is balanced to be delivered at essentially the same velocity through the two ducts 17 and 18 and air is delivered at a sufficient pressure to be emitted down through the slot 35 at high velocities approaching or exceeding sonic velocity. It has been discovered that contrary to limitations experienced in structures which directed the air against the plastic in sheet flow heretofore, velocities in excess of sonic velocities can be utilized in the instant structure embodying the principles of the invention. Improved attenuation of the fibers and improved uniform temperature in the fibers is obtainable by utilizing high velocity flow of air or other gas.
As the sheets of air descend downwardly through the upper parts of the ducts 17 and 18, the air will enter the upper portion of the air slot 35 at 33 and 34 and will surround the tubes 15. Because the air is brought downwardly through the ducts which extend in a converging direction, each of the streams will tend to flow against the outer surface of the tubes and be turned downwardly to flow in a direction parallel to the tube through the throat or gap 35. In the spaces between the tubes, shown at 32 in FIG. 2, the flows will impact on each other and will turn downwardly to flow between the tubes and in contact with the walls thereof in a direction parallel to the tubes downwardly to the throat. Thus, the air will mix uniformly around the tubes to attain uniform velocity throughout the circumference of each of the tubes to be flowing in a surrounding jacket encircling or encompassing the filament of plastic as it emerges from the lower opening 16 of the tube.
Also, the air is maintained in good contact for heat transfer during its flow downwardly over the outer surfaces of the head so that the temperatures of the plastic and the air tend to approach each other as closely as possible and, of course, the input controls for the plastic temperature and heated air maintained for optimum performance. In some instances, a temperature differential may be desired to be maintained between the air and the plastic, and in this instance the effect of the heat of the head will be uniform on the air as it descends, and the heat of the plastic will uniformly heat the tube circumferentially so that the effect on the air surrounding the tube will be uniform and the impact between the air and the plastic filament will be uniform.
An important factor is that the attenuation effect of the air moving at high velocities relative to the plastic filament is uniform for the full circumference of the filament, and the effects of the fricitional resistance of the filament against the air and the pressure of the air against the filament, i.e., the dynamic and static effect of the air relative to the filament will be uniform circumferentially. This obtains a more uniform and more desirable effect between the air and plastic for an improved product. While air is preferred, other forms of gases may be employed. | A mechanism and method for producing a plurality of elongate filaments of plastic material from a die head which has a plastic flow chamber for receiving a flow of heated plastic material with the chamber leading to parallel small flow passages having individual tubes extending from the individual passages and having gas flow ducts positioned laterally outwardly of the die head for receiving a flow of heated gas with the ducts directed in a converging direction outwardly of the die head and permitting the opposed streams of gas to merge around the tubes and flow parallel thereto so that a high velocity stream of gas emerges with the plastic and attenuates the plastic stream for strength. | 3 |
REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to Provisional U.S. Patent Application No. 60/765,012, file on Feb. 3, 2006, the entire content of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to actuators and corresponding methods and systems for controlling such actuators, and in particular, to actuators providing independent lift and timing control with minimum energy consumption.
BACKGROUND OF THE INVENTION
[0003] Variable valve actuation (VVA) systems are used to actively control the timing and lift of engine valves to achieve improvements in engine performance, fuel economy, emissions, and other characteristics. Depending on the means of the control or the actuator, VVA systems are classified as mechanical, electrohydraulic, and electromechanical (sometimes called electromagnetic). Depending on the extent of the control, they are classified as variable valve-lift and timing, variable valve-timing, and variable valve-lift. They are also classified as cam-based or indirect acting and camless or direct acting. In the case of a cam-based system, the traditional engine cam system is kept and modified somewhat to indirectly adjust valve timing and/or lift. In a camless system, the traditional engine cam system is completely replaced with electrohydraulic or electromechanical actuators that directly drive individual engine valves. All current production automotive variable valve systems are cam-based, although camless systems will offer broader controllability, such as individual valve control and cylinder or valve deactivation, and thus better fuel economy.
[0004] The most prevailing design of an electromechanical VVA (or EMVVA) actuator includes an armature moving longitudinally between first and second electromagnets, a rod connected with the armature and an engine valve, and a pair of actuation springs attached to the rod and urging or centering the moving mass to a zero spring force or neutral position when the armature is not latched on either of the electromagnets. The engine valve is kept to closed and open positions when the armature is latched to the first and second electromagnets, respectively. For a simple, full-lift valve actuation, this spring-mass pendulum system is energy efficient, with the springs storing and releasing potential energy and the moving mass accumulating and releasing kinetic energy.
[0005] The prevailing EMVVA design does have several problems or potential problems. One of them is its power-off state. When engine power is off, the net spring force of the two actuation springs keeps the engine valve half open and the armature at the middle point between the two electromagnets. In certain vehicle regulations, it is required to keep engine valves closed at power-off. Also, to initialize an EMVVA actuator at the start of power-on, great effort and a large amount electrical current are spent to pull the armature from the middle point to either of the two electromagnets because of the nonlinear nature of the electromagnetic force. Therefore, it is desirable to keep the engine valve at the closed position and the armature near the first electromagnet.
[0006] With its fixed placement of the electromagnets and the actuation springs and nonlinear magnetic forces, prevailing EMVVA actuators also have trouble actuating an engine valve with a short stroke or lift, which is generally desirable and in some cases necessary for low load and idle engine operations. Some prevailing EMVVA actuators may perform short-lift actuation, but at great expense of electrical energy sustaining a large electromagnetic force through a substantial air gap to counter the spring centering force. This additional electrical energy further stretches the limit of a vehicle electrical system, especially during low load and idle operations when the vehicle alternator or electrical generator is the least efficient.
[0007] Disclosed in U.S. Pat. No. 5,996,539, assigned to FEV Motorentechnik GmbH &Co KG, is an EMVVA actuator including an adjusting device to vary the valve strokes. The adjusting device supports and controls the displacement of a base of the opener spring, thus controlling the pre-stress of the two actuation springs and the neutral position of the armature. At the least and most pre-stressed states of the actuation springs, the engine valve operates at partial and normal strokes, respectively. The design has the potential to resolve the valve stroke variability issue associated with most EMVVA designs. However, it fails to provide a solution to meet the need to keep the engine valve closed at power-off.
SUMMARY OF THE INVENTION
[0008] Briefly stated, in one aspect of the invention, one preferred embodiment of an electromechanical actuator comprises a housing, first and second electromagnets rigidly disposed in the housing and separated from each other by an armature chamber, an armature disposed in the armature chamber and movable between the first and second electromagnets, an armature rod rigidly connected with the armature and operably connected with a load, at least one first actuation spring biasing the armature in a first direction, at least one second actuation spring biasing the armature in a second direction, and one fluid-operated spring controller capable of controlling the position of the first-direction end of the at least one second actuation spring.
[0009] In operation, the actuation springs drive the armature and the load through pendulum motions between the first and second electromagnets, which in turn latch, over desired periods of time, and release the armature. The spring controller allows the actuation springs at their least compressed state and the engine valve closed when power is off or when the control fluid pressure is below a certain level or threshold. The spring controller may also be adjusted, with a low or moderate control fluid pressure, to allow the engine valve to operate with a partial lift.
[0010] In another embodiment, the spring controller allows the engine valve to operate with a small lift when the control fluid pressure is below a certain level or threshold.
[0011] The present invention provides significant advantages over the prevailing EMVVA actuators and their control. For example, it can effectively close the engine valve at power-off to meet certain vehicle regulations. The closed engine valve is also a good start-up point for the next power-on procedure or initialization. The invention also provides means to efficiently and effectively operate engine valves with a small lift. The present invention thus provides, with one mechanism, at least three significant functions: a closed engine valve at power-off, easy start-up, and partial or variable stroke.
[0012] The present invention, together with further objects and advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic illustration of one preferred embodiment of the electromechanical actuator, at its zero-lift state;
[0014] FIG. 2 is a schematic illustration of the embodiment of FIG. 1 at the end of the start-up process, when the second actuation spring is greatly compressed.
[0015] FIG. 3 is a schematic illustration of the embodiment of FIG. 1 when the actuation springs are substantially equally compressed, the net spring force is zero, the armature is at the middle point between the electromagnets, and the engine valve is half open.
[0016] FIG. 4 is a schematic illustration of the embodiment of FIG. 1 with the spring controller experiencing a small displacement when the fluid supply pressure is adjusted to a low or moderate value.
[0017] FIG. 5A is a schematic illustration of another preferred embodiment including an intentional, substantial gap between the spring-controller cylinder and the spring-controller piston outer dimension to pressurize both spring-controller first and second chambers.
[0018] FIG. 5B is a schematic illustration of yet another preferred embodiment including at least one spring-controller orifice that is to equalize steady-state pressures in the spring-controller first and second chambers and provide damping effect to reduce oscillation the spring controller may experience.
[0019] FIG. 5C is a schematic illustration of another preferred embodiment including a housing extension.
[0020] FIG. 6 is a schematic illustration of another preferred embodiment with the second actuation spring and the spring controller relocated to the first-direction end of the actuator.
[0021] FIG. 7 is a schematic illustration of another preferred embodiment, in which the steady-state or power-off armature first air gap and the engine valve opening are equal to a small value, instead of zero, when the spring-controller first surface is up against the spring-controller cylinder first surface.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Referring now to FIG. 1 , a preferred embodiment of the invention provides an engine valve control actuator 100 . The actuator 100 includes a housing 32 . Rigidly disposed within the housing 32 , along the longitudinal axis 102 and from a first to a second direction (from the top to the bottom in the drawing), are a first electromagnet 34 , an armature chamber 46 , a second electromagnet 36 , and a spring-controller cylinder 68 . The first and second electromagnets 34 and 36 further include their electrical windings and lamination stacks. An armature 38 is disposed inside the armature chamber 46 and between the first and second electromagnets 34 and 36 and is rigidly connected to an armature rod 40 . The armature rod 40 is slideably disposed through the first and second electromagnets 34 and 36 , the housing 32 , and a spring controller 70 . The spring controller 70 is slideably disposed within the spring-controller cylinder 68 and through the second-direction end of the housing 32 . The armature rod 40 is operably connected, at its second-direction end, with the stem 24 of an engine valve 20 , which is guided by an engine valve guide 52 rigidly disposed in the cylinder head 50 . The engine valve 20 includes an engine valve head 22 with first and second surfaces 28 and 30 exposed to gaseous pressure forces. The engine valve head 22 moves relative to a valve seat 26 , defining an engine valve opening Xev and controlling air exchange for an engine cylinder in an internal combustion engine (not shown in FIG. 1 ). The peak value of a cyclic valve opening is called the stroke or lift.
[0023] The actuator 100 further includes first and second actuation springs 42 and 44 , concentrically wrapped around the engine valve stem 24 and the armature rod 40 , respectively. The first actuation spring 42 is supported by a first spring retainer 54 and the cylinder head 50 at its first- and second-direction ends, respectively. The second actuation spring 44 is supported by a third spring retainer 58 and a second spring retainer 56 at its first- and second-direction ends, respectively. The first and second spring retainers 54 and 56 are fixed on the engine valve stem 24 and the armature rod 40 , respectively, whereas the third spring retainer 58 is fixed on and thus moves with the second-direction end of the spring controller 70 .
[0024] The first and second actuation springs are preferably substantially identical or symmetric in major geometrical, physical parameters, such as stiffness and preload to have an efficient pendulum system. They may be purposely designed to be somewhat asymmetric to achieve asymmetric needs for engine valve opening and closing, which, for example, experience dissimilar frictional forces and need different seating or slow-down strategies. For simplicity, the spring symmetry is assumed in many parts of the specification of this application, which does not however exclude the applicability of the embodiments and teachings of this invention to situations where asymmetric springs are more desirable.
[0025] The spring retainers 54 and 56 are illustrated to be of the shape generally used in current production engines. They do not have to be that way. In fact, when possible and practical, they may be combined into a single mechanical piece.
[0026] The spring controller 70 partitions the spring-controller cylinder 68 into spring-controller first and second chambers 72 and 74 . The first chamber 72 is fed with a working fluid through a spring-controller port 60 and from a fluid supply at a pressure Psp. The fluid supply Psp is switched on and off by a spring-controller on-off valve 62 . The second chamber is generally not pressurized and is exposed to either atmosphere or a fluid return line to the tank of the working fluid (not shown). Therefore there is negligible force on a spring-controller second surface 78 . The fluid pressure force on a spring-controller first surface 76 balances the spring force on the third spring retainer 58 from the second actuation spring 44 , resulting in the longitudinal position of the spring controller 70 and thus that of the third spring retainer 58 , which in turn controls the neutral position of the armature and the engine valve. A neutral position is defined as a steady-state position only under spring forces, without electromagnetic forces and contact forces at electromagnets and the engine valve seat and generally ignoring gravitational and frictional forces. At a neutral state or position, the two spring forces are equal in magnitude and opposite in direction, and the net spring force is thus equal to zero. The position or travel of the armature and engine valve assembly is also limited in the first direction when the engine valve head 22 comes in contact with the engine valve seat 26 and in the second direction when the armature 38 comes in contact with the second electromagnet 36 . The position or travel of the spring controller 70 is limited by spring-controller cylinder first and second surfaces 92 and 94 in the first and second directions, respectively.
[0027] The spring controller 70 can be alternatively designed without the flange feature that gives off, or is characterized in the form of, the spring-controller second surface 78 shown in FIGS. 1-7 . The elimination of the flange feature may facilitate the assembly process in certain situations. Without the flange feature, the travel of the spring controller 70 may be limited by some other lock-up mechanisms. For example, a mechanical block, not shown in FIGS. 1-7 , may be placed at a predetermined longitudinal position to limit the range of the travel of the third spring retainer 58 and thus that of the spring controller 70 in the second direction.
Power-Off State
[0028] At power-off, the spring-controller on-off valve 62 is at its default or open position, and the fluid supply pressure Psp is generally at the atmosphere pressure or zero gage pressure. The spring controller 70 is thus at its farthest position in the first direction, with its first surface 76 butting against the spring-controller cylinder first surface 92 , and the actuation springs 42 and 44 are at their least compressed states. The actuator 100 is so geometrically and physically designed such that the engine valve 20 is fully closed with a finite seating or contact force, if desired, and the armature 38 is substantially approximate, depending on the lash, to the first electromagnet 34 . The armature and engine valve assembly are not exactly in the neutral position if the seating force is not zero.
[0029] Because of thermal expansion, wear and elasticity in an engine valve mechanism, the longitudinal dimension stack-up is not exact, and lash adjustment has to be considered. When the armature 38 is latched to the first electromagnet 34 , they may not necessarily be in real physical or metal-to-metal contact. For simplicity of discussion and illustration, the clearance between the armature 38 and the electromagnet 34 and its variation, when they are latched, are to be ignored or de-emphasized. But that does not exclude the general applicability of the embodiments and teachings of this invention to situations with substantial lash.
[0030] Symbolically in FIG. 1 , the variable Xsp is defined the spring controller displacement, which is a distance between the spring-controller first surface 76 and the spring-controller cylinder first surface 92 . The variable Xev is defined as the engine valve opening, a longitudinal distance between the engine valve head 22 and the engine valve seat 26 . The variables Xar 1 and Xar 2 are defined as armature first and second air gaps, respectively, for the distance between the armature 38 and the first electromagnet 34 and that between the armature 38 and the second electromagnet 36 . Ignoring the engine valve lash and at power-off, one generally has
[0031] Xsp=0,
[0032] Xev=0,
[0033] Xar 1 =0, and
[0034] Xar 2 =Xspmax−Xar 1 =Xspmax,
[0000] where Xspmax is the maximum spring-controller displacement.
[0035] The actuator 100 falls into the power-off state soon after the engine power is turned off, either intentionally or by accident, keeping the engine valve closed as required in some vehicle regulations. From this power-off state, it is also easy to initialize the actuator 100 at the engine start-up, without spending too much energy (see the following discussion).
Start-Up
[0036] At the power-off state as shown in FIG. 1 , the armature first air gap Xar 1 is substantially equal to zero. The actuator 100 can be initialized by energizing only the first electromagnet 34 to a holding level of force, thus latching the armature 38 to the first electromagnet 34 , mostly by force and not by physical contact. The holding level of force is much smaller than the force otherwise needed to attract the armature 34 if it is in the middle of the armature chamber 46 .
[0037] Also at the start-up, the fluid supply builds up its pressure Psp, and the pressure force starts pushing the spring controller 70 in the second direction until it is against and limited by the spring-controller cylinder second surface 94 , with Xsp=Xspmax. However, this pressure build-up and the subsequent spring controller displacement are much slower than the action to energize the first electromagnet 34 and latch the armature 38 , and the armature-and-engine valve assembly stay securely latched as shown in FIG. 2 . FIG. 2 illustrates the state of the embodiment at the end of the start-up process, when the second actuation spring 44 is greatly compressed, the spring controller 70 is secured by the working fluid at the farthest position in the second direction, and the engine valve 20 is fully closed.
Full Lift Operation
[0038] For the normal, full or maximum lift operation, the spring controller 70 remains in the position as shown in FIG. 2 , and the actuator 100 operates otherwise like a prevailing EMVVA actuator. The two actuation springs 42 and 44 alternatively store and release potential energy, and the armature-and-engine valve assembly travels like a pendulum, with the armature 38 being latched at the two electromagnets 34 and 36 for fully closed and open positions, respectively. Between the two end positions is a neutral position as shown in FIG. 3 , where the actuation springs 42 and 44 are substantially equally compressed, the net spring force is zero, the armature 38 is at the middle point between the electromagnets 34 and 36 with Xar 1 =Xar 2 =0.5 Xspmax, and the engine valve 20 is half open with Xev=0.5 Xspmax.
Small Lift Operation
[0039] The actuator 100 is also able to operate at a small lift. The spring controller 70 illustrated in FIG. 4 experiences a small displacement Xspsmall when the fluid supply pressure Psp is adjusted or controlled to a low or moderate value. The resulting neutral positions (shown in FIG. 4 ) for the armature and the engine valve are not far away from the fully closed positions, with Xar 1 =0.5 Xspsmall and Xev=0.5 Xspsmall. The armature 38 and the engine valve 20 are held in these neutral positions by the force balance between the two actuation springs 42 and 44 while the position of the third spring retainer 58 results from the balance between the fluid force on the spring-controller first surface 76 and the spring force from the second actuation spring 44 . Therefore, the small engine valve opening Xev=0.5 Xspsmall is achieved and maintained without the usage of electrical power or energy. It is however conceivable to use a smaller electromagnetic force from the first electromagnet 34 to perform a closed-loop position control if better opening accuracy is desired, with the correctional electromagnetic force increasing with the engine valve opening overshoot beyond the target value to pull the armature 38 and thus the engine valve 20 in the first direction to reduce the deviation. One can purposely bias the open-loop engine valve opening data points more into the overshoot (vs. undershoot) range to deal with the inability of the first electromagnet 34 to push the armature 38 in the second direction because of the nature of the electromagnetic force and the ineffectiveness of the second electromagnet 36 to pull the armature in the second direction because of the large second air gap Xar 2 during the small lift operation.
[0040] It is also possible to use a lock-up mechanism, such as a fluid actuated lock pin (not shown in FIG. 1 ) to accurately pin-down the spring controller 70 to the small displacement Xspsmall. To close the engine valve 20 , the first electromagnet 34 is energized to pull the armature 38 in the first direction and hold it once the engine valve is closed, all against the net spring force. To open the engine valve 20 afterwards, the first electromagnet 34 is de-energized for the armature 38 and the engine valve 20 to return, under the net spring force, to the neutral positions as shown in FIG. 4 .
[0041] This small lift operation operates differently from that with the full lift, and the engine valve opens and closes under the net spring force and the electromagnetic force, respectively, instead of under generally symmetric, pendulum dynamics. The armature 38 is latched at the closed position and balanced at the open position by the first electromagnet 34 and the actuation springs 42 and 44 , respectively, instead of by the first and second electromagnets 34 and 36 , respectively. In fact, the second electromagnet 36 may not be involved at all. This asymmetric operation is, in theory, not energy efficient, but it is, in absolute terms, still efficient because of its much reduced lift. In addition, the balance at the engine valve open position, a neutral position, is achieved by the actuation springs 42 and 44 , without consuming electrical energy. With a prevailing EMVVA actuator, a substantial amount of electrical energy has to be consumed to counter a large spring return force at this position, which is not a neutral position in a prevailing design.
[0042] During the operation, the second actuation spring 44 does change its level of compression and offers a varying force to the spring controller 70 , which makes it necessary to incorporate design considerations to damp out oscillatory displacement for the spring controller 70 .
[0043] It is generally preferred for all VVA actuators 100 in an engine to use a single fluid supply. When the system changes its supply pressure Psp from a high pressure to a lower pressure for a small lift operation or vice versa, timing of the system pressure change may not be ideal for individual actuators 100 . The system control may purposely closes off an individual spring-controller on-off valve 62 by energizing its solenoid to momentarily isolate its associated spring controller 70 . Otherwise, the spring-controller on-off valve 62 may be eliminated from the system to simplify.
[0044] The spring controller 70 and its associated fluid actuation design illustrated in FIGS. 1 to 4 are only one of many possible combinations of piston-cylinder designs and fluid supply systems. FIGS. 5A , 5 B, and 5 C illustrate a few other embodiments, with graphic details only around the spring controller 70 and its fluid supply subsystem to emphasize their variations. The embodiment in FIG. 5A features an intentional, substantial gap or clearance between the spring-controller cylinder 68 and the spring-controller piston, or flange, outer dimension 90 to pressurize both spring-controller first and second chambers 72 and 74 . The gap may function as a damping orifice, or flow restriction, between the two pressurized chambers 72 and 74 to counter the oscillatory force from the second actuation spring. This substantial gap eliminates one pair of tightly sliding surfaces and reduces manufacturing cost. This embodiment offers, as a design option, a reduced effective pressure area, which is equal to the differential area between the first and second surfaces 76 and 78 . The embodiment in FIG. 5A also features no spring-controller on-off valve 62 (used in the embodiment illustrated in FIG. 1 ), which reduces some control flexibility while simplifying the overall structure of the actuator or system.
[0045] The embodiment in FIG. 5B features at least one spring-controller orifice 88 , a flow restriction, that is to equalize steady-state pressures in the spring-controller first and second chambers 72 and 74 and provide damping effect to reduce oscillation the spring controller 70 may experience. This embodiment also offers, as a design option, a reduced effective pressure area, which is equal to the differential area between the first and second surfaces 76 and 78 . This embodiment features a spring-controller pressure control valve 64 , which is able to provide individualized pressure control for the actuator. If needed, the feedback control can be incorporated based on the position information of the spring controller 70 . Physically, the spring-controller pressure control valve 64 can be any of many possible proportional pressure control valve, such as a variable force solenoid (VFS) valve which delivers an output pressure either proportional or inversely proportional to the input current. Functionally, a VFS valve can also be replaced by a pulse width modulation (PWM) valve combined with a proper position or pressure feedback control (not shown here).
[0046] The embodiment in FIG. 5C features another variation in the spring control mechanism. In this embodiment, the spring controller bore 80 slides over a housing extension 86 , instead of the armature rod 40 . The housing extension 86 does not have to be an inseparable part of the housing 32 and can be a separate part but rigidly assembled or connected to the housing 32 . This design can greatly reduce the potential for the working fluid to leak into the armature chamber 46 (see FIG. 1 ) through the clearance around the armature rod 40 . It also provides more solid bearing or support to the traveling armature rod 40 . The embodiment also features a spring-controller 3 -way valve 66 that selectively feed the spring-controller first chamber 72 with the working fluid either from a high-pressure fluid supply Ph or a low-pressure fluid supply Pl. Ideally, the high-pressure Ph is set to push the spring controller 70 all the way against the spring-controller cylinder second surface 94 while the low-pressure Pl is set to drive the spring controller 70 to the small displacement Xspsmall designed for idle and low load engine operations. Although the fluid power symbol for the 3-way valve 66 indicates the Ph connection to be its default position, it is also feasible to have the Pl connection to be the default position. Alternatively, one may choose, for the valve 66 , actuation means other than a combination of one return spring and one solenoid.
[0047] The design variations of the spring controller mechanisms and the fluid supply schemes illustrated in FIGS. 5A , 5 B, and 5 C can be recombined among themselves and with other possible variations.
[0048] FIG. 6 demonstrates a variation of the embodiment illustrated in FIG. 1 . In this case the second actuation spring 44 and the associated spring controller 70 b are relocated to the first-direction end of the actuator 100 b. The spring-controller first chamber 72 b is pressurized, and it can be supplied, through the spring controller port 60 b, by several possible fluid sources like those for the embodiments in FIGS. 1-5C . The spring-controller second chamber 74 b is generally not pressurized and is fluid communication (details not shown in FIG. 6 ) either with the atmosphere or a return line to the tank of the working fluid. Basic schemes utilized for the spring controller in the embodiments in FIGS. 5A , 5 B, and 5 C can also be incorporated in this embodiment.
[0049] When the spring-controller first surface 76 b is in contact with the spring-controller cylinder first surface 92 b (as shown in FIG. 6 ), the steady-state net spring force secures the armature 38 substantially approximate to the first electromagnet 34 and the engine valve 20 at its closed position, with the required contact force. This is an ideal situation for power-off or default position and actuator initialization. When the spring-controller second surface 78 b is in contact with the spring-controller cylinder second surface 94 b (not shown in FIG. 6 ), the steady-state net spring force moves the neutral position of the engine valve 20 to be in the substantially middle point, if so desired, between the closed and full open positions.
[0050] Refer now to FIG. 7 , which is a drawing of yet another preferred embodiment of the invention. When the spring-controller first surface 76 is up against the spring-controller cylinder first surface 92 , the steady-state or power-off armature first air gap Xar 1 and the engine valve opening Xev are not equal to zero, and, instead, Xar 1 =Xev=Xevsmall, where Xevsmall is small valve opening. This embodiment is useful in applications where engine valves are not required to be closed at power-off, and at the same time, the accuracy of the small valve opening Xevsmall is stringent, which can be greatly helped by the position accuracy of the spring controller 70 c guaranteed by a solid stop against the cylinder first surface 92 . The actuator 100 c also features other design variations. The armature rod 40 c does not extend beyond the armature 38 in the first direction, which may reduce the design complexity and weight. The rod 40 c also slides inside an added sleeve 84 to provide proper mechanical support and specific material match.
[0051] In all the above descriptions, the first and second actuation springs 42 and 44 are each identified or illustrated, for convenience, as a single spring. When needed for strength, durability or packaging, however each or any one of the first and second actuation springs 42 and 44 may include a combination of two or more springs. In the case of mechanical compression springs, they can be nested concentrically, for example. The spring subsystem may also include a single mechanical spring (not shown) that can take both tension and compression. The spring subsystem may also include a combination of pneumatic and mechanical springs, or even two pneumatic springs.
[0052] Also in some illustrations and descriptions, the fluid medium may be assumed or implied to be hydraulic or in liquid form. In most cases, the same concepts can be applied, with proper scaling, to pneumatic actuators and systems. As such, the term “fluid” as used herein is meant to include both liquids and gases. Also, in many illustrations and descriptions so far, the application of the actuator 100 or 100 b or 100 c is defaulted to be in engine valve control, and it is not limited so. The actuator 100 or 100 b or 100 c can be applied to other situations where a fast and/or energy efficient control of the motion is needed.
[0053] Although the present invention has been described with reference to the preferred embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. As such, it is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is the appended claims, including all equivalents thereof, which are intended to define the scope of this invention. | Actuators, and corresponding methods and systems for controlling such actuators, provide independent lift and timing control with minimum energy consumption. In an exemplary embodiment, an electromechanical actuator comprises a housing, first and second electromagnets rigidly disposed in the housing and separated from each other by an armature chamber, an armature disposed in the armature chamber and movable between the first and second electromagnets, an armature rod rigidly connected with the armature and operably connected with a load, at least one first actuation spring biasing the armature in a first direction, at least one second actuation spring biasing the armature in a second direction, and one fluid-operated spring controller capable of controlling the position of the first-direction end of the at least one second actuation spring. The spring controller allows the actuation springs at their least compressed state and the engine valve closed when engine power is off. The spring controller may also be adjusted, with a low or moderate control fluid pressure, to allow the engine valve to operate with a partial lift. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system for assembling two components of a prosthesis in a plurality of adjustable positions.
It is known that the alignment and orientation of parts of a prosthesis must be carried out with care, and relatively complicated and expensive junction pieces are often used for this purpose.
It has already been proposed to use modular junction members which are intended to form part of a prosthesis of a limb of the human body and to join two components of this prosthesis to one another in an adjustable manner.
2. Discussion of the Prior Art
Thus, GB-A-2,141,345 describes an adjustable connection device for joining two parts of a prosthesis, this device comprising first and second connection elements which are each intended to be fixed on the parts of the prosthesis to be joined, the connection elements being in mutual contact or in contact with an intermediate connection member via flat or spherical parts bearing directly against one another and capable of being displaced with respect to one another by sliding or by pivoting, screws being provided for locking them in position after adjustment.
In one of the embodiments described in this prior document, a projecting member, integral with a part of the prosthesis, is housed in a recessed portion, in the form of a cellular or hollow part, of an intermediate connection member and bears via a flat part against the base of the part in the form of a hollow part, against which it can thus slide in order to be brought by translation from the desired position. Screws engaged in internal threads arranged transversely in the lateral walls of the hollow part can bear via a free end against the lateral flanks of the projecting member, which are inclined with respect to the base of the hollow part, with a view to locking this member in position.
On account of the direct contact between the base of the hollow part and the projecting part, very substantial moments are exerted on the latter, which thus risks breaking or cracking and which must consequently be made of a material capable of withstanding the stresses which are applied to it.
SUMMARY OF THE INVENTION
The present invention aims to overcome this disadvantage by providing a system for assembling two components of a prosthesis in a plurality of positions which are adjustable in translation, in rotation and angularly, in which system a projecting part integral with one of the these components is, as previously, engaged in a recess, forming a hollow part, of the other component of the prosthesis or of an intermediate connection element (or vice versa), while screws arranged transversely with respect to the lateral walls of the cell come into abutment, as in the prior art, against the lateral flanks of the projecting part, but without the base of the hollow part bearing directly against the facing surface of the projecting part, thereby preventing the latter from being subjected to very substantial stresses or moments.
To this end, in accordance with the present invention, the outer edge of the recess forming the hollow part bears in such a way as to be able to slide in a rectilinear manner in at least one direction on a surface of the component with which the projecting part is integral, this projecting part furthermore being spaced apart, in any position, from the base of the recess forming the hollow part.
When, in this definition of the invention, mention is made of a recess forming a hollow part, this is not of course intended to limit the invention to a precise form of hollow part. The same applies to the projecting part, which can have any form lending itself to a locking by screws coming into abutment against its lateral flanks.
In practice, it is therefore via the edges of the hollow part that the part in which this recess is formed bears, in such a way as to be able to slide, against a surface of an element integral with the base of the projecting part, and the stresses which will be exerted by the portion in which the hollow part is formed are not therefore transmitted to the projecting part, but are distributed in a ring around the latter onto the element which is integral therewith, thereby preventing risks of breakage or damage of the projecting part.
By means of relative sliding between the element integral with the base of the projecting part and the edges of the recess forming the hollow part, it will thus be possible to adjust in translation, as desired, the position of the two parts of a prosthesis, or of one part of a prosthesis and an intermediate connection element between this part and another part of the prosthesis.
It will be possible for the edge of the hollow part to bear via at least one first flat surface against at least one second flat surface of the element integral with the projecting part and, in such a form of implementation of the invention, by means of relative sliding of the first flat surface against the second flat surface, it will be possible to adjust in translation, in any direction, the position of the two parts of a prosthesis, or of one part of a prosthesis and an intermediate connection element.
It will also be possible for the edge of the hollow part to bear via at least one first cylindrical surface against at least one second cylindrical surface of complementary profile of the element with which the projecting part is integral, and in such an embodiment it will be possible for the first and second surfaces to slide with respect to one another in a direction parallel to the axis of the cylindrical surfaces and to pivot with respect to one another about the axis of the cylindrical surface, in order to permit the adjustment of their relative positions.
Finally, the various elements will advantageously be adjustable with respect to one another by rotation about an axis perpendicular to the flat sliding surfaces or to the axis of cylindrical sliding surfaces.
In the embodiments which will be described hereinbelow with reference to the attached drawings, the projecting parts will have the form of a truncated pyramid with a rectangular base, and they will project from a cylindrical part to which the projecting part will be connected via the small base of the truncated pyramid. These forms of implementation of the invention are preferred forms, by virtue of their simplicity, but they are of a non-limiting nature.
One embodiment of the invention thus consists of a modular connection device, which is adjustable in position, between two components of a prosthesis, this device comprising a first element capable of being made integral with a first component of the prosthesis, a second element capable of being made integral with a second component of the prosthesis, and an intermediate element capable of being made integral, in an adjustable position, with the first and second elements, respectively, by cooperation of a male part and/or a female part, respectively, of this intermediate element, with a female part and/or a male part of the first and the second elements, assembly members such as screws being provided for locking with respect to one another, in a plurality of positions, on the one hand the first element and the intermediate element, and on the other hand the second element and the intermediate element, this device being characterized in that each of the said male parts comprises a portion in the form of a truncated pyramid with a rectangular base projecting from a portion of cylindrical form, to which it is connected via its small base, the axis of the cylindrical portion being substantially parallel to two sides of the base of the associated truncated pyramid, while each female part comprises a portion of a form complementary to that of the cylindrical element and a recessed portion in the form of a groove capable of receiving the portion of the associated male element in the form of a truncated pyramid, the groove having dimensions greater than those of the portion in the form of a truncated pyramid, parallel to the axis of the cylindrical portion and perpendicular thereto, in such a way as to afford a double freedom of movement, in rotation with respect to this axis and in translation parallel to this axis, of the male portion with respect to the associated female portion, the cylindrical parts associated with each of the first and second elements furthermore having axes which are non-parallel and, preferably, perpendicular to each other.
By virtue of this connection device, it is thus possible, as indicated hereinabove, to pivot each of the male cylindrical portions with respect to the corresponding female portion and to displace each of the male portions in the form of a truncated pyramid in translation with respect to the groove of the associated female part in which it is housed, which thus affords two possibilities of angular adjustment of the components of the prosthesis with respect to one another, and two possibilities of adjustment in translation.
In the definition of the invention given hereinabove, the term cylindrical form encompasses all the surfaces allowing the female parts and the associated male parts to pivot with respect to one another about a common axis of rotation.
It will be possible for the intermediate element of the connection device to comprise two male parts each associated with a female part of the first and second elements of the device. Conversely, it will be possible for the intermediate element to comprise two female parts, each associated with a male part of the first and second elements of the connection device. Finally, as an alternative, it will be possible for the intermediate element to comprise a single male part associated with a female part of one of the first and second elements, and a single female part associated with a male part of one of the first and second elements of the device.
Screws, which are screwed into threaded recesses in the first and second elements of the device and come into abutment against the flanks of the portions in the form of a truncated pyramid, make it possible, after adjusting the relative positions of the components of the prosthesis which are integral, respectively, with the first and second elements of the device, to lock these elements in their respective positions.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described hereinbelow in greater detail, with reference to the attached diagrammatic drawings in which:
FIG. 1 is a perspective partial view of two parts of a prosthesis or of one part of a prosthesis and a part of an intermediate connection element, in mutual contact via coplanar surfaces;
FIGS. 2 and 3 are sections along the lines II--II and III--III in FIG. 1, respectively;
FIG. 4 is a diagrammatic perspective view of another embodiment of the device according to the invention;
FIGS. 5 and 6 are sectional views along the lines V--V and VI--VI in FIG. 4;
FIGS. 7 and 8 are diagrammatic perspective views of two other forms of implementation of the invention;
FIGS. 9, 10 and 11 are diagrammatic perspective views of alternative embodiments of the devices in FIGS. 4, 7 and 1, respectively.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
It will be seen that the system according to the invention comprises two pieces 1 and 2 which can each be joined to a part of a prosthesis or of a connection element between two parts of a prosthesis, but which can also form an integral part of this prosthesis part or this connection part.
The piece 1 comprises a flat plate 3, from the surface of which there projects a part 4 which here has the form of an inverted truncated pyramid, that is to say a truncated pyramid whose larger base is remote from the plate 3, but which could have any other form. In the case of the drawing, the piece 1 is represented as being monobloc, but the plate 3 and the part 4 could just as well be separate and be made integral with one another by any means known in the art.
The piece 2 can have any form. It comprises a recess forming a hollow cell 5, the edges of which rest via a flat part against the surface of the plate 3 from which the part 4 projects. The latter is engaged in the recess 5 forming the hollow cell, but without coming into contact with the base thereof, in contrast to the systems of the prior art.
In a manner known per se, screws engaged in threaded transverse recesses in the lateral walls of the hollow cell 5 can come into abutment against the inclined flanks of the part 4 in order to immobilize the latter in position and, consequently, to lock the part 1 with respect to the part 2.
When the screws 6 are not holding the pieces 1 and 2 in the assembled state, it is possible to slide these pieces against one another in any direction in order to adjust their relative position in translation.
Since the piece 2 does not bear against the projecting part 4, the latter is not subjected to any stress and does not risk breaking, cracking or being damaged, as in the prior art. In contrast, the stresses of the part 2 are exerted against the surface of the plate 3, all around the part 4, and are thus distributed over this entire surface, which withstands them without any problem.
FIGS. 4 to 6 represent a preferred form of implementation of the invention.
As can be seen, the device comprises two plates, 11 and 12 respectively, which are capable of being made integral, respectively, with two parts of a prosthesis, by conventional means (not shown) and an intermediate element 13 which is capable of being made integral, in a plurality of positions, with each of the elements 11 and 12.
The element 13 consists of a nut comprising two cylindrical portions 14 and 15, having perpendicular axes, from each of which there projects, respectively, two portions 16 and 17, in the form of a truncated pyramid with a rectangular base, which adjoin, via their small base, the associated cylindrical portion, with their large base being spaced apart from this cylindrical portion. The large sides of the large bases of the portions 16 and 17 in the form of a truncated pyramid are parallel to the axes of the cylindrical portions 14 and 15.
Female parts hollowed out in the elements 11 and 12 are intended to receive, respectively, on the one hand, the male portions 14 and 16 of the element 13, and on the other hand, the male portions 15 and 17 of this element.
The female part hollowed out in the element 11 comprises a cylindrical portion 18, of a form complementary to that of the part 14, and a groove 19, having a substantially parallelepipedal section, directed parallel to the axis of the cylindrical part 14. The transverse dimension of this groove 19, that is to say the dimension perpendicular to the direction of the axis of the cylindrical part 14, is greater than the corresponding dimension of the part 16 which it is intended to receive. Similarly, the longitudinal dimension of the groove 19, that is to say the dimension parallel to the axis of the cylindrical portion 14, is greater than the corresponding dimension of the part 16.
It is thus possible, on the one hand, to pivot the elements 11 and 13 with respect to one another about the axes of the cylindrical portions 14 and 18 in order to adjust their relative angular position, and, on the other hand, to slide the elements 11 and 13 with respect to one another, by longitudinal displacement of the portion 16 in the groove 19, in order to adjust their respective positions in translation.
In an analogous manner, the female part hollowed out in the element 12 comprises a cylindrical portion 20, of a form complementary to that of the part 15, and a groove 21, having a substantially parallelepipedal section, directed parallel to the axis of the cylindrical part 15. The groove 21 has a length and a width which are greater than the corresponding dimensions of the portion 17, which makes it possible to pivot the cylindrical portions 15 and 20 with respect to one another and to adjust the position of the parts 17 and 21 by translation.
A double adjustment of position is thus possible, in a particularly simple manner, at the level of each of the plates 11 and 12, thus making it possible to adjust the relative positions, both angular and in translation, of the prosthesis parts integral with the plates 11 and 12.
Once this adjustment has been carried out, it will suffice to lock the elements 11 and 13 on the one hand, and 12 and 13 on the other hand, in their relative position in order to retain the position adopted for the prosthesis element. To this end, threaded recesses will be formed transversely in the parts 11 and 12, and screws 22 and 23 on the one hand, and 24 and 25 on the other hand, which are screwed into these recesses, will come into abutment, respectively, against the lateral flanks of the parts 16 and 17 in the form of a truncated pyramid.
It will be noted that the device which has just been described is of great simplicity.
Alternatively, as represented in FIG. 7, the male parts can be supported by the elements 41 and 42 which are intended to be made integral with the parts of the prosthesis, and the female parts can be formed in the intermediate element 43.
The male part of the element 41 comprises a cylindrical portion 44 from which there projects a portion 45 in the form of a truncated pyramid, the large base of which is remote from the portion 44. This portion 44 will cooperate with a female portion 46 of complementary profile in the element 43, while the portion 45 is housed in a groove 47 of this element 43, the flanks of which are substantially parallel to the axis of the cylindrical part 44. The transverse and longitudinal dimensions of the groove 47 are greater than the corresponding dimensions of the portion 45, in such a way as to permit a pivoting of the portion 44 with respect to the portion 46 and a sliding of the portion 45 with respect to the groove 47.
In an analogous manner, the element 42 comprises a male cylindrical portion 48, from which there projects a portion 49 in the form of a truncated pyramid. The axis of the portion 48 is perpendicular to that of the portion 44. The portion 48 will be housed in a female portion 50 of complementary profile in the element 43, while the portion 49 will be housed in a groove 51, the flanks of which are parallel to the axis of the part 48, and the longitudinal and transverse dimensions of which are greater than those of the part 49, in such a way as to give the latter a double freedom of movement, permitting a rotation of the portion 48 with respect to the portion 50 and a translation of the portion 49 with respect to the portion 51.
Finally, as represented in FIG. 8, one of the elements intended to be made integral with the parts of the prosthesis, for example the element 61, can comprise a female cylindrical part 62 and a groove 63 with flanks parallel to the axis of the portion 62, these being intended to receive, respectively, a male cylindrical part 64 and a part in the form of a truncated pyramid 65 of the intermediate element 66, while, conversely, a female cylindrical part 67, having an axis perpendicular to that of the part 64, and a groove 68 of the intermediate element 66, with flanks which are substantially parallel to the axis of the cylindrical part 67, will receive, respectively, a male cylindrical part 69, of complementary profile, and a part 70 in the form of a truncated pyramid, projecting with respect to a second element 71 which is intended to be made integral with one of the parts of the prosthesis. As before, the grooves 63 and 68 will have transverse and longitudinal dimensions greater than those of the corresponding parts 65 and 70.
In these three embodiments, the adjustment of the position of the three components of the device is particularly easy to carry out, but it is still possible to provide a further degree of adjustment of the position of these components, in rotation about an axis perpendicular to the axis of pivoting of the cylindrical surfaces.
This is what is illustrated by FIG. 9 which is to be compared with FIG. 4 described hereinabove and on which the members already described in relation to this FIG. 4 are designated by the same references allocated the prefix "100".
In this embodiment, the intermediate piece 103 consists of two parts 103a and 103b in contact via a flat surface parallel to the axis of the cylindrical surfaces, assembled together with the aid of a screw 28 perpendicular to this axis and screwed into threaded recesses 26 and 27, respectively, in the part 103a and the part 103b.
It is thus possible to adjust, as desired, the angular position of the parts 103a and 103b with respect to one another and then to lock them in position with the aid of the screw 28.
In an analogous manner, the intermediate piece 43 in FIG. 7 could be divided into two parts in mutual contact via a flat surface parallel to the axis of pivoting of the cylindrical parts and assembled with the aid of a screw perpendicular to this axis. Alternatively, at least one of the pieces 32 or 34 in this same FIG. 7 could be divided into two parts which are in mutual contact via a flat surface parallel to the axis of pivoting of the cylindrical surfaces and joined via a screw perpendicular to this axis.
Thus, by way of example, FIG. 10, in which the members already described in relation to FIG. 7 are designated by the same references allocated the prefix "100", represents a device in which the part 143 consists of two parts 143a, 143b, each comprising a female recess, in mutual contact via a flat surface parallel to the axis of the cylindrical surfaces and assembled in a position adjustable in rotation by a screw 60 perpendicular to this axis, while the part 142 is divided into two parts, a plate 142a and a male nut 142b, in mutual contact via a flat surface parallel to the axis of the cylindrical surfaces, and assembled in a position adjustable in rotation by a screw 61.
The additional possibilities of positional adjustment by pivoting one piece with respect to the other are not limited to pieces having a cylindrical surface of corresponding profile.
Thus, for example, in the embodiment in FIG. 11, in which the members already described in relation to FIG. 1 are designated using the same references allocated the prefix "200", the male piece 201 consists of two parts, a plate 201a, on which the female part 202 bears, and a male part 204a, the parts 1'a and 204a being in mutual contact via a flat surface and being assembled via a screw 7 perpendicular to this surface. The recess 205 could of course have a profile other than the parallelepipedal profile represented in this figure. | A system for assembling two components of a prosthesis in a plurality of positions which are adjustable in orthogonal translation, and selectively in rotation and angularly. In the system, a projecting part integral with one of these components is engaged in a recess, forming a hollow part of the other component of the prosthesis, or of an intermediate connection element, while screws arranged transversely with respect to the lateral walls of the cell come into abutment, as in the prior art, against the lateral flanks of the projecting part, but without the base of the hollow part bearing directly against the facing surface of the projecting part. Outer edges of the recess forming the hollow part bear in such a way against sets of screw so as to be able to slide in a rectilinear manner in at least one direction relative to the extent of a surface of the component with which the projecting part is integral, this projecting part being spaced in any position thereof from the base of the recess forming the hollow part. | 8 |
FIELD OF THE INVENTION
[0001] The invention relates to delay locked loop based circuits and in particular to delay locked loop based circuits for use with an IEEE 1394-1995 decoder, IEEE Std 1394-1995, published Aug. 30, 1996.
BACKGROUND
[0002] IEEE 1394-1995 decoders are based on a non return to zero (NRZ) transmission of data signal in which a strobe is also transmitted to recover the digital data from the NRZ data signal. From the NRZ data signal and the strobe, a recovery clock may be constructed which is used to extract the actual digital data from the NRZ data signal. The transmission of NRZ data signal and the strobe allows for a reliable transmission and receipt of digital data. During packet transmission, there is only a single node transmitting on the bus, so the entire media can operate in a half duplex mode using the two signals: Data and Strobe. As shown in FIG. 1, NRZ data is transmitted on Data and is accompanied by the Strobe signal which changes state whenever two consecutive NRZ data bits are the same, ensuring that a transition occurs on either Data or Strobe for each data bit. FIG. 2 illustrates an example of an IEEE 1394-1995 decoder 5 . Decoder 5 receives the NRZ data signal and the strobe to generate a recovery clock using a plurality of flip flops 10 , 15 , and 20 to generate data data_ 1 , data data_ 0 and a quarter clock qrt_clk, respectively. The three signals are then used to construct the original digital data transmitted by the source. A clock that transitions each bit period can be derived from the exclusive—or of Data with Strobe. The primary rationale for use of this transmission code is to improve the skew tolerance of information to be transferred across the serial bus.
[0003] However, the generated signals from the decoder are not useful because the recovered data and the recovered clock need to be in sync with the local clock of the circuit using the data. Generally, this function is performed by a data re-timing circuit. Previously, a phase locked loop (PLL) circuit was used for timing and carrier recovery to ensure optimal data sampling using a local clock. However, there are many disadvantages to using a PLL based circuit, in particular, in high speed and low power applications. For example, PLL based circuits require a long acquisition time, normally in the range of 100-2000 cycles before a “lock” takes place. In high speed circuits, such delay is not acceptable. To minimize the acquisition time, one previous method maintained a certain level of transition activity as to maintain a PLL lock. However, such transition activity generally resulted in power dissipation which in certain instances is undesirable.
[0004] Accordingly, there is a need for an IEEE 1394-1995 compatible resync circuit that is suitable for high speed low power applications and that has a relatively short acquisition time.
SUMMARY
[0005] In accordance with an embodiment of the invention, there is disclosed an apparatus including three sampling circuits to sample incoming data and a quarter clock. A clock generation unit is included to generate at least three sampling clocks from a local clock. Each of the three sampling clocks are configured to sample the incoming data and the quarter clock. A phase detector is also included to detect a phase difference between the quarter clock and the local clock and to generate a recovered quarter clock. A delay line is further included to delay the sampled incoming data and the recovered quarter clock by the detected phase difference.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. In the drawings,
[0007] [0007]FIG. 1 illustrates a timing diagram for Data-Strobe decoding, that is, a clock that transitions each bit period derived from the exclusive-or of Data with Strobe, in accordance with an embodiment of the invention.
[0008] [0008]FIG. 2 is a schematic diagram of an IEEE 1394-1995 Decoder in accordance with an embodiment of the invention.
[0009] [0009]FIG. 3 is a schematic diagram of system comprising of a clock generation (CKGEN) unit, a fine digital delay line (FDDL) unit, a coarse digital delay line (CDDL) unit, a phase detector (PD) unit, and three over-sampler units (OS) units in accordance with an embodiment of the invention.
[0010] [0010]FIG. 4 is a schematic diagram of the CKGEN that divides the local clock by 2 to generate 4 equally spaced clocks, the rising edges of these clocks being used as time references to synchronize the operation, of the entire system in accordance with an embodiment of the invention.
[0011] [0011]FIG. 5 illustrates OS sampling points and further decoding by the OS 2 unit to determine the time location of the incoming data transition in accordance with an embodiment of the invention.
[0012] [0012]FIG. 6 illustrates a state machine that issues control signals to the delay lines based on the current system state and the incoming data transition location in accordance with an embodiment of the invention.
[0013] [0013]FIG. 7 illustrates region e 1 which corresponds to the region between the first and second sampling points, e 2 which corresponds to the region between the second and third sampling points, and so forth in accordance with an embodiment of the invention.
[0014] [0014]FIG. 8 is a schematic diagram of the FDDL unit comprising four 4-to-1 multiplexers used to select the optimal in-cycle delay data (dn) from the 4 delayed data of both data_ 0 and data_ 1 paths and a dual-data port (dd) used when two data transitions are detected in a single cycle in accordance with an embodiment of the invention.
[0015] [0015]FIG. 9 is a schematic diagram of the CDDL unit comprising a multi-stage first-in first-out (FIFO) register array, where the outputs from the twin FIFO are combined into one using a multiplexer at the end of the FIFO in accordance with an embodiment of the invention.
[0016] [0016]FIG. 10 is a schematic diagram of a peripheral controller comprising a data resynchronization circuit, and coupled to a processor that is adapted to access data from the peripheral controller.
DETAILED DESCRIPTION
[0017] In one aspect, the invention describes a technique to ensure safe data capture and resynchronization of serial data obtained from an IEEE 1394-1995 decoder to a local clock of a circuit using the data. In one embodiment, the invention uses a digital delay locked loop based circuit to adaptively adjust the optimal sampling position thereby re-synchronizing the incoming data with the local clock.
[0018] As shown in FIG. 3, a re-timing circuit 25 according to one embodiment of the invention, comprises three over-sampler units 30 , 35 , and 40 , a clock generation (CKGEN) unit 45 , a phase detector 50 , a coarse digital delay line (CDDL) 55 and a fine digital delay line (FDDL) 60 . Because a digital delay line is used to synchronize the incoming data with the lock clock, acquisition time of 4-10 cycles is possible thereby eliminating the need for transition activities as in a PLL circuit. Over-sampling unit 30 is used to over-sample data_ 1 . Conversely, over-sampling unit 35 over-samples data_ 0 and over-sampling unit 40 over-samples the quarter clock. The over-sampling clocks are provided by CKGEN 45 . CKGEN 45 receives the local clock and generates clocks ck, dlck, ckb, and dlckb. As shown in FIG. 4, the four equally spaced clocks are phase shifted by a quarter cycle with respect to each other. In one embodiment, CKGEN 45 generates the four clocks by dividing the local clock by two using a frequency divider (e.g., flip flop). The rising edge of the first clock, ck, is then made to synchronize with a rising edge of the local clock. The rising edge of the second clock, dlck, is synchronized with the immediate falling edge of the local clock. The third clock, ckb, may be generated by inverting the first clock, ck, and the fourth clock, dlckb, may be generated by inverting the second clock, dlck. CKGEN 45 may comprise flip flops and inverters to generate the four equally spaced clocks in the manner described above.
[0019] The generated four equally spaced clocks are used as sampling points to sample the data data_ 1 , data data_ 0 , and the quarter clock. Because the sampling points derive from the local clock, as will be apparent below, the sampled data is in sync with the local clock and suitable for processing by the receiving circuit. Although four sampling points are shown in FIG. 5, more sampling points may be used.
[0020] The sampling points of the over-sampling unit 40 are used to determine the phase difference between the quarter clock, qrt_clk, and the local clock, clk. Assuming that only two sampling points are used, it would be difficult to determine if the quarter clock, qrt_clk, is leading or lagging the local clock. Using three or more sampling points, this determination is possible and is used by phase detector 50 to align the local clock with the quarter clock.
[0021] [0021]FIG. 6 is a phase detector 65 in accordance with one embodiment of the invention. At the core of phase detector 65 , there is a four-state state machine 70 corresponding to the number of sampling points. Thus, if the number of sampling points is three, a three-state state machine would be used. The regions e 1 -e 4 of the state machine are the sampled points of the over-sampling unit 40 which are further decoded to determine the phase transition of the quarter clock qrt_clk. As shown in FIG. 7, region e 1 corresponds to the region between the first and second sampling points. Region e 2 corresponds to the region between the second and third sampling points and so forth. As shown in FIG. 6, with the use of flip flops 80 and 83 , q 0 and q 1 , which represent data_ 0 and data_ 1 of the current state, are being input into four-state state machine 70 along with a receiving input from regions e 1 -e 4 . Thus, depending on the detected phase transition and the current state of machine 70 , phase detector 65 will transmit various control signals. Control signals including shift left (SL), shift right (SR), and dual data enable (DDE) control the coarse digital delay line (CDDL). The single data select (S) and dual data select (T), which are obtained using a plurality of flip-flops 75 , control the fine digital delay line (FDDL).
[0022] The operation of phase detector 65 is as follows: Assuming initially, a clock transition of the quarter clock qrt_clk occurs between the second and third sampling points, the region between the two will be decoded as e 2 which is inputted into state machine 70 . A data select (S) is transmitted to the fine digital delay line (FDDL) 85 . As will be described further below, FDDL 85 controls the phase difference within the local clock cycle (in-cycle). Thus, if the phase error is more than one local clock cycle, coarse digital delay line (CDDL) 110 is used to compensate for the multi-local clock cycle phase difference. SL or SR signals are transmitted to CDDL 110 if the quarter clock transition occurs before region e 1 or after region e 4 respectively. Assuming that state machine 70 is at state 2 , which reflects the inputted region e 2 , and the next sampling round shows that the quarter clock transition is occurring at region e 1 , this indicates that the quarter clock is leading. The state machine transmits the appropriate signals to FDDL 85 to compensate for the phase difference. State machine 70 appropriately updates its state to state 1 reflecting the inputted region e 1 . If a subsequent sampling round shows that the quarter clock transition is in region e 4 , then state machine 70 will recognize that the phase difference is multi-local clock cycle phase difference. Having detected a single data transition to FDDL 85 , state machine 70 will transmit an SL signal to CDDL 110 and an S signal while updating the state machine to state 4 .
[0023] [0023]FIG. 8 illustrates a fine digital delay line (FDDL) 85 in accordance with one embodiment of the invention. FDDL 85 comprises a crossbar structure of 4-to-1 multiplexers 90 , 95 , 100 , and 105 to select the optimal in-cycle delay of data_ 0 and data_ 1 . The operation is as follows: Assuming that signal e 2 has been inputted into state machine 70 , state machine 70 transmits an S signal to the second control line of multiplexers 90 and 95 . This causes the second sampled data point of over-sampling unit 30 and oversampling unit 35 which are in sync with the local clock, to be selected and passed through. In addition, a dual-data port (dd) is designed to cover the situation when two data transitions are detected in a single cycle. These multiplexers 90 , 95 , 100 , and 105 are controlled by S and T signals from phase detector unit 65 . Of course, this is but one embodiment of a delay line and other delay lines may be used to perform this function.
[0024] [0024]FIG. 9 illustrates a coarse digital delay line (CDDL) 110 in accordance with an embodiment of the invention. CDDL 110 comprises a plurality of first-in first-out (FIFO) registers 115 where each register is equivalent to one local clock cycle delay. CDDL unit 110 comprises of a twin 7-stage first-in-first-out (FIFO) register array to cover a ±6 cycle delay adjustment range, in order to account for a possible 6 bit-error in the IEEE 1394-1995 decoder. The input-to-output delay adjustment of CDDL 110 is done through controlling the data injection pointer 125 along FIFO 115 . Initially, the data injection pointer 125 is pre-set to the center of the FIFO array 115 and then adaptively controlled by the shift left (SL) and shift right (SR) signals from phase detector 65 . The operation is as follows: Assuming phase detector 65 detects a clock transition in region e 4 from the previous clock transition in region e 1 , phase detector 65 will recognize that the data transition is now occurring out of cycle. In this instance, state machine 70 in FIG. 6 transmits an S signal to the fourth control line of the multiplexers in FDDL 85 and also a shift-left (SL) signal to FIFO registers 115 of CDDL 110 . On receipt of the SL signal, CDDL 110 shifts left one bit delaying the data by one cycle to compensate for one cycle lead of the quarter clock over the local clock. The design allows up to two sets of data (dn and dd) to be injected into FIFO 115 simultaneously to cover non-, single-, and dual-data receiving in a single local clock cycle, as resulted from the time variation of the input data. Finally, the outputs from the twin FIFO 115 are combined into one using a multiplexer 120 at the end of FIFO 115 before sending out the sync data.
[0025] [0025]FIG. 10 is a schematic diagram that illustrates a system 130 wherein a peripheral controller 150 comprises a data resynchronization circuit 155 . Peripheral controller 150 is coupled to processor 140 via a serial or parallel bus 145 . Processor 140 is adapted to access data from peripheral controller 140 via bus 145 .
[0026] Memory 135 , and display controller 160 , may also be coupled to peripheral controller 150 via bus 145 . Monitor 165 may also be coupled to display controller 160 . Other peripheral devices 170 , such as a mouse, CD-ROM and video, may also be coupled to peripheral controller 145 .
[0027] [0027]FIG. 10 illustrates but one application of the invention, that is the personal computer, but may be used with other applications such as a work station, server, Internet driver or other fabric channels.
[0028] Compared to the analog delay locked-loop (DLL) synchronization approaches, the digital delay locked-loop (DLL) solution described in the invention is very suitable for system integration using advanced digital processes technology and design environment. Other advantages of this invention include: a full digital circuit implementation using highly reusable blocks for shorter development time, lower development cost, and higher manufacture yield; a twin-pipe (data_ 0 and data_ 1 ) architecture doubling the throughput of the data path and consequently allowing the core logic to operate at half of the core frequency; a scaleable architecture allowing extension of a locked-in range by simply increasing the delay line stage. Although the current circuit is implemented for IEEE 1394-1995 data communication, the technique described in this invention can also be used for most other data communication systems, such as a Community Access Television (CATV) network, the Public Switched Telephone Network (PSTN), the Integrated Services Digital Network (ISDN), the Internet, a local area network (LAN), a wide area network (WAN), over a wireless communications network, or over an asynchronous transfer mode (ATM) network.
[0029] In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will, however, be evident that various embodiments and changes can be made thereto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. | An apparatus comprising three sampling circuits to sample incoming data and a quarter clock. A clock generation unit is included to generate at least three sampling clocks from a local clock. Each of the three sampling clocks are configured to sample the incoming data and the quarter clock. A phase detector is also included to detect a phase difference between the quarter clock and the local clock and to generate a recovered quarter clock. A delay line is further included to delay the sampled incoming data and the recovered quarter clock by the detected phase difference. | 7 |
RELATED APPLICATION
[0001] This application is related to and claims the benefit of priority from French Patent Application No. 06 50030, filed on Jan. 4, 2006, the entirety of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a method of cross-linking a composition associating a polyethylene-based silane-grafted polymer with a filler of any kind.
[0003] A particularly advantageous, but non-exclusive application of the invention lies in the field of insulating materials for power and/or telecommunications cables.
BACKGROUND OF THE INVENTION
[0004] Polyethylene is known for presenting excellent dielectric properties, and also low cost price. That is why it is nowadays in widespread use for making insulating layers of power and/or telecommunications cables.
[0005] In order to provide improved thermomechanical properties, polyethylene is generally used in a cross-linked form. It is known that establishing a lattice of chemical bonds extending in all three dimensions serves to increase the high temperature behavior of this particular type of insulating material.
[0006] Cross-linked polyethylene is usually fabricated by silane cross-linking. That now-conventional technique consists initially in grafting the base polyethylene with a silane, by adding radicals using a peroxide. Thereafter, the compound as grafted in that way is subjected to cross-linking by hydrolysis and then to condensation, which requires the presence of water and a condensation catalyst. It should be observed that the catalyst is commonly constituted either by dibutyl tin laurate (DBTL) or by dibutyl tin dilaurate (DBTDL).
[0007] With a polyethylene, the silane cross-linking technique nevertheless presents the drawback of being unsuitable for being implemented directly in ambient air if said polyethylene is filled. Unfortunately, in cable making, it is extremely common practice for insulating materials to include fillers. This applies in particular to flame-retardant fillers for improving the behavior of power cables and/or telecommunications cables in the event of fire.
[0008] In order to remedy that difficulty, the only solutions presently in use consist in implementing the second cross-linking step of the silane technique either in a pool for 24 hours (h) at 63° C., or else in a sauna for 15 h at 90° C.
[0009] Nevertheless, both of those solutions are particularly expensive because of the cost of the extra equipment that is needed, because of the cost of the energy required for operation, and because of the cost of maintaining the installation.
[0010] Furthermore, since marking inks do not withstand passing through a pool or a sauna, it is not possible to mark each cable directly on leaving an extruder, and the marking operation must necessarily be performed as an extra operation on leaving the bath of liquid water or of steam. Thus, a consequence of using a pool or a sauna is to complicate quite considerably the industrial fabrication method in terms of logistics, and that again constitutes more extra costs.
OBJECT AND SUMMARY OF THE INVENTION
[0011] Thus, the technical problem to be solved by the subject matter of the present invention is to propose a method of cross-linking a composition comprising both a polyethylene-based silane-grafted polymer and a filler, which cross-linking method makes it possible to avoid prior art problems, in particular by being substantially less complicated to implement and thus implicitly being less expensive.
[0012] According to the present invention, the solution to the technical problem posed lies in the fact that the cross-linking method consists in mixing the composition with a condensation catalyst constituted by lauryl stannoxane having the following formula [(C 4 H 9 ) 2 Sn(OOCC 11 H 23 )] 2 O.
[0013] It should be understood that the term “silane-grafted polymer” conventionally designates a polymer on which a silane type compound has previously been grafted.
[0014] The concept of a “polyethylene-based polymer” relates to any low, medium, or high density polyethylene, and also any polyethylene-octene elastomer (POE), and regardless of the polymerization system involved.
[0015] Furthermore, it should be observed that the filler could, a priori, be of absolutely any kind.
[0016] The invention as defined presents the advantage of enabling a filled polyethylene to be cross-linked in ambient air and in a few days, with complete cross-linking being achieved within a period of less than 45 days. It is thus entirely appropriate to speak of self-cross-linking.
[0017] Consequently, the invention makes it possible to abandon the expensive and complicated step of passing through a pool or a sauna, and thus to eliminate the corresponding equipment. Independently of the purely monetary financial advantage associated with such omission, the resulting saving in time that results also serves to improve productivity.
[0018] Because of the self-cross-linking, cables can advantageously be marked continuously, directly at the outlet from an extruder. This also leads to a gain in productivity.
[0019] Furthermore, the use of a new catalyst does not require significant change to the overall industrial process of cable fabrication, and thus does not require significant change to the installations presently in use. In other words, this means that the cross-linking method of the invention can be implemented very easily using existing fabrication equipment.
[0020] According to a feature of the invention, the condensation catalyst is packaged in the form of a master batch.
[0021] This characteristic enables the lauryl stannoxane to be better dispersed within the batch, thereby achieving significantly greater effectiveness. For equivalent effect, it is consequently possible to use significantly less catalyst, thus implying a significant saving in terms of cost.
[0022] Packaging the lauryl stannoxane in the form of a master batch also makes it possible to measure out accurately the quantity of catalyst that is really necessary, which can be particularly advantageous given that the catalyst is liquid and is for use in very small quantities.
[0023] In particularly advantageous manner, the master batch comprises a polymer matrix having the lauryl stannoxane dispersed therein.
[0024] This naturally assumes that the polymer matrix of the catalyst master batch is compatible with the base polymer of the composition.
[0025] The polymer matrix of the master batch is preferably identical in nature with the base polymer of the composition.
[0026] This characteristic makes it possible in particular to avoid modifying the mechanical and dielectric properties of the final material.
[0027] In accordance with another advantageous feature, the composition contains 0.0036% to 0.0108% of condensation catalyst.
[0028] According to another advantageous characteristic, the composition contains 90 pcr to 190 pcr of filler.
[0029] In this respect, it should be understood that throughout this specification, the abbreviation “pcr” has the conventional meaning of percent of resin. Consequently, it designates the percentage by weight of a compound in question relative to the weight of the base polymer set arbitrarily as being 100.
[0030] According to another feature of the invention, the composition is also provided with at least one additive selected from a processing agent, an anti-oxidant, a colorant, an anti-UV agent, an anti-copper agent.
[0031] In particularly advantageous manner, the composition contains less than 3 pcr of processing agent.
[0032] According to another advantageous characteristic, the composition includes 0.5 pcr to 5 pcr of anti-oxidant.
[0033] According to another feature of the invention, the cross-linking method is implemented at ambient temperature.
[0034] According to another advantageous characteristic of the invention, the cross-linking method is implemented in ambient air.
[0035] Naturally, the invention also relates to any power and/or telecommunications cable including at least one insulating covering that is made from a composition cross-linked in application of the above-described method.
DESCRIPTION OF THE INVENTION
[0036] Other characteristics and advantages of the present invention appear from the following description of two comparative examples, said examples being given by way of non-limiting illustration.
[0037] The object of each of these Examples I and II is to compare the level of cross-linking in two identical filled polymer materials when left to cross-link in the open air, one of the materials including a condensation catalyst in accordance with the invention, and the other having only a prior art catalyst.
EXAMPLE I
Preparation of Samples
[0038] Two samples of materials A and B were prepared from two compositions that thus differed from each other solely in the nature of their respective condensation catalysts.
[0039] Specifically, the various ingredients for each of the compositions A and B were mixed, the resulting mixture was extruded, and the corresponding extruded sample was allowed to cross-link in the open air. It should be observed that in each case the condensation catalyst was added during extrusion, in the form of a master batch.
[0040] Table 1 below gives the respective compositions of the two material samples A and B.
[0000]
TABLE 1
Sample
A
B
Silane-grafted polymer (pcr)
100
100
Filler (pcr)
110
110
Processing agent (pcr)
3
3
Anti-oxidant (pcr)
1
1
DBTL (%)
0.072
—
Lauryl stannoxane (%)
—
0.072
[0041] It should be observed that the silane-grafted polymer in this first example was constituted by a linear low-density polyethylene grafted to 1% with a silane cocktail, which cocktail associated a peroxide and silane. Specifically, it was the composition sold under the name “CLDO” by the supplier Polimeri Europa.
[0042] The filler was of the flame-retardant type, being constituted by aluminum trihydroxide (ATH).
[0043] The DBTL used in sample A was as sold by the supplier Goldschmidt, under the reference Tegokat 218.
[0044] The lauryl stannoxane used in its sample B was as sold by the supplier Goldschmidt, under the reference Tegokat 225.
Hot-Set Test Under Mechanical Stress at 200° C.
[0045] In order to verify that each sample A and B had indeed cross-linked, it was subjected to a standardized hot-set test (HST) under mechanical stress.
[0046] That type of test is governed by the standard NF EN 60811-2-1. Specifically, it consists in loading one end of a dumbbell H2 type test piece with a mass corresponding to applying stress equivalent to 0.2 megapascals (MPa), and in placing the assembly in an oven that is heated to a given reference temperature to within ±2° C. for a duration of 15 minutes (min). After that time, the elongation of the test piece while hot and under stress is measured as a percentage. The suspended mass is then removed, and the test piece is kept in the oven for five more minutes. The permanent elongation that remains, also known as remanence, is then measured and expressed in percentage.
[0047] The greater the extent to which a material is cross-linked, the smaller the values of elongation and of remanence. Furthermore, in the event of a test piece breaking during the test or in the event of its elongation exceeding 100%, under the combined effects of mechanical stress and temperature, then the result of the test is logically considered as being a failure.
[0048] The results of the hot-set tests under mechanical stress at 200° C. are summarized in Table 2 below.
[0000]
TABLE 2
Sample
A
B
Hot-set test (200° C.)
failure
success
Time
D + 36
D + 15
Elongation (%)
—
50
Remanence (%)
—
10
[0049] It should be observed firstly that only sample B was successful in passing the hot-set test at 200° C., and was capable of so doing after 15 days only. This means that only the catalyst of the invention is capable of enabling the filled polyethylene to self-cross-link in open air.
[0050] In contrast, it can be seen that sample A was not capable of passing the hot-set test at 200° C. successfully, even after 36 days. This confirms the known fact that a typical prior art catalyst is not capable of generating fast cross-linking in a filled polyethylene.
EXAMPLE II
Preparation of the Samples
[0051] The two material samples C and D of the second example were prepared in a manner analogous to that described above for Example I.
[0052] Table 3 specifies the respective compositions of the samples in question.
[0000]
TABLE 3
Sample
C
D
Silane-grafted polymer (pcr)
100
100
Filler (pcr)
110
110
Processing agent (pcr)
3
3
Anti-oxidant (pcr)
3
3
DBTL (%)
0.0036
—
Lauryl stannoxane (%)
—
0.0036
[0053] The major difference compared with the first example comes from the specific nature of the silane-grafted polymer common to samples C and D. Specifically, it was a polyethylene octene grafted to 3% with a silane cocktail, which in this example likewise associated a peroxide and a silane. Specifically, the composition sold under the name “Exact8203/LL4004(70/30)” from the supplier Exxon was used.
[0054] The filler was still of the flame-retardant type, and specifically was still constituted by aluminum trihydroxide (ATH).
[0055] The DBTL and the lauryl stannoxane used respectively in samples C and D were identical in kind to those used respectively in samples A and B.
Hot-Set Test Under Mechanical Stress at 200° C.
[0056] Samples C and D were subjected to the same hot-set test under mechanical test as in Example I. The results of the various tests are summarized in Table 4 below.
[0000]
TABLE 4
Sample
C
D
Hot-set test (200° C.)
failure
success
Time (days)
D + 27
D + 20
Elongation (%)
—
60
Remanence (%)
—
0
[0057] The conclusions are entirely similar to those formulated for Example I.
[0058] It can thus be seen that only sample D was successful in passing the hot-set test at 200° C., and it could do so after only 20 days. This confirms the fact that only a catalyst in accordance with the invention is capable of causing a filled polyethylene to self-cross-link in the open air.
[0059] It should also be observed that sample C was not capable of passing the hot-set test at 200° C. successfully, even after 27 days. This is further proof that a typical catalyst of the prior art cannot lead to rapid self-cross-linking of a filled polyethylene. | A method of cross-linking a composition comprising firstly a polyethylene-based silane-grafted polymer, and secondly a filler. The invention is remarkable in that the cross-linking method consists in mixing the composition with a condensation catalyst constituted by lauryl stannoxane of formula [(C 4 H 9 ) 2 Sn(OOCC 11 H 23 )] 2 O. | 8 |
FIELD OF THE DISCLOSURE
The present disclosure relates to a measuring apparatus, and more particularly to a singularly housed retractable tape measure and range finder.
BACKGROUND OF THE DISCLOSURE
In the construction trades, many distances need to be measured quickly and accurately. These distances include the lengths of lumber to be cut, the internal dimensions of a room, dimensions of objects to be placed in rooms and through doorways, distances from a point to a house, and so on. For many years, the tool of choice for each of these dimensions was the conventional retractable tape measure. As is known, the retractable tape measure includes a tape wound about itself inside a housing that is spring loaded such that when the tape is extended and released, the tape is pulled back within the housing. The tape includes indicia to indicate to the user the distance measured. The tape measure can measure any distance, including the length to which a piece of lumber must be cut.
The tape measure is an excellent tool, but extending the tape over a long distance can be somewhat clumsy and slow. To address this issue, a sonic range finder was developed. In use of this tool, the user points the range finder at a specified target and presses a button. The range finder emits a waveform which is then reflected off the target back to the range finder. The ranger finder calculates the distance from itself to the target by measuring the time it takes for the reflected waveform to return.
The sonic range finder is also an excellent tool, however it is limited in that it can only measure internal dimensions, and not external dimensions. The term internal dimension is used to define a dimension in which at least one of the endpoints includes an inner surface facing the other of the endpoints. The term external dimension, on the other hand, is used to define a dimension in which neither of the endpoints include an inner surface that faces the other of the endpoints.
Thus, the dimension between a first and a second wall is an internal dimension, and the sonic range finder can measure such a dimension quickly and accurately, because the waves can be reflected off either wall. However, the dimensions of a piece of lumber are an external dimension, because there is no surface at the end of the piece of lumber to reflect the waveform. Thus, a sonic range finder cannot measure the length of a piece of lumber or the dimensions of a dresser, for example. Further, the sonic range finder cannot indicate a cut location on a piece of lumber at which point the user needs to cut the lumber to a predetermined length.
Thus, a user must carry both tools to be efficient. In many situations a user will measure the dimensions inside a room, then cut lumber to fit therein. The user first uses the sonic range finder to measure the internal dimensions of the room. The user then puts away the sonic range finder and grasps a tape measure. The user can then measure the lumber to be cut to fit within the room.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a combination measuring apparatus, constructed in accordance with the teachings of this disclosure.
FIG. 2 is a second perspective view of the combination measuring apparatus of FIG. 1 .
FIG. 3 depicts the apparatus of FIG. 1 being used to measure an internal distance.
FIG. 4 depicts the apparatus of FIG. 1 being used to measure an external distance of an object related to the internal distance of FIG. 3 .
While the disclosure is susceptible to various modifications and alternative constructions, certain illustrative embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the disclosure to the specific forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and the equivalents falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION
Referring now to the drawings, and in particular to FIGS. 1 and 2 , a combination tape measure and waveform range finder assembly 10 is disclosed. The assembly 10 includes a housing 12 . The housing can include a left side 14 , a right side 16 , a front side 18 , a back side 20 , a top side 22 , and a bottom side 24 . Disposed within the housing 12 is a tape measuring unit 26 , a waveform range finder unit 28 , and a display unit 30 . Further disposed on the housing is a belt clip 32 which the user can employ to store the assembly 10 on his or her belt. In this example, the belt clip 32 is disposed on the right side 16 .
The tape measuring unit 26 includes a retractable tape 34 with a free end 36 . A hook 38 is fastened to the free end 36 . In FIG. 1 , the retractable tape 34 is shown in an extended position in which the free end 36 has been pulled away from the housing 12 . The retractable tape 34 includes indicia 40 , disposed along its length. The indicia 40 comprise a plurality of individual marks 42 that indicate a distance from the free end 36 to that individual mark 42 , as is known. The retractable tape 34 is wound about itself into a winding (not seen) inside the housing 12 . The retractable tape 34 is spring loaded such it is urged back into the housing 12 and onto the winding, as is known.
The tape measuring unit 26 further includes a thumb lock 44 . The thumb lock 44 includes a thumb lever 46 that is disposed in a slot 48 in the housing 12 and is slidable between a first end 50 and a second end 52 of the slot 48 . When the thumb lever 46 is adjacent the first end 50 , the retractable tape 34 can move freely, albeit either with or against the force generated by the spring loading. When the thumb lever 46 is adjacent the second end 52 , the retractable tape 34 is locked and cannot extend or retract from the position that it is in. This functionality of locking the retractable tape 34 in a position is well known by those of skill in the art.
In another example not shown, the retractable tape 34 can include optical markings such that the distance indicated by the retractable tape can be read photoelectrically and the measurement can be stored digitally. Such a system is disclosed in U.S. Pat. No. 5,433,014 to Falk, et. al.
The waveform range finder unit 28 includes a cone 54 disposed on the front side 18 of the housing 12 . Inside the cone 54 is a pulse generator (not seen). A laser 56 is also disposed on the front side 18 of the housing 12 . A read button 58 and laser button 60 are both disposed on the left side 14 of the housing 12 .
Referring now to FIG. 3 , by pressing the read button 58 , a dimension is measured from the housing 12 to a target 62 . When the read button 58 is pushed, the pulse generator emits waveform pulses 64 . The cone 54 directs the pulses 64 to a predefined projection angle. The emitted pulses 64 travel to the target 62 and are reflected off the target 62 back to the housing 12 . The distance between the housing 12 and the target 62 is calculated from the time interval between the emission of the pulses 64 and their return. Other waveform measuring devices are well known in the art. The scope of this disclosure includes all such devices and is in no way limited to the example given herein.
The target 62 can be located by pressing the laser button 60 . When the laser button 60 is pressed, the laser 56 emits a laser beam 66 that projects linearly and results in a small dot 68 on the target 62 . The laser beam 66 is substantially coaxial with the emitted pulses 64 . The user of the device sees the dot 68 on the target 62 and understands that the distance being measured is between the housing 12 and the dot 68 . Although in this example two separate buttons 58 , 60 are shown, it is possible for a single button to actuate both the pulse generator and the laser 56 .
Referring back to FIGS. 1 and 2 , the waveform range finder unit 28 can further include a switch 70 disposed on the back side 20 of the housing 12 . In one example, when the switch 70 is not engaged, the waveform range finder unit 28 calculates the dimension from the target 62 to the front 18 of the housing 12 . In this example, when the switch 70 is engaged, such as when the back side 20 of the housing 12 is placed flush against a wall, the waveform range finder unit 28 calculates the dimension from the target 62 to the back side 20 of the housing 12 . In another example not shown, a two-position thumb-actuated switch can be implemented to instruct the waveform range finder unit 28 to measure from the target 62 to either the front side 18 or the back side 20 of the housing 12 . In another example, the waveform range finder unit 28 does not include any type of switch 70 , and only measures from either the front side 18 of the housing 12 or the back side 20 of the housing 12 to the target 62 . Although this is the least flexible, it is the least expensive.
The display unit 30 includes a display window 72 (hereinafter “window”) and a plurality of control buttons 74 adapted to control the display in the window 72 . The window 72 can be used to digitally display the dimension calculated by the waveform range finder unit 28 . If the tape measuring unit 26 includes components to optically read and digitally store the measurements of the retractable tape 34 as detailed previously, the window 72 can digitally display that dimension, too.
The plurality of control buttons 74 can include a standard button 76 , a metric button 78 , a save button 80 , and a toggle button 82 . By pressing the standard button 76 , the window 72 displays the dimensions in standard units. By pressing the standard button 76 multiple times, the display of the window 72 switches between a first display of feet and inches (i.e., 6 feet 2 inches) to a second display of total inches (i.e., 74 inches). Other units are, of course, possible.
By pressing the metric button 78 , the window 72 displays the dimensions in metric units. By pressing the metric button 78 multiple times, the window 72 switches between a first display of meters to a second display of centimeters. Again, other units such as millimeters or decimeters are possible.
When the save button 80 is pressed, the dimension displayed in the window 72 is saved to a memory (not shown). The memory can save any number of dimension depending on the configuration of the controller, although it is believed that a total of five dimensions would be a sufficient amount to retain and not be confusing to the operator. For example, if 15 dimensions were stored, the user might not remember which dimension corresponded to which of the objects or distances that were measured. However, in other situations this may not be a problem, and it may be desirable to store a number of dimensions even greater than 15.
When the toggle button 82 is pressed, the window 72 displays a first of the saved dimensions. The first displayed dimension can be the most recently saved dimension. When the toggle button 82 is pressed again, a second of the saved dimensions is displayed. The second displayed dimension can be the next most recently saved dimension, and so forth. Thus, the user can sequentially review each of the saved dimensions by repeatedly pressing the toggle button 82 .
Referring now to FIG. 3 , to use the assembly 10 , the housing 12 can be pointed at a target 62 . In this example, the housing 12 is pointed at a cabin 84 in preparation for constructing a deck. The housing 12 is placed at an end location 86 where the end of the deck is desired to be. The laser button 60 is pressed to locate the target 62 on the cabin 84 . The read button 58 is then pressed to determine the dimension between the end location 86 and the target 62 . The dimension calculated by the waveform range finder unit 28 is then displayed on the window 72 . If the user would like to change the units of the dimension displayed in the window, the standard button 76 or the metric button 78 can be pressed. The dimension can then be saved into the memory by depressing the save button 80 .
Referring now to FIG. 4 , lumber 88 can then be cut to build the deck. The assembly 10 can then be placed on the piece of lumber 88 with the hook 38 on the free end 36 disposed about the end of the piece of lumber 88 . The retractable tape 34 can be extended as is known to locate the desired cut length. If the user has forgotten the dimension measured by the waveform range finder unit 28 , the dimension can be accessed by pressing the toggle button 82 until the desired dimension is displayed.
Thus, assembly 10 can quickly and efficiently measure both internal and external dimensions. The waveform range finder unit 28 can measure the internal dimension between a first endpoint and a second endpoint. In the example detailed herein, the cabin 84 provides the inner surface facing the end location. The tape measuring unit 26 can measure an external dimension between a third endpoint and a fourth endpoint. In the example detailed herein, the dimension of the length of the piece of lumber 88 is an external dimension because neither of the endpoints include an inner surface that faces the other of the endpoints. By using a single piece of equipment, both internal and external dimensions can be measured and saved, thereby saving time and improving accuracy. The user does not have to carry separate pieces of equipment. Further, by using the save function, the dimensions can be stored directly in the assembly 10 itself, thereby eliminating the possibility that the user will forget or lose the dimension, i.e., lose a piece of paper the dimension was written on, prior to cutting a piece of lumber related to the dimension.
The shape of the housing 12 disclosed in FIGS. 1–4 is that of a typical tape measure that is extended on its front side 18 to accommodate the extra components such as the display unit 30 and the waveform range finder unit 28 . However, those of ordinary skill in the art may determine a different configuration for a housing 12 that includes the components detailed herein. Accordingly, the claims as detailed herein shall in no way be limited to the configuration and/or layout of the housing 12 as disclosed in the FIGS. 1–4 .
From the foregoing, one of ordinary skill in the art will appreciate that the present disclosure sets forth a measuring apparatus. However, one of ordinary skill in the art could readily apply the novel teachings of this disclosure to any number of situations. As such, the teachings of this disclosure shall not be considered to be limited to the specific examples disclosed herein, but to include all applications within the spirit and scope of the invention. | A measuring apparatus includes a housing with a retractable tape, a waveform range finder, and a laser pointer disposed within the housing. The retractable tape includes indicia corresponding to a distance. A save button is further disposed on the housing, wherein upon the depression of the save button, the distance measured by waveform range finder is saved to a memory. A display on the housing indicates the dimension measured by the waveform range finder. | 6 |
FIELD OF INVENTION
The present invention relates to a method for reducing the polymer and bentonite requirement in papermaking wherein medium and high molecular weight polymers are reacted with bentonite. Further, mechanical shearing of the furnish after polymer addition is not required.
BACKGROUND OF INVENTION
Economy and quality are concerns in the art of paper making. Those skilled in the art are always seeking to optimize these two features of the paper making process. The basic paper making process is known to those skilled in the art. For the sake of completeness, a general description of the paper maker's art is presented herein.
The material that paper is made from is called "furnish". Furnish is mostly fiberous material, to which is sometimes added mineral fillers, and chemical additives. The most common fiberous material is wood pulp. Grasses, cotton, and synthetics are used occasionally. Wood is made up of fibers (cells) which are held together with lignin.
Wood pulp is made by either chemically or mechanically separating the fibers. Different methods give variations in quality. Chemical wood pulp is typically of high quality. It as long smooth fibers, but is expensive to produce. Mechanical pulp is less expensive. The fibers are shorter, often with a very rough surface. Recycled pulp is made by slurrying waste paper in water. The fibers come out shorter and more degraded than they were originally. A variety of methods are used to bleach the fibers whiter, and remove contaminants. Some of these methods further degrade the fibers. Extremely short fibers are called "fines" and are less than 1/100 of an inch long. Fines can amount to over 50% of the total fiber.
The wood pulp or furnish is transferred to the paper machine as a slurry of about 4% fiber and 96% water and is called "thick stock". Mineral fillers may be added to this slurry. A typical addition is 10% filler, which is commonly either kaolin clay, or calcium carbonate (e.g., chalk). These fillers are very small particles, typically around 1 micron in size. Chemicals are then added to improve the properties of the paper, such as strength, water resistance or color.
At this point the furnish is ready to be added to the paper machine. In order to make paper, the furnish is further diluted down, to approximately 1.0% solids. This is referred to as "thin stock". The "thin stock" goes through screens and cleaners which impart a great deal of shear into the slurry. The "thin stock" then goes into the "headbox" which delivers the slurry onto a moving "forming" fabric or "wire".
After the furnish is put on the forming fabric or "wire", most of the water is removed by gravity and vacuum. The fines (much of the mechanical and recycled fiber) and all of the filler are small enough to go through the fabric or "wire". In order to keep these particles in the paper, they must be flocculated into larger particles.
While on the "wire" the solids content is raised up to around 15%. The paper is then run through presses that squeeze more water out to give solids of approximately 40-50%. The systems that use high molecular weight polymers give good dewatering on the wire, but often retard dewatering in the press section.
The final water removal stage uses steam dryers. A very small change in water removal in the press section makes a huge difference in the dryer section. The dryer section is the largest part of the machine, and typically limits the production rate.
Those skilled in the art of papermaking are always seeking ways to improve the paper manufacturing process. Specifically, U.S. Pat. No. 4,305,781, assigned to Allied Colloids Limited, discloses a method of making paper with improved drainage and retention properties of a cellulosic suspension. The method involves the addition of polymers having a molecular weight of above 500,000 to about 1,000,000 or above (column 3, lines 8-13) to the suspension. The polymers employed must be substantially non-ionic such as polyacrylamides (column 3, lines 14-16 and lines 27-33). The polymer is added the suspension after the last point of high shear prior to sheet formation (column 3, lines 66-68). The bentonite is added to the suspension in the thick stock, the hydropulper, or the re-circulating white-water (column 4, lines 3-8). The bentonite must be added prior to the polymer and at least one shear point will occur between the bentonite and polymer addition. The patent does not disclose the formation of small flocs.
U.S. Pat. No. 5,015,334, assigned to Laporte Industries Limited, discloses a colloidal composition and its use in the production of paper and paperboard (column 1, lines 9-11). The patent discloses that a polymer can be added to paperstock followed by adding bentonite to the paperstock without shearing between the addition of the polymer and the bentonite (column 2, lines 38-52 and column 4, lines 19-29). The polymer employed is a low molecular weight water-soluble, high charge density polymer having a molecular weight below 100,000 (column 3, lines 12-25).
Although the patent discloses that shearing is excluded between the addition of the polymer and bentonite in treating the paperstock, the patent does not disclose the formation of small flocs as the subject invention. Also, the patent employs low molecular weight polymers, not the medium molecular weight polymers, i.e., 100,000-2,000,000, as the process of the present invention.
U.S. Pat. No. 5,393,381, assigned to S N F, France, discloses a process for the manufacture of paper or cardboard having improved retention properties (column 1, lines 6-8). The process involves adding a branched, high molecular weight polymer such as a polyacrylamide (column 2, lines 43-56) to paper pulp followed by shearing the mixture (column 3, lines 28-34) then adding bentonite to the mixture (column 3, lines 34-37).
The high molecular weight branched polymers are employed because such polymers retain bentonite on a paper sheet better than non-branched polymers (column 2, lines 14-23).
The patent does not disclose employing the specific medium molecular weight branched polymers of the subject invention. Further, there is no discussion of the formation of small flocs. Additionally, the patent employs a shearing process between the addition of the polymer and the bentonite to the pulp unlike the present invention which eliminates the shearing process.
U.S. Pat. No. 5,676,796 assigned to Allied Colloids Limited, discloses a method for making paper or paperboard (column 1, lines 1-5). The method is directed to improving the retention, drainage, drying, and formation properties in paper making (column 3, lines 42-51). The process involves forming a thick cellulosic stock suspension and flocculating (column 3, lines 54-61 and column 4, lines 4-8) with a first polymer (column 6, lines 64-67 and column 7, lines 1-7). The first polymer employed can be a low anionic, a non-ionic, and a low and medium cationic polymer (column 9, lines 63-67 and column 10, lines 1-6). The thick stock is then diluted to form a thin stock (column 3, lines 62-63). The large flocs are then formed into small dense flocs in the thin stock by adding a coagulant such as a non-ionic polymer having a molecular weight of below 1,000,000 or 500,000 (column 4, lines 8-14, column 7, lines 8-33, and column 11, lines 42-51). In addition to the first and second polymer, bentonite can be added either before, with, or after the addition of the flocculant polymer (column 6, lines 50-63).
Preferably, the bentonite is added after the addition of the second polymer to the thin stock (column 4, lines 20-24). Prior to adding the bentonite, the stock is sheared (column 6, lines 58-63 and column 12, lines 36-39).
Although U.S. Pat. No. 5,676,796 discloses the formation of small flocs, by adding a polymer having a molecular weight of below 1,000,000, the method of the present invention employs a medium molecular weight polymer to form small flocs without the formation of large flocs by high molecular weight polymers as disclosed in U.S. Pat. No. 5,676,796. The present invention employs some high molecular weight polymers only to maintain the stability of the small flocs. Further, the method disclosed in U.S. Pat. No. 5,676,796 always employs shearing prior to adding bentonite. In contrast, the present invention does not employ shearing between adding the polymer and bentonite to the papermaking furnish.
Applicants' invention improves on the art because their program uses less polymer than a conventional bentonite program, improves press section dewatering, which increases the solids going into the dryers, and reduces drying requirements. Further, one less shear step is required.
DEFINITIONS AND USAGES OF TERMS
The term "furnish," as used herein, means a mostly fiberous material, to which is sometimes added mineral fillers, and chemical additives. The most common fiberous material is wood pulp. Grasses, cotton, and synthetics are used occasionally.
The term "bentonite", as used herein, means an alkaline activated montmorillonite or similar clay such as hectorite, nontrite, saponite, sauconite, beidellite, allevardite, halloysite, and attapulgite. The bentonite clay must be swelled in water to expose maximum surface area. If the clay does not swell naturally, it must be activated, or converted to it's sodium, potassium, or ammonium form. This type of activation is obtained by treating the clay with a base such as sodium or potassium carbonate.
The term "copolymer," as used herein means a polymer produced from more than one type of monomer.
The term "homopolymers," as used herein means a polymer produced from a single type of monomer.
The term "floc," as used herein, means: an agglomeration of long fibers, fines and fillers.
The term "retention," as used herein, means that portion of the solid phase of the furnish that is retained on the forming fabric (i.e., wire).
The term "first pass ash retention," as used herein, means the amount of ash retained on the wire compared to the total amount of ash delivered to the wire.
The term "charge density," as used herein, means the amount of positive electrical charge relative to the mass of the polymer.
The term "Canadian Standard Freeness (CSF)," as used herein, means a measure of the rate at which pulp will allow water to freely drain out; it is an indication of the relative amounts of long and short fibers in the furnish.
SUMMARY OF THE INVENTION
The present invention relates to a method for improving the retention and drainage of papermaking furnish comprising the steps of:
a. adding 0.005% to 0.25% by weight of at least one cationic high charge density polymer of molecular weight 100,000-2,000,000 having a charge density in excess of 4.0 Meq. to said furnish, after all points of high shear, to form small flocs having a size range of less than 1/4 inch in diameter;
b. Adding 0% to 0.20% by weight of at least one polymer having a molecular weight greater than 2,000,000 and a charge density of less than 4.0 Meq;
c. adding 0.025-2.0% by weight water swellable bentonite clay.
The present invention further relates to a method for improving the retention and drainage of papermaking furnish comprising the steps of:
a. adding 0.005% to 0.25% by weight of at least one cationic high charge density polymer of molecular weight 100,000-2,000,000 having a charge density in excess of 4.0 Meq selected from the group consisting of crosslinked polyethyleneimine homopolymers or copolymers or polymers produced from ethyleneimine, amidoamine, acrylamide, epichlorhydrate, diallyldimethylamonium halides, allylamines, etheramines, vinylamines, vinyl-heterocycles, N-vinylimidazole and methylacrylates, to said furnish, after all points of high shear, said high shear occurring prior to said polymer addition, to form small flocs having a size range of less than 1/4 inch in diameter;
b. adding 0% to 0.20% by weight of at least one polymer having a molecular weight greater than 2,000,000 having a charge density of less than 4.0 Meq selected from the group consisting of, polyacrylamides produced by copolymerizing acrylamide and/or methacrylamide with anionic monomers such as acrylic acid, methacrylic acid, maleic acid, vinyl sulphonic acid, or cationic monomers such as C 1 - or C 2 -alkylamino-C 2 -C 4 alkyl (meth)acrylates, diethylamino-Ethyl acrylate, diethylaminoethylmethacrylate, dimethylaminopropyl acrylate, dimethylaminobutyl acrylate, dimethylaminopentyl acrylate and the corresponding methacrylates;
c. adding 0.025-2.0% by weight of a hydrated slurry of a swellable bentonite clay.
All dosages are based on dry polymer or pigment as a weight percent (weight %) of dry furnish unless otherwise indicated.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a method for improving the retention and drainage of papermaking furnish comprising the steps of:
a. adding 0.005% to 0.25% by weight of at least one cationic high charge density polymer of molecular weight 100,000-2,000,000 having a charge density in excess of 4.0 Meq. to said furnish, after all points of high shear, to form small flocs having a size range of less than 1/4 inch in diameter;
b. Adding 0% to 0.20% by weight of at least one polymer having a molecular weight greater than 2,000,000 and a charge density of less than 4.0 Meq;
c. adding 0.025-2.0% by weight water swellable bentonite clay.
The present invention further relates to a method for improving the retention and drainage of papermaking furnish comprising the steps of:
a. adding 0.005% to 0.25% by weight of at least one cationic high charge density polymer of molecular weight 100,000-2,000,000 having a charge density in excess of 4.0 Meq selected from the group consisting of crosslinked polyethyleneimine homopolymers or copolymers or polymers produced from ethyleneimine, amidoamine, acrylamide, epichlorhydrate, diallyldimethylamonium halides, allylamines, etheramines, vinylamines, vinyl-heterocycles, N-vinylimidazole and methylacrylates, to said furnish, after all points of high shear, said high shear occurring prior to said polymer addition, to form small flocs having a size range of less than 1/4 inch in diameter;
b. adding 0% to 0.20% by weight of at least one polymer having a molecular weight greater than 2,000,000 having a charge density of less than 4.0 Meq selected from the group consisting of, polyacrylamides produced by copolymerizing acrylamide and/or methacrylamide with anionic monomers such as acrylic acid, methacrylic acid, maleic acid, vinyl sulphonic acid, or cationic monomers such as C 1 - or C 2 -alkylamino-C 2 -C 4 alkl (meth)acrylates, diethylamino-Ethyl acrylate, diethylaminoethylmethacrylate, dimethylaminopropyl acrylate, dimethylaminobutyl acrylate, dimethylaminopentyl acrylate and the corresponding methacrylates;
c. adding 0.025-2.0% by weight of a hydrated slurry of a swellable bentonite clay.
All dosages are based on dry polymer or pigment as a weight % of dry furnish unless otherwise indicated.
THE PRACTICE OF THE PRESENT INVENTION
STEP a:
Any cationic polymer with a charge density greater than 4.0 Meq, and molar mass in excess of 100,000 can be used as the medium molecular weight polymer in Step 1 of the present invention.
Selection of the proper medium molecular weight cationic polymer, is critical. There are two performance factors to consider. A substantial difference in retention and drainage has been observed between polymers. In addition, some polymer types control the level of additional flocculation of the high molecular weight polymer far better than others. Improved total performance typically occurs with increasing charge density, molecular weight and significant branching or crosslinking in the polymer chain. Preferred polymers include those with charge densities of 6.0 Meq or higher, and molecular weight in excess of 250,000. More preferred are those polymers containing ethyleneimine, or amidoamine with molecular weight in excess of 500,000. The most preferred polymers are modified polyethyleneimine polymers which are graft copolymers of polyethyleneimine and amidoamine crosslinked to form a highly branched structure, such as POLYMIN® SKA available from BASF, Mt. Olive, N.J. The POLYMIN® products have a molecular weight of about 1,200,000 and a charge density in the range of 8 to 14 Meq at a 4.5 pH.
The cationic medium molecular weight polymer is used at levels of 0.005 to 0.25 weight %. The preferred use level is 0.01 to 0.2 weight %, the more preferred use level is 0.015 to 0.15 weight %. The most preferred use level is 0.02 to 0.10 weight %.
When the forming section of the paper machine has only low to moderate shear, the high charge density cationic polymer of Step a followed by bentonite will normally be sufficient. Under higher shear conditions, the microflocs formed by the high charge density cationic polymer may not have sufficient stability. A second polymer must now be added. This is Step b. of the present invention.
STEP b:
The polymer(s) used in Step b. can be any polymer with a molecular weight in excess of 2 million, and which is reactive to the furnish. It will typically be used at dosages below 0.1 weight %. Preferred level is 0.001 to 0.1 weight %. Most preferred level is 0.01 to 0.06 weight %. Preferred products are polyacrylamides with a molecular weight of 4 million or greater. More preferred are cationic acrylamides, and most preferred are cationic acrylamides with a charge density of less than 4.0 Meq, preferably between 0.8 and 2.5 Meq. An example of a suitable high molecular weight polymer is Polymin® KE78 (cationic polyacrylamide) from BASF AG, Ludwigshafen, Germany.
Typically, Step a. precedes Step b. However, it is often possible to premix the Step a. and b. polymers and use a single addition point. The two polymers must of course be compatible for this type application. Use of this simultaneous addition technique is especially well suited when a combination of modified polyethyleneimine, and cationic polyacrylamide is used. In this case, not only is polymer addition simplified, but a slight improvement in polymer efficiency is often observed.
STEP c:
After the microflocs are formed, bentonite clay is added to the furnish. The normal application rate is 0.025 to 2.0 weight %, based on furnish solids. Preferred application rates are 0.05 to 1.5 weight %, more preferred 0.1 to 1.0 weight %, and most preferred 0.2 to 0.5 weight %. The bentonite clay may be any silicate that has charged sites capable of reacting with polymer. Preferred clay is an alkaline activated montmorillonite or similar clay such as hectorite, nontrite, saponite, sauconite, beidellite, allevardite, halloysite, and attapulgite. More preferred are the montmorillonite clays, and most preferred are those that exhibit substantial viscosity when slurried in water at 5 to 10 percent solids, and allowed to age. An example of this type product is Opazil® NH from BASF Corp.
The bentonite clay must be swelled in water (hydrated) to expose maximum surface area. This occurs after the pigment is slurried in water and allowed to age. The aging process typically takes 30 to 150 minutes. If the clay does not swell naturally, it must be activated, or converted to it's sodium, potassium, or ammonium form. This type of activation is obtained by treating the clay with a base such as sodium or potassium carbonate. Application of shear to the slurry can reduce the time required for some clays to swell.
The application point for the bentonite is after the polymer has been mixed with the urnish. This will typically be just before the headbox or vat. Optimum results are obtained when there are no shear points between or after the polymer and bentonite applications.
OPTIONAL INGREDIENTS
Some papermaking systems have high levels of contaminants in the water circuit. These contaminants are typically anionic materials in either a colloidal state, or in solution. Some examples include wood resins, deposit control agents, pulping, bleaching or deinking chemicals, waste paper contaminants, and humic acid. In the case of heavily contaminated systems, it may be preferable to pretreat the furnish with at least one anionic scavenger.
The anionic scavenger can be any cationic substance. Preferred substances have a high cationic charge, such as aluminum containing compounds including, but not limited to, aluminum sulfate, polyaluminum chloride and/or high charge density (Meq>6.0), cationic polymers such as polyethyleneimine, polydadmac, polyvinylamine, or any other high charge density cationic polymer. More preferred are those polymers with a charge density of 8.0 Meq or higher. Most preferred are polyethyleneimine cationic polymers with a charge density above 10.0 Meq, and a molecular weight of about 750,000. An example of this type product is Polymin® PL from BASF Corp.
In some cases it may be possible to use the same polymer for charge neutralization as is used in Step a. This is done for the sake of simplifying the number of products needed. If on the other hand, maximum polymer efficiency is sought, the anionic scavenger will typically be higher in cationic charge, and lower in molecular weight than the Step a. polymer.
In addition, standard papermaking additives typically can be used in combination with this invention. This includes products that improve wet or dry strength, sizing or absorbency, reduce foam, bacterial growth or deposits as well as pigments or coloring agents. If any of the additives are highly anionic, it is normally preferable to add them with at least one shear point between the additive, and the cationic polymers.
THE FOLLOWING NON-LIMITING EXAMPLES ILLUSTRATE THE PRESENT INVENTION
Basic Lab Protocol:
A mixture of 50 percent bleached kraft softwood with a Canadian Standard Freeness (CSF) of 700, 40 percent thermomechanical pulp with a CSF of 10, and 10 percent recycled coated paper is diluted to 0.6 weight percent solids with white water. Alum is added to achieve a 4.8 pH. The furnish (1000 ml) is treated with polymer, then the microparticle bentonite or colloidal silica (if any) is added. The suspension is placed in a Modified Schopper Reigler drainage tester (MSR), and the time required for 300 cc of filtrate to drain is logged. The solids in the filtrate is then determined by filtering the 300 cc of filtrate through a No. 4 Watmanno filter paper under vacuum.
EXAMPLE 1
Example 1 lab series was run with each polymer added at 0.025 weight % and activated bentonite added at 0.25% based on dry product on paper stock. No shear was added in this first series the tests. The effect on fines and filler retention is shown below.
______________________________________ Unretained Solids (mg)/300 mg of filtratePolymer Type Polymer only After Bentonite______________________________________No polymer 1270 1190Modified Polyethyleneimine 940 420Polyamidoamine 1050 550Polyethyleneimine 1070 510PolyDADMAC 1230 670Polyetheramine 1140 710______________________________________
As can be seen, the addition of bentonite clay after a high charge density polymer resulted in improved retention. The polymers were listed in descending molecular weight. The first three products were substantially branched while the last two products were predominantly linear. The benefits of higher molecular weight and a branched configuration are apparent.
EXAMPLE 2
The following chemicals were used in these comparisons:
Polymer A; Modified polyethyleneimine (Polymin® SKA from BASF Corp.) Polymer A is produced by grafting polyethyleneimine onto polyamidoamine, and then crosslinking to form a product with a molecular weight of slightly over 1,000,000 and a cationic charge density of 9 Meq/gram. reported as dry product.
Polymer B, a high molecular weight cationic polyacrylamide emulsion with a molecular weight of approximately 5,000,000 and a charge density of 1.8 Meq/gram (Polymin® PR8578 from BASF Corp.)
Microparticle C, activated bentonite clay (Opazil® NH by BASF Corp) formed by slurrying a sodium carbonate activated montmorillonite clay and water, and gently agitating until the viscosity peaks. Reported as dry product.
Microparticle D, colloidal silica dispersion, as received (BMA® 780 from Akzo Nobel)
Polymer E, a nonionic polyacrylamide. (Polymin® NP4 from BASF Corp.)
Polymer F is polyethyleneimine with a molecular weight of 700,000 and a charge density of 20 Meq. (Polymin® PR971L from BASF Corp.)
Unless stated otherwise, the order of addition is polymer first, shear (if applied) followed by the microparticle.
______________________________________ Unretained Drainage Solids-mg/Test#Polymer Shear Microparticle time 300 mg of filtrate______________________________________1 blank no none 178 11902 0.02% A no none 149 10103 0.02% B no none 147 7504 0.01% A0.01% B no 0.25% C 45 3055 0.02% B yes 0.25% C 143 9206 0.04% B yes 0.25% C 112 7107 0.06% B yes 0.25% C 53 2658 0.02% B yes 0.25% D 74 4709 0.03% B yes 0.50% D 42 32010 0.01% A0.01% B yes 0.25% C 48 46011 0.01% A0.01% B no 0.50% C 47 600 added first12 0.02% E no 0.50% C 64 640 added first______________________________________
In these tests, Test 12 is the organosorb system as disclosed in U.S. Pat. No. 2,368,635, incorporated by reference herein, and Test 11 is described in U.S. Pat. No. 4,749,444, incorporated by reference herein. Both of these tests, as well as Tests 2 and 3 (polymer only) gave insufficient retention. Test 9 is the optimized Composil® collodial silica system, while Test 7 is the Hydrocol®, bentonite system as described in U.S. Pat. No. 5,676,796, incorporated by reference herein. Note that the present invention (Test 4) gives equivalent performance with significantly lower chemical applications. The floc size for Tests 4 and 7 were similar, while Test 9 had slightly larger floc size. Test 10 indicates that the addition of shear to the invention reduces system performance.
EXAMPLE 3
The benefits of utilizing an anionic scavenger was investigated. These tests used the same furnish as in Example 2, with the exception that Test #4 and #5 deleted the treatment with alum. The polymers used were also the same as those used in Example 2, Polymer A is modified polyethyleneimine, Polymer B is cationic polyacrylamide, and Polymer F is polyethyleneimine with a molecular weight of 700,000 and a charge density of 20 Meq. (Polymin® PR971 L from BASF Corp.)
______________________________________ UnretainedTest#Polymer Shear Microparticle Drainage time Solids-mg______________________________________1 0.01% A no 0.25% C 45 3050.01% B2 0.01% F no 0.25% C 35 2200.01% A0.01% B3 0.02% A no 0.25% C 39 2350.01% B4 0.01% A no 0.25% C 54 3600.01% B5 0.01% F no 0.25% C 37 2500.01% A0.01% B______________________________________
Test #4 is the invention with no prior treatment of the furnish to reduce detrimental anionic substances. Test #5 utilized an anionic scavenger (Polymer F) in addition to the invention. In test #1, 2, and 3, alum was added prior to the polymers at approximately 0.5% based on dry furnish. Tests #2 used an anionic scavenger (Polymer F) in addition to the alum. Test #3 utilized additional medium molecular weight polymer from the invention (Polymer A) in place of the anionic scavenger in test #2.
Use of an anionic scavenger improved retention and drainage in all 4 cases. Note that the lowest retention, and slowest drainage where obtained on test #4 which used no anionic scavenger. Comparing Test #2 and #3 reveals that using Polymer F to pretreat the furnish gave superior results to using additional Polymer A. Comparing Test #1 with Test #5 indicates that polymer as a neutralizer gives superior performance over alum. However, the greatest effect was observed in Tests #2 and #3 using both polymer and alum.
EXAMPLE 4 (Plant Trial)
Further evidence of the superiority of the invention, is exhibited in the following paper machine plant trial data. The twin wire machine was running lightweight coated paper at 3600 feet per minute using 44% thermomechanical pulp, and 56% bleached softwood kraft. The furnish had been treated with alum and polyethyleneimine prior to the paper machine to neutralize and fixate detrimental substances. The polymers (A, B and C) utilized are the same as those in the prior examples. The polymers were applied after the last point of high shear, to the discharge of the headbox screens, and the bentonite clay was added 15 feet farther downstream. The first pass ash retention is calculated by the difference in ash concentration between the headbox and tray water, divided by the headbox concentration.
______________________________________ Trial (Applicant's Standard Program Invention)______________________________________Retention Aids 0.025% A 0.025% A 0.02% B 0.02% B 0.30% CTray Solids 0.62% 0.53%Headbox Drainage Time 134 sec 109 secFirst Pass Ash Retention 28% 36%Formation Index 91 91______________________________________
As can be seen, the invention improved retention and drainage without an increase in polymer flow. Sheet formation was unaffected, proving that the proper chemical selection can modify the floc structure without the need for shear. | The present invention relates to a method for reducing the polymer and bentonite requirement in papermaking wherein medium and high molecular weight polymers are reacted with bentonite. Further, mechanical shearing of the furnish after polymer addition is not required. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application is a Continuation-in-Part of U.S. patent application Ser. No. 09/515,870 filed Feb. 29, 2000, now abandoned, which is a Continuation of U.S. patent application Ser. No. 09/051,976, filed Sep. 14, 1998 now U.S. Pat. No. 6,053,197, and PCT Application Ser. No. PCT/US95/17187, filed Oct. 25, 1995, which is a Continuation-In-Part of both U.S. patent application Ser. No. 08/548,281, filed Oct. 25, 1995, now abandoned, and PCT Application No. PCT/US95/16064, filed Dec. 11, 1995, both entitled Horizontal-Flow Oil-Sealant-Preserving Drain Odor Trap.
REFERENCE REGARDING FEDERAL SPONSORSHIP
Not Applicable
REFERENCE TO MICROFICHE APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to sealed odor traps for waterless urinals, anti-evaporation floor drain traps and, more particularly, to improvements in the internal structure of oil-sealed odor traps for prolonging sealant retention and for protection against high pressure water flushing.
2. Description of Related Art and Other Considerations
With increasing emphasis on water conservation, there is continuing interest in toilets and urinals designed to minimize the amount of water consumed in flushing, to mitigate excessive demands on both water supplies and wastewater disposal systems, both of which have tended to become overloaded with increasing populations.
Sanitation codes require urinals to provide an odor seal to contain gasses and odors which develop in the drain system; this function is conventionally performed by the well known P-trap or S-trap in which the seal is formed by a residual portion of the flushing water. This seal effectively provides a barrier to sewer odors from passing from the drainpipe beyond the trap. However, the upward-facing liquid surface communicates freely with the user environment and, therefore, the trap must be kept free of residual urine by copious flushing to prevent unacceptable odor levels from the liquid in the trap. As a result, a large amount of water is consumed in flushing these conventional urinals. Especially in the United States over many years when water was cheap and plentiful, conventional flushing type urinals and water-wasteful toilets held an unchallenged monopoly. However, more recently, threatened and real water shortages have aroused new environmental concerns and heightened conservation awareness as evidenced by the introduction of low flush toilets.
As the cost of water increases and budgets tighten, the prospect of a viable waterless urinal system becomes extremely attractive to a wide range of public agencies, cities, states, penal institutions, defense establishments, recreational and parks departments and the like. Waterless urinals utilizing oil-sealed odor traps are becoming viable. However, the present inventor has discovered that a key factor in their potential is the attainment of low maintenance, and that this is largely dependent on the longevity of the liquid sealant which, in turn, is related to the internal structure of the odor trap. Thus, the present inventor has recognized that improvements are desirable both in the rate of depletion under normal service conditions and in protection against catastrophic sealant loss due to high pressure water flushing which, though not required, can occur inadvertently.
Known prior art is listed, as follows.
List of References
U.S. Pat. No.:
Patentee:
Patent No:
Patentee:
303,822
D'Heureuse
4,411,286
Ball
1,050,290
Posson
4,432,384
Guiboro
3,829,909
Rod, et al.
4,773,441
Biba
4,026,317
Ekstrom
5,159,724
Vosper
4,028,747
Newton
5,203,369
Hwang
4,045,346
Swaskey
318264 Germany
Zeigler
4,244,061
Webster, et al.
2816597.1 Germany
Ernst
4,263,934
Redden, et al.
606,646 Switzerland
Ernst
Statement of the Prior Art
U.S. Pat. No. 303,822 (D'Heureuse) discloses a wastewater pipe S-trap into which a disinfectant or deodorizer is introduced.
The use of an oil as a recirculated flushing medium in a toilet system is disclosed in U.S. Pat. No. 3,829,909 (Rod, et al.).
The use of oil in toilets to form an odor trap is disclosed in German Patent No. 121356 (Beck, et al.) and in U.S. Pat. Nos. 1,050,290 (Posson) and U.S. Pat. No. 4,028,747 (Newton).
Bell traps, essentially a coaxial form of S-trap, have been known for over a century; a popular form is exemplified in German Patent No. 318264 (Zeigler). A multiple baffle structure is disclosed in U.S. Patent No. 4,026,317 (Ekstrom). Center-entry coaxial trap configurations are shown in U.S. Pat. No. 4,045,346 (Swaskey) and U.S. Pat. No. 5,203,369 (Hwang).
Beetz introduced an oily liquid layer floating in the trap as an odor barrier through which urine and water can permeate downward. Beetz makes the oil mixture have disinfectant properties and to have “innate adhesion power to attach itself to the odor lock parts so that the latter cannot be attacked by urine”. The Beetz disclosure includes daily maintenance, including cleaning, and coating the cast iron parts of the urinal, including the housing of the odor trap, with the oil mixture that “the oil has the property that said parts absorb so much of it that the oil film somehow repels the urine”. Beetz requirement for daily cleaning and maintenance dictates an easily-disassembled-three piece structure with a leakage-prone bottom interface joint, and this requirement for the sealant to also act as a disinfectant is now believed to have caused excessive depletion of the sealant.
Other examples of oil-sealed traps are found in German Patent No. 2816597.1, and Swiss Patent No. 606,646 (Ernst), practiced under the trademark SYSTEM-ERNST.
The foregoing examples of traps found limited use in Europe. Typically, they are utilized in a “low flush” rather than a “waterless” manner, e.g. the Beetz patent was classified under water pipe lines, and the specification thereof refers to “water and urine”. The odor trap is mounted beneath the floor level and set in a concrete swale, functioning as an occasionally-flushed trough type or stall urinal of a type which is no longer recognized in United States building and sanitation codes.
A flushless urinal disclosed in U.S. Pat. No. 4,244,061 (Webster, et al.) uses no oil, but instead relies on a small “plug flow” entrance opening associated with a P-trap, and is based on the premise that “the urine in the trap during normal use will be fresh and therefore without unpleasant odor.”
A unitized cylindrical cartridge odor seal for a waterless urinal is disclosed by the present inventor as a joint inventor in U.S. patent application, Ser. No. 08/052,668 filed Apr. 27, 1993 and in a continuation-in-part thereof Ser. No. 08/512,453 filed Aug. 8, 1995, in the category of an oil-sealed coaxial edge-entry trap having a cap part with an attached downward-extending tubular vertical partition.
A key parameter of oil-sealed odor traps for waterless urinals is the amount of sealant depletion that takes place under normal service conditions over periods of time and frequency of usage. Related to this is the possible partial or complete loss of sealant due to the abnormal condition of unnecessary but unavoidable high pressure flushing with water. While some modern oil-sealed odor traps are considerably improved over early versions, there remains an unfulfilled need for further improvements in the above-described aspects of sealant preservation; such improvements are provided by the present invention.
SUMMARY OF THE INVENTION
These and other problems are successfully addressed and overcome by the present invention, which comprises a unitized oil-sealed odor trap that departs from conventional practice of predominantly vertical liquid flow through the trap. Instead, the trap is constructed and arranged in a special manner to provide minimum turbulence on the oil sealant.
Preferably, minimization of turbulence is effected by a design in which a substantial portion of the total flow path is directed in a generally horizontal path and stray droplets of sealant, due to buoyancy, are encouraged to migrate upwardly back to the main body of the sealant, either directly or as guided by a sloping baffle configuration. Turbulence may be further discouraged by preventing direct contact of waste liquid from impinging directly on the sealant. In addition, an air vent in a shelter region above the sealant acts as a safety outlet against unusually high pressures exerted upon the sealant. Thus, escaping of sealant down the drain is largely prevented.
The odor trap is configured such that it can be economically made, for example, from two molded plastic parts, i.e., a main compartment part and a cap/baffle part, that can be molded from plastic and joined by thermal bonding into a unit configured as a replaceable cylindrical cartridge that can be charged with sealant and sealed with a sticker for shipment so that, upon installation, it is necessary only to install the cartridge and remove the sticker.
In service, required maintenance, i.e., sealant checking and replenishment, if and when needed, can be easily performed with the unit in place.
The cartridge is shaped to be easily pushed into place by hand and held frictionally in a mating recess provided by a casing that can be installed as part of the host plumbing, either in a urinal or in a floor drain. For drain cleaning or replacement purposes, the odor trap can be removed with a special simple hand tool.
However, should it be desired, the odor trap may be integrated into a urinal or similar device.
The shape of the entry compartment provides a sheltered region to which sealant tends to be temporarily displaced in the event of high pressure water flushing, thus avoiding catastrophic sealant loss.
Several advantages are derived from this arrangement. The usual objectives of eliminating the need for a P-trap in the drain line are met, while complying with United States sanitation standards. Turbulence in the sealant layer is at least minimized, if not essentially eliminated. Manufacturing and installation is economical and easy. Performance is reliable and efficient, with low maintenance requirements. Particularly with regard to depletion of oily liquid sealant, any stray droplets of sealant drift buoyantly in the flow path and return to the main sealant body. The odor trap configuration is such as to enable easy installation and removal from a permanent drain terminal plumbing fixture. Loss of sealant in the event of high pressure flushing with water is minimized, if not prevented
Other aims and advantages, as well as a more complete understanding of the present invention, will appear from the following explanation of exemplary embodiments and the accompanying drawings thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of an oil-sealed coaxial odor trap of known art;
FIG. 1A is functional diagram representing the left hand half of the trap illustrated in FIG. 1;
FIGS. 2 and 3 are functional diagram illustrating alternate descriptions of the principles of the present invention utilizing methods for minimizing turbulence in the oil sealant, such as by predominantly horizontal flow and a barrier or shield to direct contact of the waste liquid with the sealant;
FIGS. 4 and 5 are functional diagrams illustrating two different baffle configurations in edge-entry coaxial trap structures according to the present invention;
FIGS. 6-9 are functional diagrams illustrating different baffle configurations in center-entry coaxial odor trap structures according to the present invention;
FIG. 10 is a three-dimensional view of a center-entry cylindrical odor trap cartridge;
FIG. 11 is a three-dimensional cutaway view of an embodiment of a horizontal-flow odor trap cartridge of the present invention having a cylindrical container and a non-coaxial internal configuration with vertical and horizontal baffle portions and an offset tubular drain stand;
FIG. 12 shows an alternative illustrative embodiment derived from FIG. 11 with a flat-partitioned drain stand;
FIG. 13 shows a cross-sectional view of a preferred embodiment of the present invention, similar to FIGS. 11 or 12 , but having the lower baffle portion sloped for additional recovery of stray sealant;
FIG. 14 shows a cross-sectional view of another preferred embodiment of the present invention;
FIG. 15 shows an example of a wall mounted urinal in which an odor trap can be incorporated;
FIGS. 16-19 show one preferred construction of the preferred embodiment of FIG. 14 . FIG. 16 is a bottom view of a top member thereof; FIG. 17 is a perspective side view of a middle member thereof; FIG. 18 is a perspective side view of a bottom member thereof (with upper and middle members represented in part in dotted lines); and FIG. 19 is a perspective side view of a plug-handle member capable of being included in this embodiment; and
FIG. 20 depicts an alternate construction of the plug-handle member illustrated in FIG. 19 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a mid cross-sectional view of an odor trap 10 A of the edge-entry trap configuration of known art as described above, and configured as a cylindrical cartridge.
Odor trap 10 A has a main liquid container 14 extending from an outer wall to an inner wall that forms a drain stand pipe 14 A which defines, at its upper edge, the overflow level of liquid in the container 14 . An overhead cap portion 16 is formed to provide a vertical baffle 16 A which extends down into container 14 and divides it into an inner discharge compartment and a surrounding entry compartment. A body of residual urine 18 extends up to the overflow level at the top of stand pipe 14 A and, in conjunction with the overhead plenum region formed by the cap portion 16 , the residual body of urine 18 serves to trap sewer gasses from the external drain line in accordance with plumbing codes.
A body of oily liquid sealant 20 , lighter than water or urine, floats in the entry compartment on top of the trapped body of urine 18 , and serves to trap urine odors from escaping from trap 10 A.
In operation of the urinal, urine from above, near the outer edge, separates into droplets that permeate through the layer of sealant 20 and then joins the main body of urine 18 . As additional urine enters the body of urine 18 , it overflows stand pipe 14 A and the overflow portion gravitates down the drain.
Known oil-sealed odor traps are configured as in FIG. 1 with a vertical baffle 16 A. From actual experience, traces of sealant can escape during usage. Such depletion occurs as follows. Due to turbulence or emulsification during each usage event, and despite the inherent buoyancy of sealant 20 due to its low density and the non-affinity to water/urine, some droplets of sealant can separate from the main body and get swept downward along with the main flow of urine in the outer chamber. These stray droplets tend to decelerate due their inherent buoyancy and, depending on downward urine flow velocity and travel depth, some of them may come to rest, then reverse and rise against the flow, and return to the main sealant body above. Such droplets thus are recovered. However, any droplets, that are dragged by the urine flow past the bottom of baffle 16 A, will then, due to their buoyancy, accelerate upwardly in the inner compartment, defined by drain stand pipe or overflow riser 14 A and vertical baffle or portion 16 A. Such droplets will then escape through exit opening 14 E and down the drain conduit through reduction portion or drain housing 12 B.
The present invention, operating on a modified form of the basic principle described above and teaching novel internal structure, can be implemented with the same general cylindrical exterior shape as that of the odor trap shown in FIG. 1, and can be made to fit into a cavity receptacle that is part of a urinal system having an 12 A above, leading to tapered upper edges of the outer wall of the main liquid container of odor trap 10 A and extending downward around trap 10 A to a reduction portion 12 B which connects by regular plumbing attachments to the external drain system.
FIG. 1A is a simplified schematic representation of the left hand half of the symmetrical configuration of FIG. 1 which is coaxial about a central axis C-C′, showing again the relation of sealant 20 , urine 18 and a sealant flow path 22 in the urine in the entry compartment. It is evident that in this configuration, due to the vertical orientation of baffle 16 A, flow path 22 is predominantly vertical, that is, downward in the outer compartment as shown and upward in the inner chamber, with only relatively small horizontal components around the bottom of baffle 16 A and around the top of stand tube 14 A. Flow path 22 , having sealant 20 overhead, is the only portion of the total flow path where sealant recovery can occur; thus a corresponding parameter can be estimated as indicated by dimension x, representing the effective sealant-recovery horizontal flow path length. In a typical odor trap of the category of FIGS. 1 and 1A, with main liquid container 14 having an inside radius R of 5.4 cm, and the baffle 16 A having an outside radius of 4 cm, the horizontal recovery dimension x is about 0.8 cm, from which is obtained the unitless ratio x/R=14.8% which characterizes this particular internal structure.
Component x labelled in the figures is an approximate average of the horizontal vector components x of the wastewater flow, extending from the middle of the entry opening (e.g. the point of average entry of the wastewater into the sealant) to a furthest point along the flow path (e.g. around the baffle) in which sealant recovery can occur. Although the invention contemplates a value x based on the approximate average, preferably, generally all of the wastewater will follow a flow math having a component x, e.g., any wastewater not following such a flow path would be insubstantial enough to effect the proper functioning of the invention, such as if extraneous openings were provided to allow a minimal volume flow rate therethrough.
A vertical vector component y of the flow path may be approximately defined as the vertical distance from the top of stand pipe 14 A to the bottom of baffle 16 A. Accordingly, an alternative feature may be based on a ratio x/y, for use in estimating an effective slope of the flow path, e.g., x/y<1 to indicate a predominantly vertical flow path and x/y>1 to indicate a predominantly horizontal flow path.
This category of odor trap is vulnerable to total loss of sealant if subjected to water-flushing at high pressure, due to the relatively narrow width of the outer compartment and absence of any sizeable shelter compartment around the entry region to which sealant can be displaced temporarily by the flushing water instead of being forced down the drain.
FIGS. 2-9 are simplified cross-sectional functional diagrams representing various odor trap configurations illustrating principles of the present invention, which is directed to preservation of sealant. For simplicity, as in FIG. 1A, only half of symmetrical cross-sections is shown, along with a central axis. The shapes generally apply to structure that is coaxial about the axis as shown, but the present invention can be practiced by applying such cross-sections to other, non-coaxial and/or non-symmetrical configurations such as rectangular containers or cylindrical containers with non-coaxial internal structure.
FIG. 2 is a conceptual diagram illustrating basic principles of the present invention wherein an odor trap 10 B is structured in a novel manner. Rather than configuring the baffle vertical as illustrated in FIGS. 1 and 1A, at least a portion of the baffle is shaped in a non-vertical manner to cause the liquid flow path to be predominantly horizontal, as a major departure from entirely vertical baffles and consequent predominantly vertical liquid flow that has been universal in the known art as described above.
The baffle in FIG. 2 has a vertical portion 16 A, facing the vertical wall of drain riser 14 A, and an inclined, but substantially horizontal portion 16 B sloping up to cover 16 C which has an- entry opening 16 D at the left. Cover 16 C may be defined as an entry region. The contour of bottom portion 14 B of main liquid container 14 is shown for simplicity as forming a flow path of substantially constant depth; however in practice, there can be a much greater variation in depth along the flow path.
From an entry opening 16 D at the left, the flow is to the right. The liquid flow path has two recovery portions 22 A and 22 B. In portion 22 A, starting at the entry inlet, the flow is horizontal, passing under the main body of sealant 20 . Then, in portion 22 B, the flow path slopes downward but remains predominantly horizontal as directed by sloping baffle portion 16 B. The flow path turns abruptly upward at the plane of vertical baffle portion 16 A, to overflow riser 14 A and then exits down the drain in the same manner as in FIGS. 1 and 1A.
It is evident that, in both flow path portions 22 A and 22 B, the flow path is predominantly horizontal, in distinction from the predominantly vertical flow paths in FIGS. 1 and 1A.
In FIG. 2 within the path length x indicated, practically all stray sealant droplets migrating upwardly to the top side of the flow path will be recovered and returned to the main body of sealant 20 . In flow path portion 22 A, the body of sealant 20 is directly overhead, and along portion 22 B the slope of baffle 16 B redirects upwardly-migrating stray sealant back to the main body of sealant 20 , as indicated by the curved arrows. Since sealant recovery occurs along both of these portions, the recovery dimension x as shown is the sum of the horizontal components of the two portions.
The cross-section of FIG. 2 can be applied to a coaxial cylindrical structure having a central axis about line C-C′ and the outer wall of cylindrical container being at D-D′, such as wall 14 is shown. Alternatively, the cross-section of FIG. 2 can be applied in reverse manner to provide a coaxial cylindrical odor trap structure of the central-entry type with a central axis at D-D′, and outer wall of the cylindrical container at C-C′.
As a further alternative, the cross-section of FIG. 2 can represent that of an enclosure that is other than cylindrical, e.g., rectangular. In addition, the container can alternatively be made with side walls at both D-D′ and C-C′, such that a non-symmetrical, non-axial, device is formed.
A coaxial structure based directly on FIG. 2 would tend to be shallower and larger in diameter than cartridges shaped as shown in FIG. 1 . As a practical limitation, a minimum liquid depth is required in the trap to meet regulations regarding containment of sewer gas pressure in the drain system, e.g., 2 inches in the United States and 50 mm in Europe. Due to existing urinal space limitations, cylindrical traps are typically limited to a maximum diameter of about 150 mm (5.9 inches) and a maximum height of about 90 mm (3.54 inches). To function properly in such a compact size, the conceptual example shown in FIG. 2 is preferably reconfigured in shape with the wasted space between baffle portions 16 A, 16 B and cover 16 C more preferably being utilized.
The above stated principles may also be understood with reference to a specific odor trap, such as that depicted in FIG. 3 . Here, an odor trap 30 , like odor trap 10 B of FIG. 2, includes a discharge section 32 which incorporates a similar outlet defined by exit drain stand pipe or overflow riser 14 A and vertical baffle or vertical upper portion 16 A so that wastewater or urine 18 may be conducted to the external drain system. The wastewater enters odor trap 30 from an entry section or region 34 , having an inlet cover 36 having and entry opening defining one or more openings 38 therein to provide a similar function as entry opening 16 D. Positioned below openings 38 is a layer of sealant 20 floating upon wastewater 18 . The wastewater contacts, flows into and passes through sealant layer 20 , and flows atop and beneath portion 16 B on its journey into discharge section 32 and out of the odor trap. Such flow of the wastewater ofttimes creates turbulence in the sealant, and results in displacement of the sealant and formation of droplets therefrom, which droplets will migrate beneath portion 16 B and pass from the odor trap if not otherwise prevented. The extent of the turbulence and the displacement of sealant layer 20 is directly related to the force of the wastewater contacting the sealant layer, and to the time in which the turbulence can subside.
To mitigate against such force and to provide sufficient time, the extent of the passage of the wastewater atop portion 16 B must be controlled. Such control is effected by sufficiently lengthening the passage e.g., by distance x or the like, so that the effect of the wastewater to cause sealant turbulence will be adequately dissipated and so that the sealant likewise will have adequate opportunity to become sufficiently quiescent.
Odor trap 30 also incorporates an additional feature by which turbulence in the oil sealant is minimized. A shield or barrier 40 is positioned between openings 38 and sealant layer 20 to prevent the wastewater from directly striking or otherwise impinging or impacting upon the sealant. Thus, excessive force against and resultant turbulence of the sealant is minimized, if not altogether avoided. Shield 40 is secured to inlet cover 36 by any suitable means, such as by a connector 42 . The shield is further oriented with respect to portion 16 B so that the shield opens at its terminus 44 towards baffle or baffle portion 16 A, and in a direction opposite from terminus 46 of portion 16 B. As a result, the distance by which the wastewater passes from openings 38 to terminus 46 of portion 16 B is accordingly increased while, at the same time, the wastewater will contact sealant layer 20 with minimum force. The outcome is minimization, if not elimination of sealant droplets passing underneath portion 16 B.
The principles and advantages in sealant retention illustrated in FIGS. 2 and 3 can be realized in various odor trap configurations according to the present invention, and constructed and arranged to meet particular practical requirements, such as shown in the following examples.
FIG. 4 depicts the structure of an edge-entry odor trap 10 C having the baffle configured with a vertical upper portion 16 A and a sloped portion 16 B as shown, providing a flow path 22 corresponding to horizontal recovery dimension x as shown, extending from an averaged entry point to the extremity of sloped baffle portion 16 B.
In FIGS. 3 and 4 which depict visible baffle shape variations, the vertical portion 16 A can be located anywhere along the sloped portion 16 B between the extremes shown in these two figures, while keeping the sloped portion 16 B as shown; basic functioning and dimension x would be virtually unaffected.
FIG. 5 depicts an odor trap 10 D as a variation of FIG. 4 having baffle 16 B sloped in its entirety. The flow path 22 and the dimension x are approximately the same as in FIG. 4 .
FIG. 6 depicts a center-entry odor trap 10 E wherein the baffle is configured with a vertical upper portion 16 A and a horizontal lower portion 16 B flanged outwardly as shown. This creates a folded liquid path having, upper portion 22 A above and lower portion 22 B as shown. Only the upper portion 22 A will be effective in returning stray sealant because baffle 16 A is not sloped.
Thus, stray sealant in the portion 22 B will tend to get swept along to the right and escape to the drain along with the effluent. Horizontal recovery dimension x will be as indicated, derived from upper flow path portion 22 A.
FIG. 7 depicts an odor trap 10 F as a variation of FIG. 6 wherein lower baffle portion 16 B is sloped as shown so as to recapture stray sealant from lower horizontal flow path 22 B, thus adding to upper path 22 A to yield the indicated much greater horizontal recovery dimension x.
FIG. 8 depicts an odor trap 10 G as a variation of FIG. 7 wherein the sloped flange portion 16 B is made to have an oppositely-slope upper surface which serves to prevent accumulation of debris on the flange's upper surface which could otherwise occur in this region in the structure of FIG. 7 . Dimension x is virtually the same as in FIG. 7 .
FIG. 9 depicts an odor trap 10 H as a reversed version of the foregoing center entry coaxial configurations which achieves a form of predominantly horizontal flow path with a simple vertical baffle 16 A surrounded by a drain stand wall 14 A′ which sets the overflow level. Wall 14 A′, surrounded by an outer wall extending down from the circumference of cover 16 C, is attached to the circumference of floor 14 B so as to form a simple cylindrical main container pan 14 which can be supported by surrounding cover 16 C or drain housing 12 B by radial vanes (not shown). The center entry causes the liquid to spread out radially in a sloped but substantially horizontal flow path 22 leading to the bottom edge of baffle 16 A as shown, corresponding to recovery dimension x as indicated.
In FIGS. 6-9, a triangular-shaped empty region can be seen in cross-section above the sealant, as formed by the slope of the cover. This triangular region serves an important function as a sealant shelter region into which the sealant tends to be displaced in the event of high-pressure water flushing, instead of being forced down the drain ahead of the flushing water, as could occur with trap structure of known art, such as in FIGS. 1 and 1A, having the conventional vertical baffle 16 A and the conventional predominantly vertical flow paths.
FIG. 10 is a three-dimensional view of a cylindrical odor trap cartridge 10 I with center entry 16 D in accordance with a preferred embodiment of the present invention. The upper surface slopes downward in a shallow inverted cone toward the center where entry opening 16 D is fitted with a filter screen or a fine perforation pattern formed in the cover material.
The enclosure can be, for example, dimensioned about 4½ inches (11.4 cm) in diameter and 2¾ inches (7.0 cm) in height. As noted, due to existing industry limitations, the size of the trap is to be limited. For example, the diameter of the trap is preferably between about 2 to 2½ inches. It is preferably molded from polyethylene, or from another suitable plastic material such as polypropylene, ABS or polystyrene, to provide a smooth stain-resistant surface. The material can also include a fiberglass reinforced polyester. Other suitable materials can also be utilized. Typically, main container 14 and cap/partition part 16 are molded as separate parts and then bonded together to form an integral enclosure, since access to the interior is not normally required. The entry configuration of trap 10 I makes it feasible to seal entry opening 16 D (with the bottom exit opening, not visible in FIG. 10, sealed in a similar or other manner) for shipment as a cartridge already charged with sealant, ready for deployment. For example, to seal opening 16 D, a sticker can be attached thereto, and can further include labelling, etc., such as installation instructions and product labelling.
FIG. 11 is a three-dimensional cutaway view of a center-entry cylindrical odor trap 10 J having a non-coaxial interior configuration, shown without liquid for clarity. The baffle has two flat portions. Vertical portion 16 A extends downward from the upper surface offset to the right of entry opening 16 D. At the bottom of vertical baffle portion 16 A, a horizontal portion 16 B extends fully to the left hand wall of odor trap 10 J. A round opening 16 E, about the same size as opening 16 D, is configured in a horizontal baffle portion 16 B at the edge furthest from vertical baffle portion 16 A. Opening 16 E leads into a lower compartment which is configured with a flat floor 14 B of which a portion is extended upwardly at the right hand side to form tubular drain stand 14 C whose top edge defines the overflow level of the container as in the figures described above. Liquid flow paths 22 A and 22 B are shown and corresponding recovery path dimension x is indicated as derived from path 22 A.
FIG. 12 depicts an odor trap 10 K which is a variation having a baffle configured as in FIG. 11 but wherein drain riser 14 D is here configured as a flat vertical riser wall 14 D attached integrally to floor 14 B and to the interior wall of main enclosure 14 of odor trap 10 L, preferably molded together in one piece.
FIG. 13 is a central cross-section depicting an odor trap that represents an important variation applicable to both FIG. 11 and FIG. 12 . Horizontal baffle portion 16 B is sloped in a manner to recover stray sealant and return it to the main body of sealant 10 . The resultant horizontal recovery dimension x is much longer than in FIGS. 11 and 12 due to the additional recovery provided by sloped baffle portion 16 B.
It is seen that the cross-sections of FIGS. 11 and 12 generally resemble that of FIG. 6, and the cross-section of FIG. 13 generally resembles that of FIG. 7 . However, preferred constructions according to FIGS. 6 and 7 as shown imply fully coaxial internal and external configuration centered on axis C-C′ whereas the internal structure in FIGS. 11-13 is clearly non-coaxial with the outlet offset rather than centered and the baffles flat rather than cylindrical.
The relative sealant recovery effectiveness of the above configurations as approximated by the recovery-effective length of the horizontal flow paths x relative to container radius R can be compared in the following estimated table. The following Table I lists examples of estimated values which can be achieved for x/R in the illustrated embodiments, the illustrated embodiments not being limited thereto:
TABLE 1
FIG.
x/R
FIG.
x/R
1, 1A
15%
8
56%
2
76%
10
71%
3, 4, 5
50%
12
165%
6, 7
105%
Alternatively, the relative sealant recovery effectiveness of the above configurations, as a few examples, can be expressed as a function of the flow path slope x/y. The following Table 2 lists estimated examples of values which can be achieved for x/y in the illustrated embodiments, the illustrated embodiments not being limited thereto.
TABLE 2
FIG.
x/y
FIG.
x/y
1, 1A
0.12
7
8.60
2
4.64
8
3.67
3, 4
3.50
10, 11
3.08
5
5.50
12
5.82
6
5.75
According to the preferred embodiments of the present invention, the inlet and outlet locations and the baffle configuration, etc., result in a predominantly horizontal flow. For example, in some preferred embodiments, the present invention yields preferred values of x/R>30%, as distinguished, for example, from predominantly vertical flow of known art in the above table. As seen in Table 1, the present invention can even yield values greater than 50%, allowing for a wide margin above the 15% estimated for the noted prior art. As another example, the present invention can yield preferred values of x/y of greater than 1.0, while the above-noted estimate of the noted prior art achieves a value substantially less than 1.0. Although clearly less preferred, it is contemplated that values less than the preferred examples of x/R and/or x/y can, in some cases, be used according to principles of the invention.
It is recognized that a one-dimensional parameter, such as x/R, is merely a first approximation of effectiveness; a more refined two-dimensional parameter would take into account the effective horizontal recovery area located above the flow path. An even more refined three-dimensional parameter would take into account fluid viscosities, width, depth and length and resulting flow velocities at various incremental points in the flow paths.
The relative effectiveness indicated by the above tables apply to normal operation and does not necessarily include the additional improvement provided by the present invention in protection against catastrophic loss of sealant under the condition of high pressure water flushing as described above. In this regard, according to another aspect of the invention, a shelter region is provided for the sealant, and can be provided in any of the embodiments of the invention. The configurations of the embodiments of, for example, FIGS. 11-13, include entry compartments with shelter regions (e.g., as identified by indicium T shown in FIG. 13) wherein high-pressure flushing water tends to take a direct path from entry opening 16 D to baffle opening 16 E while parting much of the sealant and temporarily pushing it into the shelter regions at both sides. In addition to their other functions, the angled top wall and the wide entry compartment help provide such shelter regions. The shelter region is preferably formed by an airspace T above the normal sealant level, such as shown in FIG. 13 . In order to allow the sealant to quickly enter the shelter region, the device can include one or more air vents to allow air within the shelter region to vent outside thereof. For example, the embodiment shown in FIG. 13 includes at least one air vent 16 F at an upper end of the trap. Air vent 16 F is sized to allow air to pass therethrough while substantially preventing fluid flow therethrough, and preferably has a diameter of about 1-2 mm. As shown, the air vent is preferably in the top wall of the device. In this manner, in the event that any sealant is forced through the air vent, the sealant can be redirected along the upper surface and into upper opening 16 D so as to return to the body of sealant.
FIG. 14 shows another preferred embodiment of the invention. The device shown in FIG. 14 employs a number of features which are similar to certain features shown in FIGS. 11-13. FIG. 14 is a three-dimensional cutaway view of an odor trap 10 M having a non-coaxial interior configuration. The baffle has a generally vertical portion 16 A extending downward from the upper surface, offset to the right of entry opening 16 D, and a horizontal portion 16 B extending fully to the left hand wall of odor trap 10 M at the bottom of vertical baffle portion 16 A. The horizontal baffle extends only partially across the trap so as to leave an opening 16 E at the edge furthest from vertical baffle portion 16 A. Opening 16 E leads into a lower compartment which is configured with a floor 14 B. A tubular drain stand 14 C is provided which extends upward at the right hand side of floor 14 B. The top edge of drain stand 14 C defines the overflow level of the container. Liquid flow oaths 22 A and 22 B provide a corresponding recovery path dimension x similar to that shown in FIG. 13, e.g., the sum (x 1 +x 2 ) from the paths 22 A and 22 B, respectively. As shown in FIG. 14, a body of wastewater 18 has sealant layer 20 buoyantly floating thereon. Wastewater 18 follows the flow path (a) 22 I into the entry opening 16 D, (b) 22 A above the baffle, (c) 22 B below baffle 16 B, (d) 22 C up and over the top edge of drainstand 14 C, and (e) 22 D down drainstand 14 C.
FIGS. 16-19 show a preferred construction of the embodiment shown in FIG. 14 . This preferred construction includes a top member 150 (FIG. 16 ), a middle member 160 (FIG. 17 ), a bottom member 170 (FIG. 18 ), and a plug member 180 (FIG. 19 ). Top member 150 includes a generally cylindrical perimeter wall 151 , a downwardly inclined top wall 152 having a center area 152 A, and an entry opening 153 at the center area of the top wall. Top wall 152 is inclined in a manner like that in FIG. 14 . As shown, the entry opening preferably includes three holes 154 in center area 152 A of the top wall. In addition to their function as described below, holes 154 also serve as the openings for passage of urine or other wastewater into the odor trap. The top wall also preferably includes two sealing ridges 155 for receiving and sealing baffle 165 , as discussed below.
Middle member 160 includes a perimeter wall 161 and a baffle having a generally vertical portion 165 and an upwardly inclined portion 166 . Portion 166 has a generally straight upper edge 167 providing a fluid passage 168 around the baffle.
Bottom member 170 includes a perimeter wall 171 , a bottom wall 172 , and a upwardly extending drain stand 173 . The drain stand preferably is a cylindrical tube extending above wall 171 with an upper opening 175 and a lower opening 176 . The lower edge of the bottom member can, for example, as shown include a tapered wall 174 .
The device is assembled with the middle member fitted such that perimeter wall 161 snugly fits within perimeter wall 151 and baffle portion 165 snugly fits between ridges 155 . Wall 151 only extends down over part of the height of wall 161 . Lower member 170 fits with drain stand 173 within the area to the right of baffle portion 165 and the lower portion of cylindrical wall 161 snugly fitted within cylindrical wall 171 . As a result, a sealed container can be constructed having separately isolated entry and discharge compartments.
FIGS. 19 and 20 show plug-handle members 180 and 180 A which can be included in this latter embodiment. Each plug-handle member 180 ( 180 A) preferably includes a tubular member 181 ( 181 A), handle projections 182 ( 182 A) and hook-shaped projections, such as L-shaped and T-shaped projections 183 and 183 A, at upper wall 184 ( 184 A). Each projection 183 and 183 A includes a vertical portion 186 ( 186 A) and one horizontal portion 188 for projection 183 and two horizontal portions 188 A for projection 183 A. The plug is preferably shaped and sized so as to snugly fit within drain stand 173 . With this construction, the odor trap can be transported with a body of sealant within the assembled structure, if plug 180 ( 180 A) is inserted in opening 176 and a seal (such as an adhesive backed label) is placed over opening 153 . As shown, the L-shaped and T-shaped projections are sized and shaped to fit within holes 154 so that the assembled device can be carried by simply inserting the projections into the holes 154 and by rotating plug 180 ( 180 A) in the direction L of respective FIG. 19 and similarly in FIG. 20, so that the L-shaped and T-shaped projections engage under top wall 152 . Thus, member 180 ( 180 A) provides a tool that can be used to seal a new, unused unit and to remove a dirty, wastewater filled, unit. Although the plug and handle functions are preferably combined into single tool 180 ( 180 A), it is contemplated that separate devices embodying these features can be included and/or either the plug or handle can be eliminated depending on the desired handling.
Sealant 20 is preferably a biodegradable oily liquid. A preferred composition of liquid 20 comprises an aliphatic alcohol containing 9-11 carbons in the chemical chain, wherein the specific gravity is 0.84 at 68° Fahrenheit. Since the operation of the urinal is based on the differential between the specific gravity of the oily liquid and that of urine, typically near 1.0, the specific gravity of the oily liquid should be made as low as possible, preferably not exceeding 0.9 and, preferably, well under 0.9. Sealant 20 preferably is chosen to have a very low affinity to water so that the sealant and the urine strongly repel each other physically and so that there is no chemical or other interaction apart from a purely physical separation which allows urine/water from above to divide finely and permeate downwardly through the sealant layer. Sealant 20 is preferably colored, e.g., blue, for maintenance and identification purposes.
FIG. 15 shows one example of type of urinal into which the various odor traps, shown generally as 10 , can be located. The illustrated urinal, designated by indicium 140 ,is a wall mounted unit attached above a floor surface (not shown). The urinal shown is for illustrative purposes only; a trap of the present invention can be used in any type of urinal. More notably, the utility of the invention, while directed in some aspects to waterless urinals as illustrated above, is not restricted thereto. The present odor trap is applicable to other drained surfaces and the like. For example, since the preferred sealant utilized is considerably more stable than water with regard to evaporation, the present invention has widespread utility as floor drains, solving, for example, problems of sewer gas release from conventional S-type floor drains resulting from, for example, total seal failure due to evaporation of the residual water and lack of replenishment thereof, particularly in hot, dry climates.
Although the invention has been described with respect to particular embodiments thereof, it should be realized that various changes and modifications may be made therein without departing from the spirit and scope of the invention. | Improvements in retention of the oily liquid sealant ( 20 ) in a oil-sealed odor trap ( 10 B- 10 M), for drain applications such as a waterless urinal or anti-evaporation floor drain, are accomplished by minimizing turbulence in the oil sealant, such as by making the liquid flow path ( 22 A, 22 B) substantially horizontal as a departure from conventional practice of substantially vertical flow and by positioning a barrier ( 40 ) above the oil sealant to prevent direct impingement of urine or other waste products onto the sealant. The trap is thus structured to realize the substantially horizontal liquid flow path and to locate the flow path immediately beneath the sealant layer or beneath a baffle portion ( 16 B). The baffle portion may be sloped such that stray sealant droplets are encouraged to migrate upwardly to the upper surface of the flow path due to their buoyancy and, therefore, the stray droplets will be recaptured and returned to the main sealant layer. To accomplish substantially horizontal flow, the entry compartment can be made to have entry and exit openings ( 16 D, 14 E) substantially offset from each other. The baffle between the entry compartment and the discharge compartment, which has traditionally been made entirely vertical, is made to have a non-vertical portion that is preferably sloped for sealant recovery. A sealant sheltering region (T) with an air vent ( 16 F) can be provided in the vicinity of the entry region to prevent catastrophic loss of sealant in the event of high pressure water flushing. When the trap is embodied as a replaceable cartridge, a tool with hook-shaped projections, such as L-shaped or T-shaped projections ( 183, 183 A), engageable with openings ( 154 ) in an upper wall ( 152 ) of the cartridge is used to help removal and replacement of the cartridge. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to automotive refinish compositions and to methods for preparing and using such compositions.
BACKGROUND OF THE INVENTION
[0002] Automotive topcoat finishes today are predominantly basecoat/clearcoat topcoats, in which the topcoat is applied in two layers, a first layer of a pigmented basecoat composition and a second layer of a clearcoat composition. Basecoat/clearcoat coatings are desirable for their high level of gloss and depth of color. In addition, basecoats having special effect pigments, e.g., flake pigments such as metallic and pearlescent pigment, can achieve excellent gonioapparent effect in basecoat/clearcoat coatings.
[0003] In order to provide optimum match to the appearance of the original finish, automotive refinish topcoats are also being applied in separate layers of basecoat and clearcoat. Unlike the original finish coating compositions, which are typically cured at temperatures of 110° C. or higher, automotive refinish coatings must be formulated as either thermoplastic compositions or thermosetting compositions that cure at relatively low temperatures because many components of a finished vehicle cannot withstand high temperature bakes. Nonetheless, thermosetting compositions are generally preferred as providing more durable and scratch- and mar-resistant coatings. Thermosetting refinish compositions are usually designed to cure at ambient temperatures, including by oxidation or radiation curing, or low bakes. Although the coating may not develop full cure for hours or days, it is desirable to have the coating become “dry to handle” (that is, not tacky) within a reasonably short time. Shorter dry to handle times also reduce the chance that the coating could become contaminated with airborne particulates. This is particularly true for clearcoat compositions, which are not covered by other coatings layers and for which a smooth, unblemished surface is critical to obtaining the desired appearance.
[0004] In many thermosetting automotive refinish clearcoat compositions the curing agent reacts with the main resin or polymer at room temperatures within a reasonable amount of time without heating or with heating at low temperatures of perhaps up to 150° F. Given the reactivity between the curing agent and the main resin or polymer at typical storage temperatures, these materials are segregated into separately stored components until just shortly before application of the coating composition to the substrate. This type of coating composition, in which the materials that react to cure the coating are segregated in two separately stored components, is referred to in the art as a “two-component” or “two-package” or “ 2 K” coating composition. Refinish clearcoat compositions, which are unpigmented, are often two-package compositions. Refinish clearcoats may also be three-component or three-package systems, in which a third component contains solvents or resin solutions for adjusting the viscosity of the clearcoat or contains other reactants.
[0005] Cost and solvent content are further concerns in formulating automotive refinish coating compositions. For example, cellulose acetate butyrate (CAB) resins have been used to shorten the dry to handle time and as rheology control additives in refinish coatings, but coating compositions containing these CAB materials require an undesirably high amount of organic solvent. In addition, these CAB materials are relatively expensive and require added steps in the coatings manufacturing process. Finally, the CAB materials are specialty products that are not widely manufactured.
[0006] It would be desirable, therefore, to have a coating composition (whether in a single package or as a multi-component system) with a short tack-free drying time, good metal control, that is less expensive, and that could be applied with a lesser amount of regulated emissions.
SUMMARY OF THE INVENTION
[0007] The invention provides a refinish clearcoat composition including an hydroxyl-functional acrylic polymer. The hydroxyl-functional acrylic polymer has a number average molecular weight of at least about 5000 daltons and contains at least about 45% by weight of one or more cycloaliphatic monomers. The refinish clearcoat composition further includes at least one film-forming polymer. The hydroxyl-functional acrylic polymer is at least about 5% by weight, and up to about 60% by weight, of the combined weights of the hydroxyl-functional acrylic polymer and the film-forming polymer(s). Preferably, the refinish clearcoat further includes at least one curing agent. The acrylic polymer of the invention provides excellent fast drying after application with good application and physical properties. In particular, the clearcoat coating composition can be applied without sagging, popping or cratering.
[0008] The invention further provides an multi-component coating system for preparing the clearcoat composition of the invention. The multi-component system includes a package or component containing the hydroxyl-functional acrylic polymer and at least one film-forming polymer and a second package containing a curing agent that cures the acrylic polymer and/or the film-forming polymer in the first package. The multi-component system optionally includes a third component containing solvent, optionally one or more polymers or resins, and optionally other cure catalysts or reactants.
[0009] Still further, the invention provides a method of refinishing a substrate, which includes steps of applying a refinish basecoat composition to a desired area of the substrate, allowing the applied basecoat layer to dry, and then applying over the basecoat layer the clearcoat composition of the invention. The clearcoat composition is fast drying. Optionally, the clearcoat is cured by low temperature baking. The clearcoat surface may be taped without leaving tape marks as soon as the substrate is cooled.
[0010] It is particularly desirable for the clearcoat composition to be thermosetting in order to provide a durable, scratch- and mar-resistant coating. In the composite basecoat/clearcoat coating. The clearcoat may undergo wet sanding after baking as soon as the part is cooled, and can then be buffed back to a high gloss finish after sanding and washing.
DETAILED DESCRIPTION OF THE INVENTION
[0011] The refinish clearcoat composition includes an hydroxyl-functional acrylic polymer and a film-forming polymer in a transparent composition. The hydroxyl-functional acrylic polymer has a number average molecular weight of at least about 5000, preferably at least about 8000, and even more preferably at least about 10,000, and preferably up to about 30,000. The hydroxyl-functional acrylic polymer also preferably has a weight average molecular weight of at least about 17,000, more preferably at least about 19,000, and even more preferably at least about 20,000 daltons. Molecular weights may be determined by gel permeation chromatography using polystyrene standards.
[0012] The acrylic polymer is polymerized using one or more cycloaliphatic monomers. Suitable examples of cycloaliphatic monomers include, without limitation, cyclohexyl (meth)acrylate, (meth)acrylate esters of alkyl-substituted cyclohexanol, and (meth)acrylate esters of alkanol-substituted cyclohexane, such as 2-tert-butyl and 4-tert-butyl cyclohexyl (meth)acrylate, 4-cyclohexyl-1-butyl (meth)acrylate, and 3,3,5,5,-tetramethyl cyclohexyl (meth)acrylate; isobornyl (meth)acrylate; isomenthyl (meth)acrylate; cyclopentyl (meth)acrylate, (meth)acrylate esters of alkyl-substituted cyclopentanols, and (meth)acrylate esters of alkanol substituted cyclopentanes; adamantanyl (meth)acrylates; cyclododecyl (meth)acrylate; cycloundecanemethyl (meth)acrylate; dicyclohexylmethyl (meth)acrylate; cyclododecanemethyl (meth)acrylate; menthyl (meth)acrylate; and so on, as well as combinations of these. The term (meth)acrylate is used herein to indicated both the acrylate ester and the methacrylate ester. Preferred among these are cyclohexyl (meth)acrylate and isobornyl (meth)acrylate.
[0013] The cycloaliphatic monomer units are included in the acrylic polymer in amounts of at least about 45% by weight, preferably at least about 60% by weight, and more preferably at least about 65% by weight of the polymer. It is advantageous for the cycloaliphatic monomer units to be included in the acrylic polymer in amounts of up to about 85% by weight, particularly up to about 80% by weight, and especially up to about 75% by weight of the polymer. The upper limit on the amount of cycloaliphatic monomer unit depends upon factors such as the particular monomer used, the viscosity obtained in the acrylic polymer using the monomer, the amount of hydroxyl monomer and other monomers used, and so on.
[0014] The acrylic polymer also has hydroxyl functionality. Hydroxyl functionality can conveniently be introduced to the polymer by copolymerizing at least one hydroxyl-functional monomer. The hydroxy-functional ethylenically unsaturated monomer is preferably an alkyl ester of acrylic or methacrylic acid. (In the context of describing the present invention, the term “(meth)acrylate” will be used to indicate that both the methacrylate and acrylate esters are included.) Suitable examples of hydroxyl-functional monomers include, without limitation, hydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylates, hydroxybutyl (meth)acrylates, hydroxyhexyl (meth)acrylates, other hydroxyalkyl (meth)acrylates having branched or linear alkyl groups of up to about 10 carbons, and mixtures of these. Preferably, at least about 5% by weight hydroxyl-functional monomer is included in the polymer. It is also preferred to include up to about 15% by weight hydroxyl-functional monomer in the polymer. Caprolactone esters of these hydroxyl-functional monomers are also included among preferred compounds. Alternatively, caprolactone can be reacted with the hydroxyl group of the addition polymer after the polymerization reaction according to known methods. Particularly preferred as the hydroxy-functional ethylenically unsaturated monomer are hydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylates, and mixtures of these. The person skilled in the art will appreciate that hydroxyl groups can be generated by other means, such as, for example, the ring opening of a glycidyl group, for example from glycidyl methacrylate, by an organic acid or an amine. Hydroxyl functionality may also be introduced through thio-alcohol compounds, including, without limitation, 3-mercapto-1-propanol. 3-mercapto-2-butanol, 11-mercapto-1-undecanol, 1-mercapto-2-propanol, 2-mercaptoethanol, 6-mercapto-1-hexanol, 2-mercaptobenzyl alcohol, 3-mercapto-1,2-proanediol, 4-mercapto-1-butanol, and combinations of these. In one preferred embodiment, the acrylic polymer has an hydroxyl number of at least about 15 mg KOH/g polymer, more preferably at least about 40 mg KOH/g polymer, yet more preferably at least about 45 mg KOH/g polymer, and still more preferably at least about 50 mg KOH/g polymer. It is also preferred for the acrylic polymer to have an hydroxyl number of up to about 115 mg KOH/g polymer, more preferably up to about 90 mg KOH/g polymer, more preferably up to about 75 mg KOH/g polymer, still more preferably up to about 60 mg KOH/g polymer. The hydroxyl functionality may be incorporated by any method or by any combination of methods.
[0015] Other monomers may be copolymerized with the cycloaliphatic monomer and the hydroxyl monomer (and/or the hydroxy thiol compound and/or monomer that provides hydroxyl functionality through further reaction after polymerization). Examples of suitable co-monomers include, without limitation, α, β-ethylenically unsaturated monocarboxylic acids containing 3 to 5 carbon atoms such as acrylic, methacrylic, and crotonic acids and the esters, nitriles, or amides of these acids; α, β-ethylenically unsaturated dicarboxylic acids containing 4 to 6 carbon atoms and the anhydrides, monoesters, and diesters of those acids; vinyl esters, vinyl ethers, vinyl ketones, vinyl amides, and aromatic or heterocyclic aliphatic vinyl compounds. Representative examples of suitable esters of acrylic, methacrylic, and crotonic acids include, without limitation, those esters from reaction with saturated aliphatic alcohols containing 1 to 20 carbon atoms, such as methyl, ethyl, propyl, isopropyl, n-butyl, isobutyl, tert-butyl, hexyl, 2-ethylhexyl, dodecyl, lauryl, and stearyl acrylates, methacrylates, and crotonates; and polyalkylene glycol acrylates and methacrylates. Representative examples of other ethylenically unsaturated polymerizable monomers include, without limitation, such compounds as fumaric, maleic, and itaconic anhydrides, monoesters, and diesters with alcohols such as methanol, ethanol, propanol, isopropanol, butanol, isobutanol, and tert-butanol. Representative examples of co-polymerizable vinyl monomers include, without limitation, such compounds as vinyl acetate, vinyl propionate, vinyl ethers such as vinyl ethyl ether, vinyl and vinylidene halides, and vinyl ethyl ketone. Representative examples of aromatic or heterocyclic aliphatic vinyl compounds include, without limitation, such compounds as styrene, α-methyl styrene, vinyl toluene, tert-butyl styrene, and 2-vinyl pyrrolidone. The co-monomers may be used in any combination. In one preferred embodiment, the hydroxyl-functional acrylic polymer is prepared using a mixture of monomers that includes styrene, n-butyl acrylate, and n-butyl methacrylate (at least about 1% and up to about 20% by weight in combination, based on the total weight of monomers polymerized) and an amine functional acrylic or methacrylic ester (at least about 0.25% and up to about 20% by weight, based on the total weight of monomers polymerized). The monomers are preferably selected and apportioned so that an about 55% by weight solution of the acrylic polymer in n-butyl acetate has a viscosity of up to about 10 Stokes at 25° C., more preferably up to about 8.8 Stokes at 25° C.
[0016] The acrylic polymer may be prepared using conventional techniques, such as by heating the monomers in the presence of a polymerization initiating agent and optionally chain transfer agents. The polymerization is preferably carried out in solution, although it is also possible to polymerize the acrylic polymer in bulk.
[0017] Typical initiators are organic peroxides such as dialkyl peroxides such as di-t-butyl peroxide, peroxyesters such as t-butyl peroxy 2-ethylhexanoate, and t-butyl peracetate, peroxydicarbonates, diacyl peroxides, hydroperoxides such as t-butyl hydroperoxide, and peroxyketals; azo compounds such as 2,2′azobis(2-methylbutanenitrile) and 1,1′-azobis(cyclohexanecarbonitrile); and combinations of these. Typical chain transfer agents are mercaptans such as octyl mercaptan, n- or tert-dodecyl mercaptan; halogenated compounds, thiosalicylic acid, mercaptoacetic acid, mercaptoethanol and the other thiol alcohols already mentioned, and dimeric alpha-methyl styrene.
[0018] The reaction is usually carried out at temperatures from about 20° C. to about 200° C. The reaction may conveniently be done at the temperature at which the solvent or solvent mixture refluxes, although with proper control a temperature below the reflux may be maintained. The initiator should be chosen to match the temperature at which the reaction is carried out, so that the half-life of the initiator at that temperature should preferably be no more than about thirty minutes.
[0019] The clearcoat composition also includes at least one film-forming polymer. The film-forming polymer may be any polymer useful in clearcoat compositions. Examples include, without limitation, polyesters, polyurethanes, and other acrylic polymers.
[0020] Film-forming polyesters are formed from the esterification products of polycarboxylic acids or anhydrides of such acids with polyols and/or epoxides. Useful polyesters are linear, formed by reaction products of dicarboxylic acids and diols, or have a limited amount of branching, introduced by a reactant with a functionality greater than two. Preferably, an excess of equivalents of the polyol is used so that the polyester has terminal hydroxyl groups. Alternatively, if an excess of equivalents of acid functionality is used so that an acid-terminated polyester is formed, the acid groups can be reacted with a compound that has one or more hydroxyl groups and one or more groups reactive with acid groups, such as a triol, tetraol, and the like. The film-forming polyester may have a number average molecular weight of from about 3000 to about 25,000.
[0021] Examples of useful dicarboxylic acids and anhydrides include, without limitation, oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, maleic acid, pimelic acid, terephthalic acid, isophthalic acid, phthalic acid, tetrahydrophthalic acid, hexahydrophthalic acid, fumaric acid, azelaic acid, sebacic acid, dimer fatty acid, benzenetricarboxylic acids, methyl hexahydrophthalic acid, glutamic acid, the anhydrides of these acids, and combinations of these acids and anhydrides. Monocarboxylic acids may be included in limited amounts, particularly when tri- or tetracarboxylic acids are included.
[0022] Examples of useful polyols include, without limitation, 1,4-butanediol, 1,3-butanediol, 2,3-butanediol, 1,2,4-butanetriol, 1,6-hexanediol, 1,2,6-hexanetriol, neopentyl glycol, ethylene glycol, propylene glycol, pentaerythritol, oligomers of these such as diethylene glycol, triethylene glycol, dipropylene glycol, and dipentaerythritol, glycerol, trimethylolpropane, cylcohexanedimethanols, 2-methyl-2-ethyl-1,3-propanediol, 2-ethyl-1,3-hexanediol, 1,5-pentanediol, thiodiglycol, 1,3-propanediol, 2,2,4-trimethyl-1,3-pentanediol, cyclohexanediols, mannitol, sorbitol, and combinations of these. Compounds having both acid and alcohol groups may be included, non-limiting examples of which are dimethylolpropionic acid, ricinoleic acid, and 12-hydroxylstearic acid.
[0023] Polyesters may also be prepared using lactones such as ε-caprolactone and δ-butyrolactone or diols thereof, for example the reaction product of ε-caprolactone and a diol such as ethylene glycol. The polyol or polyacid may also include fluorine or silane groups.
[0024] A film-forming polyurethane can be synthesized by reacting a polyol, preferably a diol, with a polyisocyanate, preferably a diisocyanate. The polyisocyanate can be an aliphatic polyisocyanate, including a cycloaliphatic polyisocyanate, or an aromatic polyisocyanate. The term “polyisocyanate” as used herein refers to any compound having a plurality of isocyanate functional groups on average per molecules. Polyisocyanates encompass, for example, monomeric polyisocyanates including monomeric diisocyanates, biurets and isocyanurates of monomeric polyisocyanates, extended poly-functional isocyanates formed by reacting one mole of a diol with two moles of a diisocyanate or mole of a triol with three moles of a diisocyanate, and the like. Aliphatic polyisocyanates are preferred when the coating composition is an automotive topcoat composition. Useful examples include, without limitation, ethylene diisocyanate, 1,2-diisocyanatopropane, 1,3-diisocyanatopropane, 1,4-butylene diisocyanate, lysine diisocyanate, 1,4-methylene bis (cyclohexyl isocyanate), isophorone diisocyanate, toluene diisocyanate, the isocyanurate of toluene diisocyanate, diphenylmethane 4,4′-diisocyanate, the isocyanurate of diphenylmethane 4,4′-diisocyanate, methylenebis-4,4′-isocyanatocyclohexane, isophorone diisocyanate, the isocyanurate of isophorone diisocyanate, 1,6-hexamethylene diisocyanate, the isocyanurate of 1,6-hexamethylene diisocyanate, 1,4-cyclohexane diisocyanate, p-phenylene diisocyanate, triphenylmethane 4,4′,4″-triisocyanate, tetramethyl xylene diisocyanate, and meta-xylene diisocyanate.
[0025] The polyol can be the same as the polyols described above for the preparation of polyesters. In a preferred embodiment, at least one oligomeric or polymeric polyol is used to prepare the polyurethane. Non-limiting examples of oligomeric or polymeric polyols are polyester polyols and polyether polyols. Polyester polyols or polyether polyols used in the synthesis of a film-forming polyurethane typically have a number average molecular weight of about 400 to about 5000.
[0026] Two general synthetic approaches may be utilized to prepare the polyurethane resin. A polyurethane having terminal hydroxy functionality can be obtained by reacting a diisocyanate and a diol in an OH:NCO equivalent ratio of greater than 1:1. In this case, the polyurethane resin formed will have terminal hydroxyl groups as a result of the equivalent excess of the polyol. Alternatively, the polyurethane may be formed by reacting polyisocyanate and polyol in an OH:NCO ratio of less than 1:1, thus forming a polyurethane having terminal isocyanate functionality, and then reacting the terminal isocyanate groups in a second step, sometimes called a capping step, with a compound having at least one group reactive with isocyanate functionality, which may be, for example, a hydroxyl group or a primary or secondary amine group, and at least one (or at least one additional) hydroxyl group or at least one group that can be converted into a hydroxyl group. Suitable capping agents include, without limitation, aminoalcohols such as ethanolamine and diethanolamine, solketal, diols such as neopentyl glycol, triols such as trimethylolpropane, and mixture of these. This method is useful for providing a plurality of hydroxyl groups at each end of the polymer.
[0027] Non-limiting examples of polyether polyols are polyalkylene ether polyols that include poly(oxytetraethylene) glycols, poly(oxy-1,2-propylene) glycols and poly(oxy-1,2-butylene) glycols. Also useful are polyether polyols formed from oxyalkylation of various polyols, for example, glycols such as ethylene glycol, 1,6-hexanediol, Bisphenol A and the like, or other higher polyols, such as trimethylolpropane, pentaerythritol and the like. Useful polyols of higher functionality can be made, for instance, by oxyalkylation of compounds such as sorbitol or sucrose. One commonly utilized oxyalkylation method is to react a polyol with an alkylene oxide, for example, ethylene or propylene oxide, in the presence of an acidic or basic catalyst.
[0028] The film-forming polyurethane may have a number average molecular weight of from about 4000 to about 25,000.
[0029] In one preferred embodiment the refinish clearcoat composition includes at least one further hydroxyl-functional acrylic polymer. The further acrylic polymer preferably has a number average molecular weight of less than about 5000, preferably less than about 4000. The further acrylic polymer is also preferably readily miscible with the hydroxyl-functional acrylic of the invention.
[0030] If a polymer other than the hydroxyl-functional acrylic resin of the invention polymerized using one or more cycloaliphatic monomers is included in the refinish clearcoat composition, then it is preferred that the nonvolatile binder material include at least about 2% by weight, preferably at least about 5% by weight, of the acrylic polymer of the invention, and up to about 95%, preferably up to about 80% of the nonvolatile polymers.
[0031] The refinish clearcoat composition may contain other materials, including additives such as rheology control agents, surfactants, stabilizers, UV absorbers, hindered amine light stabilizers, and so on. Optionally, the invention may include one or more waxes such as poly(ethylene-vinyl acetate) copolymers or other rheology control agents.
[0032] Preferably, the refinish clearcoat further includes a curing agent reactive with the acrylic polymer or another resin or polymer in the refinish clearcoat, for example a polyisocyanate such as, but not limited to, the isocyanurate of hexamethylene diisocyanate. If the curing agent is reactive at room temperature with the acrylic polymer or other polymer, then the curing agent is kept separately from the acrylic polymer or other reactive polymer until just prior to application, as a two-component (two-package) paint.
[0033] In one contemplated embodiment, the clearcoat composition is an ambient curing composition. One example of an ambient curing composition is a composition containing a polyisocyanate, as already described. Another example of an ambient curing composition is one containing an oxidatively-curing polymer, such as an alkyd. A further example of an ambient curing composition is a composition containing a resin or oligomer having ethylenically unsaturated functionality that is cured by exposure to actinic rations, such as from UV or visible light. The composition may further include a catalyst for the radiation cure.
[0034] In another embodiment, the invention provides an three-package system for preparing the clearcoat composition of the invention. The three-package system includes a first component containing the hydroxyl-functional acrylic polymer polymerized with the cycloaliphatic monomer, optionally in combination with one or more other resins or polymers. The second component includes a curing agent reactive with the hydroxyl-functional acrylic polymer and/or another polymer or resin of the first component. A third component includes a reducing solvent, optionally a further resin or polymer, and optionally a catalyst for the curing reaction.
[0035] The clearcoat composition may include one or more solvents. In general, the solvent can be any organic solvent or solvents suitable for the binder materials. The solvent or solvents may be selected from aliphatic solvents or aromatic solvents, for example ketones, esters, acetates, toluene, xylene, aromatic hydrocarbon blends, or a combination of any of these.
[0036] In the multi-component coating, the solvent can be included in any of the components. Generally, each of the components will include one or more kinds of organic solvent.
[0037] The refinish clearcoat of the invention is applied in a layer to a desired area of the substrate to be refinished over an applied basecoat layer. The basecoat layer is allowed to dry before the clearcoat composition is applied. The clearcoat composition is then cured, if it is a thermosetting composition. When the clearcoat composition is formulated as a low temperature bake composition, the clearcoat of the invention provides an advantage in it may be taped or sanded immediately after baking.
[0038] The refinished substrate may be an automotive vehicle or a component of an automotive vehicle. The coating compositions of the invention may, however, be applied to other articles for which a protective and/or decorative coating is desirable. Such articles may be those having parts or substrates that cannot withstand high temperature curing conditions or that cannot easily be placed in a high-bake oven.
[0039] The invention is further described in the following examples. The examples are merely illustrative and do not in any way limit the scope of the invention as described and claimed. All parts are by weight unless otherwise indicated.
EXAMPLE 1
Preparation of Acrylic Polymer
[0040] An acrylic polymer was prepared by polymerizing in about 93.6 parts by weight n-butyl acetate 69.3 parts by weight of isobornyl methacrylate, 10.5 parts by weight of 2-hydroxyethyl methacrylate, 19.6 parts by weight of addition polymerizable co-monomers, and 0.6 parts by weight of 2-mercaptoethanol with about 0.4 parts by weight of an azo-type initiator. The acrylic polymer product was reduced to about 55% nonvolatile with additional n-butyl acetate. The acrylic resin had a number average molecular weight of about 9000.
EXAMPLE 2
Preparation of a Clearcoat Composition
[0041] A Component A was prepared by combining 10.3 parts by weight of the acrylic resin of Example 1, 16.1 parts by weight of ethyl-ethoxypropionate, 61.2 parts by weight of a hydroxyl-functional acrylic (acid number of about 10 mg KOH/g, hydroxyl equivalent weight of about 450 g/eq OH, number average molecular weight of about 1000, about 79% nonvolatile in a blend of methyl isoamyl ketone, Aromatic 100, and n-butyl acetate), 9.2 parts by weight of xylene, and 3.3 parts by weight of an additive package containing UV absorbers, a tin catalyst, and other customary additives.
[0042] A clearcoat composition was prepared by combining three parts by volume of the Component A with one part by volume of DH-46 Hardener (available from BASF Coatings and Colorants, Automotive Refinish Division) and one part by volume of reducer UR-50 (also available from BASF Coatings and Colorants, Automotive Refinish Division).
Comparative Example A. Preparation of Comparative Clearcoat Composition
[0043] A clearcoat composition was prepared as in Example 2, but without the acrylic resin of Example 1. The Component A of Comparative Example A was prepared by combining 16.1 parts by weight of ethyl-ethoxypropionate, 61.2 parts by weight of the same hydroxyl-functional acrylic (acid number of about 10 mg KOH/g, hydroxyl equivalent weight of about 450 g/eq OH, number average molecular weight of about 1000, about 79% nonvolatile in a blend of methyl isoamyl ketone, Aromatic 100, and n-butyl acetate), 9.2 parts by weight of xylene, and 3.3 parts by weight of the same additive package. The Comparative Example A clearcoat composition was prepared by combining three parts of volume of this Component A with one part by volume of DH-46 Hardener and one part by volume of reducer UR-50.
[0044] Testing of Example 2 and Comparative Example A
[0045] The coating compositions of Example 2 and Comparative Example A were sprayed with a SATA 95 HVLP spray gun with a 1.5 mm tip at 2.96485×10 5 N/m 2 (43 psi) onto 30.5 cm×45.7 cm (12 inch×18 inch) primed aluminum panels. The coated panels were baked at 71° C. (160° F.) for 15 minutes. Both coatings had a film build in the target range of 45.7-55.9 microns (1.8-2.2 mils).
[0046] After cooling, a portion of each panel was taped off with masking tape. The remainder of each panel was wet sanded with 1200 grit paper and then buffed.
[0047] Sanding and buffing the clearcoat obtained from Example 2 was easy. No tape marks were left on the clearcoat from Example 2 when the tape was removed.
[0048] In comparison, the clearcoat produced from the Comparative Example A composition was hard to buff; in other words, it was difficult to bring on the shine again after the sanding. In addition, tape marks remained on the Comparative Example A panel when the tape was removed. The clearcoat in the area that had been taped was visibly disturbed by the tape removal.
Examples 3 and 4.
[0049] These examples demonstrate the preferred embodiments of the invention.
[0050] The Component A of Example 3 was prepared by combining 4.8 parts by weight of the acrylic resin of Example 1, 15.4 parts by weight of ethyl-ethoxypropionate, 64.7 parts by weight of the same hydroxyl-functional acrylic as in Example 2 (acid number of about 10 mg KOH/g, hydroxyl equivalent weight of about 450 g/eq OH, number average molecular weight of about 1000, about 79% nonvolatile in a blend of methyl isoamyl ketone, Aromatic 100, and n-butyl acetate), 8.8 parts by weight of xylene, 2.9 parts by weight of n-butyl acetate, and 3.02 parts by weight of the same additive package as Example 2. A clearcoat composition was prepared by combining three parts by volume of the Component A of Example 3 with one part by volume of DH-46 Hardener and one part by volume of reducer UR-50.
[0051] The Component A of Example 4 was prepared by combining 10 parts by weight of the acrylic resin of Example 1, 15.9 parts by weight of ethyl-ethoxypropionate, 60.6 parts by weight of the same hydroxyl-functional acrylic as in Example 2 (acid number of about 10 mg KOH/g, hydroxyl equivalent weight of about 450 g/eq OH, number average molecular weight of about 1000, about 79% nonvolatile in a blend of methyl isoamyl ketone, Aromatic 100, and n-butyl acetate), 9.1 parts by weight of xylene, 1.1 parts by weight of n-butyl acetate, and 3.02 parts by weight of the same additive package as Example 2. A clearcoat composition was prepared by combining three parts by volume of the Component A of Example 3 with one part by volume of DH-46 Hardener and one part by volume of reducer UR-50.
[0052] Testing of Examples 3 and 4
[0053] The coating compositions of Examples 3 and 4 were sprayed as for Example 2, but onto automotive front hoods. The applied coating layers were baked at 71° C. (160° F.) for 15 minutes. Both coatings had a film build in the target range of 45.7-55.9 microns (1.8-2.2 mils).
[0054] After cooling, a portion of each hood was taped off with masking tape and the remaining portion was wet sanded with 1200 grit paper and then buffed. Both Examples had good sanding and did not leave tape marks, although tape tracks were noted for Example 3. Example 4 was easier to polish, though, and was more resistant to fingerprints. It was also noted that Example 4 was particularly resistant to staining by the polishing compound.
[0055] The invention has been described in detail with reference to preferred embodiments thereof. It should be understood, however, that variations and modifications can be made within the spirit and scope of the invention. | A refinish clearcoat composition includes an hydroxyl-functional acrylic polymer. The acrylic polymer has a number average molecular weight of at least about 5000 and is polymerized using at least about 45% by weight cycloaliphatic monomer, based on total monomer weight polymerized. The clearcoat composition is fast drying. Optionally, the clearcoat is cured by low temperature baking. The cured clearcoat surface may be taped without leaving tape marks as soon as the substrate is cooled. The cured clearcoat may undergo wet sanding after baking as soon as the part is cooled, and can then be buffed back to a high gloss finish after sanding and washing. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of activating a silver halide photographic developer using a metal salt as a developing agent.
2. Description of the Prior Art
Commonly used developers for silver halide photographic light-sensitive materials are an aqueous alkaline solution of an organic compound such as a 3-pyrazolidone, a p-aminophenol derivative, a p-phenylenediamine derivative or hydroquinone as a developing agent, and, as is well known from the literature, an inorganic metal having a reducing property for exposed silver halide grains can be used as a developing agent but, in practice, is seldom used.
The reason for the non-use of such inorganic metals is that an organic developing agent as described above reduces a silver salt during developing and, thereafter changes into a relatively stable oxidation product which has no influence upon the reaction system, whereby the reduction potential of the developer remains stable and at a sufficiently active level, while an inorganic metal developing agent changes during development or during storage into a high valency metal which tends to change reversibly into a low valency metal, whereby the oxidation-reduction potential of the developer changes with an increase in the amount of materials developed, and cannot be kept at an active level.
Therefore, in order to maintain a stable active level using an inorganic metal as a developing agent, development must be carried out while electrolytically reducing the high valency metal formed in the developing reaction or uneconomical procedures must be taken such as using a large quantity of supplemental developing solution or throwing away the developer after use. However, such inorganic metal developing agents do have advantages in that they can be used in an acidic or neutral solution and the concentration of the developing agent can be raised, so it is very important to establish an economical method for using such solutions.
SUMMARY OF THE INVENTION
It is thus one object of the invention to establish a new development method wherein an inorganic metal developer which exhibits lowered activity is activated, thereby regenerating the developing capacity and decreasing the quantity of developer required.
It is another object of the invention to make it possible to carry out an economical development in stable manner for long periods of time by using such a method.
In accordance with the invention, there is provided a method of activating a developer, which comprises adding to a silver halide photographic developer containing a metal capable of reducing exposed silver halide as a developing agent a compound of the same metal as the metal present as a salt, or more preferably, adding additional amounts of the metal per se, said metal having a large contact area, for example, in powdered, granular, wooly or sponge form.
DETAILED DESCRIPTION OF THE INVENTION
The silver halides to which the developer of the invention can be applied show the well-known form of commonly used silver halide photographic light-sensitive materials, e.g., to a material capable of holding a coating in layer form (support member) such as baryta paper or plastic film there is coated an aqueous solution of a water-soluble film-forming material such as gelatin, polyvinyl alcohol or polyvinylpyrolidone in which fine grains of a non-exposed silver halide (which do not form developing nuclei) are dispersed (photographic emulsion), and then dried in layer form.
At present, there are miscellaneous silver halide photographic materials differing in the variety and shape of the support, composition of the coating solution, variety and grain size of the silver halide, additives in the coating solution and the construction of coating layer and support, depending upon the exact use of the material. The developer of the invention is applicable to any of these light-sensitive materials, e.g., the method of the invention can be applied to all photographic material such as in a black and white developer including a first developer in a color reversal process.
In the developer of the present invention there is contained a metal capable of reducing exposed silver halide as a developing agent. The preferred metals used for this purpose are the lower valency transition metals which have an oxidation-reduction (redox) potential lower than that of silver. Specific examples of useful metals include titanium, iron, vanadium, cobalt and nickel.
These metals can, of course be introduced into the developing solution as a salt and, in fact, this is the usual method of introduction. Illustrative of metals used are the lower valency transition metals or complex salts thereof, "lower valency" meaning the lower of two or more valence states such as Fe + + and Fe + + + . Examples of lower valency metal salts are titanium trichloride, vanadium sulfate, ferrous oxalate, ferrous sulfate, titanium tribromide, titanium triiodide, vanadium trichloride, ferrous chloride and ferrous bromide.
The compounds of the following formulae (I) and (II) are illustrative of ligands which form a complex compound with a lower valency metal ion such as Fe + + or Ti + + +: ##EQU1## In this formula, L is --COOM or ##EQU2## M is H, Na, K, Li, NH 4 or a substituted ammonium group such as a trialkanol or trialkyl ammonium group where the alkanol or alkyl group has 1 to 4 carbon atoms such as a triethyl ammonium group or a trialkanol ammonium group, Q and Q' are H, Na, K, Li, NH 4 , a substituted ammonium group such as a trialkanol or trialkyl ammonium group where the alkanol or alkyl group has 1 to 4 carbon atoms such as a triethyl ammonium group or a trialkanol ammonium group alkul or aralkyl, a, b, c and d are 1, 2 or 3, Z is a divalent group such as a phenylene group (o- or p-), a cyclohexylene group or ##EQU3## where R, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 and R 7 are H, OH, NH 2 , a substituted amino group such as a C 1 -C 4 trialkanol or trialkyl amine, e.g., triethanoamine or triethylamine, halogen, alkyl or alkoxy of four or less carbon atoms, C 4 , f is 0, 1, 2 or 3 and e is 1, 2 or 3.
In the above formulae all alkyl groups, including those present in an aralkyl or alkoxy group, preferably have 1 to 4 carbon atoms and the aralkyl group includes both mono- and polyaryl groups.
Specific examples of compounds represented by the above formulae are:
1. ethylenediaminetetraacetic acid
2. diethylenetriaminepentaacetic acid
3. ethylenediamine-N,N,N',N'-tetramethylenephosphoric acid
4. 1,3-diaminopropanol-N,N,N',N'-tetramethylenephosphoric acid
5. 1,2-cyclohexanediamine-N,N,N',N'-tetramethylenephosphoric acid
6. 1,3-propanediamine-N,N,N',N'-tetramethylenephosphoric acid
7. 1,6-hexanediamine-N,N,N',N'-tetramethylenephosphoric acid
8. Li, Na, K or NH 4 salts of the above mentioned compounds ##EQU4## (II) where R--R 1 are as described above. In this formula, X is a divalent group such as O or S or ##EQU5## or >NR 10 in which R 8 , R 9 and R 10 are H, alkyl (e.g., methyl, chloromethyl, hydroxyethyl, ethoxyethyl,bromoethyl, propyl, butyl, cyclohexyl), aralkyl (benzyl, β-phenylethyl), alkoxy (methoxy, ethoxy, butoxy), phenyl, substituted phenyl group (tolyl) or --(CH 2 ) f --L (where f and L are as defined in formula (I)), g, h, i and j are 0, 1, 2 or 3, and k is 0 or 1. The same material regarding preferred alkyl groups in formula (I) apply to formula (II).
Examples of the compounds represented by the above general formula are:
8. nitrilotriacetic acid
9. oxalic acid
10. malonic acid
11. chloromalonic acid
12. ethylmalonic acid
13. aminomalonic acid
14. succinic acid
15. glutamic acid
16. adipic acid
17. diglycolic acid
18. ethyliminodipropionic acid
19. ethylenedithioglycolic acid
20. thioglycolic acid
21. malic acid
22. tartaric acid
23. citric acid
24. nitrilo-N,N,N-trimethylenephosphoric acid
25. propylamino-N,N-dimethylenephosphoric acid
26. o-carboxyanilino-N,N-dimethylenephosphoric acid
27. o-acetamidobenzylamino-N,N-dimethylenephosphoric acid
28. o-toluidine-N,N-dimethylenephosphoric acid
29. 2-pyridylamine-N,N-dimethylenephosphoric acid
30. methylenediphosphoric acid etraethyl ester
31. cyclohexylmethylenediphosphoric acid
32. benzylidenephosphoric acid tetraethyl ester
33. methylenediphosphoric acid
34. tetraethylnonadecylidenephosphoric acid
35. Li, Na, K and NH 4 salts of the above mentioned compounds
Ligand materials which can be used include polycarboxylic acids such as citric acid for ferrous ions.
Useful compounds and metals as can be used in the present invention are summarized J. Willems: "Belgische Chemische Industrie" Vol. 21, page 325-358 (1956) and Vol. 23, page 1105-1115 (1958), "Photographic Processing Chemistry" by Mison (Focal Press), pages 173-176, in N. I. Kirillov: "Problems in Photographic Research (Focal Press)" page 65, page 134 (1967) and C. E. K. Mees and T. H. James: "The Theory of Photographic Process" (3rd Ed.) (The Macmillan Co. N.Y.) page 279-280 (1966) inorganic metal salts. All of these are incorporated by reference.
The developer may further contain known prehardeners and additives such as, for example, alkali halides, sodium sulfate, magnesium sulfate, sodium acetate, sodium nitrate, fog inhibitors such as 1-phenylmercaptotetrazole, 6-nitrobenzimidazole or benzotriazole, phosphates, borates, potassium alum and chrome alum. There may also be used as the prehardener one or more known aldehyde hardeners such as formaldehyde, glutaraldehyde, succinaldehyde, glyoxal, thiobisacetaldehyde, α-methylglutaraldehyde, β-methylglutaraldehyde, methylsuccinaldehyde, maleicdialdehyde and coutaraldehyde. These hardeners can be used in the form of an aldehyde or an adduct with a bisulfite, or in the form of a precursor such as dimethoxytetrahydrofuran.
The developer has a pH of 0.5 to 7, preferably 4 to 6. The concentration of metal developing agent in the developer of this kind is ordinarily within the range of 1-200 g/l when a ligand is not used, and 1-400 g/l when a chelate compound of a metal ion is used. A metal and a ligand can be added respectively within a concentration range of 1-200 g/l to thus form a chelate compound in the developer per se.
The feature of the invention resides in that a developer which is fatigued by development and which exhibits lowered activity is contacted with the same metal as that originally present in the developing agent, and thus the activity of the developer is recovered in a short time. Therefore, more light-sensitive materials can be handled with a certain quantity of developer where developer is disposed of after use, or the activated solution can be repeatedly used as a supplementary solution when carrying out development with the addition of make-up or supplementary developer. During or after use, the developer can be reacted with the complementary metal, e.g., metallic iron (woolly, powdered or granular) in the case of an iron or iron salt developer and with metallic titanium in the case of a titanium or titanium salt developer.
Contact with such metal may preferably be carried out by passing the developer through a filtering tank using as a filter a metal having a large contact area, for example, in powdered, granular, woolly or sponge form. Of course, other suitable methods may be employed such as by charging a piece of the metal into the developing tank. In some embodiments of the invention, a metal filtering tank is provided in the circulation system of a developing tank system, whereby the developer is activated through circulation to prevent it from lowering in activity during continuous development, and the overflow from a developing tank is passed through a filtering tank to regenerate the activity thereof and reuse the same as a supplementary solution, if necessary, after any desired concentration control.
Using the principle of activation as one embodiment of the application of the present invention, a lower valency metal salt developer can be produced from the corresponding higher valency metal salt having intrinsically no developing action. For example, a mixed aqueous solution of ferric sulfate and ethylenediaminetetraacetic acid capable of oxidizing and bleaching developed silver but which is not a developer per se can be converted into an active developer by the above mentioned iron treatment.
The following examples are to illustrate the invention in greater detail without limiting the same.
EXAMPLE 1
An oxidizing solution having the following composition was prepared:
ferric sulfate 10 gdisodium ethylenediaminetetraacetate(dihydrate) 36 gsodium carbonate (monohydrate) 10 gboric acid 10 gwater to make 1000 ml
This solution had no developing capacity. To this solution was added 5 g of commercially available metallic iron powder, the mixture stirred and the precipitate filtered. The resulting solution blackened an exposed silver halide, but gradually lost developing capacity when allowed to stand. However, the developing activity of the solution was recovered by treatment again with metallic iron powder as described.
EXAMPLE 2
Similar results were obtained by repeating the procedure of Example 1 but using 30 g of nitrilotriacetic acid per 1000 ml in place of the 36 g of disodium ethylenediaminetetraacetate dihydrate.
EXAMPLE 3
A continuous treatment with an iron (II)-EDTA developer was carried out using a small developing machine. A black-and-white positive film (fine grain positive movie film made by Fuji Photo Film Co.) was exposed and then continuously treated with a black-and-white developer having the following composition by means of the small developing machine. The residence time of the film in the developing tank was 2 minutes and 45 seconds and the temperature was 27°C. This developing tank had a capacity of 3.5 l and a circulation system wherein the developer was guided via a pipe to a temperature control section from the upper portion of the tank and then returned via a small pump to the developing tank from a feed port at the lower portion of the developing tank.
______________________________________ Composition of developerSolution A ammonia water (sp. gr. 0.91) 50 ml disodium ethylenediaminetetraacetate 140 g (dihydrate) water to make 1000 mlSolution B ferrous sulfate 100 g water to make 300 ml______________________________________
At the time of use, solutions A and B were mixed. During development, a supplementary solution having the same composition as the above described developer (tank solution) was supplemented at a rate of 35 ml per 1 minute to prevent quality deterioration.
A cartridge flled with steel wool was then fitted to the circulation section of the developing tank so that the developer was passed through the cartridge, contacted the steel wool and returned to the developing tank. The cartridge was cylindrical and filled with 1 kg of steel wool. The developer was pumped to the bottom and delivered from the upper portion of the cartridge. The inner volume of the cartridge was about 2000 ml and the flow rate of developer was 1000 ml/min. The quantity of the supplementary solution could be reduced to 1/3 of the above value by the provision of the cartridge. The composition of the supplementary solution used was free of iron salt, as shown below:Composition of supplementary solutionammonia water (sp. gr. 0.91) 30 mldisodium ethylenediamintetraacetate(dihydrate) 140 gwater to make 1000 ml
In accordance with the method of this invention, the quantity of developer used can largely be reduced and a stable development can be carried out for a long time. Moreover, the photograhic qualities compare favourably with those of prior art processes.
EXAMPLE 4
A reversal color film of the multi-layer type containing a cyan coupler in a red-sensitive layer, a magenta coupler in a green-sensitive layer and a yellow coupler in a blue-sensitive layer was exposed and then subjected to reversal color development using a hardening developer having the following composition for the first development:
titanium trichloride 20 gtetrasodium ethylenediaminetetraacetate 70 gformalin (37 wt %) 14 mlsuccinaldehyde 6 gKBr 2 gpH 4.2water to make 1000 ml
After hardening development at 38°C for 3 minutes, the steps of neutralization, color forming development, stopping, water washing, bleaching, fixing, water washing and stabilizing were carried out in the recited order, thus obtaining a reversal image.
Since the life of this hardening developer was short, the developing capacity lowered after one day, and only a low sensitivity image having a high density at high light areas was obtained. However, the activity of the solution was recovered by adding 0.5 g of metallic titanium per 1000 ml of the low activity solution.
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 method of activating a photographic developer which comprises contacting the photographic developer, which contains a metal capable of reducing an exposed silver halide as a developing agent, with a metal the same as the metal as the developing agent. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International Application No. PCT/EP2004/008446 filed Jul. 28, 2004, the disclosures of which are incorporated herein by reference, and which claims priority to German Patent Application No. DE 103 35 616.9 filed Aug. 4, 2003, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a method of automatically suppressing or preventing noise generation during the actuation of a vehicle brake system comprising two or more wheel brakes. The invention further relates to a noise-reduced vehicle brake system.
[0003] It is generally known that during the actuation of a vehicle brake system often noises occur that are perceived as unpleasant. One example that may be cited is the squealing that occurs in specific operating states of the vehicle brake system.
[0004] Various procedures are known for reducing or even pre-empting disturbing noises linked to the actuation of a vehicle brake system. As many instances of noise generation in vehicle brake systems are attributable to resonance effects, it has for example been proposed to dispose additional masses in the region of the wheel brakes. By means of the additional masses, critical resonant frequencies are shiftable into ranges that are not reached or reached only in exceptional situations upon an actuation of the vehicle brake system.
[0005] The provision of additional masses in the region of the wheel brakes is generally perceived as disadvantageous. One reason for this is the fact that the additionally provided masses for shifting the resonant frequencies increase the total unsprung mass of the motor vehicle. What is more, determining the resonant frequencies and locating a suitable position for mounting the additional masses during development of the brake involves a high outlay. From WO 92/07742, and corresponding U.S. Pat. No. 5,108,159, the disclosures of both of which are incorporated by reference herein, a method of suppressing noise generation in a vehicle brake system is known. In the vehicle brake system, a vibration sensor is associated with each wheel.
[0006] The vibration sensors make it possible to measure vibrations (and noises resulting therefrom) as a consequence of the brake shoes coming into abutment with a brake disk. As soon as the vibrations exceed a limit frequency of 8 Hz, by means of suitable control signals the pressure of a brake fluid is modulated at a predetermined frequency. Obviously, such pressure modulations are suitable for reducing the vibrations arising during the generation of the brake forces and reducing the noises linked to the vibrations.
[0007] From DE 198 04 676 A1 a further method of preventing noise generation in a vehicle brake system is known. In this method, the occurrence of noises is detected by measurement and the noises that occur are eliminated in accordance with the teaching of WO 92/07742 by modulating the brake pressure at one or more or all of the wheel brakes. Instead of a pulsating pressure modulation, a slight pressure increase of the or a pressure reduction may be adjusted. Should noises occur at several or all of the wheel brakes, the brake pressure may be increased at the wheel brakes of one of the vehicle axles and at the same time the brake pressure may be reduced at the wheel brakes of a further vehicle axle.
[0008] The underlying object of the invention is to indicate an efficient method of suppressing or preventing noise generation during the actuation of a vehicle brake system comprising two or more wheel brakes. A further underlying object of the invention is to indicate a vehicle brake system that allows the implementation of such a method.
BRIEF SUMMARY OF THE INVENTION
[0009] According to the invention, for automatically suppressing or preventing noise generation during the generation of brake forces by means of the wheel brakes of a vehicle brake system it is proposed to acquire one or more parameters that allow a conclusion to be drawn about noise generation, to evaluate the parameter or parameters to detect the occurrence or imminent occurrence of noises and to change a brake force distribution when the evaluation reveals the occurrence or imminent occurrence of noises. Changing of the brake force distribution between the wheel brakes is effected in such a way that a vehicle deceleration desired by a driver or set by a control system is retained.
[0010] To suppress noises or prevent the occurrence of noises, according to the invention influence is therefore purposefully brought to bear upon the brake force distribution. This occurs advantageously in such a way that the one or more wheel brakes, in the region of which noise generation occurs or is to be expected, in a departure from the customary or planned actuation profile are actuated in such a way that the noise generation is counteracted.
[0011] To prevent the altered actuation operation of one or more of the wheel brakes from leading to a, for the driver, possibly surprising change of the vehicle deceleration, a brake force redistribution may be effected in such a way that the sum of all of the brake forces does not alter despite the changed actuation profile of one or more of the wheel brakes. The marginal condition of retaining the desired vehicle deceleration despite an intervention into the actuation profile of one or more of the wheel brakes leads, as a rule, to a change of the brake force distribution among all of the wheel brakes compared to a braking operation without this intervention to counteract noise generation.
[0012] The changed brake force distribution may also include a wheel brake, at which no noise generation occurs or is to be expected. In the case of a wheel brake affected by the noise generation, a change of the (standard) brake force distribution may involve the brake pressure, in the event of the occurrence or imminent occurrence of noise generation, not being increased further, i.e. being limited.
[0013] The at least one parameter that allows a conclusion to be drawn about possible noise generation is preferably evaluated for the existence or occurrence of a critical condition. The critical condition may be, for example, the reaching or exceeding of a threshold value. It is further conceivable for the critical condition to be defined in such a way that the at least one parameter lies within a critical parameter range. Should a plurality of parameters be used to detect the occurrence or imminent occurrence of noises, the critical condition may be defined individually for each parameter or jointly for a set of parameters.
[0014] The brake force distribution is advantageously changed if the critical condition is met or its occurrence is imminent. The change of the brake force distribution may be geared towards the critical condition no longer being met or its occurrence being prevented.
[0015] In the event of successive, noise-related changes of the brake force distribution, it is advantageous generally alternately to increase and reduce the brake force at one of the wheel brakes or axles. In this way, it is possible to avoid uneven wear. The wheel brakes or axles affected by the alternating brake force changes are advantageously in each case those at which no noise generation has to be counteracted.
[0016] For changing the brake force distribution, an additional control and/or regulating device may be provided. Preferably, however, this purpose is served by a pre-existing brake pressure regulating device that is provided also for other purposes. Examples that may be cited in this connection are the regulating devices of an antilock braking system (ABS), acceleration spin regulation (ASR) or an electronic stability program (ESP).
[0017] Changing the brake force distribution may be effected in different ways. For example, it is conceivable to use one or more characteristics maps in order, in the event of the occurrence or imminent occurrence of noises, to activate a predetermined brake force distribution or a predetermined brake force distribution profile. The brake force distribution may be effected in a controlled manner that simultaneously takes into consideration a change of the at least one acquired parameter that results from the changed brake force distribution (closed-loop control).
[0018] Various parameters may be acquired and evaluated to detect the occurrence or imminent occurrence of noises. The essential point here is that the considered parameter or parameters, individually or in combination, allow a conclusion to be drawn about noise generation. As a suitable parameter according to the invention, the output signal of a noise sensor or vibration sensor may for example be used. By means of a noise sensor (e.g. a microphone), noise generation is directly acquired. This means that noises have already occurred and are therefore detectable. The invention is geared in this case towards suppressing the noises or further, more extreme noise generation.
[0019] The wheel peripheral speed and/or associated wheel brake force may be cited as further examples of suitable parameters according to the invention. In practice, it has emerged that in the region of a wheel brake, in the event of critical combinations of wheel peripheral speed and wheel brake force, an undesirable generation of noise is to be expected. In the case of the acquisition and evaluation of wheel peripheral speed and associated wheel brake force, it is often possible to pre-empt the occurrence of undesirable noises.
[0020] Preferably, the acquisition or the evaluation or both the acquisition and the evaluation of the at least one parameter is effected in a wheel-related manner, i.e. individually for each wheel. It is however also possible to select an axle-related approach. Changing of the brake force distribution may be effected in an axle-related manner. A wheel-related change of the brake force distribution is however equally conceivable.
[0021] A vehicle brake system that is suitable for implementing the method according to the invention comprises two or more separately controllable wheel brakes, at least one sensor for acquiring at least one parameter that allows a conclusion to be drawn about noise generation, an evaluation device for evaluating the at least one parameter for the occurrence or imminent occurrence of noises, and a command-generating device. The last-mentioned device generates commands for changing a brake force distribution e.g. between the wheel brakes, should the evaluation reveal the occurrence or imminent occurrence of noises. As already mentioned, changing of the brake force distribution is effected while simultaneously retaining a desired or set vehicle deceleration.
[0022] The vehicle brake system according to the invention may be designed as a conventional hydraulic brake system or be based on the brake-by-wire principle. According to this principle, the braking request of a driver is supplied electrically or electronically, i.e. not hydraulically, to an actuator unit for the wheel brakes. This is the case, for example, in so-called electrohydraulic brake systems (EHB) or electromechanical brake systems (EMB).
[0023] The command-generating device of the vehicle brake system according to the invention may be a device specially provided for the purpose of suppressing or preventing noise generation. Preferably, however, the functionality of the command-generating device is fulfilled by a pre-existing brake pressure regulating device that is provided also for other purposes such as ABS, ASR or ESP.
[0024] Other advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 illustrates a first embodiment of a vehicle brake system according to the invention;
[0026] FIG. 2 is a schematic diagram relating to the change according to the invention of the brake force distribution between a rear axle and a front axle of a motor vehicle; and
[0027] FIG. 3 illustrates a second embodiment of a vehicle brake system according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] In FIG. 1 a first embodiment of a vehicle brake system 10 according to the invention is illustrated. The vehicle brake system 10 according to the invention is designed to interact with four wheels 12 A, 12 B, 12 C, 12 D of a motor vehicle. The two wheels 12 A and 12 B are disposed on the front axle (VA) of the motor vehicle and the two wheels 12 C and 12 D on the rear axle (HA).
[0029] The vehicle brake system 10 according to the invention comprises one wheel brake 14 A. . . 14 D for each wheel 12 A. . . 12 D. In the case of the example, the wheel brakes 14 A. . . 14 D are based on a hydraulic operating principle. This means that the brake force generation is based on the generation of a hydraulic pressure in the region of the individual wheel brakes 14 A. . . 14 D. The hydraulic pressure, also described as brake pressure, may be built up in accordance with the brake-by-wire principle by means of a hydraulic pump or in a conventional manner by the driver, using a master brake cylinder. The brake pressure may be built up wheel by wheel or axle by axle.
[0030] As FIG. 1 reveals, a sensor device 16 A. . . 16 D is associated with each of the wheel brakes 14 A. . . 14 D. The sensor devices 16 A. . . 16 D allow the determination of the wheel peripheral speed and the associated hydraulic wheel brake pressure for each wheel.
[0031] The vehicle brake system 10 according to the invention further comprises a central evaluation device 18 that evaluates the sensor signals of the sensor devices 16 A. . . 16 D (or more precisely: the individual wheel peripheral speeds and associated wheel brake pressures). The purpose of this evaluation is to detect the occurrence or imminent occurrence of noises.
[0032] The vehicle brake system 10 according to FIG. 1 further possesses a brake pressure regulating device 20 with ABS/ESP functionality.
[0033] Resonance effects are usually one of the main causes of the occurrence of undesirable brake noises. In this respect, a particular susceptibility to resonance effects is presented by the wheel brake/axle stub system. It has been found that the wheel brakes 14 A. . . 14 D and, more precisely, their brake linings from a mechanical viewpoint each represent a spring having properties dependent on the brake pressure. This means that the resonant frequencies of the wheel brake/axle stub system have a dependence upon the brake pressure. Undesirable resonance effects and associated noise generation occur whenever, because of a brake pressure change, a resonant frequency is shifted into a critical range in terms of excitation, i.e. for example, whenever the resonant frequency of a specific wheel brake/axle stub combination correlates with the peripheral speed of the corresponding wheel.
[0034] To prevent resonance effects and/or undesirable noise generation, in the vehicle brake system 10 according to the first embodiment it is provided that by means of the evaluation device 18 critical combinations of wheel peripheral speed and associated wheel brake pressure are detected already in the run-up to a resonance-related noise generation. If noise generation is to be expected, by means of the regulating device 20 influence is brought to bear upon the brake pressure of the relevant wheel in such a way that during a braking operation critical combinations of wheel peripheral speed and associated wheel brake pressure are avoided. This process of preventing noise generation is now described in detail with reference to FIG. 2 .
[0035] FIG. 2 is a time diagram illustrating the automatic intervention according to the invention to prevent noise generation. In the time diagram of FIG. 2 , for an exemplary braking operation the characteristic curves of several parameters characterizing the braking operation are represented in relative units. The top characteristic curve is the time-dependent course of the brake force distribution. In the case of the example, the brake force distribution is defined as the ratio of the brake force fraction of the front axle VA to the total brake force at front and rear axle VA+HA. The reason for the axlerelated definition of the brake force distribution is the fact that the brake pressure is also set in an axle-related manner. Should the brake pressure be set in a wheel-related manner, a wheel-related brake force distribution might be defined.
[0036] Below the characteristic curve of the brake force distribution, the time-dependent course of the brake pressure at the rear axle HA and, below it, the time-dependent course of the brake pressure at the front axle VA are shown in the diagram of FIG. 2 . The bottom characteristic curve reflects the time-dependent course of the vehicle speed. Clearly visible is the substantially uniform reduction of the vehicle speed resulting from the actuation of the vehicle brake system.
[0037] If at time t 0 a driver initiates a braking operation, the brake pressures at the front axle and rear axle gradually increase. At the same time, the vehicle speed starts to drop. The brake force distribution presents a characteristic course that is defined by means of a usually provided brake force distributor.
[0038] During the braking operation, in the region of each of the four wheel brakes 14 A. . . 14 D of the vehicle brake system 10 according to the first embodiment a wheel-related monitoring of the wheel peripheral speed and the associated wheel brake pressure or, synonymously, of the associated wheel brake force is effected. The monitoring occurs for each wheel individually by means of the evaluation device 18 coupled to the individual sensor devices 16 A. . . 16 D. In the evaluation device 18 the parameters acquired by the sensor devices 16 A. . . 16 D, namely the wheel peripheral speed and the wheel brake pressure, are compared with previously defined limit values. In said case, it is provided that the evaluation device 18 activates the brake pressure regulating device 20 only if, at a wheel, the limit value of the brake force or the limit value of the wheel peripheral speed is exceeded. It might alternatively be provided that an activation of the regulating device 20 occurs only if both limit values are exceeded. It might also be conceivable to define wheel peripheral speed windows and/or brake force windows with upper and lower limit values. In this case, an activation of the regulating device 20 occurs only if one of the two relevant parameters or both parameters lies or lie within the critical parameter range defined by the upper and lower limit values.
[0039] In the scenario illustrated in FIG. 2 , at time t 1 at the two wheel brakes 14 A, 14 B of the front axle VA a brake pressure limit value is reached, which if exceeded may lead to braking noises. The evaluation device 18 therefore activates the regulating device 20 . The regulating device 20 then generates commands to change a standard brake force distribution between the wheel brakes of the front axle, on the one hand, and the wheel brakes of the rear axle, on the other hand. The commands are geared towards achieving the effect whereby, on the one hand, the brake pressure at the noise-critical wheel brakes 14 A, 14 B of the front axle VA does not exceed the brake pressure limit value (pressure limitation) but, on the other hand, the brake pressure at the wheel brakes 14 C, 14 D of the rear axle HA increases to such an extent that the sum of the brake pressures and hence the desired vehicle deceleration do not change. The driver of the motor vehicle is consequently totally unaware of the automatic intervention into the brake force distribution. This is clear from the fact that the vehicle speed, despite the control intervention, falls even after time t 1 with a substantially constant slope.
[0040] At time t 2 the braking operation has progressed to such an extent that the brake pressure at the wheel brakes 14 A, 14 B of the front axle VA may (likewise) be reduced. In other words, at time t 2 there may be a switch back to the original (standard) brake force distribution.
[0041] The intervention according to the invention into the brake force distribution consequently occurs for the length of time t 2 -t 1 . In the time diagram according to FIG. 2 it may clearly be seen that during this length of time the brake force distribution among the wheel brakes 14 A. . . 14 D changes. It should however be taken into account that the intervention into the brake force distribution between t 1 and t 2 generally does not involve an intervention into the course of the total brake force. For this reason, by means of the intervention into the brake force distribution between t 1 and t 2 the occurrence of undesirable noises may be prevented without changing the vehicle deceleration desired by the driver (or set e.g. by a control system).
[0042] In FIG. 3 a further vehicle brake system 10 according to a second embodiment of the invention is illustrated. Identical components are denoted by the same reference characters as in the vehicle brake system of the first embodiment.
[0043] Unlike the first embodiment, in the vehicle brake system 10 illustrated in FIG. 3 the brake pressures are set, not axle by axle, but wheel by wheel. A further difference lies in the fact that in the second embodiment the noise generation is acquired directly by means of a noise sensor 22 . This means that in the second embodiment noise generation is not prevented, rather noises that have already occurred or the swelling of noises that have already occurred is to be suppressed.
[0044] As may be seen from FIG. 3 , the noise sensor 22 (e.g. a microphone) is disposed in the region of the wheel brakes 14 C, 14 D of the rear axle. The output signal of the noise sensor 22 is evaluated by the evaluation device 18 . The evaluation is geared towards detecting the reaching of a noise threshold value. If the noise threshold value is reached, the evaluation device 18 activates the regulating device 20 and the previously discussed control intervention illustrated in FIG. 2 occurs.
[0045] As regards the design of the noise sensor 22 , various possibilities are available. For example, it is conceivable to integrate the noise sensor 22 in a brake lining wear sensor. Another possibility is to fit noise sensors on the individual vehicle wheels and inject the signals produced by the noise sensors into wheel peripheral speed sensors and transmit them jointly with signals of these sensors. Piezoelectric elements, for example, may be used as noise sensors.
[0046] There now follows a description of several developments of the invention that apply both to the vehicle brake system according to the first embodiment and to the vehicle brake system according to the second embodiment.
[0047] It has proved advantageous, for detecting the occurrence or imminent occurrence of noises, simultaneously to take into account further parameters such as the laden state of the vehicle, the static and dynamic force distribution of the vehicle, uphill and/or downhill braking operations, cornering braking operations with increased transverse acceleration, and braking operations on so-called split mue roads, etc. This information is generated by brake pressure regulating devices with ESP functionality that are usually already provided.
[0048] It has further emerged that, in the event of braking operations or driving manoeuvres that are critical in terms of stability and lead to the activation of safety-relevant control mechanisms such as ESP or ABS, these control mechanisms should be given priority over the previously described, noise-reducing control mechanisms. In other words, safety aspects should not be neglected in favour of comfort aspects.
[0049] To prevent uneven wear of the brake linings, the interventions into the brake force distribution may be effected in such a way that in the region of a specific wheel brake, in the event of successive, noise-related changes of the brake force distribution, the brake force is alternately increased and reduced. If, for example, during an intervention into the brake force distribution at specific wheels the brake forces are reduced and at other wheels the brake forces are increased, then during the next noise-related intervention into the brake force distribution at the individual wheels brake force changes in the opposite direction should be used to compensate.
[0050] The comparison curves used by the evaluation device to evaluate the sensor signals may be determined as early as during the brake design stage and then stored in the evaluation device or a separate device. After delivery of the vehicle, the comparison values may if necessary be altered and/or adapted when the vehicle is in the workshop (e.g. for servicing). For this purpose, the evaluation device or the separate device may be provided with an interface that affords access to memory areas for the purpose of altering or supplementing relevant parameters, characteristics maps (e.g. a look-up table) etc.
[0051] The parameters for detecting the occurrence or imminent occurrence of noises that are stored in e.g. a look-up table may include one or more of the values: wheel brake pressure, wheel speed (wheel rotational speed), temperature, brake wear (e.g. time factor, brake abrasion or running capacity). It is also conceivable, when exchanging components of the brake system such as e.g. the brake linings, to use the interface to load new parameters, characteristics maps, etc., which take into consideration the characteristic properties of the exchanged components.
[0052] Compared to noise absorption by means of additional masses, intervention into the brake force distribution makes it possible to shorten development times and reduce fuel consumption. At the same time, it is not impossible, for particularly effective noise reduction, to combine the intervention according to the invention into the brake force distribution with the provision of additional masses.
[0053] In accordance with the provisions of the parent statutes, the principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope. | A method of automatically suppressing or preventing noise generation during the actuation of a vehicle brake system comprising two or more wheel brakes is described. For this purpose, a parameter that allows a conclusion to be drawn about noise generation is acquired and evaluated to detect the occurrence or imminent occurrence of noises. Should the evaluation reveal the occurrence and imminent occurrence of noises, the brake force distribution between the wheel brakes is changed. This change of the brake force distribution is effected while simultaneously retaining a desired and/or set vehicle deceleration. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to construction industry modular insulating panels having foam cores covered by metallic skin that interlock with one another along abutting edges.
2. Description of the Prior Art
U.S. Pat. Nos. 4,769,963, (B1 4,769,963), and 5,086,599 to Meyerson disclose an interlocking panel that produces a very tight lateral interlock between contiguous panels but which permits up and down movement of contiguous panels when they are walked upon. Its structure limits its versatility because adjacent panels can be interlocked with only one type of interlocking procedure; they must be pushed straight in toward one another. More particularly, contiguous panels are first positioned in a common plane and then interlocked by pushing the panel to be installed into engagement with the already-installed panel. This "straight in" method is disadvantageous where space is limited because both panels must be positioned in a common plane as aforesaid. When the panels are so interlocked, they cannot be disassembled by pulling the panels apart from one another. Disassembly is possible if space permits lateral sliding of the panels. Thus, a homeowner who notices a scratch or other defect in a panel might request that the panel be inverted to hide the scratch from view, but such inversion is not practical. The panels may even be damaged if an effort is made to disengage them.
In limited space applications, the preferred method of assembly is known as the "rock and lock" method. This method is practiced by positioning a first panel in a first plane, positioning a second panel contiguous thereto at an angle such as forty five degrees relative to the plane of the first panel, bringing the two panels together, and lowering the second panel into the same plane as the first panel while pressing said second panel toward said first panel.
What is needed, then, is a panel design that enables disassembly of panels when desired without damage to the foam cores thereof. Moreover, there is a need for a design that enables use of the straight in assembly method, as well as the rock and lock method, and which permits lateral displacement of interlocked panels. However, in view of the prior art as a whole at the time the present invention was made, it was not obvious to those of ordinary skill in this art how these needs could be fulfilled.
SUMMARY OF THE INVENTION
The present invention modifies the Meyerson panel in a highly novel, nonobvious way. The modification preserves the straight in assembly method, the lateral displacement disassembly method, adds the rock and lock assembly method, and prevents up and down movement of interlocked panels. It is the first interlocking panel that includes all of these important features.
The novel panel construction includes a foam core having a top surface and a bottom surface. The foam core has a sculpted first edge that forms an outwardly extending protrusion and a second edge that is complementally sculpted to form an inwardly extending recess for receiving the protrusion.
The protrusion has a flat formed in an outermost edge thereof that is normal to said top and bottom surfaces; it further includes a top and a bottom inclined wall that extend inwardly from opposite ends of the flat toward the top and bottom surfaces, respectively, at a predetermined angle of inclination. The protrusion further includes a top and a bottom channel formed in an innermost end thereof; each of the channels has a flat bottom parallel to the top and bottom surfaces of the foam core, and each of the flat bottoms are spaced further from the respective top and bottom surfaces of the foam core than inwardmost ends of said first and second inclined walls.
The top and bottom surfaces of the foam core are covered by a top and a bottom metallic skin, respectively.
A first end of the top and bottom metallic skins have plural bends formed therein to overlie the channels and a preselected extent of the inclined walls contiguous to the channels.
A second end of the top and bottom metallic skins each have a first unbent part that extends in cantilever relation relative to the second edge of the foam core, and said first unbent part of said top and bottom metallic skins are disposed in parallel relation to one another. The second end of the top and bottom metallic skins also have second parts bent toward one another at a substantially ninety degree angle, and each of said second parts have an extent less than the depth of the channels. Third parts of each of said metallic skins are bent toward one another and inwardly toward the second edge of the foam core, said second and third parts having a combined extent substantially equal to the depth of the channels. Fourth parts of said skins are bent toward the top and bottom surfaces of the foam core, respectively, and inwardly toward the second edge of the foam core. Fifth parts thereof are disposed in parallel relation to the top and bottom surfaces of the foam core, and said fifth parts extend toward the second core edge by a predetermined distance and form a flat. Sixth parts of said respective metallic skins are bent toward the second edge of the foam core at an angle substantially complementary to the angle of inclination of said inclined walls of said protrusion.
The flat fifth part of the second end of the metallic skin abuttingly engages and overlies a linear edge formed by the angle between the inclined walls and the channels of the protrusion when contiguous panels are assembled in edge-to-edge relation to one another. A second linear edge is formed by the angle between the third and fourth parts of the second end of the top and bottom metallic skins; said second linear edge overlies and abuttingly engages the bottom wall of the top and bottom channels when said contiguous panels are joined. Thus, the panels meet along two linear edges; this reduces the friction therebetween and enables joined panels to be laterally displaced with respect to one another. Moreover, the flat formed in each skin increases the flexibility of the skin to enable straight in interconnection and disassembly of panels, while also allowing rock and lock installation when space permits. The mating of panels along said linear edges also prevents vertical motion when the panels are walked upon.
Thus it is understood that the primary object of this invention is to advance the art of interlocking foam panels by providing the world's first interlocking panel that is assembleable and disassembleable by the rock and lock method and the straight in method.
Another important object is to provide interlocking panels that are laterally displaceable with respect to one another.
Another object is to provide such panels in a way that prevents vertical motion between contiguous panels when they are walked upon.
These and other important objects, features and advantages of the invention will become apparent as this description proceeds.
The invention accordingly comprises the features of construction, combination of elements and arrangement of parts that will be exemplified in the construction hereinafter set forth, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:
FIG. 1 is a side elevational view of a pair of confronting panels disposed in a common plane prior to their interlocking by the straight in method;
FIG. 2 is a side elevational view of said panels depicting the transient deflection of the cantilevered parts during performance of said straight in method;
FIG. 3 is a side elevational view of the panels of FIG. 1 when they are almost fully interlocked, depicting said cantilevered sections after having returned to their respective positions of repose;
FIG. 4 is a side elevational view after full interlocking has been achieved;
FIG. 5 is a side elevational view of a pair of confronting panels disposed in angular relation to one another preparatory to a rock and lock-type of interconnection; and
FIG. 6 is a side elevational view similar to FIG. 5, depicting a unique installation procedure made possible by the inventive structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the Figures, it will there be seen that an illustrative embodiment of the invention is denoted as a whole by the reference numeral 10. Panel construction 10 includes a first panel edge 12 and a second panel edge 14, it being understood that a single panel has opposed edges in the form of first and second edges 12 and 14.
Panel edge 12 has a shape generally similar to that of heretofore known panels in this art. It includes a foam core 16 having top and bottom surfaces 22 and 24, respectively; the core is sculpted into an outwardly extending protrusion in the form of a flat tip arrowhead profile; the flat tip 17 is normal to the plane of the top and bottom surfaces 22, 24 of the core. The protrusion also includes a top and a bottom inclined wall 15, 15 that extend inwardly from opposite ends of flat 17 toward said top and bottom surfaces, respectively, at a predetermined angle of inclination.
A pair of transversely extending square channels 18, 20 are formed in the top and bottom surfaces at an innermost end of the protrusion. Note that each channel has a trailing wall 19, a truncate leading wall 21 parallel thereto, and a bottom wall 23 parallel to the bottom and top surfaces of the foam core. The depth of each channel is selected so that each bottom wall 23 is further from top and bottom surfaces 22, 24 of foam core 16 than the inwardmost ends of the inclined walls 15, 15 that form a part of the protrusion.
A metallic skin 22a, 24a overlies said top and bottom surfaces 22, 24, respectively. Said skins are bent ninety degrees as shown to overlie trailing walls 19 as at 19a, leading walls 21 as at 21a, bottom walls 23 as at 23a, and about half of each inclined wall as at 15a. The point where parts 15a and 21a meet is denoted 13; said point is of course a transversely extending linear edge.
The present invention differs from the earlier designs of this type in that the width of channels 18, 20, i.e., the distance between said trailing and leading walls, is greater than the width of the corresponding channels of the prior art for reasons that will become clear as this description proceeds, and in other ways as well.
The second edge 14 of foam core 16 is complementally sculpted and forms an inwardly extending recess 25 having flat wall 26 and inclined walls 27, 27 for receiving the outwardly extending protrusion of the first edge of the core. Each second end of the top and bottom metallic skins 22a, 24a has a first unbent part 30 that extends in cantilever relation relative to the second edge of the foam core, and said first unbent parts 30, 30 are disposed in parallel relation to one another. Second metallic parts 32 are bent toward one another at a substantially ninety degree angle relative to the first parts 30, 30; each of said second parts has an extent less than the depth of channels 18 and 20. Third metallic parts 34 are bent toward one another and inwardly toward the second edge of the foam core at an angle of about forty five degrees; the second and third parts have a combined extent substantially equal to the depth of the channels. Fourth parts 36 are bent toward the top and bottom surfaces of the foam core, respectively, and extend inwardly toward the second edge of the foam core; the angle between each fourth part 36 and its contiguous third part 34 is about ninety degrees. Said third and fourth parts meet at transversely extending peak 35. Fifth parts 38, 38 are disposed in parallel relation to the top and bottom surfaces of the foam core; each fifth part extends longitudinally toward the second core edge by a predetermined distance (preferably about one-eighth of an inch) and forms a flat as depicted. The angle of inclination between the fourth and fifth parts is about forty five degrees. Sixth parts 40 are bent toward the second edge of the foam core at an angle substantially complementary to the angle of inclination of the inclined walls 15, 15 of the flat-tipped arrowhead protrusion, i.e., at the same angle as inclined walls 27, 27 of recess 25. Accordingly, the angle between the fifth and sixth parts 38, 40 is about forty five degrees and the angle between the fourth and sixth parts 36, 40 is about ninety degrees.
FIG. 2 depicts an intermediate, i.e., transient position of the above-described parts during the straight-in interconnection process. In this Figure, panel edge 14 is stationary and its complementary panel edge 12 is being pushed toward it in the direction indicated by directional arrow 50, although opposite displacement of said panels is equally permissible. Importantly, third parts 34 are sliding relative to their associated inclined wall 15a of the protrusion and fifth parts 38 are flexing toward their respective top and bottom panel surfaces to allow such sliding.
In FIG. 3, the interlocking is nearly completed and full interlocking is depicted in FIG. 4. The resiliency of first parts 30 has restored said parts to their position of repose, and third and fourth parts 34 and 36 have entered into the channels 18, 20 as shown. Note the position of transversely extending peaks 13 and 35 in both of said Figs. Peak 13 slides along flat 38 during the assembly process, and peak 35 slides along part 23 that forms the bottom of grooves 18 and 20.
FIGS. 1-4 may also be interpreted as disclosing the step of disengaging said panels, i.e., the drawings would look the same if directional arrow 50 were pointing the opposite way. Note that during such reverse motion, inclined wall 36 rides on peak 13, as perhaps best understood in connection with FIGS. 3 and 4.
Note that peak 35 forms a transversely extending line of contact with its associated channel bottom walls 23. Thus, there is very little friction along said line of contact; this enables lateral displacement of the mating panel edges. Moreover, the contact ensures that mating panels will not slide relative to one another in a vertical plane when walked upon. Earlier panels in this field lack such contact and thus are subject to such movement as mentioned earlier.
Significantly, peak 13 forms a similar low friction line of contact with flat 38; note how peaks 13 and 35 work together to allow said lateral displacement while preventing vertical motion of the panels when they are walked upon. Such low friction lines of contact also provide a part of the play that facilitates the straight in assembly and disassembly method disclosed herein.
FIG. 5 discloses that this novel design also enables conventional rock and lock installation.
The ease with which the interlocking panels may be assembled is depicted in FIG. 6. There, a single finger 60 is pressing in the direction of arrow 62. The novel panel is the only interlocking panel, anywhere in the world, that can be installed by a pressure so low it can be exerted easily by a single finger. The earlier designs, mentioned above, require considerable force to achieve interlocking.
Another feature of this design that distinguishes it from the art is the width of channels 18, 20, as mentioned earlier. Such broad channels introduce play into the structure, and such play facilitates connection and disconnection of mating panel edges. In the earlier devices in this field of invention, no play was provided; as a result, the panels of the prior art are difficult to interlock and almost impossible to disengage once interlocked.
Caulking compound 70 may be advantageously employed in connection with the novel panel design. As indicated in all of the Figures, said compound is initially deposited into channels 18 and 20 and is spread to opposite sides of transversely extending peak 35 during the interconnection process. Although the Figs. depict voids in the compound, it should be understood that an increased amount of compound eliminates such voids.
This invention is clearly new and useful. Moreover, it was not obvious to those of ordinary skill in this art at the time it was made, in view of the prior art considered as a whole as required by law.
It will thus be seen that the objects set forth above, and those made apparent from the foregoing description, are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing construction or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
Now that the invention has been described, | Modular panels having foam cores covered by metal skins are interlocked to one another by complementally formed bends in the metal skins. A flat is formed in one of the metal skins to introduce flexibility and play into the interlocking mechanism, and both interlocking skins have a transversely extending bend formed in them that makes a line of contact with the mating interlocking skin to reduce the friction between them and to allow lateral movement of the interlocked panels. The play and flexibility introduced by the flat enable adjacent panels to be interlocked to one another by a straight-in movement and by an angular movement known as a rock and lock. | 4 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The invention relates to a method of manufacturing a 3D micromirror, and more particularly, to a method of manufacturing a 3D micromirror using a silicon micro-machining process.
(2) Description of the Prior Art
Micromirror devices based on MEMS technology had a humble debut in the late eighties as display devices. However, a spurt in research activities took place in the mid to late nineties after they were identified as most promising candidates for futuristic all-optical communication networks. There are two basic configurations for micromirror arrays based on MEMS technology, namely 2D in-plane and 3D free space out of plane. This division is based on MEMS silicon process technology. The 3D free space switching array is more efficient than the 2D configuration because it requires a smaller number of mirrors for a similar cross switching function. However, it is more challenging from a packaging and fiber coupling alignment point of view. The requirement for other parameters such as surface reflectivity, curvature, switching speed, cross talk, etc., is similar in both configurations.
There has been some recent work on 3D free space MEMS micromirror technology. Single crystal silicon material is a natural choice for high reliability, very good polished surface, and better flatness. U.S. Pat. No. 6,563,106 to Bowers et al and U.S. Pat. No. 6,556,737 to Miu et al disclose mirrors fabricated from thick single crystal silicon and actuators fabricated from thin single crystal silicon. The actuators of Bowers et al are electrostatic and parallel plate actuators requiring high voltage. Miu's actuators are electromagnetic. U.S. Pat. No. 6,504,643 to Peeters et al has a single crystal silicon mirror and MoCr electrostatic and parallel plate actuators requiring high voltage. U.S. Pat. No. 6,480,320 to Nasiri describes thick single crystal silicon mircomirrors and silicon-on-insulator (SOI) single crystal silicon electrostatic and parallel plate actuators requiring high voltage. Other materials can be used to fabricate micromirrors. For example, U.S. Pat. No. 6,386,716 to Hagelin et al shows polysilicon micromirrors and electrostatic actuators requiring high voltage.
The article “Micromirrors for Adaptive-optics Arrays” by Michael A. Helmbrecht et al, Transducers ' 01 Eurosensors XV , June 2001, describes micromirrors built using wafer bonding techniques. The article “Three-dimensional structures obtained by double diffusion and electrochemical etch stop” by S. Marco et al, Journal of Micromech. Microeng. 3 (1993) pp. 141–142, shows a two-step silicon layer method of forming non-uniform diaphragms and bridges. This disclosure does not anticipate using the two-step silicon method to build a 3D micromirror device. There is no recognition of the need to prevent breakage by cutting thick silicon having thinner edges.
SUMMARY OF THE INVENTION
A principal object of the present invention is to provide an effective and very manufacturable method of fabricating a 3D free space micromirror device.
Another object of the invention is to provide a 3D free space micromirror device having a thick silicon micromirror and thin silicon springs and thermal actuators.
A further object of the invention is to provide a method for fabricating a 3D free space micromirror device monolithically from a single crystal silicon substrate.
In accordance with the objects of this invention a single crystal silicon micromirror device is achieved. The three-dimensional free space micromirror device comprises a single crystal silicon micromirror, single crystal silicon thermal actuators, and single crystal silicon flexible springs connecting the thermal actuators to the micromirror.
Also in accordance with the objects of this invention a method of fabricating a single crystal silicon micromirror device is achieved. A p-doped single crystal silicon substrate wafer is provided having a frontside and a backside. First and second n-doped regions are formed at a surface of the substrate wherein the first n-doped regions have a first thickness and the second n-doped regions have a second thickness larger than the first thickness. A hard mask is formed on the backside of the wafer. An oxide layer is formed on the frontside of the wafer. An aluminum layer is formed on the thermal oxide layer and patterned to leave aluminum overlying some of the second n-doped regions to form thermal actuators and to form an oxide mask for actuator springs over portions of the first n-doped regions. A dielectric layer is deposited overlying the patterned aluminum layer and the thermal oxide layer. A metal layer is deposited overlying the dielectric layer and patterned to form bond pads to the thermal actuators contacting the patterned aluminum layer through openings in the dielectric layer and to form reflecting mirror surfaces overlying others of the second n-doped regions not covered by the patterned aluminum layer to form micromirrors. The substrate is etched away from the backside of the wafer stopping at the first and second n-doped regions. Then the wafer is diced into mirror array chips. The dielectric layer is etched away from the frontside of the wafer to expose portions of the first n-doped regions. The exposed first n-doped regions not covered by the oxide mask are etched away from the frontside to form flexible springs in the first n-doped regions wherein the second n-doped regions covered by the patterned aluminum layer form thermal actuators and wherein the flexible springs connect the micromirrors to the thermal actuators.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings forming a material part of this description, there is shown:
FIG. 1 schematically illustrates in top view a single crystal silicon micromirror device of the present invention.
FIG. 2 schematically illustrates in a three dimensional view a single crystal silicon micromirror device of the present invention.
FIGS. 3 through 10 schematically illustrate in cross-sectional representation a preferred embodiment of the present invention.
FIG. 11 schematically illustrates in top view a step in the process of the present invention.
FIGS. 12 , 13 , 15 and 16 schematically illustrate in cross-sectional representation a preferred embodiment of the present invention.
FIG. 14 schematically illustrates in cross-sectional representation an alternative in a preferred embodiment of the present invention.
FIG. 17 schematically illustrates in cross-sectional representation a completed micromirror device of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention discloses a novel design and process for making a 3D free space micromirror device with thick mirror and thin flexible springs and actuators which are monolithically fabricated from a single crystal silicon substrate. Key features of the present invention include the use of 1) a thermal actuator fabricated by a unique process sequence, 2) thin silicon for springs and the actuator and thick silicon for the mirror plate, 3) one monolithic process sequence for fabrication of the actuator, spring, and mirror, and 4) five masking steps, making the process simple and less cumbersome. Silicon is the core material for all components. Silicon dioxide and aluminum are used respectively for electrical isolation and thermal actuation purposes only.
Top and three-dimensional views of the device can be seen in FIGS. 1 and 2 , respectively. The mirror plate 40 is joined with actuators 50 through four flexural springs 45 at four corners symmetrically. Other ends of the actuators have fixed supports 47 on the substrate 10 . For example, the mirror size is 400 microns in diameter and fabricated in 10 μm thick n-silicon. The actuators are 300 to 500 μm long multilayered composites of 2 μm thin silicon, 0.2 μm silicon dioxide, and 1 μm aluminum. The flexural springs are fabricated of 2 μm thin silicon. In the actuators, n-silicon and aluminum are bi-morph materials for thermal actuation/bending and the silicon dioxide provides electrical isolation between the two. Mirror sizes can range from 50 μm to 1000 μm in diameter depending on the application. Actuators can also be varied from 50 μm to 1000 μm if required.
There are many structures such as cantilever beam, doubly supported beam, diaphragm, complicated multi component structures, flexure springs etc. that are basic building blocks for MEMS devices. The process of the present invention offers thickness variation flexibility for single crystal silicon MEMS.
The micromachining fabrication process begins with a p-type silicon substrate, for example, 6 inches in diameter. Referring now more particularly to FIG. 3 , there is shown a cross-section of the semiconductor substrate 10 , preferably composed of P-doped monocrystalline silicon. A portion of the active area of one mirror element is shown. A thermal oxide layer 12 is grown on the surface of the substrate to a thickness of between about 275 and 325 Angstroms.
Phosphorus implantation and diffusion steps are used to obtain a two-step p-n junction having two different thicknesses. A first phosphorus implant is made through a mask, not shown. The impurity is diffused to a first depth, for example 8 μm, to form first diffusions 16 . Now, a second global phosphorus implantation and diffusion are carried out for a shallower depth of about 2 μm to form second diffusions 18 , as shown in FIG. 4 . This forms the n-silicon layer with two thicknesses 2 μm and 8 μm.
Alternatively, an n-silicon layer can be grown on the p-substrate using an epitaxial silicon process. The n-silicon layer can be etched to form portions having different thicknesses using a deep reactive ion etching (DRIE) process.
Now, open frame implantations/diffusions are carried out for P+ and N+ contacts which are required for four electrode electrochemical (ECE) etch-stop at the n-silicon layer. These contacts are far away from the active area shown in the drawing figures and so are not illustrated.
The oxide layer 12 is stripped, for example, by wet etching. Now a second thermal oxide layer 24 is grown on the surface of the substrate to a thickness of between about 270 and 330 Angstroms, as illustrated in FIG. 5 . Next, a silicon nitride layer 26 is deposited by low pressure chemical vapor deposition (LPCVD) over the thermal oxide layer 24 on the frontside of the wafer and on the backside of the wafer (illustrated as the bottom of the drawing figure) to a thickness of between about 1200 and 1800 Angstroms. A TEOS oxide layer 28 is deposited by plasma enhanced chemical vapor deposition (PECVD) on the backside of the wafer to a thickness of between about 800 and 1200 Angstroms. A silicon nitride layer 30 is deposited by PECVD on the backside of the wafer to a thickness of between about 1500 and 2500 Angstroms. The oxide/nitride layer will act as a hard mask on the backside of the wafer.
Referring now to FIG. 6 , the oxide and nitride layers 24 and 26 are etched away on the frontside of the wafer. Now, a tetraethoxysilane (TEOS) oxide layer 32 is deposited on the frontside of the wafer by PECVD to a thickness of between about 1800 and 2200 Angstroms. An aluminum layer 34 is deposited over the TEOS oxide layer 32 on the frontside of the wafer to a thickness of about 1 μm. The TEOS oxide layer provides electrical isolation between the n-silicon and the aluminum film. Aluminum is used both as a bimorph material for thermal actuation and as a resistive heater.
Using a second mask, the aluminum film 34 is patterned and etched, as illustrated in FIG. 7 . A TEOS oxide layer 36 is deposited by PECVD on the patterned aluminum to a thickness of between about 4500 and 5500 Angstroms. Referring now to FIG. 8 , the PETEOS layer 36 is patterned and etched using a third mask. This oxide layer 36 covers and passivates the previously patterned aluminum from the ambient and also is used as a hard mask in the subsequent silicon etching cut to define the device.
Referring now to FIG. 9 , a layer of chromium is deposited over the substrate to a thickness of between about 100 to 200 Angstroms followed by deposition of a layer of gold having a thickness of between about 400 and 600 Angstroms. The two layers are patterned to form a mirror reflecting surface 40 and bonding pads 56 .
Now, an aluminum thin film 44 is deposited for silicon electrochemical etch-stop (ECE) electrical contacts, as shown in FIG. 10 . The aluminum film 44 is patterned using a paper mask to separate the n-silicon and p-silicon areas, as shown in top view in FIG. 11 . This area is far away from the mirror active area.
The final masking step is performed to pattern the nitride/oxide/nitride layer 26 / 28 / 30 on the backside of the wafer as shown in FIG. 12 .
Now the processed wafer is ready for backside four probes ECE of silicon in an aqueous solution of KOH. Etching in KOH is carried out at about 75° C. for about 15 hours to etch through the wafer and stop at the n-silicon layer 16 / 18 . During ECE, electrical potential is applied such that the p-silicon 10 is etched while etching stops on the n-silicon layer at the junctions 16 and 18 . Etch stop on the n-silcion layer is detected by an electric current method. The etched wafer is shown in FIG. 13 .
In a process variation, a combination of DRIE and ECE KOH etching can be used. For example, in a silicon wafer of about 680 μm thickness, initial etching to a depth of about 600 μm is carried out without applying any electrical potential; that is, DRIE. The final 50–60 μm are etched using the 4 probes ECE method in aqueous KOH. The size of the DRIE window can be calculated using 54.7°, <111> plane slope in <100> oriented wafer. As shown in FIG. 14 , the window size required for KOH is much larger than the size required for a combination of DRIE and KOH etch. For example, the savings in area can be large enough for one mirror element.
Referring now to FIG. 15 , photoresist 52 is backfilled from the backside of the wafer. Its role is to protect the surface from contamination and provide some extra stiffness during dicing. Now, the processed wafer is diced into small mirror array chips. After dicing, the ECE metal 44 is stripped off the front side of the wafer. Then, the silicon 10 is cut through the silicon dioxide mask 32 / 36 as shown in FIG. 16 to realize the mirror array of devices. This step is preferably a deep reactive ion etching (DRIE) process. The two-step n-silicon diffusion was designed such that all components of the array devices are realized at the same time, thus avoiding overetching and further thinning of the flexural springs. In the design process, n-silicon used in the actuators and in the springs is about 2 μm thick; the edges of the thick mirror plate are also kept at 2 μm thick for achieving simultaneous release of the structure. This mechanism has proved to be very useful, resulting in a high yield of about 80%.
After photoresist strip and etching away of the silicon dioxide mask on the front side of the wafer, the completed device is shown in FIG. 17 . Mirror 40 , flexural springs 45 , and bond pads 56 are shown. Bond pads are the areas where wire bonding is done for electrical connections. Actuator areas 50 consist of thin silicon-oxide-aluminum composite. A thermal actuator is a composite cantilever type structure where the difference in thermal expansion coefficient makes it bend due to change in temperature. In the current process, silicon, oxide, and aluminum are used to form this composite. There are many other thin films such as polycrystalline silicon, oxide, aluminum, gold, titanium, TiN, nickel etc., which can be used to form this composite structure. Oxide and aluminum will make an excellent combination for bi-morph thermal actuation. There can be many factors such as manufacturing capabilities, for choosing a particular combination. We need a single crystal silicon mirror plate so fabricating everything using silicon has been easier. Silicon is a better mechanical material, which adds to better reliability of the device.
In one embodiment of the invention, the mirror is thick and as the springs extend away from the mirror, the springs become progressively thinner. In an implemented process variation, the springs are fully thinner and the thickness variation from thick to thin is at the edge of the circular mirror plate. Wherever the silicon is cut to release structures, it is kept thinner to have uniform etching across all the structures. If there is one thickness, etching will be stopped at the same time and it will be uniform too.
The following Table 1 provides an overview of the properties of the design and experimental results.
TABLE 1
Property
Description
Results
3D
The device is capable of deflecting light into 3-
Up to +/−10 degrees
micromirror
dimensional space; i.e. in x, y, and z. This is the
deflection has been
maximum degree of motion possible of any
demonstrated.
micromirror device.
Monolithic
The device is etched from a single silicon wafer. This
Up to 10 million cycles
fabrication
exploits the defect-free single-crystal properties of
actuation without
silicon wafers to give the device superior strength and
failure has been
fatigue resistance.
demonstrated.
Non-uniform
Double-diffusion with 4-electrode electrochemical
2 micron thick
structure
etch-stop was used to fabricate the non-uniform single-
actuators and springs
crystal structures. This allows us to simultaneously
and 10 micron thick
fabricate thick mirrors (for rigidity) and thin actuators
mirrors have been
and springs (for flexibility). In this way, the
fabricated.
performance of different components of the
micromirror can be optimized separately.
5 mask process
A lower mask count helps to lower the fabrication cost.
The device has been
realized using 5 masks.
Single wafer
A single wafer process helps to lower the fabrication
The device has been
process
cost and makes fabrication easier because wafer
realized using a single
bonding is not needed.
wafer process.
Low actuation
This allows low-voltage control electronics to be used
Maximum deflection of
voltage
which are easier and cheaper to assemble.
about +−10 degrees can
be obtained by
operating the device at
<2 volts.
Flat mirror
Flat mirrors are characterized by having a large radius
An average radius of
of curvature. Flatter mirrors deflect light with less loss.
curvature of 29 cm has
been achieved.
Smooth mirror
Smooth mirrors deflect light with less loss.
An average RMS
roughness of 7.15 nm
has been achieved.
The structure and process of the present invention have a number of advantages over the prior art:
1) Mechanical strength and reliability—single crystal silicon is inherently very insensitive to fatigue failure when subjected to high cyclic loads. It is also relatively stress-free and has high yield strength. Hence, the invention, whose moving parts are monolithically fabricated entirely out of single crystal silicon, is believed to be superior to the prior art in mechanical strength and reliability. The invention has been tested to 10 million cycles without failure.
2) Optimized performance—this method allows etching of the single crystal silicon to different thicknesses so that the thin flexible springs and actuators can be fabricated together with the thick mirrors. This is an improvement over micromirrors fabricated using SOI. In this way, the design of the mirror as well as the springs and actuators can be independently optimized for flatness and flexibility, respectively.
3) Simplicity and cost—the current invention can be realized with a 5 mask process on a single wafer, eliminating the need for wafer bonding. The simple design and fabrication method may result in better yield and measurable cost savings over the prior art.
4) Integration with electronics—the actuation voltage required for the thermal actuators is an order of magnitude less than that required for electrostatic actuators. This low voltage (<2 volts) makes it easier to integrate with control electronics.
5) Linearity—the angular deflection of the present invention has been shown to be linear with actuation voltage. This is an advantage over electrostatically actuated micromirrors which exhibit snap-in behavior.
The present invention provides a unique method of fabrication of a free space 3D micromirror device. The invention solves the problem of spring breakage by modifying the thick structure edges which are made of the same thickness as the thinner single crystal silicon structures. This suppresses overetching, thus leaving springs stronger as designed for better reliability. Simultaneous release of the structure in one monolithic process sequence is a key feature of the invention. The structure material for all components of the device is single crystal silicon. Silicon dioxide and aluminum have electrical and thermal roles only.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention. | First and second n-doped regions are formed at a surface of a p-doped single crystal silicon substrate. An aluminum layer is patterned overlying some of the second n-doped regions to form thermal actuators. A dielectric layer is deposited overlying the patterned aluminum layer and an underlying thermal oxide layer. A metal layer is deposited thereover and patterned to form bond pads to the thermal actuators and to form reflecting mirror surfaces overlying others of the second n-doped regions to form micromirrors. The substrate is etched away from the backside stopping at the first and second n-doped regions. Then the wafer is diced into mirror array chips. Portions of the first n-doped regions are etched away from the frontside to form flexible springs wherein the second n-doped regions covered by the patterned aluminum layer form thermal actuators and wherein the flexible springs connect the micromirrors to the thermal actuators. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an electronic lock core structure, especially to an electricity-saving type infrared electronic lock core combined with a radio frequency identification system and an infrared sensor for controlling the startup of an identifying device so as to attain the objective of saving electric power.
[0003] 2. The Prior Arts
[0004] Nowadays, locks have been developed much quickly and the type of the locks is diversified. The structures of all the conventional mechanical locks are to make use of the lock bolt in the lock core and the special key having concave grooves and convex faces corresponding to the lock bolt and further to make the lock bolt in the concave groove of the key to move to the prearranged position, thus the lock bore can be turned or moved axially so as to achieve security objective. But this kind mechanical lock only has one simple locking function and it can be easily unlocked by making use of proper tools. Furthermore, the key of the mechanical lock can be copied easily and the protective function is not perfect.
[0005] The radio frequency identification system can transmit and receive the unique recognition data in tags by making use of the radiofrequency signals in wireless way. When the system is startup, a reader can produce a certain frequency radio signal to start up the program on a chip in a tag, and then generate a radio frequency electric wave, and transmit the identification code in the memory of the chip or other stored information to the reader. After the identification code or the stored information is decoded, the identification and the decoding are completed. The system has many advantages of, such as a convenient use because it can directly identify an object, and a high safety because an authorized identification code can not be copied easily. And the card or the tag does not need to be applied an outer electrical source, so it has been widely used in daily life. But in order to keep the reader produce one certain frequency radio signal continually for detecting the card or the tag at any moment, the power should be provided continually to the reader to keep it in stand-by state and thus much electric power would be wasted. Especially for the electronic lock which uses batteries as the electric source, it wastes more electric power. So, if a radio frequency identification system is positioned on a lock core and further combined with a sensor system and the radio frequency identification system, by means of firstly detecting a person or an object entering into the sensing area and then starting up the reader, the system can save the electric power and the lock safety can be further improved.
SUMMARY OF THE INVENTION
[0006] In order to solve the disadvantage of wasting electric power because the radio frequency identification system disposed on the electronic lock has to be in stand-by state continually, the present invention provides an electricity-saving type infrared electronic lock core combined with an infrared sensor. By making use of the detection of the infrared sensor, only when the person or the object comes into the sensing area, the radio frequency identification system in the electronic lock core can be started up to identify it so as to unlock the lock. Therefore, saving electric power and improving security can be achieved.
[0007] In order to achieve above invention objective, the present invention provides an electricity-saving type infrared electronic lock core which comprises a body, an infrared sensor, a radio frequency identification system and a power supplier. The infrared sensor positioned on one end of the body, comprises an infrared receiver-transmitter. The radio frequency identification system positioned on one end of the infrared receiver-transmitter can be electrically connected with the infrared sensor, the power supplier and relative elements for unlocking the body. When the infrared receiver-transmitter on the infrared sensor detects a person or an object in the scheduled area, the radio frequency identification system can identify it and drive the relative elements to unlock the body if the identification is correct. When the infrared sensor does not detect a person or an object, the radio frequency identification system can not be started up. Therefore, the identifying device does not need to transmit frequency signal constantly and thus the electric power can be saved.
[0008] The electricity-saving type infrared electronic lock core according to the present invention, not only has a high safety and guarding function against theft because of the special high security identification code of the radio frequency identification system, but can save the electric power consuming on standby by means of an infrared sensor on which an infrared receiver-transmitter is positioned to start up an identifying device, only when a person or an object is detected.
[0009] Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Although the present invention has been described with reference to the preferred embodiment thereof, it is apparent to those skilled in the art that a variety of modifications and changes may be made without departing from the scope of the present invention which is intended to be defined by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention will be apparent to those skilled in the art by reading the following detailed description of a preferred embodiment thereof, with reference to the attached drawings, in which:
[0011] FIG. 1 is an exploded perspective view of an electricity-saving type infrared electronic lock core according to an embodiment of the present invention,;
[0012] FIG. 2 is a perspective view of the electricity-saving type infrared electronic lock core according to the embodiment of the present invention,;
[0013] FIG. 3 is a cross-sectional schematic view showing a front clutch and a back clutch unconnected with each other before unlocking the electronic lock, according to the present invention; and
[0014] FIG. 4 is a cross-sectional schematic view showing the front clutch and the back clutch connected together after unlocking the electronic lock, according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] With reference to FIGS. 1-3 , which respectively show an exploded perspective view, a perspective view and a cross-sectional view of an electricity-saving type infrared electronic lock core in accordance with an embodiment of the present invention, the electricity-saving type infrared electronic lock core comprises an infrared sensor 10 , a body 20 , a front clutch member 30 , a back clutch member 60 , a motor section 70 , a knob core 80 and a radio frequency identification system 110 . The infrared sensor 10 is electrically connected with the radio frequency identification system 110 and one end of the body 20 is connected with the infrared sensor 10 and the other end is contacted with the front clutch member 30 . In addition, one end of the motor section 70 is connected with the back clutch member 60 which can be assembled with the front clutch member 30 and the other end of the motor section 70 is connected with the knob core 80 . Other more, the radio frequency identification system 110 can drive the motor section 70 to drive relative elements so as to unlock the lock. Therefore when a person or an object in the sensing area, the infrared sensor 10 can detect it and start up the radio frequency identification system 110 to identify it. Once the identification information is confirmed to be correct, the motor section 70 can be further driven to push the back clutch member 60 to move forward and engage with the front clutch member 30 and in the meantime the body 20 and the knob core 80 can be turned at the same time, other more the turned knob core 80 can drive a cam 50 to unlock the lock. But when no any person or object is in the sensing area, the radio frequency identification system 110 can not be started up and it will not transmit the radio frequency signal constantly so as to achieve the objective of saving electric power.
[0016] The infrared sensor 10 connected on one end of the body 20 , comprises an infrared receiver-transmitter 14 one end of which is connected with the radio frequency identification system 110 and the radio frequency identification system 110 is electrically connected with the infrared sensor 10 . The infrared receiver-transmitter 14 is positioned in a containing section 15 and is covered with a light-transmitting shade 12 which can keep the humidity from coming in the electronic lock so as to guarantee the infrared receiver-transmitter 14 and other electronic elements to work in order and make the infrared ray penetrate through the electronic lock to detect the objects. The whole infrared sensor 10 is positioned in a housing 13 , on one end of which a cover 11 is covered, and the cover 11 which the light-transmitting shade 12 is positioned therein is hollow, so that the light-transmitting shade 12 can be positioned here firmly. In addition, the infrared receiver-transmitter 14 is composed of a transmitter 141 and a receiver 142 , and the transmitter 141 can transmit an infrared ray to detect any person or object in the sensing area. When a person or an object is detected, the infrared ray is reflected back to the receiver 142 and then the receiver 142 further starts up the radio frequency identification system 110 to identify it. Only once the identification information is confirmed to be correct, the electronic lock can be unlocked. After the electronic lock is unlocked about 5 seconds or nothing is detected in the inducing area, the infrared sensor 10 can control the radio frequency identification system to be in battery saving mode so that the radio frequency identification system 110 does not transmit frequency signal constantly and the electric power is saved. On the other hand, the infrared sensor 10 can adjust the transmitting frequency of detecting, so even if in low energy consuming condition the detecting function still can be kept and the needed electric power is saved.
[0017] One end of the body 20 is connected with the infrared sensor 10 and the other end is contacted with the front clutch member 30 . After the identification information is confirmed to be correct and the relative elements are driven to make the back clutch member 60 and the front clutch member 30 to be engaged together, turn the body 20 and the knob core 80 at the same time. Thus the electronic lock can be unlocked.
[0018] The front clutch member 30 is contacted with the other end of the body 20 and the other end of the front clutch member 30 is formed with a shaft section 31 which is provided to make the front clutch member 30 and the back clutch member 60 to be connected together.
[0019] The back clutch member 60 is coupled with the motor section 70 and can be moved backward and forward. When the back clutch member 60 is moved forward, it can be connected with the front clutch member 30 and then the body 20 can be turned, thus the lock can be unlocked.
[0020] Other more, the motor section 70 is electrically connected with the radio frequency identification system 110 . By means of the driven of the radio frequency identification system 110 , the motor section 70 can start up the relative elements of the body 20 in sequence. Besides, one end of the motor section 70 is connected with a knob core 80 and the other end is connected with a screw 73 engaged with a screw cap 72 , which is clipped and embedded in a cover body 74 . But because the cover body 74 is limited to move, the cover body 74 and the screw cap 72 can not rotate following with the screw 73 . Therefore, as the motor section 70 drives the screw 73 to rotate, it can drive the screw cap 72 and the cover body 74 to slide forward but not to rotate in original position so as to push the back clutch member 60 . When the radio frequency identification system 110 confirms the identifying information to be correct, it can transmit signal to the motor section 70 so as to further run it and make it drive and push the relative elements to unlock the body 20 . Furthermore, a connecting hole 61 is formed on the back clutch member 60 and is provided to contain the shaft section 31 of the front clutch member 30 as the back clutch member 60 is driven to move forward by the motor section 70 , thus the back clutch member 60 can be connected with the front clutch member 30 . Besides, between the back clutch member 60 and the front clutch member 30 a conducting component 40 is positioned for electrically connecting the two members.
[0021] Except for the infrared sensor 10 and the radio frequency identification system 110 , all the above members are mounted in a housing 90 which can be connected with a knob 100 by means of one end of the knob core 80 . A power supplier 101 is positioned in the knob 100 and in the embodiment the power supplier 101 is a battery which can be electrically connected with the radio frequency identification system 110 and provide electric power to the electronic apparatus in the body 20 . Other more, a gap is formed on the housing 90 to contain a cam 50 that is connected firmly with the knob core 80 and on which a shifting block 51 is formed, so when turning the body 20 and the knob core 80 , it can drive the cam 50 and the shifting block 51 so as to unlock the lock.
[0022] With reference to FIG. 4 , which shows a cross-sectional view of an electricity-saving type infrared electronic lock core in accordance with an embodiment of the present invention, the transmitter 141 can transmit infrared ray that can be reflected back to the receiver 142 by the person or the object in the sensing area and then the receiver 142 can further start up the radio frequency identification system 110 (see FIG. 1 ) to identify identification information or other stored information possessed by the person or object. If the identification result is correct, the radio frequency identification system 110 (see FIG. 1 ) would transmit signals to the motor section 70 and start up it according to the preset program and drive the screw 73 connected with the motor section 70 to rotate and then drive the screw cap 72 and the cover body 74 to slide forward to a certain distance, so the back clutch member 60 is driven to move forward and the connecting hole 61 (see FIG. 1 ) of the back clutch member 60 is driven to connect with the shaft section 31 (see FIG. 1 ) of the front clutch member 30 . At the same time to rotate the body 20 and the knob core 80 which can drive the shifting block 51 of the cam 50 to rotate so as to unlock the lock. On the other hand, when the infrared sensor does not detect any person or object, the radio frequency identification system 110 (see FIG. 1 ) will not start up and not transmit frequency signal constantly so as to be able to save the electric power. | An electricity-saving type infrared electronic lock core is disclosed herein, which includes a body, an infrared sensor, a radio frequency identification system and a power supplier. The infrared sensor is disposed on one end of the body and includes an infrared receiver-transmitter, and the radio frequency identification system is electrically connected with the infrared sensor, the power supplier and the relative elements for unlocking the body. When the infrared sensor detects a person or an object within the scheduled area, the radio frequency identification system can identify it and further drive the relative elements for unlocking the body if the identification is correct. But when the infrared sensor does not detect a person or an object, the radio frequency identification system enters into an electricity-saving mode for saving the electric power. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to an automated control system and method that furnishes viewers with individualized automated editing and retrieval capabilities over the contents and length of a variable content video program in order to produce a transparently continuous and complete show. The system capabilities include an automated flexible control system design that enables an operator to selectively apply different editing criteria to the variety of subject matters that may be contained within the program. The system controls also include an automated capability for efficiently previewing program scenes of pre-identified categories and classes of subject matter and a capability for determining their inclusion in the program seen by the viewer.
[0003] Finally, the control system provide a keyword/menu segment/program retrieval facility from an existing program and program database, and a requesting capability for programs to be produced according to viewer-specified requirements.
[0004] 2. Background of the Prior Art
[0005] Artistic expression in films often surrender to the requirements of marketing and other forms of censorship, both subtle and obvious. Individual viewers once they elect to view a program, subject themselves to the results of this censorship or lack thereof.
[0006] One form of industry censorship is content rating which is a label attributed to each film by the Motion Picture Association of America (“MPAA”). The label serves as a broad generalized guide for the public as to the overall level of “objectionable” content, as the MPAA defines various types of content that may be included in a movie. In the MPAA published booklet “The Voluntary Movie Rating System”, the MPAA spells out the purpose of the rating system: “if you are 17 or over, or if you have no children, the rating system has no meaning for you. Ratings are meant for parents, no one else.” Accordingly, the rating system used by the MPAA has adopted a generalized structure that has inherent limitations since it admittedly has ignored the varying sensibilities and tastes among different adults e.g. non-parents, young adults, or senior citizens. The rating system is thus inadequate for a large portion of the viewing public. Nonetheless, any reviews that may have been obtained, the public must elect the option of viewing the film or not. Having decided to do so, the viewer, must accept the content of the film in its entirety.
[0007] User content requirements may also include the knowledge level required to view the program, its level of detail and complexity such as would be the case in educational programs. In programs that include a number of segments such as is generally the case with news programs, there is no choice provided to the user as to the viewing of only the user specified program segments. Similarly, while the viewer has the option to truncate the length of a program by either terminating viewing the program, or if recorded to fast-forward certain scenes, there is no option of receiving a program at a user specified length.
[0008] Presently, all form of viewer editing, such as permitted by the use of a VCR, requires the interactive participation of the viewer and some knowledge as to the location of the scene in question.
[0009] Many methods and systems found in the prior art do not incorporated current basic technology and methods to produce an automatic viewer editing capability that produces a transparently complete program.
[0010] For example, the patent to Von Kohorn, U.S. Pat. No. 4,520,404, discloses a remote recording and editing system. In particular, the invention discloses an editing system whose functions include the activation or deactivation of a television receiver and a recording apparatus by the transmission of control or editing command signals, generated from a central station where an operator monitors a broadcast transmission. The receiver and recorders in a viewer's home are provided with inhibiting circuitry that respond to the transmitted control signals from the central station to prevent the re-broadcast or recording of unwanted material in the home.
[0011] The patent to Chard, U.S. Pat. No. 4,605,964, discloses a television controller that utilizes coding for identifying and automatically deleting undesirable sound and visual events broadcast with a program. The content signals associated with Chard also teaches that undesirable events are graded to permit editing according to personal taste.
[0012] Also, the patent to Olivo, Jr., U.S. Pat. No. 4,888,796, discloses a screening device capable of automatically disabling the TY or video receiving device in response to the receiver's recognition of a non-interfering material content signal co-transmitted with the program signals.
[0013] However, Von Kohorn, Chard, and Olivo, have various drawbacks. The material content signal may only be applied to portions of a program signal, in order to edit out only the objectionable parts of a program. Thus by disabling the replay of segments of the program material, these methods ignore the fact that dead segments would result from the edited out segments. Also, while Chard suggests setting grading levels independently for sound (four levels) and vision (four levels), it does not teach providing grading levels for a variety of subject matters. Additionally, while Olivo, illustrates incorporating the rating structure provided by the MPAA for the programs, and suggesting that different material content signals can distinguish between different forms of subject matter, it does not teach using a number of different ratings for each class of subject matter. In this regard, Voael's disclosure of three broad classifications (advertisement, non-program material, restricted) does not enhance Olivo. The above teachings therefore together show a method whose rating structure is based on the MPAA rating system applied to different subject matters. However, as previously discussed, the MPAA rating system was designed and intended as an overall program guide for parents. The MPAA rating system does not by, deliberate design, address segment specific subject matter information that is required to provide adults with a highly discriminatory control over the content of segments contained within the selected program.
[0014] The patent to Vogel, U.S. Pat. No. 4,930,160, addresses the above deficiency by providing a facility for displaying alternative material during the dead segments. The alternative material selected during censorship periods can originate from a remote source, for example, another television broadcast, or locally, for example, from a video disk or tape player. The local source may also simply be a black signal generator which essentially reproduces the same drawback noted above. An alternate source to a dead segment may also be provided by the system disclosed in Boyd et al., U.S. Pat. No. 5,023,727. Boyd teaches a method for forming a substantially continuous composite video signal by combining a video segment received from a video signal with a video segment produced from digital data.
[0015] The patent to Lindstrom, U.S. Pat. No. 5,060,068, discloses an optical laser disc based broadcasting method and system wherein promotional segments of a program are played from the same source recordings as the program itself. Lindstrom discloses utilizing at least two disc players in timed synchronization to generate a transparently continuous video signal.
[0016] The patent to Kiesel, U.S. Pat. No. 4,729,044, discloses a plurality of video tape recorders that similarly provide for continuous replay without the need for creating a master tape.
[0017] Neither Lindstrom nor Kiesel however teach a single player that can provide transparently continuous video signals, nor do these references suggest utilizing a control system that provides a variety of different and complete edited versions of the same program obtained from the same single source recording.
[0018] Neither Boyd nor Vogel, however, provide a system that creates, from a single source, a viewer-edited transparently continuous and harmonious program that replaces a dead segment with other parts of the same program.
[0019] Generally, to the extent that the above patents act to censor a video program they direct themselves to providing viewer control over the form of the expression. This is in contrast to those patents, that provide viewers the means to participate, and thereby affect, the program's story lines or plot. An example of the latter type of patent is Best, U.S. Pat. No. 4,569,026. Which discloses a video entertainment system where human viewers conduct simulated voice conversations with screen actors or cartoon characters in a branching story game shown on a television screen. Best is further characterized by the interactive nature of viewer participation, since at frequent points in the game the system presents the viewer with two or more alternatives. Is the interactive participation of the viewer that sustains the logical progression of the game. As many games are directed at children, and are educational in nature, or contain primitive subject matter, they have not dealt with issues raised by the more complex adult forms of expression inherent in contemporary films. Games have provided setup editing capabilities (selection of: level of difficulty, character, weapons, etc.), not censoring editing capabilities.
[0020] The present art thus fails to suggest combining interactive and set up capabilities, automated editing capabilities, and directing capabilities to provide the user with control over a program's story line, content, and form of expression.
[0021] The patent to Freeman, U.S. Pat. No. 4,573,072, discloses a method for expanding interactive CATV displayable choices for a given channel capacity. The preferred embodiment of the invention includes a program segment stacking method and a subscriber profile utilized to transmit one of a plurality of the stacked program segments. The subscriber's selection profile disclosed therein is demographic in character and can be changed from the head end of the transmission, and not editorial and controlled by the viewer. Further, the method of Freeman teaches that the stacked segments beginning at any one moment of time to be of equal duration to restore the transmission to the common prerecorded television message. This structure, which serves Freeman's objectives of tailoring advertising to the demographics of the viewer, is inferior to a variable length stacking structure that would provide far superior tailoring of the program content.
[0022] The patent to Bohn, U.S. Pat. No. 4,888,638, shows a market research system for substituting stored television programs for regularly scheduled, broadcast television programs having a particular identification code wherein the substitute television programs may be transmitted via telephone lines to the households of cooperating panelists for storage. The operational difference between Freeman and Bohn is the method of transmitting the alternate advertising segment to the viewer. In Freeman different advertising segments are contemporaneously transmitted during the broadcast of the program, while in Bohn differing advertising segments are transmitted prior to the broadcast of the program. Bohn teaches the use of a laser disc to store the substitute television advertising. Based on the identification code contained in the broadcast program a controller may substitute the broadcasted advertisement.
[0023] The patent to Skutta, U.S. Pat. No. 5,055,924, discloses a method for the remote-controlled replacement of a TV advertising spot by another advertising spot for a new product to be tested.
[0024] The teachings of the above references would not furnish a system that provides each viewer with automated non-previewed control over the program content from a single program source by a single device that generates a transparently seamless program matching the viewers pre-established content requirements. Among the additional elements and enhancements required by such a system would be producing and providing coherent parallel and overlapping program segments. Some of these parallel segments differ only in the form of expression (i.e. explicitness) of a given scene.
[0025] The patent to Hashimoto, U.S. Pat. No. 4,745,549, discloses a method of generating an individualized listing of programs that meet an individual viewers stated program preferences. This is accomplished on the basis of a generalized survey of a viewers program classification preferences and viewer response to the list selected.
[0026] The patent to Hallenbeck, U.S. Pat. No. 5,038,211, relates to television (TV) program schedule guides and in particular to a method and apparatus for efficiently transmitting, receiving and storing television program schedule information. In Hallenbeck, schedule information is retained that meets predetermined selection criteria to minimize storage and processing requirements.
[0027] The above patents do not suggest viewer direct selection of a program from a variety of programs by means of a database architecture that would permit keyword and interactive menu searches.
[0028] The patent to Monslow, U.S. Pat. No. 4,995,078, teaches a television broadcast system using land lines for the real time transmission of a viewer chosen program. The patent to Way, U.S. Pat. No. 4,891,694, is entitled “Fiber optic cable television distribution system”. The patent to Walter, U.S. Pat. No. 4,506,387, discloses a programming on demand fiber optic based system. These patents together with the references cited therein teach a variety of land line and fiber optic transmission of programs with varying degrees of viewer capabilities in the selection of programs. While these do not teach transmission of a variable content program, said works are, incorporated by reference herein to establish that such a transmission is possible and to assist the reader interested in obtaining a more detailed disclosure of the hardware of such systems than is necessary to provide here.
SUMMARY OF THE INVENTION
[0029] In view of the foregoing shortcomings of the prior art, it is evident that there exists a need for a system that furnishes viewers with individualized automated non-previewed control over a program's content in a single program source, and broadcast on a viewing device, by a transmitting device that generates a transparently seamless video program matching the viewers preestablished content requirements.
[0030] It is also an object of the present invention to include the capabilities for automatically selecting among parallel and overlapping segments to provide a video program that is highly responsive to viewer control over its content. A further object of the invention is to provide content control that includes any of the following: the program's form of expression, subject matter, element development, expertise level, detail level, and program length.
[0031] It is yet another object of the invention to provide a TV control system where the control is exercised automatically, by means of a preestablished content preference structure and keyword subject listing, individualized for each viewer and subject to password control by a system administrator. This first form of control is applied universally to each selected program content map. Each map contains detailed information as to the location and program characteristics, such as categories and subject matter, of the various segments of the program. The second form of control may be established interactively and individually with each selected program prior to initiating viewing.
[0032] It is also an object of the present invention to provide the capability for efficiently previewing selected scenes in order to indicate their inclusion for viewing. Inclusion/exclusion control is automatically accomplished by modification of the program content map as may be required for example by a parent editing a children's program. Additionally, the viewer accessible copy of the program's content map may be modified contemporaneously with the viewing of the program, generating a variety of any one of the following preselected automated system responses: updating the copy of the program's content map, skipping to the next logical segment, or any combination of the two. The skipping to the next logical segment feature may be accessed independently without affecting the content map.
[0033] It is also an object of the present invention to provide automated capabilities to efficiently view only a specified class, category, or subject matter included in segments within the selected program or programs.
[0034] It is also an object of the invention, to provide information as to the viewer preference structure and the program content map to which it was applied to assist in determining viewer preferences.
[0035] It is also an object of the present invention to provide viewers the means of accessing available programs, segments from a program, and or segments from a plurality of programs by the use of keyword or a classification tree structure as would be required by a user accessing a very large program or segment database.
[0036] It is also an object of the present invention to provide the means for a viewer to detail the subject matter, story line, and or general content of a desired program so that producers of programs may elect to produce and provide said program.
[0037] Briefly these and other objects of the invention are accomplished by a system comprising: program production, editing, and recording techniques, assignment to segments of a program the appropriate descriptors and creating a map of those segments and their descriptors, a structure to record the viewer's content preferences, the means by which the user content preference structure is matched to the programs's content map to produce the desired program, means of accessing and retrieving programs, and means of indicating program preferences.
[0038] With these and other features, advantages and objects of this invention, the invention is shown in the detailed description of the invention and in the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1A is a video segment rating chart for subject matter as per the present invention;
[0040] FIG. 1B is video segment rating chart for elements as per the present invention;
[0041] FIG. 1C is a video segment rating chart for inclusion as per the present invention;
[0042] FIG. 2 is a schematic diagram representing the steps of producing a variable content program of the present invention;
[0043] FIG. 3 is a set of diagrams and rating chart of three versions of a video segment, each a variation of the other as per the present invention;
[0044] FIG. 4 is a sample viewer scene selection screen of a program's content rating as per the present invention;
[0045] FIG. 5 is a schematic diagram of the video disk player as per the present invention; and
[0046] FIG. 6 is a flow chart summarizing the process of a laser videodisc playing as per the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] As used herein segments refers to a sequence of frames. The segment or frame sequence may form a single image, a shot, a scene, or a sequence of scenes. Any number of segments that may comprise a program may be logically organized by means of the programs segment map. Program refers herein to any image displayed on any device including but not limited to televisions, CRT, film screens; and transmitted to the device by any number of means including but not limited to broadcast, cable, telephone, fiber optic network, tape, videodisc, magnetic media, memory devices, chips and modules.
[0048] Referring now in detail to the drawings wherein like parts are designated by like reference numerals, throughout, FIG. 1A illustrates an example of the generalized rating structure 100 utilized to review the contents of each segment contained in a given program. The structure of chart 100 includes a number of categories 102 that might apply to most films. The generalized rating scale 104 mirrors the rating system utilized by the Motion Picture Association of America (General Audiences, Parental Guidance Suggested, Parents Strongly cautioned, Restricted, No Children Under 17 Admitted, G, PG, PG-13, R, NC-17 respectively), but provides a more descriptive rating scale for the group, as shown. Each number in the matrix 106 in the chart 100 represents the particular scene rating choices for a specific scene or segment. A more individualized rating scale for each of the categories is also available as will be described below with respect to FIG. 1C .
[0049] Referring now to FIG. 1B , the contents of a segment may be further represented by chart 200 in order to analyze the development of a number of elements 202 such as character, location, and time, as well as the degree of detail 204 and the level of expertise 206 that may be appropriate for a program. These elements are provided at a variety of levels and are rated accordingly. FIG. 1B for example indicates that the program's character element development may range from none to extensive.
[0050] Referring to FIG. 1C , a separate category 300 provides criteria for condensed versions of the program. In this chart, the segments may be classified according to the level of inclusion/exclusion that the user may desire 302 . The ratings indicates if the segment is required for a highlight, summary, condensed, or detailed versions 304 of the program. In a similar manner, an individualized tailored and descriptive rating scale may be provided for any one category or group of categories.
[0051] In a preferred embodiment, each segment is analyzed as to subject matter and assigned the necessary keyword to provide effective keyword retrieval and additional user viewing control capabilities. This will be of significant value in retrieving video segments from a program database (“programbase”), such as may be constructed from a collection of news or educational programs, where each program comprises a number of segments each a whole in itself.
[0052] Keyword indexing of the segments provides the capability for inhibiting the viewing of undesirable subject matter, or assisting in the retrieval of desirable subject matter, where the rating structure may not adequately cover a specified category or subject matter. For example, a viewer may not desire viewing scenes of a flag burning. Key word control would inhibit the segments containing that scene or scenes from being viewed by that particular viewer. Alternatively, a key word search would permit a system user to efficiently retrieve all flag burning segments that may be included in the programbase.
[0053] FIGS. 1A, 1B , IC are examples of an overall framework for segment analysis, the actual structure and complexity utilized may be highly tailored, as disclosed in conjunction with FIG. 1C , by the producer of a program to reflect the specific content of a program without being limited by the structures which may be found to be commonly utilized in other works. Each program producer is offered the flexibility within the overall architecture of this rating system to determine and include only those categories that may be relevant to a particular program, and to add categories as the producer requires. Similarly, the producer is offered some flexibility in determining the labelling of the rating scale.
[0054] Meeting the objectives of being able to provide both a standardized set of rating structures that will permit the automatic application of a viewers preestablished preference structure on a variety of programs, and provide the producer of the program the flexibility described above, are accomplished by assigning unique classification codes to each set of preestablished standardized categories and by reserving a range of classification codes that will be recognized by the system as requiring interactive input by the viewer. In the example of FIGS. 1A, 1B , 1 C, codes ending in 9, codes with a tens digit being a 9, and or codes from 900 to 999 (“producer code”) are reserved as independent of the standard categories shown.
[0055] Producer codes would signal the system to elicit the viewer preference. Similarly, as the rating scale is relative in structure, different descriptions for any category rating scale might be utilized without affecting the applicability of a preestablished viewer preference structure for that category. In instances where the rating scale is not accommodated by the standardized structure supplied, the producer need only assign a producer code and build whatever scale he may deem desirable, from a simple “Yes/No” to a sophisticated three dimensional representation.
[0056] Additionally, commands may be issued by the program to inhibit the application of a preestablished viewer preference structure and require the viewer to address the program's segment rating structure regardless of the category codes utilized.
[0057] Referring to FIG. 2 , in the preferred embodiment of the present invention a view of the method for mapping the scenes 400 is provided. Each scene or fragment of a scene on a video script is reviewed 430 according to a producer-selected segment rating structure, as indicated in FIGS. 1A-1C above. The screenwriter now has the freedom to expand the scenes to cover a wider rating range without the concern for the limitations inherent in the present art. Without the artificial limitations that a program fit a specified time frame, the screenwriter may additionally expand scenes to provide whatever level of detail or development they may desire. Additionally, the screenwriter may elect to provide any number of scene options and or transitions to each of the scenes identified 340 .
[0058] Most scenes can be constructed by means of transition segments to provide for content at varying points of the grading scale and or the avoidance of a particular segment and yet retain harmony with the preceding and following segments. It should be noted that any given idea or scene may be expressed in a variety of forms, whether implied as in the closing of a bedroom door, to the graphic treatment as might be found in an “X” rated film. Both of these versions may be provided as parallel segments in a program, challenging the artist to create greater variety in the form of expression permitting the viewer to decide for themselves the level of censorship that they may desire.
[0059] A successful filming of this architecture 450 is a function of the skill of the director(s), actors, animators, etc. that may be required to provide for parallel and transition segments with the required transparent harmony.
[0060] Existing program editing requires producing a unique linear sequence of segments. The editing of the present invention 460 requires a parallel non-sequential logical arrangements of segments. It should be emphasized that the art of program editing under the present invention transfers censorship and time constrained editing decision making from the producer to the viewer.
[0061] The beginning frame and end frame in each of the relevant segments is identified, the segment content is assigned a descriptor as per the category and rating structure, and logical entry and exit references are assigned 470 . Any given segment may be assigned a variety of category codes and keywords (“category codes”), and the segment assigned a category code may be congruent in one or more frames with a segment assigned a different category code. Where necessary, a video segment may be associated with more than one audio segment and corresponding separate voice and video category codes may be provided. The complexity of the arrangement is only limited by the requirements, desires, skill, intelligence, hardware, and software available to the program editor.
[0062] The resulting segment information is mapped and the required user interface produced 480 to permit the viewer, by selecting the desired rating level in each of the categories, to view a unique continuous sequence of segments consistent with the designated viewer preference structure.
[0063] Programs which have been already produced would not offer the same parallel and transition segments, and other opportunities, available to programs produced under this system. A program may, however, nonetheless be mapped to provide an editing-out capability to produce, if not entirely transparently, a continuous program.
[0064] To further explain the methods of the present invention, and referring to FIG. 3 , and consistent with definitions established at the outset, illustrated is a program consisting of five scenes 501 , each scene of the program may comprise any number of segments 502 , each segment may include any number of frames 503 . In this example, scene three includes four segments, segment 3 b begins at frame 4112 and ends at frame 6026 . The next segment, 3 c , begins at frame 6027 . Brakes between set of frames serve to illustrate the beginning and ends of a segment and not to indicate a non-continuous transmission.
[0065] Segment 3 b of scene three 511 , which might generate an “R” rating for an entire program, includes frames depicting explicit bloodshed. In this example the rating of the segment is indicated by the numeral 3 in the appropriate cell 521 of that segments rating chart.
[0066] To provide for the option of editing-out the explicit bloodshed, the program content map includes an additional segment definition beginning at frame 4112 and ending at frame 5205 . The end of this segment 512 is linked to a new transitional segment 513 beginning at frame 35205 and ending at 35350 , the end of which is linked to frame 6027 . In this fashion, frames are omitted and added to provide a continuous transparent edited version of segment 3 b . This frame sequence is associated with the corresponding segment content rating to indicate the absence of bloodshed 522 . In all other respects the segments 512 / 513 is equivalent to the original segment 511 . For programs produced prior to the present invention, the
[0000] editing-out would work in a like manner except that the transitional segment 513 would not be available to make the continuous transmission from frame 5206 to 6027 transparent.
[0067] To provide for the option to include a graphic level of bloodshed, the program content map includes an additional segment definition. In this case, only 66 frames of the “original” segment 511 are deleted to accommodate the graphic bloodshed included in segment 516 beginning at frame 35351 and ending at frame 38975 . This frame sequence ( 514 to 516 to 515 ) is associated with the appropriate segment content rating 523 .
[0068] In this manner, parallel and transitional segments provide a rating selection mix ranging from a segment excluding bloodshed 522 to a segment including graphic bloodshed 523 , as well as the segment including explicit bloodshed. As a result, the particular scene of which these segments are a part may be viewed at any of the three rating levels.
[0069] A scene may include subject matter of more than one category. In such cases overlapping segments and transitional segments may be provided to permit viewing of one subject matter at one rating level and viewing of another subject matter at another level. For example, barroom brawl of the first westerns were violent but devoid of bloodshed. A current “R” program may result from the contents of twenty or more segments, which would generate forty to sixty additional parallel and transitional segments.
[0070] FIG. 4 illustrates a program's content rating chart. This chart merges each of the segment's content ratings of the program for each category. For example, the category bloodshed indicates options to omit the viewing of bloodshed in the program or include explicit or graphic segments 541 . Depicted by bold boxes is the viewer selected level for each category 542 . The viewer in this case has elected to omit bloodshed in his/her viewing of the program. Each of the viewer's selections may modify or automatically add to the viewer preference structure that is internally saved by the system and applied to other programs that include the same category codes.
[0071] The software routines that elicit viewer preference may be as conceptually simple as that illustrated in FIG. 4 . A screen display of the program's categories and the optional rating levels and the appropriate viewer selection requests 543 . The viewer indicates the category and desired viewing level by depressing a numeric key on the player's remote control unit 544 . Indicated on the screen is the function in this context of the control unit command keys. In this illustration, depressing the “Pause” key 545 will cause the display of context sensitive “Help” screens. Context sensitive functions and label of the keys of the control unit enhances the level of communication of the limited number of control keys.
[0072] In simplified terms, any segments with a rating higher (abstract) than the viewer-selected rating for a given category would not be included in the program produced for the viewer. The segment selected for viewing (a rating level equal to or next lowest rating) provides the next segment beginning frame information. This will skip over parallel segments of a lower rating than the viewed segment.
[0073] As indicated at the outset, the architecture of the system is intended to be hardware independent. That is, a variety of hardware, firmware, and software architectures are possible in the implementation of the present invention. An example of such an implementation of an aspect of the present invention relies on the use of existing laser video disk random access technology to provide the basic apparatus to transmit video information from a single video disk source to a television. The technology supporting a video disk implementation is well established in the art, in fact the hardware required and its operation mirrors that extensively disclosed in the patent to Best (cited previously) and by reference incorporated herein. Therefore, reviewed here and illustrated in FIG. 5 are only those elements of particular interest to the present invention.
[0074] Referring now to FIG. 5 , the video disk player of the present invention enhances existing readily available video disk player unit 601 and random access technology 602 by including video buffers 612 of sufficient size to permit random positioning of the head (measured in microseconds) to retrieve subsequent frame information from the videodisc without altering the transmission of the required frames per second to provide a transparently continuous video signal transmission to the monitor.
[0075] In addition, the video disk player includes a number of computing elements readily available in personal computers to add data retrieval and processing capability. These capabilities permit the control programs to manage the logical retrieval of data and video information. The control program 621 , installed in firmware or memory, utilizes micro processor 603 and resident memory 604 to manage the random disk head controller 602 in the retrieval of data 631 and video information 611 .
[0076] Upon a “play” command, the control program causes the retrieval 631 of the program specific routines 632 , and program content map 633 from the video/data disk. The disk contains the map of the program segments, any user interface routines particular to the program, and player control codes, in a format similar to that required by the actual program contained therein. Where the player and the disk include write capabilities, whether in a format similar to the program information or supplementary, as is for example provided by the magnetic architecture disclosed in the patent to Smith, U.S. Pat. No. 4,872,151 incorporated herein by reference, the control program 621 may store in the disk the viewer content preference structure 651 as it relates to the video program contained therein. The control program's storage of user specific information on a video disk is conceptually similar to the storage of user information in game cartridges.
[0077] The control program 621 , enhanced by the program routines 632 , causes the retrieval of the viewer preference structure 651 from either the disk, the player's resident memory 604 , fixed storage subsystem 652 (e.g. hard disk drive), removable storage subsystem 653 (e.g. micro floppy disk), or by means of the viewer control interface 654 . The latter described in more detail in connection with FIG. 6 .
[0078] Where the player contains a fixed storage subsystem 652 or removable storage subsystem 653 , as indicated above, user information associated with a program may be stored therein, such that upon replay of a program, the player software would read the program's identifier, search the storage for a corresponding viewer preference structure, and upon viewer confirmation, would apply the stored viewer preference structure to the program content map.
[0079] The control program 621 generates a segment table 622 based on the integration of the video program's content map 633 and the viewers preference structure. The segment table provides the segment scheduler 623 the data to cause the ordered retrieval of only the video segment consistent with the viewer preferences. The video segments are then transmitted in a transparently continuous manner 615 through the monitor interface 616 to the monitor 617 .
[0080] Depending on memory and processing capacity of the video disk player, retrieval of data from the appropriate sectors of the video disk, memory, or drives need not be completed prior to initiating transmission of segments of the video program. Specifically the program's content table may be logically segmented to permit concurrent processing and segment table generation with video transmission.
[0081] The video disk player's control interface 654 includes communications to the buttons and keys located on the cabinet of the disk player and to the associated control devices. The existing keys provided in these devices are augmented by the following keys or functions, as previously disclosed in FIG. 4 ,: segment skipping control, preference structure control, segment mapping control, and system menu control.
[0082] The viewer control interface 654 , in addition to supporting infrared remote control units 655 , may support a keyboard 656 . The keyboard, as in a personal computer implementation, facilitates system setup, keyword retrieval, and other system functions requiring the entry of alpha characters. A keyboard connector used to connect a standard AT keyboard or any dedicated keyboard may be supplied, or an infrared based keyboard may be implemented instead or in addition. The viewer control interface may also support voice recognition 657 . Existing technology can accommodate the few commands, such as play, stop, mute, sound, skip, required to control the basic operation of the video disk player.
[0083] In a fiber optic implementation, as will be described below, the video disk player/computer is transformed into an intelligent video retriever/transmitter (“VRT”) by adding a two way fiber optic communication interface 691 . In a such an implementation, the data retrieval 631 and the video retrieval 611 will be from a source external to the video disk player.
[0084] The above described player and disk architecture permits a viewer to interactively modify or create their unique program segment map. For example, a consumer may keyword code the subject matter of the consumer produced video segments (home videos). The keyword code permits the computer assisted retrieval of the selected segments and creation of user defined content maps and indexes. A user-defined index would span the consumer's personal library of such videos, facilitating greater utilization.
[0085] Referring now to the flow chart of FIG. 6 , the steps 700 comprising the method for operating a video disk (“disk”) on a laser video disk player (“player”) of the present invention, are detailed. The more enhanced version of the laser video disk player of the present invention includes commonly found personal computer elements such as a computer chip, memory, fixed and removable storage, video buffers, firmware, and software to permit the player to behave as a program-specific personal computer. For simplicity these elements and their capabilities are commonly identified herein as the “processor”.
[0086] Beginning at step 701 , the viewer inserts into the player of the present invention the desired disk. Upon selection of the play function 702 , the player's processor will issue a command to read the viewer control setup of the player to ascertain if viewer control is enabled 703 . If enabled, the player's handshaking routines will request viewer identification and, if required a corresponding password 704 . If the viewer identification and password are not found acceptable 705 , the appropriate error message is transmitted to the television 706 , and the player is returned to a state prior to the viewer play request 702 .
[0087] If the viewer identification and password are found acceptable 705 , the processor checks for other restrictions to a user access 707 . These additional restrictions include: time of day restrictions for the user, accumulated usage during specified time frames. If restrictions are enabled that prevent usage 707 , the appropriate error message is transmitted to the television 709 , and the player is returned to a state prior to the viewer play request 702 . The user-permission capability enables a parent to have complete control over the use of the player.
[0088] If viewer control is not enabled 703 , or if enabled, verification of the user 705 and verification of restrictions permit usage 707 , the processor instructs the player to read from the disk program identification data 711 . Based on the program identification data, which in addition to including a unique identification code may also contain qualitative and classification program information, the processor will then search to see if an existing viewer preference table for the identified viewer is available at step 712 . Otherwise at step 713 , the player reads the program category listing structure supplied from the video disk and determines if a viewer preference is established for each of the program categories. Once viewer preference structure exist, the processor verifies set up status for editing privileges 714 , so that the viewer has editing privileges for the class of programs to which the present program belongs and the categories included therein, and editing is to be exercised upon the play request. The processor may simply transmit to the television a viewer request to indicate if the existing preference structure is to be edited 715 . If at step 714 edit privileges are not available for the viewer, the processor will initiate normal play routines 721 . If the viewer indicates that no editing privileges are to be exercised 715 , than the processor will initiate normal play routines 721 as well; otherwise, editing of the viewer preference structure occurs at step 718 . The edited viewer preference structure is interactively verified 719 until an adequate category preference match as required by the program is established or the viewer selects to exit. Exiting at 719 returns the player to a state prior to the viewer play request 702 .
[0089] If a viewer preference structure for the login viewer for the program is not available 712 or at least one of the categories of the program is not contained in the viewer preference structure 713 , then the processor will verify if edit privileges are available for the viewer for the class of programs and the categories 716 . If no edit privileges are available, then the processor transmits an error message 717 to the television and returns the player to a state prior to the viewer play request 702 . If edit privileges are available, then editing of the viewer preference structure is available at step 718 .
[0090] Editing the viewer preference structure at 718 is supervised by the processor to insure that viewer modifications are consistent with the permissions established for that viewer. Individual viewer permissions may be established broadly for any one or more classes of programs or categories, or specifically for any category.
[0091] Once editing of the preference structure, as required by the program category listing, is found complete at step 719 the processor initiates play routines 721 . These include reading the program segment map 722 from the disk and applying the existing viewer preference structure 723 to determine the segments to be played and their sequence 724 . Upon which the processor issues the sequence of player commands to operate the transfer of the video information from the disk to the television 725 .
[0092] It should be noted that once a basic viewer preference structure and keyword control has been read into the player's memory, and the player viewer control is properly set up, a subsequent playing of any disk conforming to the basic category structure, need only involve inserting the disk into the player and depressing the play button, whereupon the player will automatically initiate playing of the video program without the necessity of any further viewer interaction. If viewer control is enabled, a viewer identification and or password entry would be the only other additional step required.
[0093] While an embodiment of the present invention has been explained in terms of a laser video disk player physically accessible by the viewer, variations of this embodiment of the present invention are also possible. For example, the video player need not be physically located near the television set. The patents to Fenwick et al. U.S. Pat. No. 4,947,244 and to Eggers et al. U.S. Pat. No. 4,920,432, by reference incorporated herein, disclose remote video distribution systems such as may be found in a hotel, wherein the viewer is provided remote controlled access to the video resources. Fiber optic communications would easily permit a greater distance between the player and the television.
[0094] The embodiment of the present invention also need not be limited by laser video disk technology. The program, the program content map, and user routines may be provided to the viewer in any of a variety of existing and evolving technologies. These technologies include hard formats such as tape, laser disk, magnetic disk, combination laser one side magnetic underside disk, memory chips and modules (e.g. RAM, DRAM, high capacity flash memory, bubble memory); and soft formats, such as an, analog or digital cable transmissions, fiber optic transmission, phone and satellite communications.
[0095] Additionally, the entire program including all the parallel, overlapping, and transitional segments, and the program content map need not be transmitted to the viewer. The program may be provided to the viewer in the form that results from the execution of the viewer content preference structure, i.e only those segments comprising a continuous logical program that are consistent with the viewer preference structure is transmitted in real-time or a non real-time format.
[0096] In a fiber optic based broadband integrated services digital network (“B-ISDN”) implementation of the present invention, as previously outlined, the video program is delivered to the viewer via a fiber optic network.
[0097] An internal or external modem connects the video player with the required fiber optic linkages and communication software. The capacity, and speed of the player's storage, the size and speed of the player's memory and processor, and the capabilities of the modem device or integrated service digital network retriever transmitter (“ISRT”) or video retriever transmitter (“VRT”) are dependent on the architecture implemented by the program provider. Preferably, where the entire program is downloaded together with the required program content map and user interface, the storage capacity and transfer rates included in the VRT will be significant.
[0098] This requirement may be reduced by applying the viewer preference structure to the program and transmitting, in total or in groups, only those segments to be viewed. Alternatively, where the viewer remains on-line with the program provider during the transmission of the program and utilizes the hardware capabilities of the service provider, a VRT; including only a communication unit without local storage, processing, or memory, would be adequate.
[0099] It is within these VRT implementations that the various advantages and capabilities of the present invention are realized. The versatility and usefulness is derived from its two way fiber optic digital linkage to the B-ISDN. In a preferred embodiment of the present invention within a VRT architecture, the viewer or, more appropriately, the user's control of the VRT is either through an infrared control keypad, wired or infrared alphanumeric control keyboard, voice control, or system controls directly on the VRT unit. The VRT will be linked to the user designated digital receiver monitor and to the B-ISDN by means of fiber optic based communication devices. The VRT, monitor and keyboard will provide the functional equivalent of a graphical workstation.
[0100] In operation, the VRT normally provides a variety of communication and background services (e.g. videophone, video fax, security, appliance management) to the user and therefore is ready to respond to an active user request. The user control's the VRT's functions by means of one of the control devices listed above, causing the VRT to provide power to the receiver if necessary, and transmitting an appropriate menu, entry screens, or services to the receiver as previously described. The configuration of the handshaking is provided in a flexible and user configureable manner.
[0101] The following four examples describe how a user retrieves video programs:
[0102] In a first example, a user accesses, by means of the VRT, a program provider of his choice. The user has a variety of ways to retrieve programs including: i) specifying the program's title or code obtained from a reference guide, ii) listing in alphabetical order by title, subject matter, actors, etc. in any combination, iii) tree structure of the program classifications, and iv) keyword searching and retrieval (similar to the Automated Patent Search implementation) enhanced by the program/segments descriptors. Once the program is selected, the user remains on-line utilizing the hardware of the program provider or a more local service center which obtains the program from the program provider. The off-site hardware services will respond to the VRT commands in a manner similar to that detailed previously for the player implementation of the present invention.
[0103] In a second example, a user will access a program provider and select a program, as indicated in the example above. Instead of remaining on-line, however, the user requests downloading the selected program. In addition to the program video, the program includes a map of the program segments, any user interface routines particular to the program, and VRT control codes, in a format consistent to that required by the VRT storage capabilities. Utilization of the program will then be analogous to those steps detailed previously for the player implementation of the present invention.
[0104] In a third example, a user wishing to retrieve a summary, analysis, and background regarding a particular news event, will use one of the control devices to order the automatic linkage with the B-ISDN service center. The user then enters his/her request, and a keyword analysis of the request will then result in an on-line linkage through the service center to a database containing information on the programbases for the subject matter desired. In this example, a news source remotely located will download a listing of the various sources of summary, analysis, background information, the corresponding segment descriptors where available and necessary, and the overall lengths and costs, if any, of each segment. The user may at his/her leisure produce a request for a video program for his own viewing. In this example, a program comprising a 10 min summary from a news source, a 5 min analysis from another service, a 10 min analysis from a private source, a 30 minute lecture from a university, and copies of a relevant data from the Library of Congress are available.
[0105] Once the user finalizes the program segment choices, the request is transmitted to the service center wherein the various providers (libraries) which may be located anywhere in the world are electronically requested to transmit the respective segments/programs, program content maps, and any user routines. These are logically assembled and merged by the service center and retransmitted to the user together with any billing information. The transmission and retransmission of the programs might be on a non real-time compressed digitized device.
[0106] The event duration for our example may be 15 minutes of connect time, 2 minutes of transmission time (for the 55 minute “program”). The costs for the service may be less than a conventional movie, total cost could be approximately $6.00 with a partial rebate for the user selection to activate the five minutes of targeted “commercials” that are included. The particular billing methods and apparatus required are currently implemented in other on-line data retrieval services.
[0107] Since the VRT is both a retriever and a transmitter, the above “program” might be condensed by the user into a 10 minute summary and a 2 minute personal message and transmitted to another user, incurring connect time and redistribution charges of about $2.00.
[0108] In a fourth example, a user may construct a content preference structure of any desired detail, including, for example, a variety of keywords to describe the program's subject matter, the story line, possible endings, and approximate program playing time. The user will transmit this information by means of the VRT to a program provider. The user will further indicate the program's delivery by requirement (minutes, overnight, days), and whether the request is for a single program or a series of programs and their frequency.
[0109] The program provider will analyze the user request, search the programbase for a program matching the user's requirements. If the program is found, then program information and billing, if any, are transmitted to the user for approval and subsequent program transmission to the user. If the program is not found, the user's request is forwarded to an appropriate program producer for possible production. The “custom” programs generally follow a preestablished per-transmitted viewable minute fee structure based on the subject matter and nature of the program. Although other schemes are possible, production will depend on an expected or actual critical mass of viewers and any sponsorship both public and private that may be associated with the program. The systems communication architecture facilitates the communication and marketing required to obtain the necessary viewers and sponsorship for production.
[0110] The variety of uses of such an architecture might include: i) science fiction enthusiast causing video production of a particular story, i.e a 21st century version of “Romeo and Juliet”; ii) the desirability and structure of a sequel determined by the consensus of viewers; iii) updating of news stories no longer deemed “current”; iv) Continued appraisal of developments in a specified field or subject area, i.e. significant events which might affect the price of a specified commodity; v) review of a political candidates positions; and vi) product purchasing and utilization information.
[0111] It is clearly the intent of the VRT implementation of the present invention to permit user(s) to efficiently obtain a transparently continuous program to be viewed at the time of their choosing, over which they exercise complete control as to the subject matter, form of expression, and other elements comprising the program.
[0112] In terms of product and services advertising, and commercials in general, the applicant recognizes that commercials have made possible the growth and development of freely broadcast programming. The variety of viewer supported programming such as PBS, rented video programs, and premium cable channels have struggled to maintain quality programming and remain generally free of commercials by direct viewer payments and contributions. It is intended that the methods of the present invention, that are applied to programming in general, and to commercials in particular, lead to commercials (informationals) of greater value to the viewer and not necessarily to merely censor or exclude commercials.
[0113] As alluded to earlier, a viewer may not object to, and in fact may request, the inclusion of commercials, which are informational in nature, presented in a manner consistent with their taste level, for a product or service in which they may have an interest; especially if the acceptance for viewing of such a commercial will additionally reduce the cost of other programming obtained by the viewers. In this context, the subsidizing of a program's cost to the viewer by commercials, is more closely matched to the viewers interest in the subject of the commercial, and to the potential purchase by the viewer of that product or service.
[0114] Where the inclusion of commercials is consistent with the viewer-established preference structure and is accepted by the viewer as a condition of value received by the viewer, the transmission of the commercial to the television is promoted by providing special segment codes that would inhibit the player or VRT functions (e.g. viewer preference structure, skip function) from interfering with that transmission.
[0115] While a presently preferred form of the present invention has been set forth in summary form here and above, it is to be understood that the invention is not limited thereby. In particular, the steps of the inventive process are interchangeable, may be interchanged and are equivalent. It is to be understood that the specific details shown are merely illustrative and that the invention may be carried out in other ways without departing from the true spirit and scope of the following claims. | This invention relates to an automated control system and method that furnishes viewers with individualized automated editing and retrieval capabilities over the contents and length of a variable content video program in order to produce a transparently continuous and complete show. The system capabilities include an automated flexible control system design that enables an operator to selectively apply different editing criteria to the variety of subject matters that may be contained within the program. The system controls also include an automated capability for efficiently previewing program scenes of pre-identified categories and classes of subject matter and a capability for determining their inclusion in the program seen by the viewer. Finally, the control system provide a keyword/menu segment/program retrieval facility from an existing program and program database, and a requesting capability for programs to be produced according to viewer-specified requirements. | 7 |
FIELD OF THE INVENTION
The subject matter of the present disclosure relates generally to a balance ring for an appliance.
BACKGROUND OF THE INVENTION
During the operation of a washing machine, particularly during spin cycles, the machine can sometimes experience an extreme vibration. These vibrations can even cause displacement of the washing machine as it “walks” across a surface such as a floor. Typically, this event is due to the different shapes and densities of the clothing or other articles that are being washed which, after the washing cycle and draining the wash basket, can stick together and cause differences in the center of mass inside the wash basket. The vibration problem can also be caused by the introduction of relatively heavier articles into the wash basket such as e.g., shoes.
By way of example, after the washing cycle and draining of the washing liquid from the wash basket, the shoes or other, relatively heavier articles may be located on one side of the wash basket or in a manner that causes the center of mass of the combined wash basket and articles (such as the shoes, clothes, and other items being washed) to be off center. As the wash basket is rotated, particularly at high speeds, the off centering and centrifugal forces creates an imbalance that can generate undesired strain in the washing machine components, an undesirable level of noise, and/or “walking” of the appliance. In an extreme or prolonged situation, the imbalance created by the excessive vibration can also wear-out and damage the washing machine components.
As a result, in order to counter the out of balance wash load, various devices have been proposed. For example, washing machines have been equipped with balance rings, which are typically hollow rings placed on the top and sometimes bottom of the wash basket. Inside the ring (or toroid) a weight such as a fluid and/or movable metal objects such as e.g., solid balls have been inserted. During operation, the ring will act as a counterweight to the out of balance load of clothes because the fluid and/or solid balls will move to a position within the ring that counters the centrifugal forces created by the articles in the wash basket so as to balance the overall mass of the articles in the wash basket.
Thus, for balance rings that incorporate a fluid, during spinning of the wash basket the fluid must be able to redistribute so to act as a counterweight to an out of balance of mass of the articles in the wash basket. Sometimes, however, as the rotational speed of the wash basket increases during a spin cycle, one or more critical speeds (i.e. resonant modes) are reached. At these critical speeds, the translational motion of the balance ring can be severe enough distribute the fluid in a manner that prevents it from properly counteracting the out of balance wash load. In fact, the fluid may even be distributed in a manner that reinforces the tub motion.
BRIEF DESCRIPTION OF THE INVENTION
Aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.
The present invention provides a balance ring for an appliance with features to control fluid distribution particularly during certain critical speeds where motion created by an out of balance condition might otherwise cause the balance ring fluid to redistribute improperly. The balance ring can include an inner chamber that is in fluid communication with an outer chamber. The inner chamber can include baffles that impede the movement of fluid along the circumferential direction when e.g., the balance ring experiences translational motion.
For example, in one exemplary embodiment, the present invention provides a balance ring for an appliance. The balance ring defines radial and circumferential directions. The balance ring includes an outer chamber extending along the circumferential direction and an inner chamber also extending along the circumferential direction and positioned adjacent and radially inward of the outer chamber. A dividing wall is positioned between the outer chamber and the inner chamber. A plurality of openings are defined by the dividing wall and are spaced apart along the circumferential direction. The openings provide for fluid communication between the outer chamber and the inner chamber. A fluid is located in the outer chamber and the inner chamber.
In another exemplary embodiment, the present invention provides a washing machine appliance that includes a cabinet, a wash tub received within the cabinet; and a wash basket rotatably received within the wash tub. The wash basket has an exterior surface extending circumferentially around the wash basket. A motor is connected with the wash basket and configured for rotating the wash basket. A balance ring is connected to the wash basket and has radial and circumferential directions. The balance ring includes an outer chamber extending along the circumferential direction and an inner chamber extending along the circumferential direction and positioned adjacent and radially inward of the outer chamber. A dividing wall is positioned between the outer chamber and the inner chamber. A plurality of openings are defined by the dividing wall and are spaced apart along the circumferential direction. The openings provide for fluid communication between the outer chamber and the inner chamber. A fluid is located in the outer chamber and the inner chamber.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
FIG. 1 provides a perspective view of an exemplary embodiment of a washing machine of the present invention.
FIG. 2 illustrates a cross-sectional view of the exemplary embodiment of FIG. 1 .
FIG. 3 is cross-sectional, schematic view of an exemplary embodiment of a balance ring of the present invention as viewed from the top down.
FIG. 4 is another cross-sectional, schematic view of another exemplary embodiment of a balance ring of the present invention as viewed from the top down.
FIG. 5 is a perspective view of an exemplary embodiment of a balance ring with a cross-section provided to illustrate certain internal features.
FIG. 6 is another perspective view of the exemplary embodiment of FIG. 5 ring with a cross-section provided to illustrate certain internal features.
FIG. 7 is a perspective view of a bottom portion of the exemplary embodiment of FIG. 5 .
The use of the same or similar reference numerals in the figures indicates the same or similar features.
DETAILED DESCRIPTION OF THE INVENTION
Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
FIG. 1 is a perspective view an exemplary vertical axis washing machine 50 including a cabinet 52 and a top cover 54 . FIG. 2 provides a cross-sectional, side view of the exemplary embodiment of FIG. 1 . A backsplash 56 extends from cover 54 . A control panel 58 including a plurality of input selectors 60 is coupled to backsplash 56 . Control panel 58 and input selectors 60 collectively form a user interface input for operator selection of machine cycles and features, and in one embodiment, a display 64 indicates selected features, a countdown timer, and/or other items of interest to machine users. A lid 62 is mounted to cover 54 and is rotatable about a hinge (not shown) between an open position (not shown) facilitating access to a wash tub 78 located within cabinet 52 , and a closed position (shown in FIG. 1 ) forming an enclosure over wash tub 78 .
A wash basket 76 is located within wash tub 78 in spaced apart relationship from tub 78 . Articles for washing are placed within basket 76 . A motor 80 is used to selectively spin wash basket 76 during various cycles of the appliance. Wash basket 76 includes a plurality of openings 70 that facilitate the movement of fluid in and out of basket 76 within wash tub 78 . When wash basket 76 is rotated at high speed during e.g., a spin cycle, openings 70 in wash basket 76 allow fluid to be wrung from the articles such as clothing located in basket 76 .
An agitation element such as agitator 72 with blades 74 , impeller, auger, or oscillatory basket mechanism, or some combination thereof is disposed in basket 76 to impart an oscillatory motion to articles and liquid in basket 76 using motor 80 . In different embodiments, agitation element 72 can include a single action element (i.e., oscillatory only), double action (oscillatory movement at one end, single direction rotation at the other end) or triple action (oscillatory movement plus single direction rotation at one end, singe direction rotation at the other end). As illustrated in FIG. 2 , agitation element 72 is oriented to rotate about a vertical axis A.
Operation of machine 50 is controlled by a controller or processing device (not shown), that is operatively coupled to the user interface input or control panel 58 located on washing machine backsplash 56 (shown in FIG. 1 ), which allows e.g., for user manipulation to select washing machine cycles and features. More particularly, in response to user manipulation of the user interface input, the controller operates the various components of machine 50 to execute selected machine cycles and features.
For example, in an illustrative embodiment, laundry items are loaded into basket 76 , and washing operation is initiated through operator manipulation of control input selectors 60 (shown in FIG. 1 ). Wash tub 78 is filled with water and mixed with detergent to form a wash fluid, and contents of the basket 76 are agitated with agitation element 72 for cleansing of laundry items in basket 76 . More specifically, agitation element 72 is moved back and forth in an oscillatory back and forth motion.
After the agitation phase of the wash cycle is completed, wash tub 78 can be drained with a pump assembly (not shown). Laundry items are then rinsed and portions of the cycle repeated, including the agitation phase, depending on the particulars of the wash cycle selected by a user. One or more spin cycles may also be used. In particular, a spin cycle may be applied after the wash cycle and/or after the rinse cycle in order to wring wash fluid from the articles being washed. During a spin cycle, wash basket 76 is rotated at relatively high speeds.
While described in the context of a specific embodiment of vertical axis washing machine appliance 50 , using the teachings disclosed herein it will be understood that vertical axis washing machine appliance 50 is provided by way of example only. Other washing machine appliances having different configurations, different appearances, and/or different features may also be utilized with the present subject matter as well.
As previously described, the articles inside basket 76 can sometimes cause an imbalance leading to undesirable vibrations of machine 50 during operation. Accordingly, for this exemplary embodiment, washing machine 50 is equipped with exemplary balance rings 66 and 68 that operate to counteract imbalances in the wash load placed into wash basket 76 . Balance rings 66 and 68 are shown in cross section in FIG. 2 but should be understood to extend circumferentially about wash basket 76 . For this exemplary embodiment, balance rings 66 and 68 are mounted to an exterior surface 82 of wash basket 76 and other techniques for positioning on basket 76 may also be used. Also, although shown with a balance ring positioned at both a top and bottom of wash basket 76 , it should be understood that only one such balance ring—particularly at the top of wash basket 76 as with balance ring 66 —may be used in other exemplary embodiments of the present invention. Balance rings 66 and 68 include features for controlling the movement of a fluid in such rings that offsets an imbalance of articles in wash basket 76 .
For example, FIG. 3 provides a cross-sectional, schematic view of an exemplary embodiment of a balance ring 100 of the present invention as viewed from the top down. Balance ring 100 defines a radial direction as shown by arrow R and circumferential direction C. During operation of the washing machine 50 where wash basket 76 is in spin mode, balance ring 100 rotates about the axis of rotation A. along circumferential direction C.
Balance ring 100 includes an outer chamber 102 that extends uninterrupted along circumferential direction C and contains a fluid such as e.g., a solution of calcium chloride and water. An inner chamber 104 also extends along circumferential direction C is positioned adjacent and radially inward of outer chamber 102 . Inner chamber 104 , however, is interrupted by a plurality of baffles 108 that are intermittently spaced from each other along the circumferential direction C. Baffles 108 divide inner chamber 104 into multiple sections 109 that are fully separated from each other along the circumferential direction except for openings 113 . A dividing wall 106 is positioned between the inner chamber and the outer chamber and separates the two along the circumferential direction. Openings 113 allow fluid to pass only a low speeds. Openings 113 also allow air to pass between chambers 104 . In other exemplary embodiments of the invention, baffles 108 may be provided without openings 113 .
As further illustrated in FIG. 3 , a plurality of apertures or openings 112 are defined by dividing wall 106 . Apertures 112 are spaced apart along the circumferential direction and, for exemplary embodiment, are positioned equidistant from a pair of baffles 108 with one aperture 112 located in each section 109 . However, as will be understood using the teachings disclosed herein, a different number and positioning for apertures 112 may be used in each section 109 . For the exemplary embodiment shown in FIG. 3 , a total of 8 sections 109 are shown. However, a different number of sections 109 may be used. For example, 8 to 12 sections may be used in balance ring 100 .
During operation, the spinning of balance ring 100 about axis A causes centrifugal forces to act on fluid 110 in the direction indicated by arrows CF. As a result, fluid 110 may pass from inner chamber 104 to outer chamber 102 by passing through apertures or openings 112 . Fluid 110 can also move in the circumferential direction C along outer chamber 103 and redistribute between sections 109 of inner chamber 104 as shown by arrow F in order to counter an imbalance in a load of articles placed in the wash tub 78 . However, baffles 108 prevent the redistribution of fluid along the circumferential direction C by moving between sections 109 of inner chamber 104 . As a result, the movement of fluid along circumferential direction C and between sections 109 must occur through outer chamber 102 .
By determining the size of outer chamber 102 relative to inner chamber 104 and the size openings 112 , the ability of the fluid 110 to move between sections 109 can be carefully controlled. More specifically, when oscillatory motion (e.g., along radial direction R) occurs as the spinning of balance ring 100 reaches certain critical speeds, the ability of fluid 110 to redistribute between sections 109 is hampered or delayed. As such, fluid 110 cannot redistribute in a manner that reinforces the oscillatory forces so as to further exacerbate an out of balance condition. However, fluid 110 can still redistribute as shown by arrow F so as to gradually offset in imbalance condition.
FIG. 4 provides a cross-sectional, schematic view of another exemplary embodiment of balance ring 100 of the present invention as viewed from the top down. The embodiment of FIG. 4 is similar to FIG. 3 except for differences in the width of baffles 108 along radial direction R. As shown baffles 108 extend only partially between dividing wall 106 and inner wall 107 so that inner chamber 104 is divided into partial sections 111 . As such, during spinning of balance ring 100 , fluid 110 can redistribute between partial sections 111 in a manner as previously described with regard to the embodiment of FIG. 3 . However, fluid 110 can also redistribute by spilling over a baffle 108 as shown in the lower part of FIG. 4 . Thus, for the exemplary embodiment of a balance ring 100 shown in FIG. 4 , the movement of fluid 110 during translational motion at critical rotation speeds is still impeded so as to prevent undesirable reinforcement of the out of balance condition—yet a flow of fluid between partial sections 111 is still allowed so as to provide for a redistribution of fluid 110 that can counter an out of balance condition.
Another exemplary embodiment of a balance ring 200 of the present invention is illustrated using FIGS. 5 through 7 . FIGS. 5 and 6 provide different perspective views with a cross-section to illustrate certain internal features while FIG. 7 provides a perspective view of a part of a lower portion 218 of balance ring 200 .
For this exemplary embodiment, balance ring 200 is constructed from lower portion 218 and upper portion 216 that are joined together. Upper portion 216 includes a plurality of tongues 220 separated by a groove 222 . Similarly, lower portion 218 include a plurality of tongues 224 separated by a groove 226 . Together, such features combine in a complementary manner as shown in FIGS. 6 and 7 to secure upper and lower portions 216 and 218 together. Tongues 220 and 224 create a dividing wall 206 along one side of balance ring 200 so as to separate inner chamber 204 and outer chamber 202 . An opening 212 allowing fluid to pass between inner chamber 204 and outer chamber 202 is created in part by a groove 230 formed in the top edge 228 of a tongue 224 . A baffle 208 divides inner chamber 204 into partial sections 211 . Outer chamber 202 , inner chamber 204 , baffle 208 , and openings 212 function in a manner similar to that previously described with regard to the exemplary embodiment of FIG. 4 .
For the exemplary embodiment of FIGS. 5 through 7 , balance ring 200 is also provided with a radially innermost chamber 214 . Radially innermost chamber 214 is completely sealed from inner chamber 104 and outer chamber 102 . By way of example, radially innermost chamber 214 could be provided with a fluid to provide additional weight to counter an imbalanced load of articles in the wash basket.
The present invention is not limited to the particular construction of balance ring 200 . Using the teachings disclosed herein, it will be understood the other configurations of a balance ring may be applied and such balance ring may be used on washing machines as well as other appliances for which a counter for an out of balance condition of a rotating component is desired. This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. | A balance ring for an appliance is provided that has features to control fluid distribution particularly during certain critical speeds where large oscillatory motion created by an out of balance condition might otherwise cause the balance ring fluid to redistribute improperly. The balance ring can include an inner chamber that is in fluid communication with an outer chamber. The inner chamber can include baffles that impede the movement of fluid along the circumferential direction when e.g., the balance ring experiences large oscillatory motion. | 3 |
BACKGROUND OF THE INVENTION
1. Field of Invention
When surfaces such as concrete, brick, masonry, stone, etc. are applied with waterproofing sealer compositions, they get overall protection from corrosion and general deterioration. The treatment reduces the rate of water absorption considerably, thereby preventing water related damages. There are many sealers/repellents known to the prior art. For example, acrylics, vinyls, silanes, silicones, polyurethanes, styrene-butadiene copolymers, silicates, siloxanes, siliconates etc. They are either water based or solvent based or water-solvent based.
Due to fire hazard and environmental risks associated with many known solvents, it is advantageous to use effective water based waterproofing compositions. Waterproofing sealer/repellents based on ═Si═ chemistry play a significant role in the field of waterproofing materials. There are three popular groups of silicone based materials being used as waterproofing materials namely 1. silicates, 2. silane, siloxane, siliconate and 3. silicones.
Silicates provide waterproofing properties by filling the pore structure of building materials with silicone dioxide precipitation.
Silanes, siloxanes and siliconates provide waterproofing properties by bonding with the substrate and thus offer a long lasting solution.
Silicones are present in the polymer form and they do not form chemical bonds with the substrate. They provide waterproofing properties by forming a non-bonded film.
2. Prior Art
Representative references which illustrate some of the prior art waterproofing compositions are described in the following U.S. Patents:
U.S. Pat. No. 3,772,065 to Seiler relates to alkyltrialkoxysilane solution in alcohol having up to two alkoxygroups per silicone atom for masonry applications.
U.S. Pat. No. 3,819,400 to Plankl et al. relates to a waterproofing material treated with a silane or a siloxane.
U.S. Pat. No. 3,879,206 to Nestler et al. relates to formulation containing alkyltrialkoxysilane and an organo functional silane for masonry applications.
U.S. Pat. No. 3,980,597 to Shihadeh relates to a composition containing polyurethane and neutralised bituminous material for roof waterproofing applications.
U.S. Pat. No. 4,341,560 to Saito et al. relates to a composition containing alkaline metal alkylsilioonates or phenylsiliconates along with calcium hydroxide or calcium oxide to waterproof gypsum.
U.S. Pat. No. 4,536,534 to Singer et al. relates to an aqueous primer based on alkali soluble acrylic resins and siliconates for application on strong alkaline substrate to bring about good water repellance and binding.
U.S. Pat. No. 4,814,407 to Canova et al. relates to a composition of an alkylalkoxysilane or a fluoroalkylalkoxysilane for improving resistance to absorption of water by a porous substrate.
U.S. Pat. No. 4,816,506 to Gamon et al. relates to an aqueous silicone dispersions containing polydiorganosiloxanes, organometallic compounds, siliconate and optionally a silicone resin for elastomeric coating or sealant applications.
U.S. Pat. No. 4,894,405 to Barron relates to a composition containing polyurethane and organosilane for concrete and masonry waterproofing applications.
U.S. Pat. No. 4,897,291 to Kim relates to a sealant composition containing polymeric binder, a wax hydrophobic filler and a water soluble alkalimetalsiliconate salt for sealing wood products against moisture absorption.
Siliconates are water soluble and they impart water repellency on porous surfaces. As per the conventional method of application, 30% by weight of siliconate solution is diluted to less than about 3% by weight. Dilution reduces solution viscosity and increases its penetration along the depth of the substrate.
However, there is a drawback in using diluted alkalimetal alkyl siliconate solution for waterproofing applications. When this solution is applied by brush/spray/roller to the substrate, siliconates react with carbon dioxide and carbonatious matters present in the substrate to form a water repellent, water-insoluble, white colored precipitate. This white layer may become quite visible;
1. on surfaces applied with excess waterproofing solution,
2. on less porous surfaces, and
3. on surfaces that require preservation of their external appearance and character e.g. facades, decorative tiles, colored stones etc.
Such a change in discoloration and appearance of the substrate after curing of siliconate waterproofing solution is generally not acceptable from the aesthetic point of view.
Less than 1% by weight of siliconate solution minimizes formation of white residue to some extent but it gives a very poor waterproofing property.
The object of the invention is to overcome this drawback.
SUMMARY OF THE INVENTION
This and other objects of the invention are accomplished by the novel waterproofing sealer composition for application to concrete, masonry, cloth and many other porous surfaces.
The waterproofing sealer composition (100 parts by weight) comprises;
about 1 to 3 parts by wt. of water soluble alkalimetalalkyl siliconates
about 0.2 to 10 parts by wt. of polymers(resins)
about 0 to 0.5 parts by wt. of alkali silicates
about 0.005 to 2 parts by wt. of additives
about 0 to 20 parts by wt. of diluents
the balance parts by wt. of water
A preferred waterproofing sealer composition comprises;
about 1.4 to 1.9 parts by wt. of water soluble alkali-alkyl siliconates
about 1 to 3.5 parts by wt. of polymers
about 0.001 to 0.2 parts by wt. of alkali silicates
about 0.005 to 2.0 parts by wt. of additives
about 0 to 5 parts by wt. of diluents
the balance parts by wt. of water
The waterproofing composition is applied to porous, clean surfaces such as concrete, masonry, brick, wood, stones, tiles, cloth etc. by brush, roller, spray, dipping or the like. Treated surfaces are allowed to dry and cure. The sealer composition penetrates deep inside the substrate and lines capillary walls with its active ingredients to bring about properties like hydrophobicity and resistance to water absorption.
Some of the advantages associated with this invention include:
an ability to overcome the drawback related to the formation of a white precipitate on substrate surface.
an ability to improve resistance to water absorption in porous surfaces such as concrete, brick, masonry, stones and others.
DETAILED DESCRIPTION OF THE INVENTION
Alkalimetal alkylsiliconates used can be sodium methylsiliconate, sodium ethylsiliconate, sodium propylsiliconate, potassium methylsiliconate, potassium ethylsiliconate and potassium propylsiliconate. These alkalimetal alkylsiliconates are used in an aqueous solution form. The amount of alkalimetal alkylsiliconates to be used is usually below 3 parts by weight per 100 parts by weight of waterproofing sealer. It is possible to use a single siliconate or a mixture of at least two or more of the above mentioned siliconates in the waterproofing sealer composition. Preferred amount of siliconates to be used is 1.4 to 1.9 parts by weight per 100 parts by weight of waterproofing sealer solution.
Examples of polymers in the form of emulsions/dispersions are polyurethanes, alkali stable acrylic resins, vinyls and their copolymers. Preferred polymer emulsion/dispersions are of polyurethanes. A single or a mixture of two or more of the above mentioned polymer emulsions/dispersions may be used in the formulation. Amount of parts by weight of total polymer (solid content present in emulsions/dispersions) to be used in formulation is 0.20 to 10 parts/100 parts by weight of waterproofing sealer solution. The preferred amount of parts by weight of polymer to be used in formulation is 1.0 to 3.5 parts/100 parts by weight of waterproofing sealer solution.
Polyurethane dispersions/emulsions are made from aliphatic and aromatic diisocyanates, polyisocyanates, polyols and co-solvents. Example of diisocyanates are toluene diisocyanate(TDI), diphenylmethane 4,4'-diisocyanate (MDI), hexamethylene diisocyanate(HDI), isophorone diisocyanate(IPDI). Polyisooyanates can be based on TDI, MDI and IPDI. Examples of polyols are polyethers, polyesters, acrylic based polyols, polycarbonate based polyols and the like. Examples of co-solvents are hydrocarbon solvents such as toluene; N-methyl-2-pyrrolidone, dimethyl formamide(DMF) and the like.
Examples of alkali silicates are sodium silicate and potassium silicate. A preferred silicate is sodium silicate represented by the formula
Na.sub.2 O.xSiO.sub.2 where 3.2<x>2.0.
The preferred amount of a silicate to be used is 0.001 to 1.0 parts by weight per 100 parts by weight of the waterproofing sealer.
Examples of diluents are ethylene glycol, diethylene glycol, methanol, ethanol, n-propanol, iso-propanol, n-butanol and iso-butanol. One or a mixture of two or more of the above diluents can be used. The preferred amount of diluents to be used is 0 to 5 parts by weight per 100 parts by weight of the waterproofing sealer.
Examples of additives are surfactants, wetting agents, defoamers, biocides and the like. The preferred amount of each of these additives to be used is 0.005 to 2 parts by weight per 100 parts by weight of the waterproofing sealer.
Various other ingredients such as pigments, plasticizers, ultra violet inhibitors, antioxidents and the like can also be utilised in the conventional amount.
EXAMPLE 1
METHOD OF PREPARATION
The above mentioned chemical ingredients form a representative waterproofing composition which will be better understood by the following synthesis.
A typical method of preparation involves two steps:
Step 1: A waterproofing sealer composition of the invention is prepared by using a high speed mixer, preferably with variable speed control. One half of the weight of water is first mixed with preweighed quantity of selected polymer emulsion/dispersion for 10 minutes. Sodium silicate is then added in a 35% solution form and the mixture is stirred for 5 more minutes.
Step 2: Concentrated solution of a siliconate or mixtures of siliconates (30% concentration) is mixed with the other half of water for 5 to7 minutes. To this, the mixture prepared in step 1 is added gradually and it is further mixed for 5 to 10 minutes. Finally the additives are added to the solution under constant stirring for 5 minutes.
A typical formulation and its characteristics are given below in Table 1.
TABLE 1______________________________________Formulation: By wt.______________________________________Polyurethane dispersion 5 partsgrade 140AQ ®, MilesSodium methyl siliconate, 5 partsGrade 772 Dow Corning ® orGrade R-20 Union Carbide ®Sodium silicate, Grade N ® PQ Corp. 0.1 partsSurfactant, Surfynol TG ®, Air Products 0.15 partsDemineralized water 89.75 parts 100.00 partsCharactericstics:Appearance milky water solutionCured substrate appearance unchangeddensity lbs/gallon(US) 8.55Viscosity, cps 20-40, waterlikeFlammability non-flammable______________________________________
EXAMPLE 2
To illustrate the effectiveness of the waterproofing sealer composition of the invention a water absorption test is carried out. The following waterproofing formulations are prepared.
Formulation A: as in Example 1
Formulation B: 1.5% sodium methylsiliconate water solution. (by wt.)
Two pre-weighed masonry bricks of the size 4"×2"×0.5" are immersed fully in the formulation A and B respectively for 10 seconds. They are allowed to cure at 25° C. and relative humidity of 50-55% for 24 hours.
After the curing period, these two marked bricks are dipped into 0.75" of constant level water for 24 hours in such a way that 4"×0.5" side acts as a base and 2" side becomes height.
An increase in the weight of each brick is recorded. This is a weight gain after 24 hours.
These two bricks are immediately dipped again in the same orientation for another 144 hours. At the end of 168 hours, bricks are removed and an increase in weight is recorded. This is a weight gain after 168 hours. For the purpose of comparison, a third brick of same dimension is dipped in 0.75" constant water. Readings at 24 hours and 168 hours are taken for an increase in weight. The results obtained are shown in Table 2.
TABLE 2______________________________________ Formulation Formulation A B 100% water______________________________________Wt. of brick 6.0 5.30 5.40Wt. of brick 6.0 5.32 5.65after 24 hrs.Wt. of brick 6.01 5.32 5.70after 168 hrs.% water absorbed 0 0.37 4.63in 24 hrs.% water absorbed 0.16 0.37 5.55in 168 hrs.______________________________________
All weights are measured in ounce.
Formulation A representing the waterproofing sealer of the invention shows improved resistance to water absorption over formulation B of the prior art.
Untreated brick absorbs water to its maximum.
EXAMPLE 3
The following example gives comparison in appearance of the substrate, once the waterproofing sealers are cured. Formulations A and B described in Example 2 are coated one by one with a brush on a transparent acrylic sheet having dimension of 4'×4"×0.125". Thickness of application is approximately 0.01 inch. Formulations A and B are not absorbed by the non-porous surface of acrylic sheet. Thus it is easy to observe the characteristics of cured residues A and B respectively. These coatings are allowed to cure with carbon dioxide from air for 72 hours and the following visible observations are noted in Table 3.
TABLE 3______________________________________Waterproofing Visible appearance Visible appearancesealer after 72 hours after 30 days______________________________________Formulation A semi-transparent film transluscent film with no loose powdery residueFormulation B White flaky and white flaky and powdery precipitate powdery precipitate______________________________________
The result indicate that waterproofing sealer composition of the Example 1 forms a fill that reins semi-transparent to transluscent and shows no loose powdery residue. This is a clear improvement over the prior art represented by the formulation B.
EXAMPLE 4
This example shows that the waterproofing sealer composition of the invention offers good resistance to efflorescence. To prove this a 2" size of concrete cube is coated with the waterproofing sealer composition of Example 1 on five sides at the rate of 85 square feet per gallon(US) by using a small brush.
The cube is allowed to dry and air cure for 24 hours. It is then kept in a 10% sodium sulfate solution of 0.25 inch constant level for 7 days with the uncoated side fully dipped. An untreated cube is also kept in the solution for the purpose of comparison.
At the end of 7th day, the following visible observation is made.
______________________________________Concrete cube(Untreated) white residue of sodium sulfate is seen all over the exposed surfaces.Concrete cube treated with no white residue seen onformulation A the exposed surfaces.______________________________________
EXAMPLE 5
To perform vapour transmission test, a 2" of cement concrete cube is fully dipped in the waterproofing sealer composition of the invention (formulation A) for 10 seconds. It is next cured for 24 hours and weighed (weight X).
The cube is then dipped in a 6" of water for 7 days. It is removed, surface wiped and weighed again (weight Y).
The cube is next allowed to dry at a temperature of 25° C. and relative humidity of 50-55% for 24 hours. It is weighed (weight Z).
It is found that weight Z=weight X.
This means that the amount of water absorbed evaporates out within 24 hours. This proves that the waterproofing sealer of the invention does not interfere with vapour transmission, an indicator of breathing property of the substrate.
The novel waterproofing sealer composition of Example 1 also exhibits the following characteristics;
When it is applied on the substrate, water present in the formulation begins to evaporate. The rate of evaporation depends on ambient temperatures, relative humidity and the wind velocity. As water concentration decreases, the dispersed/emulsified polymer begins to coagulate, thus forming a thin polymer film.
This polymer film exhibits good abrasion resistance property and can give increased protection against rain and wind impact, thus extending the useful life of porous substrates.
Although the preceeding specific examples which utilize specific polymers, siliconates, silicates and other ingredients; it is understood that the disclosures are made herein through examples and that many changes may be made to the formulations without departing from the spirit and scope of the invention or the scope of the appended claims. | The present invention relates to waterproofing sealer compositions that protect various types of porous substrates from deterioration due to water absorption and thus extend their useful lives. Example of porous substrate are concrete, brick, masonry, ceramics, stones, cloth, wood and the like. These waterbased compositions comprise alkali metalalkylsiliconates, alkali silicates, polymers, diluents and additives.
These sealer compositions do not change appearance and character of the substrate surface. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims priority to co-pending U.S. patent application Ser. No. 13/372,187, filed on Feb. 13, 2012, which claimed priority to then co-pending U.S. Provisional Patent Application Ser. No. 61/442,281, filed on Feb. 13, 2011.
TECHNICAL FIELD
[0002] The novel technology relates generally to materials science, and, more particularly, to a high surface area graphene composite material.
BACKGROUND
[0003] Graphene, a single-atom-thick sheet consisting of sp 2 hybridized carbon atoms arrayed in a honeycomb pattern, is the building block of graphitic carbons. Graphene may be viewed as an individual atomic plane of the graphite structure. Graphene as a two-dimensional nanosheet has attracted increasing interest due to its unique properties of high in-plane electronic conductivity, high tensile modulus, and high surface area, which make graphene an attractive candidate for applications in electronic devices and composite materials. Moreover, with its high surface area and good chemical stability, graphene may be used as a gas adsorbant, ultracapacitor material, or a supporting material for developing novel heterogeneous catalysts with enhanced catalytic activity.
[0004] Graphene may be produced by any one of several methods, including the straightforward exfoliation technique of manually peeling off of the top surface of small mesas of pyrolytic graphite, chemical vapor deposition on metal surfaces, epitaxial growth on electrically insulating surfaces, such as SiC, and the like. Although multiple production methods do exist, large-scale applications of graphene require simple and cost effective methods of production. Hence, the primary route in making graphene is still the exfoliation of graphite oxides followed by a chemical reduction.
[0005] In aqueous solvent dispersions of graphene prepared by chemical reduction, graphene sheets are separated by solvents stabilized by electrostatic forces associated with ionizable groups introduced during the exfoliation. However, like other dispersions of nanomaterials with high aspect ratios, after the solvent is removed from the dispersion, the dried graphene sheets (GSs) usually aggregate and form an irreversibly interconnected or tangled precipitated agglomerate. This agglomeration is driven by the van der Waals interactions between the neighboring graphene sheets, urging the graphene sheets to stack back together in a disorganized and typically haphazard fashion. This agglomeration also leads to a considerable loss of the effective surface area of graphene, which affects the graphene applications in, for example, supercapacitors, batteries, and catalyst supports, where a high surface area of active materials is desired for performance. Therefore, how to achieve the intrinsically ultra-high surface area of graphene in its solid state is of interest in advancing the applications of graphene materials.
[0006] Anchoring nanoparticles on the graphene surface before the GS's aggregation is one effective way to keep the GS's high surface area. The deposition of Pt nanoparticles on a graphene surface before drying has been shown to increase the surface area of the composite from 44 m 2 /g to 862 m 2 /g with the anchoring of the Pt nanoparticles on the surface. Graphene polyoxometalate nanoparticle composites have been observed to yield a graphene surface area of about 680 m 2 /g. Graphene sheet/RuO 2 composites have been observed with increased surface area increases from 108 m 2 /g to 281 m 2 /g. These composites also exhibited a high specific capacitance 570 F/g and an enhanced rate capability. Although the surface area of GSs have been increased with the addition of the nanoparticles, the resulting specific surface area was still much lower than the theoretical surface area of 2630 m 2 /g of the isolated GSs.
[0007] Thus, there is a need for graphene materials having effective surfaces areas approaching the theoretical maximum of 2630 m 2 /g. Further, there remains a need for a method of reliably producing the same. The present novel technology addresses these needs.
DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic illustration of the graphene sheet (GS) and the graphene sheet nanocarbon composites (GSNC) preparation process.
[0009] FIG. 2 graphically illustrates nitrogen adsorption and desorption of the as-prepared GNCs with different nanocarbon content.
[0010] FIG. 3A illustrates TEM images of the as-prepared GSNCs from pure GSs.
[0011] FIG. 3B illustrates TEM images of the as-prepared GSNCs with 1% nanocarbon content and a surface area of 1256 m 2 /g.
[0012] FIG. 3C illustrates TEM images of the as-prepared GSNCs with functionalized nanocarbons.
[0013] FIG. 3D illustrates TEM images of the as-prepared GSNCs with 1% nanocarbon content and a surface area of 1256 m 2 /g.
[0014] FIG. 4A presents SEM images of the pure GSs.
[0015] FIG. 4B presents SEM images of GSNCs with a 1% nanocarbon content and a surface area of 1256 m 2 /g after drying.
[0016] FIG. 5A graphically illustrates CV curves of the as-prepared GSNCs with a surface area of 1256 m 2 /g, measured at potential intervals from −0.2 to 0.8 V (vs. SHE) in 1 M H 2 SO 4 .
[0017] FIG. 5B graphically illustrates voltage curves of the GSNCs with different nanocarbon content as the function of time.
[0018] FIG. 5C graphically illustrates the capacitance of the GSNCs with different nanocarbon content as the function of current density.
[0019] FIG. 6 schematically illustrates Pt nanoparticle etching process on the surface of graphene sheets, according to another embodiment of the present novel technology.
[0020] FIG. 7A is a first atomic resolution electron micrographs showing the dynamic etching of graphene sheets by Pt nanoparticles and the resulting trenches left behind in the graphene according to the embodiment of FIG. 6 .
[0021] FIG. 7B is a second atomic resolution electron micrographs showing the dynamic etching of graphene sheets by Pt nanoparticles and the resulting trenches left behind in the graphene according to the embodiment of FIG. 7A .
[0022] FIG. 7C is a third atomic resolution electron micrographs showing the dynamic etching of graphene sheets by Pt nanoparticles and the resulting trenches left behind in the graphene according to the embodiment of FIG. 7A .
[0023] FIG. 7D is a fourth atomic resolution electron micrographs showing the dynamic etching of graphene sheets by Pt nanoparticles and the resulting tortured path left behind in the graphene according to the embodiment of FIG. 6 .
[0024] FIG. 7E is a fifth atomic resolution electron micrographs showing the dynamic etching of graphene sheets by Pt nanoparticles and the resulting etch path left behind in the graphene according to the embodiment of FIG. 7D .
[0025] FIG. 7F is a sixth atomic resolution electron micrographs showing the dynamic etching of graphene sheets by Pt nanoparticles and the resulting etch path left behind in the graphene according to the embodiment of FIG. 7D .
[0026] FIG. 8A is an electron micrograph of pristine graphene.
[0027] FIG. 8B is an electron micrograph of Pt nanoparticles etched graphene according to the embodiment of FIG. 6 .
[0028] FIG. 9 graphically illustrates the XPS spectra of graphene before and after Pt nanoparticulate etching, according to the embodiment of FIG. 6 .
[0029] FIG. 10A graphically illustrates the N 2 adsorption isotherms and CO 2 capture properties of graphene composites for graphene, Pt/Graphene, and Pt/Graphene 800° C. at 77 K. P/P°, relative pressure; STP, standard temperature and pressure.
[0030] FIG. 10B graphically illustrates the N 2 adsorption isotherms and CO 2 capture properties of graphene composites for graphene, Pt/Graphene, and Pt/Graphene 800° C. at 273 K; filled and open symbols represent adsorption and desorption branches, respectively.
[0031] FIG. 11 is a schematic illustration of a supercapacitor using electrodes made from the embodiment of FIG. 1 .
DESCRIPTION OF PREFERRED EMBODIMENTS
[0032] For the purposes of promoting an understanding of the principles of the novel technology, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the novel technology is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the novel technology as illustrated therein being contemplated as would normally occur to one skilled in the art to which the novel technology relates.
[0033] According to a first embodiment of the present novel technology, as illustrated in FIGS. 1-5B , graphene sheets 10 were prepared by the exfoliation of graphite oxide (a layered material consisting of hydrophilic oxygenated graphene sheets with oxygen functional groups on their basal planes and edges), such as in water to yield a colloidal suspension of almost entirely individual graphene sheets 10 . Nanosized carbon particles 15 , typically carbon black particles 15 , were functionalized with hydrophilic groups, such as —SO 3 H (i.e., bisulfate or hydrogen sulfite), and the GSNCs 20 were prepared with different loadings of the functionalized carbon black particles 25 by simultaneous chemical reduction of both the graphene oxides 30 and the functionalized carbon black particles 25 while in solution. Typically, functionalized carbon black particles 25 are present in amounts of between about one weight percent and about ten weight percent; but the carbon black particle loading may typically vary from less than about 1 weight percent to as much as 50 weight percent, or more. Functionalization is the addition of functional groups onto the surface of a material by chemical synthesis methods or the like, and the functional group added can be subjected to ordinary synthesis methods to attach virtually any kind of compound onto the material's surface. The nanosized functionalized carbon black particles 25 attached to the surface of the GSs 10 and served as spacers to separate/support the neighboring GSs 10 , which prevented the haphazard restacking of the graphene sheets 10 into a randomly oriented solid particulate mass, and consequently, resulted in the generation of increased surface area. The specific surface area of the composites 20 was 1256 m 2 /g, and a maximum specific capacitance of 240 F/g was observed at a current density of 1 A/g. In addition, graphene sheet composite-based capacitors using this composite material 20 for the electrodes exhibited enhanced rate capability, the maximum sustainable continuous or pulsed current output. The above improved electrochemical performance of the GSNCs 20 is a product of their high surface area and high electronic conductivity of the GSs 10 .
[0034] While the carbon nanoparticles 15 discussed herein are specifically carbon black, other allotropes of carbon may be selected. Amorphous carbon, glass carbon, coke, carbon graphitized to various degrees of graphitization, diamondlike carbon, and diamond may also be selected, with the electrical and physical properties of the resulting composite material 20 varying as a result.
[0035] In the synthesis of the GSNCs 20 , the GSs 10 were obtained by in situ chemical reduction of exfoliated graphene oxides 30 . As shown in FIG. 1 , the construction of the GSNCs involved the following steps: first, exfoliation 40 of graphite oxides, then, mixing 45 the graphene oxide sheets 30 and functionalized nanocarbons 25 , and finally, chemical reduction 50 of the mixture. The nanocarbons 15 were functionalized 55 by the dizonium reaction, and the nanocarbons 25 are highly hydrophilic after functionalization 55 . Graphene oxide sheets 30 exist in the liquid dispersion 60 . After reduction 50 of the compound 20 in its solid state, the graphene sheets 10 aggregate 65 and stack back into a layer structure like graphite. Graphene oxide sheets 30 and carbon nanoparticles 25 exist together in dispersion 60 ; in the solid state the nanocarbons 25 serve as spacers, preventing the graphene sheets 10 from restacking back to the graphite structure, and thus make the graphene sheet 10 accessible on both sides and allowing access to the high surface area graphene composite 20 . In the reduction process 50 , the well-dispersed graphene oxide sheets 30 and the functionalized nanocarbons 25 were reduced simultaneously and the functionalized nanocarbon particles 25 became anchored 75 to the graphene sheets 10 . The solid composites 20 float on the surface of the transparent liquid phase of the dispersion 60 . The resultant graphene sheets 10 with attached functionalized nanocarbons 25 aggregated together to yield the GSNCs 20 upon drying.
[0036] Graphene oxides 30 , possessing a considerable amount of hydroxyl and epoxide functional groups on both surfaces of each sheet 30 , and carboxyl groups, mostly at the sheet edges, are strongly hydrophilic and can easily disperse in water. The nanocarbons 15 were functionalized 55 by diazonium reactions as shown in FIG. 1A . In this process, the hydrophilic —SO 3 H functional group was grafted onto the surface of the nanocarbons 15 . As shown in FIG. 1 , after functionalization 55 the nanocarbons 25 can disperse well in the water even if left for several months. After adding the functionalized nanocarbons 25 into the graphene sheet dispersion 60 , the two materials were able to be easily mixed and formed uniform dispersion 60 .
[0037] In order to explore the effects of the nanocarbon content on the composite surface areas, a series of controlled experiments were conducted by varying the content of the nanocarbon in the GSNCs 20 to 0, 0.5, 0.8 and 1 wt. %. The addition of the nanocarbons 25 into the dispersion 60 of the graphene sheets 30 led to the formation of well-dispersed nanocarbon particles 25 on the surface of the graphene sheets 30 . The in situ formed nanocarbon particles 25 can serve as spacers to prevent aggregation/restacking of the individual graphene sheets 30 in the dispersion during the drying process and form a particle-sheet structured GSNC 20 in the solid state. It is reasonably expected that the in-situ-formed composites 20 have more of a rich porous structure and large available surface area for the charge-storage process than those obtained by drying the pure graphene sheets 10 , in which the restacking of the graphene sheets 10 inevitably occurs. Typically, the sheets 10 are freeze dried, although other convenient drying techniques may be employed.
[0038] The nitrogen-adsorption and -desorption isotherms of the as-prepared GSs 10 with different nanocarbon content exhibited type IV characteristics ( FIG. 2 ), which are indicative of the presence of relatively large pores in the composites 20 . It is worth noting that the Brunauer-Emmett-Teller (BET) specific surface area of the graphene sheets without the addition of nanocarbons (77 m 2 /g) was much lower than the theoretical predictions for the isolated graphene sheets (2630 m 2 /g). With the increase in nanocarbon content in the composites 20 , the specific surface area also increased. The BET-specific surface area of the composites 20 with nanocarbon content of 1 wt. % reached as high as 1256 m 2 /g, which is much higher than that of the nanocarbons 25 (790 m 2 /g) and the pure GS 10 (77 m 2 /g). In further trials, the BET-specific surface area of the composites 20 with additional nanocarbon material 25 was observed to be up to 1875 m 2 /g, and values as high as 2000, 2100 and approaching the theoretical maximum are expected.
[0039] The large specific surface area suggests that the introduction of nanocarbon particles 25 between 2D graphene sheets 10 effectively limits the face-to-face stacking from about forty layers of graphene sheets 10 per stack to about two layers of graphene sheets 10 per stack when compared with that of dried pure GS 80 .
[0040] To further characterize the structure of the GSNCs 20 , the samples were examined using transmission electron microscopy (TEM) and scanning electron microscopy (SEM) ( FIGS. 3 and 4 ). For comparison, the TEM images of the reduced GSs 10 without nanocarbons 15 and the functionalized nanocarbons 25 ( FIGS. 3A and 3D ) are also presented. FIG. 3A shows that the pure GSs 80 prepared by chemical reduction 50 were transparent with some wrinkles visible under TEM. The morphology of functionalized nanocarbons 25 can be seen in FIG. 3B , which shows that the functionalized nanocarbon particles 25 were in the range of 5-30 nm, and that they tended to spontaneously agglomerate together to form large particles. The structure of the GSNCs 20 is shown in FIG. 3C , which clearly shows that the functionalized nanocarbons 25 were homogeneously anchored 75 onto the surface of the graphene sheets 30 ( FIGS. 3C and 3D ). Through further comparisons of FIGS. 3 A & 3 B with FIGS. 3C & 3D , it is clear that the graphene sheets 30 served as substrates to anchor 75 the hydrophilic nanocarbon particles 25 . Without the addition of the nanocarbons, it can be seen that the pure GS 80 was less transparent than the as-prepared GSNCs 20 , because the pure graphene sheet 10 spontaneously agglomerated/restacked back and formed a thick graphene sheet stack 80 (which has many more layers of graphene sheet than that of the GSNC 20 ) after drying. The GSs 10 in the composites 20 were almost transparent, which suggests that the GSs 10 were well separated by the nanocarbon particles 25 . The number of layers of graphene sheets 10 in the composites 20 was lower (typically about two layers of GS 10 , as suggested by BET data). Considering that sonication was used during the preparation of TEM specimens, the above observation also demonstrates the strong interactions/bonding between the nanocarbon carbon particles 25 and the graphene sheet 10 surface. The SEM images also clearly show the difference between the pure GS agglomerations 80 and the GSNCs 20 . The pure GSs 10 after drying tended to restack and form solid particles 80 ( FIG. 4A ). However, the layered structure can be seen clearly for GSNCs 20 , as the small nanocarbon particles 25 are highly dispersed on the graphene sheet 10 surfaces and served as spacers to prevent the graphene sheets 10 from restacking, which is consistent with the observed increased surface area of the graphene sheet/nanocarbon composites 20 .
[0041] Recently, GS agglomerates 80 have been used as electrodes for supercapacitors; for example, chemically modified GSs electrode active materials in supercapacitors have been found to exhibit a specific capacitance of 135 F/g and 99 F/g in aqueous KOH and organic electrolytes, respectively. GS specimens 80 having a measured surface area of 534 m 2 /g have exhibited a capacitance of 150 F/g under the specific current 0.1 A/g. Based on the structure of the GSNCs material 20 , the composite 20 likewise is expected to have good electron conductivity, low diffusion resistance to protons/cations, easy electrolyte penetration, and high electroactive areas. Such composites 20 are promising candidates for electrode active materials for supercapacitors 100 , yielding high performance energy storage devices.
[0042] The properties of these GSNCs 20 were measured using cyclic voltammetry (CV) and galvanostatic charge/discharge. The galvanostatic charge/discharge was used to calculate the specific capacitance of the GSNCs 20 . The CV curves ( FIG. 5A ) were nearly rectangular in shape, indicating a good charge propagation within the electrode. For the supercapacitor 100 using the activated carbon-based electrodes 105 , the CV curve shape and the specific capacitance significantly degraded as the voltage scan rate increased. In contrast, as the scan rate increased, the GSNCAs 100 base electrode 105 remained a rectangular shape with little variance, even at a scan rate of 200 mv/s ( FIG. 5 ). Another indication of good charge propagation is the low variation of specific capacitance with the increase of the charge/discharge current density as shown in FIGS. 5B and 5C . The capacitance of the GSNCs 20 was 256 F/g at a discharge current density of 1 A/g, and the capacitance was 218 F/g when the discharge current density increased to 5 A/g, leaving only a 14.8% loss with the 400% increase on the discharge current density. Therefore, the added nanocarbons played a very important role in the electrochemical performance of the composites. The high performance of the GSNC electrode materials 105 in the supercapacitor 100 from the high surface area of this composite 20 is quite beneficial.
[0043] The specific capacitance of the GSNCs 20 with different amounts of nanocarbons 25 at various current densities is shown in FIG. 5C for comparison. It is worth noting that the specific capacitance of the high surface area GS composites 20 was much higher than that of the pure GSs 80 , and the capacitance increased with the increase of the surface area. Hence, the increased surface area was responsible for the increase of the capacitance. The incorporation of nanocarbon particles 25 into the GSs 20 not only increased the surface area, but also acted as spacers between the graphene sheets 10 to create diffusion paths for the liquid electrolytes, which facilitated the rapid transport of the electrolyte ions, consequently resulting in the improved electrochemical properties of the GSNCs. Therefore, GSNCs 20 with a surface area of 1256 m 2 /g exhibited the maximum capacitance of 218 F/g at a current density of 5 A/g compared with pure graphene materials 80 with a capacitance of 46 F/g at the same current density, indicating that the unique structure of the novel GSNCs 20 facilitated the rapid transport of the electrolyte ions and electrons throughout the electrode 105 .
[0044] The simple process for preparing high surface area GSs 20 by simultaneously reducing the graphene oxide sheets 30 and the functionalized nanocarbons 25 is more particularly described below. This method is easily scaled up for the mass-production of high surface area graphenes 20 . The nanocarbon particles 25 are generally dispersed uniformly on the surface of the graphene sheets 10 , serving as spacers between graphene sheets 10 , and preventing the restacking of the GSs 10 after drying or removal of the solvent. Consequently, the GSNC surface area has been observed as high as 1875 m 2 /g. The unique structure of the GSNCs 20 facilitated the high-rate transportation of electrolyte ions and electrons throughout the electrode 105 , resulting in the excellent electrochemical properties. The supercapacitor 100 based on the GSNCs 20 exhibited a specific capacitance of nearly 400 F/g at a current density of 1 A/g in a 1M H 2 SO 4 solution. The specific capacitance increased with the increase of the composite surface areas. The new high surface area GS material 20 is also useful as a sorbent for hydrogen storage, as a catalyst support for fuel cells, and as a component for other clean energy devices.
Example 1
[0045] Synthesis of the graphene oxides (GO) and the functionalized nanocarbons: GO 30 was synthesized from natural graphite powder (325 mesh) by the modified Hummer method. The GO 30 was then suspended 110 in water to yield an opaque dispersion 60 , which was subjected to separation by centrifuge (five times) to completely remove residual salts and acids. The purified GO 30 was then dispersed 120 in purified water (0.5 mg/mL). Exfoliation 40 of the GO 30 was achieved by ultrasonication of the dispersion 60 using an ultrasonic bath. During the composite preparation process, the number of single layers in the GSs 30 as a precursor are typically controlled to be as small as possible. Graphite oxide is a layered material consisting of hydrophilic oxygenated GSs (graphene oxides) 30 bearing oxygen functional groups in their basal planes and edges. Under appropriate conditions, graphite oxides can undergo complete exfoliation in water, yielding colloidal suspensions 60 wherein the suspended material is composed almost entirely of individual graphene oxide sheets 30 .
[0046] For the preparation of the nanosized carbon particles 25 , the EC300 carbon blacks 15 were modified with an —SO 3 H grafted layer in an aqueous medium by spontaneous reduction 50 of the corresponding in situ generated diazonium cation. The modification of EC300 carbon blacks 15 was prepared with a large excess of in situ-generated diazonium cations. In this experiment, 2 g of EC300 carbon blacks 15 were placed in a 0.5 M HCl solution 125 containing 3.5 g of sulfonic acid. The solution 125 was vigorously stirred for thirty minutes before sodium nitrite was added. Next, 3.6 g NaNO 2 was added to the solution 125 in order to ensure a total transformation of the amine into diazonium in spite of the nitrogen oxide gas release. For the reaction to be finished completely, the mixture was stirred for four hours and then heated up to 70° C. for another three hours. Finally, the mixture was filtrated, washed with water, and re-filtrated three times.
[0047] Synthesis of the GSNCs: GSNCs 20 with different nanocarbon content were prepared by simultaneously reducing 50 the mixture of the graphene oxide sheets 30 and the highly hydrophilic nanocarbons 25 . Graphene oxide sheets 30 dispersed in water were mixed with the nanocarbons 25 . The mixture was stirred for thirty minutes and then subjected to ultrasonication for one hour at room temperature. Subsequently, a hydrazine solution was added into the mixture and the mixture was stirred and heat treated at 100° C. for 24 hours. Then the mixture was filtered and washed with purified water several times and dried at 60° C. for 24 hours in a vacuum.
[0048] Characterization of the composites: the morphology of the graphene sheets 10 , the nanocarbons 25 , and the GSNCs 20 were characterized by a transmission electron microscope. The morphology of the composites 20 was also examined by a scanning electron microscope. The specific surface areas of the graphene sheet 10 , the nanocarbons 25 , and the GSNCs 20 were measured by the Brunauer-Emmett-Teller (BET) method of nitrogen sorption at the liquid nitrogen temperature (77 K). Further, the composite materials 20 are stable at elevated temperatures and exhibit degradation or etching at the nanocarbon particle 25 sites.
[0049] Preparation and characterization of the supercapacitor electrode: A three-electrode-cell system was used to evaluate electrochemical performance using both cyclic voltammetry and galvanostatic charge/discharge techniques using an electrochemical workstation. A 1M H 2 SO 4 aqueous solution was used as the electrolyte. A platinum sheet and a saturated Ag/AgCl electrode were used as the counter and the reference electrodes, respectively. The working electrode 105 was prepared by casting a Nafion-impregnated sample onto a glassy carbon electrode with a diameter of 5 mm. Next, 17.5 mg of composite material 20 was dispersed by sonication for ten minutes in a 10 mL water solution containing 5 μL of a Nafion solution (5 wt. % in water). This sample (10 μL) was then dropped onto the glassy carbon electrode and dried overnight before electrochemical testing. The specific gravimetric capacitance was obtained from the discharge process according to the following equation:
[0000]
C
=
I
Δ
t
Δ
Vm
[0050] where I is the current load (A), Δt is the discharge time (s), ΔV is the potential change during the discharge process, and m is the mass of active material in a single electrode (g).
[0051] Graphene 10 is generally quite inert when exposed to gases such as oxygen and hydrogen at room temperature. At high temperatures, oxygen exposure can cause preferential etching at defects and edges because the carbon atoms at the defects and edges are extremely reactive (this is because the p z electrons of these carbon atoms may not be involved in the conjugated electron system). In a hydrogen atmosphere, the carbon atoms in the graphene bulk remain inert even at high temperatures. However, carbon atoms both at defects and at the edges of a graphene sheet become very active when a reactive metal is positioned proximate to these atoms. At high temperatures, Pt nanoparticles 150 may be used to etch graphene 10 through the catalytic hydrogenation of carbon, where carbon atoms on the graphene edges dissociate on the surface of Pt nanoparticle 150 and then react with H 2 at the Pt nanoparticle 150 surface to form methane. This process is shown schematically in FIG. 6 . In contrast, such etching does not occur on graphene materials at carbon black or like carbonaceous particle sites.
[0052] The mechanism of etching of graphene 10 by Pt nanoparticles 150 at elevated temperature was observed in-situ using high-resolution environmental transmission electron microscopy. Graphene sheets 10 were loaded with 20 weight percent of Pt nanoparticles 150 , and subsequently placed onto a lacey carbon TEM grid. The Pt nanoparticles 150 are typically sized between a few nanometers up to ten microns across, and may even be larger. More typically, the Pt nanoparticles are between about 5 and about 80 nanometers in diameter, although the Pt nanoparticles 150 may more typically range from about 10 nanometers to about 50 nanometers in diameter. The Pt nanoparticles 150 are typically generally spherical, but may exhibit other morphologies. Further, the nanoparticles 150 may be made of PT-like materials, such as PT, Pd, Ni, combinations thereof, and the like. Likewise, in this example, the graphene sheets 10 were loaded with 20 weight percent Pt nanoparticles 150 , but the nanoparticle loading may typically vary from less than about 1 weight percent to as much as 50 weight percent, or more. The graphene samples 10 were heated to 800° C. and hydrogen gas was slowly introduced into the TEM objective lens, and equilibrated at a pressure of approximately 50 mTorr. As the graphene 10 began to etch adjacent the Pt nanoparticles 150 , the process was imaged continuously through the use of a high-frame rate camera. Image sequences extracted therefrom are presented as FIG. 7A-7F . Initially, the Pt nanoparticles 150 were static after the hydrogen gas was introduced. Eventually, as shown in FIGS. 7A-7C , the Pt nanoparticles 150 began to react with the graphene 10 at defect sites and the hydrogen gas to produce methane. Only those carbon atoms making up the graphene sheet 10 that were in direct contact with these Pt nanoparticles 150 were able to participate in this Pt-catalyzed hydrogenation reaction 155 . Once the process was initiated, the conversion process was able to continue, as there are an abundance of defects sites created continuously following the onset of the etching process 155 , leading to a self-sustaining reaction. In this case a straight trench was etched through the graphene sheet 10 ( FIG. 7C ). In other cases, the etching process 155 did not follow a straight line, but rather followed a more tortuous pathway ( FIGS. 7D-7F ). During the graphene etching process 155 , the Pt nanoparticles 150 were observed to maintain a crystallographic relationship with the graphene sheet 10 . After etching 155 , the Pt nanoparticles 150 are typically reclaimed and saved for future use. These observations indicate that the interaction between the Pt 150 and the graphene 10 at elevated temperature can create a variety of in-plane nanostructures 160 in the graphene 10 . The result of these interactions is the formation of nanoscale trenches, ribbons and islands 160 —and thus a dense network of edge sites 165 .
[0053] Typically, the graphene sheets 10 are heated to a temperature sufficient for the etching process 155 to occur at a desired rate. The graphene sheets 10 carrying dispersed Pt nanoparticles 150 are typically heated to at least about 700 degrees Celsius, and are more typically heated to a temperature in the range from 750 degrees Celsius to 900 degrees Celsius. Likewise, a hydrogen gas environment supports the Pt-catalyzed hydrogenation reaction 155 , although other reducing environments may also be selected.
[0054] In graphene 10 , each carbon atom uses 3 of its 4 valance band (2s, 2p) electrons (which occupy the sp 2 orbits) to form covalent bonds with the neighboring carbon atoms in the same plane. Each carbon atom in the graphene 10 contributes its fourth lone electron (occupying the p z orbit) to form a delocalized electron system. Thus, the carbon atoms in the graphene plane 10 (excluding the carbon atoms on the defect sites such as the edges and holes) are saturated carbon atoms, with the three sp 2 electrons forming three covalent bonds and the fourth p z electron forming a π bond. Real time observations indicate that the heat treatment process creates an abundance of defective edges 165 , in the form of embedded nanostructures of trenches, ribbons and islands 160 in the multilayer graphene sheets 10 (see FIGS. 7 and 8B ). The resulting materials are anisotropic, having different properties in-plane and out-plane. Importantly, the carbon atoms along the edges of the resulting trenches, ribbons, and the islands 160 are likely to be unsaturated, with one of the electrons in the sp 2 orbitals not forming a covalent bond with the other carbon atoms. These unsaturated carbon atoms were observed not only from the nano-scale in situ TEM images/video ( FIG. 7 ), but also from the macro-scale XPS results in FIG. 9 , which shows an 42.4% increase of the shake-up peak for the graphene sheet 10 after etching 155 (the shake-up peaks correspond to the unsaturated carbon atoms/dangling carbons).
[0055] The resulting material provides an important platform for a wide variety of applications, including in catalysis, biomedical science, polymer science and energy science. This is because these unsaturated carbon atoms allow graphene 10 to be functionalized by chemically grafting other compounds or groups thereonto. Thus, these functionalized graphene 170 can be used, for example, sensors, catalysts, sorbents, and the like. Without such features, it is difficult to chemically graft compounds or groups onto graphene 10 . These unsaturated carbons also promote the establishment of weak bonding between graphene and other species. One such application is gas physisorption. Of particular interest is the physisorption of carbon dioxide. The p z electrons and one sp 2 electron of these unsaturated carbon atoms at the defects sites will be available for bonding and will more readily form bonds with CO 2 molecules, which could in turn result in a significant improvement in CO 2 adsorption. The adsorbed CO 2 molecules (or other gas molecules) may be stored for later removal or reaction.
[0056] While the novel technology has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character. It is understood that the embodiments have been shown and described in the foregoing specification in satisfaction of the best mode and enablement requirements. It is understood that one of ordinary skill in the art could readily make a nigh-infinite number of insubstantial changes and modifications to the above-described embodiments and that it would be impractical to attempt to describe all such embodiment variations in the present specification. Accordingly, it is understood that all changes and modifications that come within the spirit of the novel technology are desired to be protected. | A carbon composite material, including a plurality of spaced graphene sheets, each respective sheet having opposed generally planar surfaces, and a plurality of functionalized carbonaceous particles. At least some functionalized carbonaceous particles are disposed between any two adjacent graphene sheets, and each respective at least some functionalized carbonaceous particle is attached to both respective any two adjacent graphene sheets. Each respective graphene sheet comprises at least one layer of graphene and at least portions of respective any two adjacent graphene sheets are oriented substantially parallel with one another. | 8 |
[0001] This invention relates to plastic injection molds for producing internally and externally threaded components. More particularly, it relates to a mold assembly in which an electric motor very precisely controls the various rotational speeds and amounts of torque applied to cores which extend into the mold cavities as they are withdrawn from the plastic components being molded and simultaneously directs the linear distances which the cores travel during such withdrawal. A method of accomplishing the molding of plastic components in this manner is also disclosed.
BACKGROUND OF THE INVENTION
[0002] Heretofore, a variety of limitations have affected the molding of threaded plastic components. When a hydraulically powered rack was employed for extracting a metal core from a mold cavity, the number of threads which could be made on the inside or the outside of a component was limited because the number of threads was restricted by the number of rotations required for unscrewing the metal core from the component. The number of rotations which a core could make was dependent upon the space required around the mold to accommodate the length of the rack. Moreover, hydraulically powered equipment had problems of fluid spills and fluid leakage. Keeping an adequate supply of hydraulic fluid on hand was a limitation as well. In addition, halting a hydraulically driven rack's travel precisely was difficult to achieve, and the result was that substantial tolerances in the finished components were required. Also, because substantial mechanical movement was required for the rack, the speed of ejecting finished components was restricted.
[0003] Electric motors have been used in molding machine applications also. For example, U.S. Pat. No. 3,737,268, FIG. 12, illustrates the use of an electric motor for driving a shaft connected to a metal core with a threaded end inside a molded plastic component in order to turn and loosen the core and free it. In that patent, the core is moved rotationally by a belt-driven motor. A pair of ejector rods, powered by a second motor timed to cooperate with the first, are linearly moved to push the loosened component off the core.
[0004] Another patent illustrating the use of a pair of electric motors is U.S. Pat. No. 5,110,522. This patent relates particularly to an injection molding machine in which two motors are required for handling certain rectilinear and rotative drive requirements. Similarly, two motors are required for the rectilinear and rotative drives identified in U.S. Pat. Nos. 5,792,483 and 5,911,924.
[0005] U.S. Pat. No. 6,051,896 is an example of a patent which discloses the use of servo controlled electric motors in a molding machine. In that patent, one of the motors controls linear motion, and a second motor controls rotary motion. U.S. Pat. No. 6,142,760 is generally similar, as is U.S. Pat. No. 6,267,580.
SUMMARY OF THE INVENTION
[0006] The present invention incorporates a servo motor to drive one or more cores in an injection mold. In the new mold, the motor's engagement to one or more threaded end cores turns the cores at programmed speeds and at programmed torque to withdraw the cores from the components which have been molded around or into them. The motor continues to drive the cores in a programmed manner rectilinearly backwards and away from the mold cavities and from the components. Thereafter, as the mold is opened, the components are ejected, usually by pushing them out of the mold. To repeat the operation, the motor is reversed, and the threaded ends of the cores are moved back into their original positions in the cavities to be immersed again in or filled with plasticized molding material, depending upon whether the components being molded are internally or externally threaded.
[0007] Accordingly, in its first embodiment described below, this invention is incorporated in a mold assembly for forming a continuous internal thread inside a molded plastic element. A recess in a plastic injection mold, defined by internal walls inside the mold, forms the shape of the plastic article which one desires to make in the molding process. An end cap for a pipe is an example. A core is utilized which has a body portion with an externally threaded segment extending into the recess defined by the internal walls of the mold. The core also has a drive segment on the body portion spaced apart from the threaded segment. A drive member which has a drive portion complementary to and engaged upon the drive segment on the core is connected to a programmable electric motor. The motor is arranged to move the drive member programmed distances at programmed speeds. When the motor is activated, the drive portion on the drive member and the drive segment on the core cooperatively move the core through sufficient revolutions with any desired variations in speed to disengage the threaded segment from the plastic article within the recess by the end of the molding interval.
[0008] In an alternative embodiment, largely duplicative of the first embodiment just described, the body portion of a core has a segment having an aperture or pocket which is internally threaded extending into the cavity defined by the internal walls of the mold. A molded plastic component formed on such a segment of a core has external threads arranged on the outside of the component.
[0009] From the foregoing, and from what follows, it will be apparent that the present invention achieves numerous advantages over the molding processes and equipment which preceded it.
[0010] It is an object of the present invention to provide a mold assembly for producing internally or externally threaded plastic components which have very exact tolerances with rapidly repeatable precision.
[0011] It is also an object of the present invention to provide a mold assembly for producing internally or externally threaded components with threaded segments substantially longer than those which were obtainable with rack-driven cores.
[0012] It is also an object of the present invention to provide a mold assembly for producing an internally or externally threaded component which controls the rotary distance traveled by a core used in the molding process, the various speeds to be accomplished by the core, and the linear distances to be traveled by the core.
[0013] It is also an object of the present invention to provide a mold assembly for producing an internally or externally threaded component in which only one servo controlled electric motor is needed for both rotational and linear movement of a core.
[0014] It is also an object of the present invention to provide a mold assembly for simultaneously producing numerous internally or externally threaded components during the same molding interval utilizing several cores connected to the same servo controlled electric motor.
[0015] It is also an object of the present invention to provide a mold assembly for producing internally or externally threaded components having very exact tolerances in substantial quantities in a compact portion of the production space which is available.
[0016] It is also an object of the present invention to provide a mold assembly for producing internally or externally threaded components which does not utilize hydraulic fluids.
[0017] Other objects and advantages of the invention will be apparent to those skilled in the art of designing and using molds for threaded plastic parts from an examination of the following detailed description of preferred embodiments of the invention and of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a perspective view of part of a mold assembly embodying the present invention showing an electrical control component with its front cover panel partially open and cable connections arranged to extend from the component to the mold, and also showing a motor-carrying half of the mold with its inner face exposed and turned upwardly;
[0019] [0019]FIG. 2 is a perspective view of an enlarged portion of the mold assembly shown in FIG. 1 showing the control box door fully open;
[0020] [0020]FIG. 3 is a perspective view of the motor-carrying mold half shown in FIG. 1 and also including a perspective view of a second mold half complementary to and aligned for mating engagement with the motor-carrying half of the mold;
[0021] [0021]FIG. 4 is a perspective view of the motor-carrying half of the mold shown in FIG. 1 rotated approximately 180 degrees in the direction of arrow 4 in FIG. 1;
[0022] [0022]FIG. 5 is an elevational sectional view of the mold halves shown in FIG. 3 in assembled, mating engagement taken in the direction of and also along the line of arrows 5 - 5 shown in FIGS. 1 and 4;
[0023] [0023]FIG. 6 is an enlarged perspective view isolating some of the elements of the motor-carrying mold half shown in FIG. 1;
[0024] [0024]FIG. 7 is a perspective view isolating some of the elements of the motor-carrying mold half shown in FIG. 6;
[0025] [0025]FIG. 8 is a perspective view, partly broken away, of an enlarged portion of some of the elements shown in FIG. 7 in assembled relation with elements of the mold half shown in FIG. 1;
[0026] [0026]FIG. 9 is a perspective view, partly broken away, of an enlarged portion of some of the elements of the motor-carrying mold half shown in FIG. 7 taken in the direction of arrow 9 in FIG. 7;
[0027] [0027]FIG. 10 is a diagrammatic layout of the electrical control component of the mold assembly shown in FIG. 1;
[0028] [0028]FIG. 10A is an enlarged portion of the electrical layout shown in FIG. 10 taken along the line 10 A- 10 A in FIG. 10;
[0029] [0029]FIG. 11 is an enlarged perspective view of an internally threaded plastic component molded on the assembly shown in FIGS. 1 through 10;
[0030] [0030]FIG. 12 is an enlarged perspective view, partly broken away, of the component shown in FIG. 11, taken along line 12 - 12 in FIG. 11;
[0031] [0031]FIG. 13 is a perspective view, partly broken away, of an alternative form of the partially broken away element shown in FIG. 8; and
[0032] [0032]FIG. 14 is an enlarged perspective view of an externally threaded component molded on the element shown in FIG. 13.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] The preferred embodiments of this invention shown in the accompanying drawings will now be described, it being understood that the preferred forms are illustrative and that the invention described herein is embodied in the claims which are appended hereto.
[0034] One embodiment of this invention is the mold assembly 10 which is particularly depicted in FIGS. 1 and 3. The assembly includes a controls component 12 and a mold, one half of which is the motor-carrying mold half 14 , and the other half of which is the complementary mold half 16 (See FIG. 3). The latter is configured to sealingly engage the motor-carrying mold half 14 (See FIG. 5) in order to form one or more cavities 18 and 18 a inside the mold in which plastic articles such as the fitting 20 (See FIGS. 11 and 12) may be formed. In the embodiment of the mold assembly shown in FIGS. 1 and 3, the outer configuration of a molded fitting, such as the fitting 20 in FIGS. 11 and 12, depends upon the shape of the cavity 18 . The inner configuration, namely, the internally threaded portion 22 of the fitting 20 , depends upon the outwardly facing threaded surface 46 of the end segment 24 (or 24 a shown in FIG. 5) of a cylindrically shaped metal core 26 around which the molten plastic from which the fitting 20 is made is formed.
[0035] Alignment of the mold halves 14 and 16 as they are engaged upon each other, in order to form the cavities 18 and 18 a , is achieved by lodging engagement rods 16 A (on the mold half 16 ) in sockets 14 A in the motor-carrying mold half 14 , as shown by arrows 17 in FIG. 3. Such alignment is assured further by engaging male wedge member 15 A in female wedge members 15 B on the mold halves 14 and 16 , respectively, accompanied by engagement of pins 16 B on the mold half 16 in sockets 14 B in the motor-carrying mold half 14 .
[0036] As shown in FIG. 1, the motor-carrying mold half 14 has two motors, 28 and 30 . Each motor is similarly arranged so that each one is connected to and operates a set of four cores, as will shortly be explained in detail. The motors 28 and 30 are connected to their sets of cores in gear boxes 32 and 34 , respectively. The gear boxes 32 and 34 are mounted in mold frame members such as 36 and 38 . The frame members are, in turn, mounted on support rails such as are shown at 40 in FIG. 1, and those rails are attached to a clamp plate such as is shown at 42 in FIG. 1. The clamp plate is normally attached to a platen in a molding machine, neither one of which is shown here since such molding machine configurations, and how to operate them, are well known
[0037] Injection molding machines are designed to hold various molds, and also to open and close the mold halves. When the halves are closed, molten plastic materials are injected into cavities inside the molds so that the shape of the walls of the cavities, as well as any other formative shapes inside the cavities, can be transferred to the plastic material while it is in its liquid state. After the molten plastic material has been cooled and has frozen into the shape of the cavity walls and of the other shaping forms inside the cavities, the molding machines open and separate the mold halves so that the elements formed by the molten plastic can be removed or ejected from the mold. Usually the mold halves are arranged so that the separation plane between the halves is substantially vertical. Then, when the halves are separated, the plastic elements can easily drop into a bin below the mold when they are ejected from the mold cavities.
[0038] Accordingly, with respect to FIG. 1, it will be understood that a molding machine (not shown) operates a platen holding mold half 14 and another platen holding mold half 16 . The halves are moved apart when a cycle of the molding process for creating fittings 20 has been completed, and the fittings gathered from a bin or other receptacle into which they have been ejected. Thereafter, as further fittings are needed, the halves of the mold are moved together, closing the cavities so that molten plastic may be injected into them.
[0039] The cores 26 and 26 a are identical. Each core has an end segment 46 which extends into a molding cavity such as 18 or 18 a (See FIGS. 3,4, and 5 ). Inside each core a water-cooling tube 44 extends axially to carry cooling water into the end segments 46 of the cores at appropriate intervals during the molding interval when it is desired to cool the molten plastic which has flowed around the segments 46 . The tubes 44 are connected to unions 48 which carry cooling water from hoses 50 . Notably, the unions 48 , while stationary themselves, permit the tubes 44 connected to them in junctions such as 51 adjacent motor 28 to rotate around their longitudinal axes inside the cores so that the cores 26 which contain them can be rotated too. Tubes 44 a , unions 48 a and junctions 51 a adjacent motor 30 (See FIGS. 4 and 5) are identically constructed and perform the same way as tubes 44 , unions 48 and junctions 51 , respectively.
[0040] Each of the motors 28 and 30 may be connected to a set of four cores, such as illustrated in FIGS. 6 , 7 ,and 8 , or to more or less than that number, depending upon a variety of considerations such as the size of the motor, the type of molding material which is being used, and other molding parameters. As shown particularly in FIG. 6, the motor 28 is connected to the four cores 26 inside a gear box 32 .
[0041] [0041]FIG. 7 shows the internal arrangement of gear box 32 and how the cores 26 are connected to the motor 28 . The drive shaft 52 of the motor is connected to a worm gear shaft 54 that carries a worm gear 56 for each core 26 . On each core there is a worm wheel 58 forming part of a drive segment of core 26 which the worm gear 54 is engaged upon and drives. As detailed in FIG. 7, for example, each worm wheel 58 is connected to the core 26 which it is engaged upon by splines 60 arranged about the outside surfaces of the core 26 . The splines are cooperatively engaged between and against the walls 62 of an aperture 64 formed in the center of worm wheel 58 . The walls 62 forming the aperture 64 have land portions 66 and groove portions 68 which correspond to and matingly engage the outer configuration of the splines 60 and adjacent surfaces of core 26 . When the worm gear is activated and driven by motor 28 , worm wheel 58 is rotated by the worm gear, thus moving the walls 62 of the worm wheel and causing the core 26 to rotate. When there are a number of worm gears and corresponding cores, the cores are rotated in unison in response to the rotation of the worm gears by the motor.
[0042] The splines 60 may be machined on one end of the generally cylindrical steel body of a core 26 to form, along with the worm wheel, a drive segment of the core body. Alternatively, the splines 60 may be made separately and fastened in place on the core body by appropriately sized bolts or screws (not shown).
[0043] The radially outwardly facing surfaces 70 of the splines 60 are provided with threads 72 which are cooperatively engaged in threads 74 disposed in a wall of the gear box in which the core 26 is mounted. In the embodiment illustrated (See FIGS. 8 and 9) the threads 74 are arranged inside a ring 76 that is fastened with cap screws 78 and a locking ring 80 into a socket 82 formed in a wall of gear box 32 . The ring 76 is situated adjacent the drive segment of core 26 carrying the worm wheel 58 . Splines 60 and the adjacent surfaces of core 26 move slidably past the land portions 66 and groove portions 68 of aperture 64 in the center of worm wheel 58 when the core 26 is rotated, driven by motor 28 and directed by the cooperative engagement of threads 72 and 74 . Accordingly, as the core 26 is moved in a rotating manner by motor 28 , and the segment 46 of the core 26 is moved for any rotational distance, core 26 is simultaneously moved along the threads 72 and 74 by motor 28 in a linear direction.
[0044] Motor 28 may be programmed to change from one rate of speed to another during the linear and rotational movement of core 26 , and from one rate of torque to another, with corresponding changes to the linear and rotational responses in core 26 . Thus, when it is desired to turn the core 26 with high torque and low speed, or intermittently, as when loosening and unscrewing the core from inside a hardened plastic article being molded (such as fitting 20 ), the motor may be directed by a program to operate in that manner. After the core has been loosened from the inside of the article, and it is desired to move the core 26 out of and away from the plastic article more rapidly in a linear direction, the motor 28 can be programmed to adopt a new speed and torque. The change may be made, if desired, without interrupting the continuous rotation of the core. In this assembly, the movements of the core are very precisely controlled, both linearly and rotationally, so that core movements can be limited to specified thousandths of an inch.
[0045] It will be apparent immediately to those skilled in the art of designing mold assemblies of this general type that the distance which a rack would have to travel, in a straight line pathway away from the mold, in order to equal the rotational distance traveled by a given point on the threads 72 and accomplish a specified number of rotations of core 26 would require a lengthy open space or vacant runway in a molder's plant. Such movement of a rack is not practical, even if it were possible, when a substantial number of threads are desired inside a molded plastic component which would require a large number of core rotations in order to back out of the component. In the present invention, using the motor-driven threaded splines the core can be rotated many times without taking up plant space, and consequently a longer threaded segment at the end of the core can be employed, resulting in more threads and longer threaded portions in the plastic articles being molded.
[0046] The over-all assembly 10 of the present invention is substantially illustrated in FIGS. 1 and 2. The motor-carrying half 14 of the mold has also been described with particularity above. In the embodiment referred to, the cores 26 include an externally threaded end portion 24 for forming an internally threaded component such as the component 20 shown in FIGS. 11 and 12. The present invention is also adapted to produce an externally threaded component such as the component 150 shown in FIG. 14.
[0047] A core 160 is illustrated in FIG. 13 for forming component 150 . The core 160 is rotated and linearly moved in a manner and by a physical arrangement identical to the manner and physical arrangement for simultaneously moving core 26 rotationally and linearly. However, the end portion of core 160 which extends into a mold cavity such as cavities 18 and 18 a is provided with a central aperture 164 arranged longitudinally along axis 166 and extending into the end portion 162 of core 160 . The walls 168 of the aperture 164 are provided with a thread-forming helical groove 170 for forming an external arrangement 172 of threads on the outside of component 150 . If an area without threads is desired, such as segment 174 on the end of component 150 which might be used as a cap on the finished component, a portion of the walls 168 (such as the end portion 176 ) is not formed with a helical groove 170 .
[0048] Turning now to a particular description of the assembly controls which may be used with cores formed like core 26 or like core 160 , it may be noted that the motors 28 and 30 (See FIG. 1) are connected by cables 84 to the controls component 12 . Component 12 is powered from any convenient source (See FIG. 6, for example) through cable 86 . In the component 12 which is illustrated, a box 88 contains the electrical controls for the mold. A door 90 hinged to the box 88 carries a variety of switches for the component 12 . The illustrated arrangement of the contents of box 88 may be rearranged in any order or container. For example, control component 12 could be integrated into the molding machine. However it is collected and assembled, preferably it includes the following elements.
[0049] There is a motor selector switch 92 which singles out which motor on the mold is to be activated, or it may also be used to designate which combination of motors to activate. The mold illustrated here only includes the two motors 28 and 30 , but it will be recognized that further motors and the cores associated with them in the manner described above may be used without departing from the scope of this invention. Switch 94 is the on/off switch to the motors.
[0050] Motors 28 and 30 are reversible motors. When one or the other or both of them are driven in one direction to a maximum “in” position, they position the threaded segment ends of the cores which they respectively control, through the drive shaft, worm and worm wheel rotation, in a maximum “in” position within the cores' respective mold cavities. Similarly, when the selected motors are driven in the opposite direction to a maximum “out” position, they put the ends of the cores adjacent the splines 60 , through drive shaft, worm gear and worm wheel rotation in the opposite direction, in a maximum withdrawal position from the cores' respective mold cavities. A positioning switch 96 directs the selected motors to locate their respective cores at any desired position between maximum “in” and maximum “out.” Switch 98 may be set to always return the cores to a “home” position (usually maximum “in”) so that they begin each molding cycle at a preselected starting point and produce a series of products, such as fitting 20 , having very uniform specifications.
[0051] A fourth switch, numbered 100 and located on door 90 , is provided to turn the selected motors on or off, and an indicator light 102 is provided to let an operator know that the core controls have or have not been activated. The master on/off switch to the control component 12 is shown at 104 . Cabinet door 90 is usually latched or locked in a closed position by a lock or handle 106 .
[0052] [0052]FIG. 2 illustrates the inside of the controls component 12 . Housed in the cabinet side of control box 88 are amplifiers 108 and 108 a which contain program modules controlling the movements of the cores. In particular, amplifier 108 controls motor 28 , and amplifier 108 a controls motor 30 . The program modules 109 (for amplifier 108 ) and 109 (for amplifier 108 a ) hold and transmit the programs for the motors, i.e., starting, stopping, changing speeds at specified times and intervals, and similar motor movements pursuant to programmed commands. These, in turn, control the movements of the cores, including their disposition on or adjacent to the components which are being molded. A terminal strip 110 distributes the electrical commands of the programs from the program modules 109 and 109 a and amplifiers 108 and 108 a to signal delay timers 114 . The timers 114 are also connected to the molding machine servicing the mold halves 14 and 16 , and they regulate signals from the amplifiers for the motors to stop, start or otherwise move the cores according to programmed commands. Electrical signals to the motors 28 and 30 are carried from the control component 12 through motor cables 116 and 116 a.
[0053] A diagrammatic layout of the contents of the control component 12 is shown in FIGS. 10 and 10A. The motors 28 and 30 are supplied from a 240 volt three phase line brought to the site and into the box 88 through cable 86 . In FIG. 10, the main power input, which is fused, is shown at 118 . From the main input 118 , power is supplied to the control functions 108 and 109 , and their counterparts, for motors 28 and 30 , respectively, through fused interconnects 120 (to motor 30 ) and 122 (to motor 28 ), through a 24 volt power supply 124 , and through terminal strip 110 . The connections for motor 28 duplicate those for motor 30 and are not shown in FIG. 10 simply for the purpose of avoiding visual confusion. The terminal strip 110 is primarily an organizing element to keep order among and to follow the conductors inside control component 12 . Such a strip may be as long as the unit shown in FIGS. 10 and 10A, or longer or shorter, depending mainly upon the number of motors utilized in the mold. The several inputs on the terminal strip 110 to motor 28 are shown as switches in FIG. 10A numbered 1 , 2 , 3 , 4 , 5 and 6 , and the inputs on the terminal strip 110 to motor 30 are shown as switches numbered 11 , 12 , 13 , 14 , 15 and 16 . The power-on light for motor 28 is shown as L 1 in FIG. 10A, and the power-on light for motor 30 is shown in that Figure as L 2 . A drive selector is shown as switch 45 , and the switches connecting the internal power supply to the molding machine are designated +24. Power for the various control functions is supplied through switches numbered 0 at the right end of terminal strip 110 in FIG. 10A. The motors 28 and 30 may be selectively operated to stop, start, move to a “home” position, and may be operated to withdraw the threaded molding segments of the core members at various speeds partially or completely from their respective molding chambers utilizing the channels of power connections established through the terminal strip.
[0054] It is evident from the foregoing disclosure that even though particular forms of the invention have been illustrated and described, still, various modifications can be made without departing from the true spirit and scope of the invention. Accordingly, no limitations on the invention are intended by the foregoing description of its preferred embodiments, and its scope is covered by the following claims. | A plastic injection mold assembly is disclosed in which an electric servo motor very precisely controls rotational speeds and amounts of torque applied to cores which extend into the mold cavities as the cores are withdrawn from plastic components being molded and simultaneously directs the linear distances which the cores travel during such withdrawal. A method of accomplishing the molding of plastic components in this manner is also disclosed. | 1 |
RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 10/395,608, filed on Mar. 24, 2003, entitled “Mortarless Wall Structure,” and published as US Publication No. 2003/0188497 on Oct. 9, 2003 which is a continuation in part of application Ser. No. 10/015,052, filed Dec. 11, 2001, entitled “Mortarless Wall Structure,” and issued as U.S. Pat. No. 6,691,471 on Feb. 17, 2004, which is a continuation in part of application Ser. No. 09/547,206, filed Apr. 12, 2000, entitled “Skirting Wall System,” and issued as U.S. Pat. No. 6,374,552 on Apr. 23, 2002. This application is also a continuation in part of application Ser. No. 10/363,999, filed Apr. 12, 2001, entitled “Mortarless Wall Structure,” and published as US Publication No. 2004/0006945 on Jan. 15, 2004, which is a continuation in part of application Ser. No. 09/547,206, filed Apr. 12, 2000, entitled “Skirting Wall System,” and issued as U.S. Pat. No. 6,374,552 on Apr. 23, 2002. This application also claims priority to PCT application Serial No. PCT/US01/11957 filed on Apr. 12, 2001, entitled “Wall Structure,” and PCT application Serial No. PCT/US00/25791 filed on Sep. 20, 2000, entitled “Wall Structure,” and all of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to decorative and structural blocks designed to be installed as exterior and interior walls for buildings. More particularly, the present invention relates to a system that uses specifically designed and manufactured masonry blocks that are used in conjunction with specifically designed support beams and/or brackets to provide durable, attractive, easy to assemble surfaces to a wide variety of buildings, structures, and structural elements.
BACKGROUND OF THE INVENTION
[0003] Transportable structures such as mobile homes, trailer homes, modular homes and recreational vehicles, by their very nature, are usually not intended to be built upon a conventional foundation. Rather, they are brought or driven to a location where they may remain for indeterminate periods of time. Often, over an extended period at a particular site, such structures may start to settle differentially onto or in the ground due to factors such as deflating tires or local variations in soil bearing capacities. Additionally, factors such as erosion and freeze-thaw cycles may also cause such structures to shift and/or tilt. In order to prevent such unwanted movement and ensure that a structure is level regardless of the ground's topography, the structures are often placed on stilts that extend from the structure or upon piles that extend from the ground, or even on isolated footings that distribute the weight of a structure over a relatively large surface area. While this solves the aforementioned problem of shifting/or sinking it often results in an unsightly visible gap in the area between the ground and the bottom of the structure.
[0004] Various attempts to cover the unsightly gap have included the use of plants, natural material such as rocks and wood and manmade products such as cement, masonry and plastics. These attempts have proven to be either prohibitively expensive, difficult to install and/or disassemble, or unattractive and unable to withstand sustained exposure to nature's elements. Attempts that tend to be prohibitively expensive or difficult to install include, for example, wall structures constructed of large, custom-made, cement slabs having decorative faces, and standard masonry blocks held together with mortar. Attempts that fall into the latter category include such relatively fragile and easily breakable products as wooden or plastic lattices, and synthetic panels designed to simulate stones or bricks.
[0005] Consequently, there is a need for an easy to assemble and/or dissemble, lightweight and sturdy, inexpensive wall structure for covering the gap between the ground and an elevated structure such as a mobile home.
[0006] In other applications, where brick, stone, or concrete is used as veneer or fascia, for fencing, and as load-bearing and non load-bearing walls, etc., these structures are constructed with an eye towards permanence. That is, the structures are not meant to be easily dismantled. This means that the component parts are often able to interconnect with each other and/or with a support framework in some fashion. This usually entails the use of robust connections such as mechanical fasteners, adhesives, cement, or the like. For example, many types of veneers are typically coated with adhesive or cementitious material to enable them to be securely and directly bonded to a structure. Or, as another example, walls may be constructed in a conventional manner with blocks and mortar.
[0007] Alternatively, wall structures may comprise heavy, interlocking blocks that rely on size and weight to achieve some measure of permanence. As one may well imagine, each of the aforementioned structures would be difficult and time consuming to reconfigure, remove, or repair should the need arise. And while the construction of some of these structures typically requires specialized knowledge, skills, and tools to achieve, it will be appreciated that disassembly may require other, additional specialized knowledge, skills, and tools to achieve. In light of these shortcomings, there is an additional need for a wall structure that may be easily assembled, disassembled and rebuilt or reconfigured by an unskilled user without damage to the constituent parts of the wall structure and which may be used as a veneer, fascia, cladding, fence, or as a load-bearing or non load-bearing wall.
[0008] The present invention provides a solution to these needs and other problems, and offers other advantages over the prior art.
SUMMARY OF THE INVENTION
[0009] Generally, the present invention provides a system by which structures may be provided with durable, easy to assemble externally facing surfaces, which are generally vertical and which may be used in a wide variety of applications. The system utilizes a series of particularly configured blocks that may be operatively connected to the structures by beams and/or brackets. One embodiment of the present invention provides a block wall system for use in skirting elevated structures. The blocks are shaped to be stacked in vertically independent, self-supporting columns, strengthened and linked together by specially shaped, lightweight, lateral support beams positioned between adjacent columns, and which may be stabilized by one or more inverted u-shaped brackets which are attached at or near the bottom of an elevated structure. In an alternative embodiment, a u-shaped bracket is provided with an arm that is rotatably attached thereto and which is movable into a position that facilitates attachment to a generally vertical surface. In another embodiment, the blocks are configured so that lateral support beams may be positioned not only between adjacent columns but also at intermediate positions along the block as well. In another embodiment, the lateral support beam is configured so that it can be movably coupled to a bracket, which may be attached to an existing structure.
[0010] One embodiment of the block comprises a front face, a rear face, top and bottom surfaces, and side surfaces, and each side surface includes an outwardly opening, vertically oriented groove for receiving a portion of a support beam. The top and bottom surfaces are configured to facilitate a stacking relationship between adjacent courses of blocks such that they are generally coplanar. This relationship is most easily achieved by making the top and bottom surfaces substantially collateral, planar and relatively perpendicular to rear and/or front faces. Another embodiment of the block includes the provision of externally formed channels that are configured and arranged to prevent moisture from forming and collecting at the rear face of the block. Another embodiment of the block includes at least one through hole or aperture that is substantially aligned with outwardly opening, vertically oriented grooves in the side surfaces of a block. As will be explained later, the through holes or apertures facilitate use with support beams in a variety of applications. Another embodiment of the block has viewable surfaces or facings that are angled with respect to each other and which facilitate the formation of closed structures.
[0011] One purpose of the beams is to keep vertically stacked, self-supporting columns of blocks from buckling when subjected to a force normal to the plane of the column. This strengthening is accomplished providing the beams with lateral extensions or ribs that are configured to be received in aligned grooves at the sides of the vertically stacked blocks. Another purpose of the beams is to link adjacent columns of blocks together in a colonnade-like arrangement to form a wall structure. This is also achieved with the aforementioned lateral extensions and grooves. As may be expected, the beams provide very little, if any, support in a vertical direction. The columns so constructed are considered independent because, unlike conventionally constructed masonry or stone walls, the joints between adjacent blocks are in alignment with each other rather than being offset as in a running bond. This enables the columns of blocks to move up and down relative to each other, without appreciably altering the inherent continuity of a wall structure. As will be appreciated, the rigidity of the blocks provides enough support to prevent a column from failing in the vertical direction. When a more robust wall structure is desired, blocks that have appropriately configured apertures and rearwardly facing slots may be stacked in a running bond arrangement and strengthened and linked together by support beams. Although the beams can be fabricated form a variety of materials such as metals and plastics, extruded aluminum, nylon, and polyvinyl chloride (PVC) are preferred.
[0012] It will be appreciated that the use of the lateral support beams also eliminates and/or substantially reduces the need for mortar to stabilize and unify the blocks. This wall structure system is advantageous over traditional brick and mortar walls for obvious reasons. First, fewer materials are required to build a wall. Second, the materials are easier to handle and manipulate, and no special tools or skills are required. Third, a wall can be constructed under conditions that would not be possible using traditional brick and mortar construction and a person need not be concerned about time constraints imposed by drying mortar. Fourth, the joints formed between adjacent blocks allow the wall to appear monolithic or seamless at a surprisingly close distance. Moreover, by providing blocks that have had their marginal areas modified, it is also possible to create walls that have the appearance of conventional block and mortar construction. Fifth, the block wall system can be constructed on a variety of surfaces, including sand, gravel, dirt, or building elements such as H-beams, flooring, base blocks, etc. It is not necessary to pour a foundation.
[0013] The lateral support beams also allow the blocks to be substantially thinner than conventional masonry blocks. These thin, lightweight blocks are not only easier to handle and ship, but require less material and time to fabricate. The blocks are generally about 1 to 4 inches (2.5-10 cm.) thick, about 6 to 12 inches (15-30 cm.) in height and about 6 to 24 inches (15-60 cm.) in width, and preferably have a thickness on the order of around 2 ½ inches (6.0 cm.). As one may appreciate, the combination of the thin blocks and the support beams facilitates construction of masonry wall structures in locations and configurations that were heretofore not possible using thin blocks alone. The resulting wall structure of this system is surprisingly strong and it may even be used to provide support to an elevated structure. When a wall structure is installed about an elevated structure, such as a portable home, the elevated structure may be lowered onto the blocks of the wall. Alternatively, the block wall system may serve as a skirt, which improves the aesthetics of the structure and keeps animals, litter, snow, etc. from intruding or being otherwise introduced beneath the structure. Or, the block wall system may be used with existing structures such as elevated decks and retaining walls. With these embodiments, it is not necessary that the blocks make actual contact with the structure.
[0014] The block wall system also allows the wall to be easily disassembled and reassembled. This not only gives flexibility during initial construction, but also allows later renovations to be made quickly and inexpensively. For instance, it may be desirable or required to vent elevated structures having skirting walls, to prevent the buildup of moisture or condensation between the ground and the elevated structure. Such vents can be easily installed into an existing wall, especially if they are of similar dimensions and configurations as the blocks. The blocks of a given column are simply removed and reinstalled, replacing one of the blocks with the vent. Other auxiliary items, such as an access door or lights, could be installed in a similar manner.
[0015] The wall block system of the present invention is not confined to linear structures. As will be appreciated, the system also allows walls to intersect to form angled or closed structures. In one embodiment, two intersecting walls are simply aligned to form a butt joint and fasteners such as pegs, or screws, and plastic inserts are used to fasten one wall to the other. Alternatively, construction mastic, or a similar type of adhesive, may be applied instead of or in combination with the abovementioned fasteners. In another embodiment, blocks are preformed as angled intersecting wall units that have been provided with outwardly opening, vertically oriented side grooves configured to receive portions of support beams, which may be further linked to other wall blocks as described above. As will be appreciated, such blocks may be combined together to form hollow columnar structures, or may be used to clad an existing structure such as a support post. Again, ease of installation is greatly improved by the block wall system of the present invention.
[0016] Another embodiment of the wall structure uses a differently configured bracket than the aforementioned u-shaped bracket. It, too, is used to operatively connect the wall structure to a support. The bracket of this embodiment, however, attaches in a slightly different manner than the u-shaped bracket. Instead of straddling the upper portion of a top-most block as with the u-shaped bracket of the aforementioned embodiment, this bracket has one end that is configured to be positioned within space defined by opposing vertical grooves of adjacent blocks. That is, the bracket is designed to be installed at or near the sides of a column. The other end of the bracket is configured to be attached at or near the bottom of a structure. An advantage with this bracket it that it is able to provide support for the wall structure in two directions, while allowing movement of wall components relative thereto in a third direction. As will be appreciated, this bracket may be easily installed and removed without the need for special training or tools. Preferably, the bracket of this embodiment is L-shaped, although it is envisioned that other shapes are possible. For example, the bracket may be linear, or it may be linear and have an axial twist in it. Or, the structure-engaging portion may be provided with a u-shape or even its own integral fastener.
[0017] An assembly of blocks may be operatively connected to a support using yet another embodiment of the wall skirting system. With this embodiment, the support beam is configured to be movably coupled to one or more brackets that, in turn, may be attached to the support. This allows the beam to move relative to the bracket(s) without sacrificing the strength of the assembled blocks, and also allows the beams to be connected to the structure at different locations along its length. For example, at the top, at the bottom, or anywhere in between. As will be understood, in order for the support beam and bracket to operate in such a constrained manner the bracket(s) need to be configured so that they are able to slidingly retain the beam. Thus, differently configured beams may require specially configured brackets.
[0018] In another embodiment of the block wall system, blocks are operatively connected to a structure with one or more brackets, which are configured to be able to engage the side grooves of adjacent blocks, and which may be directly attached to the structure. As will be appreciated, the brackets of this embodiment will permit the blocks to move relative thereto, but not to the degree that is available with the aforementioned support beam and bracket combination. As with the aforementioned support beams, the brackets can be fabricated form a variety of materials such as metals and plastics. However, steel, extruded aluminum, nylon, and polyvinyl chloride (PVC) are preferred.
[0019] It will be appreciated that wall structures other than linear structures are possible. For example, support beams and blocks may be used to construct circular, or sinuous structures by providing curved blocks or blocks with one curved viewable surface (when viewed cross-sectionally from a point above the top surface of the block) that are operatively connected to support beams that are similarly arranged. Alternatively, a wall structure may be constructed in a zigzag or erose form with the support beams collaterally arranged relative to each other in a zigzag manner. To reduce vertical gaps between forwardly facing viewable surfaces of adjacent blocks in such a wall structure, it would be a matter of providing support beams with ribs that are angled with respect to the web and mitering or beveling the opposing sides of the blocks, or using a combination of both angling and mitering the ribs and sides, respectively. A similarly configured wall may also be constructed using support beams arranged in a coplanar or staggered fashion relative to each other and blocks having a predetermined, angular viewable surface (when viewed cross-sectionally from a point above the top surface of the blocks). For example, a “V”, “L”, or a “W”. Such blocks may have parallel front and rear faces, if desired. With such a construction, neither the support beams nor the opposing fingers need to be modified. In a related construction, it is envisioned that blocks be constructed having angles of ninety degrees so that they may be used as inner or outer corners. With such blocks, the opposing sides and their fingers would be perpendicular to each other.
[0020] In one method of constructing a freestanding, low wall structure of the present invention, a person would prepare or otherwise select an appropriate location in which to construct a wall. The construction would begin by placing a first block having opposing side grooves in a desired position and orientation. Then, a second, similar block would be placed directly on top of the first block so that the opposing side grooves of the first and second blocks are in vertical alignment with each other and the first and second blocks form a column. Next, the first and second blocks would be operatively connected to each other along their respective sides by inserting at least one rib of first and second support beams into the aligned grooves of the respective sides of the first and second blocks and seating them securely. A second column comprising similarly configured third and a fourth blocks may now be constructed. The operation is much the same, except now the third block is positioned so that one of its sides is adjacent to one of the sides of the first block and its groove engages at least one other rib of one of the already positioned support beams. The fourth block is then positioned on top of the third block in a similar manner. That is, the fourth block is positioned so that one of its sides is adjacent to one of the sides of the second block and its groove engages at least one other rib of one of the already positioned support beam. After the second column is erected, the third and fourth blocks would be operatively connected to each other along their respective free side by inserting at least one rib of a third support beam into their aligned vertical groove of the respective sides of the first and second blocks and seating them securely. And so on.
[0021] Another, alternative method of constructing a wall structure of the present invention according to the present invention would be as follows. A person would prepare or otherwise select an appropriate substructure on which to construct a wall structure. The construction would begin by operatively connecting a first elongated support beam to the substructure. Then using the first support beam as a reference, a series of additional support beams would be operatively connected to the substructure, with all of the support beams in vertical and collateral alignment, and with the distance between adjacent support beams sufficient to enable the ribs of adjacent beams to engage opposing side grooves of a block. Once the dimensions of the wall structure have been established, the blocks with opposing side grooves may be positioned by sliding the blocks along the length of and between adjacent support beams. This may be done course by course, column by column, or in a mixture of both columns and courses, as desired.
[0022] In a variation of the aforementioned methods of construction, a person would begin by operatively connecting a first elongated support beam to the substructure in a vertical orientation. Then a first block having opposing side grooves would be placed in a desired position and orientation against the first elongate support beam so that at least one of the ribs of the first beam is seated within one of the side grooves of the block. Then, a second, similar block would be placed directly on top of the first block so that the at least one rib of the first beam is also seated within one of the side grooves of the second block so that the opposing side grooves of the first and second blocks are in vertical alignment with each other and the first and second blocks form a column. Next, the first and second blocks are operatively connected to each other along their other respective sides by aligning the grooves of the respective sides of the first and second blocks, and inserting at least one rib of a second support beam into the aligned grooves and seating it securely therein. After the second support beam is seated, it is attached to the substructure. A second column comprising similarly configured third and a fourth blocks may now be constructed. The operation is the same, with the third block positioned so that one of its sides is adjacent to one of the sides of the first block and its groove engages another rib of the already positioned second support beam. The fourth block is then positioned on top of the third block in a similar manner. That is, the fourth block is positioned so that one of its sides is adjacent to one of the sides of the second block and its groove engages another rib of the already positioned second support beam. After the second column is erected, the third and fourth blocks would be operatively connected to each other along their respective free side by aligning the grooves of the respective sides of the third and fourth blocks, and inserting at least one rib of a third support beam into the aligned grooves and seating it securely therein. After the third support beam is seated, it is attached to the substructure. And so on.
[0023] Additional advantages and features of the invention will be set forth in part in the description which follows, and in part, will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a partial, perspective view of two embodiments of the block wall system, with one preferred embodiment of blocks arranged below an elevated first (upper level) deck structure and another embodiment of blocks arranged about the perimeter of an adjacent, elevated second (lower level) deck structure;
[0025] FIG. 2 is a partial, exploded, perspective view of the block arrangement below the elevated first (upper level) deck structure of FIG. 1 ;
[0026] FIG. 2 a is a top plan view of the block arrangement of FIG. 1 , taken generally along lines 2 a - 2 a;
[0027] FIG. 3 is a side elevational, cross-sectional view of the block arrangement about the perimeter of the elevated second (lower level) deck structure of FIG. 1 taken generally along lines 3 - 3 ;
[0028] FIG. 3 a is a partial, side elevational, cross-sectional view of an alternative support for the block arrangement of FIG. 3 ;
[0029] FIG. 4 is a perspective view of an elevated structure skirted with an embodiment of the blocks of the present invention arranged in a wall structure;
[0030] FIG. 5 is a side elevational view the wall structure of FIG. 4 taken generally along lines 5 - 5 ;
[0031] FIG. 6 is a partial, perspective view of an embodiment of blocks arranged to provide a facia wall for a retaining wall;
[0032] FIG. 6 a is a partial, side elevational, cross-sectional view of the block arrangement of FIG. 6 taken generally along lines 6 a - 6 a;
[0033] FIG. 7 is a perspective view of another embodiment of a block of the present invention;
[0034] FIG. 7 a is a perspective view of another embodiment of a block of the present invention;
[0035] FIG. 7 b is a bottom plan view of the block of FIG. 7 a;
[0036] FIG. 8 is a partial, cross-sectional, plan view of an embodiment of a corner construction of a wall structure of the present invention;
[0037] FIG. 9 is a perspective view of another embodiment of a block of the present invention;
[0038] FIG. 10 is a bottom plan view of the block of FIG. 9 ;
[0039] FIG. 11 is a partial, perspective view of an embodiment of a support beam of the present invention;
[0040] FIG. 11 a is a partial, perspective view of an alternative embodiment of a support beam of the present invention;
[0041] FIG. 12 is a partial, perspective view of an alternative embodiment of a support beam;
[0042] FIG. 13 is a partial, perspective view of an alternative embodiment of a support beam;
[0043] FIG. 14 is a plan view of an alternative embodiment of a block engagement portion of a vertical support beam similar to that of FIG. 11 a, with the remainder of the support beam shown in phantom;
[0044] FIG. 15 is a plan view of an alternative embodiment of a block engagement portion of a support beam similar to that of FIG. 11 a, with the remainder of the support beam shown in phantom;
[0045] FIG. 16 is a partial, perspective view of an embodiment of a support beam of the present invention;
[0046] FIG. 17 is a partial, perspective view of another embodiment of a support beam in conjunction with a bracket, with the bracket configured to be attached to a sub structure;
[0047] FIG. 18 is a partial, perspective view of another embodiment of a support beam in conjunction with another embodiment of a bracket, with the bracket configured to be attached to a sub structure;
[0048] FIG. 19 is a partial, perspective view of another embodiment of a support beam in conjunction with another embodiment of a bracket with the bracket configured to be attached to a substructure;
[0049] FIG. 20 is a partial, perspective view of an embodiment of a support beam having an integrally formed aperture and an integrally formed bracket, with the support beam able to be used with the support beam of FIG. 19 to construct/form a double sided wall structure;
[0050] FIG. 21 a partial, perspective view of another embodiment of a support beam;
[0051] FIG. 22 is a partial, top plan view, taken generally along lines 22 - 22 of FIG. 4 , of showing adjacent blocks of the present invention in conjunction with a support beam;
[0052] FIG. 23 is a partial, top plan view of the two blocks abutted with a support beam of FIG. 22 , but with the support beam arranged in an alternative configuration;
[0053] FIG. 23 a is a partial, top plan view of the blocks of FIG. 23 as they may be assembled into a wall structure, or as a wall structure is disassembled;
[0054] FIG. 24 is a partial, top plan view of two blocks, a support beam, and a support bracket that have been assembled into a wall structure;
[0055] FIG. 24 a is a partial, top plan view of a portion of the blocks, support beam, and bracket of FIG. 24 , as they may be assembled into a wall structure, or as a wall structure is disassembled;
[0056] FIG. 25 is a partial, top plan view of two blocks of the present invention in conjunction with an alternative embodiment of a support beam;
[0057] FIG. 26 is a partial, top plan view of two blocks of the present invention in conjunction with another alternative embodiment of a support beam;
[0058] FIG. 27 is a partial, top plan view of the support beams shown in FIGS. 12 and 13 in conjunction with blocks of the present invention;
[0059] FIG. 28 is a partial, top plan view of two blocks of FIG. 7 a that are operatively connected to the support beam of FIG. 11 a ;
[0060] FIG. 29 is a partial, top plan view of the support beam of FIG. 16 as it may be used to operatively connect blocks of the present invention to a substructure;
[0061] FIG. 30 is a perspective view of a wall structure construction using another preferred embodiment of support beams and blocks of the present invention;
[0062] FIG. 31 is a partial, top plan view of the support beam and bracket of FIG. 17 as they may be used to operatively connect blocks to a substructure;
[0063] FIG. 32 is a partial, top plan view of the support beam and bracket of FIG. 18 as they may be used to operatively connect blocks to a substructure;
[0064] FIG. 33 is a partial, top plan view of the support beam and bracket of FIG. 19 as they may be used to operatively connect blocks to a substructure;
[0065] FIG. 34 is a partial, top plan view of an alternative embodiment of the support beam of FIG. 21 as it may be used to operatively connect blocks to a substructure;
[0066] FIG. 35 is a partial, top plan view of the support beam of FIG. 21 as it may be used to operatively connect blocks to a substructure;
[0067] FIG. 36 is a partial, top plan view of the support beam of FIG. 20 and the support beam of FIG. 19 as they may be used to operatively connect differently sized blocks together in a dual-sided wall structure;
[0068] FIG. 37 is a partial, top plan view of the blocks of FIG. 7 in conjunction with another embodiment of a support beam, with the support beam operatively connecting the blocks to an existing structure;
[0069] FIG. 37 a is a partial, top plan view of the blocks of FIG. 7 in conjunction with another alternative embodiment of a support beam with the support beam operatively connecting the blocks to an existing structure;
[0070] FIG. 37 b is a partial, top plan view of blocks of FIG. 7 in conjunction with another alternative embodiment of a support beam with the support beam operatively connecting the blocks to an existing structure;
[0071] FIG. 38 is a partial, top plan view of a free standing dual wall structure wherein the respective walls of the wall structure are connected to each other in a spaced relation by an alternative embodiment of a support beam;
[0072] FIG. 39 is a partial, top plan view of blocks of FIG. 7 in conjunction with an alternative embodiment of the support beam of FIG. 20 , wherein the aperture is configured to received a post;
[0073] FIG. 40 is a partial, perspective view of an embodiment of a wall structure of the present invention and a preferred attachment bracket;
[0074] FIG. 41 is a perspective view of the attachment bracket of FIG. 40 ;
[0075] FIG. 42 is a side elevational view of the bracket of FIG. 41 attached to a lower surface of a structure, and as it may be attached to an upper surface of the structure (shown in phantom);
[0076] FIG. 43 is a perspective view if the attachment bracket of FIG. 41 as it may be used in conjunction with the support beam of FIG. 11 ;
[0077] FIG. 44 is an exploded, perspective view of an attachment bracket and the support beam of FIG. 11 a;
[0078] FIG. 45 is a rear perspective view of the attachment bracket and support beam of FIG. 44 after they have been operatively connected to each other;
[0079] FIG. 46 is a perspective view of an alternative embodiment of an attachment bracket suitable for use with a support beam as depicted in FIG. 11 a;
[0080] FIG. 47 is a plan view of the attachment bracket of FIG. 46 as it may be operatively connected to a support beam as depicted in FIG. 11 a;
[0081] FIG. 48 is a perspective view of an alternative embodiment of an attachment bracket having an arm that is rotatably connected thereto, and which is in a first position;
[0082] FIG. 49 is a perspective view of the attachment bracket of FIG. 48 in which the arm has been rotated to a second position;
[0083] FIG. 50 is a perspective view of an embodiment of an attachment bracket;
[0084] FIG. 51 is a partial, perspective view of a wall structure in which blocks of the present invention are operatively connected to a substructure by the vertically oriented support beams and brackets of FIGS. 2 and 2 a;
[0085] FIG. 52 is another partial perspective view of a wall structure in which blocks of the present invention are operatively connected to a substructure by horizontally oriented support beams and brackets of FIGS. 2 and 2 a;
[0086] FIG. 53 is a side elevation view of a block wall structure that is operatively connected to a structure;
[0087] FIG. 54 is an edge view of a sealing element that is used in the construction of the wall structure of FIG. 53 ;
[0088] FIG. 55 is a perspective view of the sealing element of FIG. 54 ;
[0089] FIG. 56 is an enlarged view of a portion of FIG. 53 , which depicts the sealing element of FIGS. 54 and 55 as it resides between structural elements;
[0090] FIG. 57 is a perspective view of an alternative embodiment of an attachment bracket for use in conjunction with blocks of the present invention;
[0091] FIG. 58 is a perspective view of an alternative embodiment of an attachment bracket for use in conjunction with blocks of the present invention;
[0092] FIG. 59 is a perspective view of an alternative embodiment of an attachment bracket for use in conjunction with blocks of the present invention; and,
[0093] FIG. 60 is a plan view of the brackets of FIGS. 57 and 59 operatively connecting blocks of the present invention to a substructure.
DETAILED DESCRIPTION
[0094] FIG. 1 illustrates several embodiments of the wall block system of present invention, as practiced with an elevated first (upper level) deck d 1 and an adjacent, elevated second (lower level) deck structure d 2 . The first embodiment is an elevated upper level deck structure d 1 , which is supported by a plurality of vertical posts that have been provided with an external sheathing of blocks that are operatively connected to the posts by support beams and brackets.
[0095] As depicted, the blocks used to sheath the post are angled blocks, such as depicted in FIGS. 2 and 2 a. The blocks, which are provided with grooves at their side edges, are configured to be operatively connected to a post by one or more support beams 716 , which will be discussed later in greater detail. As depicted, the support beams may be directly attached to the post. Alternatively, the blocks may also be operatively connected to the post by a support beam and a bracket 354 (see, for example, FIG. 2 a, which will be discussed later in greater detail), or by brackets alone (see FIGS. 57, 58 , 59 and 60 ). While it will be understood that a post sheathing will be relatively robust, it may be desirable to create a more permanent structure. This can be achieved, for example, by providing the horizontal and/or vertical edge surfaces of the blocks With a suitable adhesive 58 (vertical edge surfaces shown in phantom). Alternatively, the blocks may be secured by one or more circumferential bands of material (not shown).
[0096] Referring again to FIGS. 1, 2 and 2 a, it will be apparent that gaps may exist between the blocks and the post, and that moisture and debris may infiltrate the gaps from above, and/or between the joints between adjacent blocks. As will be understood, such infiltration may be substantially reduced by providing the sheathed post with cap stones, flashing gaskets or other construction elements that serve to effectively close the gaps from above. Infiltration reduction may also be achieved by providing the horizontal and vertical edge surfaces with caulking material.
[0097] The second embodiment of the block wall system of FIG. 1 depicts another application of the present invention, where blocks are used to skirt an elevated, lower level, second deck structure d 2 . In this application, the wall structure comprises several block embodiments. Starting from the left corner, the upper and lowermost courses comprise blocks that are similar to the corner blocks of FIGS. 2 and 2 a. The middle course, while it could comprise a block of FIGS. 2 and 2 a, is constructed using two linear blocks that are connected to each other by fastening element such as pins and/or adhesive material (see, for example, FIG. 8 ). Continuing towards the right, the next block embodiments, which will be discussed later in greater detail, are generally linear and as will be discussed later, configured to be operatively connected to the deck frame. Continuing on to the right corner, the arrangement of the blocks is similar to the arrangement of the blocks depicted at the left corner. The right corner differs, however, in that the corners formed by the blocks are not ninety degrees. Instead, the corner formed by the intersection of two walls is obtuse.
[0098] As will be discussed later in greater detail, the skirting structure blocks may be operatively connected to the deck frame in a manner similar to the previously discussed post sheathing. That is, through the use of support beams, support beams and bracket, or brackets. The wall structure depicted in FIG. 5 uses a support beam that is attached directly to the deck frame. As will be discussed later, the support beam serves to maintain and align a plurality of blocks. As depicted, the blocks of FIG. 5 are supported by a longitudinal L-shaped support bar that is also attached to the deck frame. With this operative connection, the blocks are not subject to external forces such as frost heave, and are generally static.
[0099] In the partial depiction wall structure of FIG. 5 a, the support beam is indirectly connected to the deck frame by one or more brackets. In this instance, the beam and bracket combination is similar to the beam and bracket combination of FIG. 2 a. This combination allows the beam (and blocks), which rest on a footing, to move in response to external forces such as frost heave. In this regard, the operative connection can be considered dynamic.
[0100] FIG. 3 is a perspective view of an elevated structure “S” skirted with a wall system 10 of the present invention. Generally, the wall structure 10 comprises of a plurality of blocks 12 forming columns 14 (see also, FIG. 4 ) partially spaced apart and held in place by vertically oriented, lateral support beams (see, for example, FIGS. 5, 11 , 22 , and 23 ). Downward opening brackets 18 (see FIGS. 5 and 22 ) that are attached to the bottom of the structure “S” being skirted, are configured to engaged the top block 12 of selected columns 14 to help prevent the wall structure 10 from tipping rearwardly or forwardly. As used herein, the term “forward” means away from the center of the elevated structure “S” and the term “rearward” means toward the center of the elevated structure “S”.
[0101] FIGS. 4 and 7 show an arrangement of blocks 12 that form a plurality of columns 14 . Referring particularly to FIG. 7 , each block 12 is generally panel-shaped and includes a front face 20 , a rear face 22 , a top surface 24 , a bottom surface 26 and pairs of side surfaces 28 a, 29 a and 28 b, 29 b, respectively. The side surface pairs 28 a, 29 a and 28 b, 29 b, respectively, are preferably somewhat perpendicular to the rear face 22 and/or the front face 20 . Side surface 28 a is spaced from side surface 28 b by a distance (taken along a “x” direction in a three-dimensional coordinate system relative to the blocks 12 ) to define a width 33 of the block 12 . Additionally, each pair of side surfaces 28 a and 29 a, 28 b and 29 b, include a substantially vertical groove 34 therebetween, which is configured to receive a portion of a lateral support beam 16 (See, for example, FIG. 11 ).
[0102] Note that while the top and bottom surfaces 24 , 26 of adjacent blocks 12 are configured to contact each other without thick layers of mortar or binding material therebetween, it is envisioned that the use of thin layers of intermediate materials, which may serve to strengthen and/or provide resistance to moisture may be practiced without departing from the spirit and scope of the invention. Moreover, it will be apparent that thin or no intermediate layers will minimize the spacing between blocks and allow the marginal areas 23 c, 23 d of adjacent blocks 12 to combine and simulate horizontally oriented splitting recesses.
[0103] As will be understood, the brackets 18 (see FIGS. 4 and 22 ) prevent rearward or forward movement of the column 14 and also work in conjunction with the beam 16 to prevent columns 14 not in direct contact with the bracket 18 from tipping over rearwardly or forwardly. It is envisioned that the beams 16 may be directly attached to the wall structure 10 (similar to FIG. 29 ) or alternatively, the bracket 18 may be solely responsible for preventing the wall structure 10 from tipping over. While it will be understood that the bracket 18 can be of any suitable material, synthetic, more preferably poly-vinyl chloride (PVC) or other durable plastic is preferred.
[0104] The bracket 18 comprises a front wall 44 , a rear wall 46 spaced apart from front wall 44 and a top wall 48 joining the front wall 44 to the rear wall 46 in a generally inverted “U”-shape. The front wall 44 and the rear wall 46 define an opening 50 , which is configured and arranged to receive an uppermost portion of the top block 12 of a column 14 . In practice, the bracket 18 is attached at or near the underside of a structure “S” to be skirted so that the opening 50 can receive the upper portion of the top block 12 of a column 14 . Preferably, the bracket 18 is positioned such that it may straddle the central region of an uppermost block 12 . It may be desired to make rear wall 46 of a greater vertical dimension than the front wall 44 to provide additional support. It may also be desired to provide a bracket 18 with a rear wall 46 , width that extends in a lateral direction further than the front wall 44 width. Furthermore, it is envisioned that the bracket 18 can be formed into a variety of lengths. For instance, the bracket 18 can be as short as one inch or as long as the entire skirted structure “S”.
[0105] While the top wall 48 of the bracket 18 is depicted in FIG. 4 as being in contact with the top surface 24 of the uppermost block 12 of the column 14 , it should be understood that this need not always be the case. In situations where the wall structure 10 is not a load bearing wall, or where the terrain shifts or changes due to climate, settling, animals, roots, etc., it may be desirable to provide a gap between the top wall 48 and the top surface of the wall structure 10 . Thus, individual columns 14 will be able to move vertically in small increments without destroying the integrity of the wall structure 10 or the skirted structure (not shown). In that regard, it should be appreciated that the beams 16 slidingly grip portions of the blocks 12 . That is to say, the beams 16 do not grip the blocks 12 with so much force as to preclude relative movement of the blocks 12 therealong in a longitudinal direction.
[0106] FIGS. 6 and 6 a show an embodiment of another application of the present invention, where blocks are used to provide a facia wall in front of an existing retaining wall. The facia wall is formed using support beams and brackets similar to the beams and brackets depicted in FIGS. 2 and 2 a. That is, the support beam 716 , as shown, comprises an elongated spine or web 718 and plurality of ribs 720 and 722 , 724 and 726 , which are arranged in a substantially coplanar and collateral relation so that the first pair of ribs 720 , 722 , which are substantially coplanar and extend away from each other. The first pair of ribs 720 , 722 are designed to engage the grooves of one or more blocks of a structure (see, for example, FIG. 6 a ).
[0107] In addition, the web 718 also includes a second pair of ribs 724 , 726 , which are also substantially coplanar and which extend away from each other. Note that the pairs of ribs 724 and 726 are in substantially collateral or parallel relation with respect to each other and are spaced apart from each other by a distance defined by the web 718 . As better shown in FIGS. 51 and 52 , he support beam 716 also includes a pair of pair of leg structures 730 having leg portions 732 a, 732 b that they extend rearwardly away from ribs 724 , 726 and which form a generally U-shaped channel therewith. One of the leg portions 732 b includes a foot 734 that extends laterally away from the leg portion 732 b and is generally parallel with ribs 724 , 726 . As with the embodiment of FIGS. 2 and 2 a, the foot may be connected directly or indirectly to a support structure. However, as depicted, the beams of FIGS. 6 and 6 a are operatively connected to a structure by a plurality of brackets 354 , which are attached to blocks of the retaining wall. With such an arrangement the beams, which are slidingly constrained by the brackets, permit blocks to move without destroying the integrity of the structure.
[0108] The brackets 354 used to operatively connect the beams 718 to the retaining wall blocks generally comprise a structure engaging portion, a web, and a support beam engaging portion. As shown in FIG. 50 , the structure engaging portion 356 of bracket 354 comprises a single or first member 357 that is provided with an aperture 360 , which is used to facilitate attachment to the retaining wall with fastening elements such as nails, threaded fasteners, or anchor bolts. It will be appreciated, however, that an aperture or apertures need not be present in order to attach the bracket to a structure. The fastening element(s) may be driven through the first member, if desired. Additionally, it will also be appreciated that attachment may also be achieved with suitable adhesives, in lieu of, or in addition to, fastening elements. The support beam engaging portion 358 comprises a web 362 and a pair of legs 364 , 366 , which are angled with respect to the web to form a generally “L”-shape. The web 362 includes an aperture 368 that is accessible through a slot 370 defined by edges 372 and 374 of legs 366 and 364 , respectively. The aperture 368 and slot 370 are configured to slidingly receive a leg portion 732 b and foot 734 of a support beam (see also, FIGS. 50, 51 and 52 ).
[0109] Attention is now directed to the individual components of a wall structure 10 . FIG. 7 depicts a preferred embodiment of a block 12 . It can be seen that the block 12 is generally panel-shaped and includes a front face 20 , a rear face 22 , a top surface 24 , a bottom surface 26 and pairs of side surfaces 28 a, 29 a and 28 b, 29 b, respectively. The block 12 is preferably made of a composite masonry material in a dry-cast molding operation. Though the general shape of the blocks 12 is more important than the material used in order to practice the present invention, composite masonry material provides the most desirable combination of strength, appearance, economy, and ease of manufacturing. It is envisioned, however, that other materials can be used, such as concrete, fiberglass, ceramics, hard plastics, dense foam, or even wood.
[0110] The front face 20 is spaced from the rear face 22 by a predetermined distance herein defining the thickness or depth 30 (generally about 1 to 4 inches (2.5 to 10.0 cm)) of the block 12 . As shown in FIG. 7 , the front face 20 is formed to have a roughened or rustic surface. Such surfaces commonly result during block fabrication, where a mold is cast and the casting is later split or fractured into two blocks along a predetermined plane, with the plane of separation between the two blocks defining a pair of opposing front faces. Splitting is not necessary to carry out the spirit of the invention, however, and the block 12 may be formed by other known methods. Moreover, the front face 20 can be dressed, modified, or otherwise worked in any desired manner.
[0111] A vertically oriented splitting recess 21 may be provided on the front face 20 of the block 12 to enable the block 12 to be fashioned into predetermined shapes. In FIG. 7 , the splitting recess 21 is depicted as bisecting the block 12 . However, it is understood that the splitting recess can be located and oriented elsewhere on the block. That is, the splitting recess can be off-center, horizontal, diagonal, etc. Moreover, it is also understood that the block can be provided with more than one splitting recess, if desired.
[0112] The front face 20 includes marginal areas 23 a, 23 b, 23 c, and 23 d. As may be expected, the number of marginal areas corresponds to the number of edges of the front face 20 . These marginal areas may be worked or modified, if desired, to produce different visual effects. Here, the desired effect is for the marginal areas 23 a, 23 b, 23 c, and 23 d to simulate splitting recesses 21 . Thus, the marginal areas 23 a, 23 b, 23 c, and 23 d are formed so that when blocks 12 are positioned in contact with each other in a wall structure 10 , the cross-sectional profiles of their marginal areas 23 a, 23 b, 23 c, and 23 d, when combined, simulate splitting recesses 21 . As depicted the splitting recesses 21 have a cross-sectional profile that is somewhat circular, and the marginal areas 23 a, 23 b, 23 c, and 23 d have cross-sectional areas that are fluted or arced. As can be appreciated, the splitting recesses 21 and marginal areas 23 a, 23 b, 23 c, and 23 d may be configured with other cross-sectional profiles, if desired. For example, a “V”-shaped cross-sectional profile.
[0113] As mentioned above, tight or thin joints 31 (See FIG. 3 ) between adjacent blocks 12 enables a wall structure to appear monolithic or seamless. This feature may be used in combination with splitting recesses 21 and marginal areas 23 a - d of the blocks 12 to create different visual effects. For example, it is envisioned that a wall structure may simulate running bonds by having the blocks of each column alternate between a block with no splitting recess and worked marginal areas and a block having a splitting recess and worked horizontal marginal areas (see, for example, FIG. 40 ). Or, it is envisioned that the splitting recesses and marginal areas be selected to enable the wall structure to simulate an ashlar block wall (not shown).
[0114] Referring again to FIG. 7 , the top surface 24 is spaced from the bottom surface 26 by a distance (taken along a “y” direction in a three-dimensional coordinate system relative to the block 12 ) to define the height 32 (about 6 to 12 inches (15 to 30 cm)) of the block 12 . When blocks 12 are arranged vertically to form a column 14 (see FIG. 4 ), the bottom surface 26 of any block 12 other than the bottom block of a column 14 (not shown) rests on the top surface 24 of the block therebelow. It is therefore preferred that the top surface 24 and the bottom surface 26 be configured to facilitate a stacking relationship between two blocks 12 . A stacking relationship is most easily achieved by making the top and bottom surfaces 24 , 26 substantially collateral, planar, and relatively perpendicular to the rear face 22 and/or the front face 20 , as best shown in FIGS. 4 and 5 . Alternatively, it is envisioned that top and bottom surfaces 24 , 26 may be complementarily shaped, and not perpendicular to the rear face and/or the front face, but which permit upper and lower blocks to be stacked in a vertical relationship (not shown). For example, the surfaces could be non-planar and/or irregular. Alternatively, the surfaces can have compound curves or even interlocking segments (not shown).
[0115] The side surface pairs 28 a, 29 a and 28 b, 29 b, respectively, are preferably somewhat perpendicular to the rear face 22 and/or the front face 20 . Side surface 28 a is spaced from side surface 28 b by a distance (taken along a “x” direction in a three-dimensional coordinate system relative to a block 12 ) to define the width 33 (6 to 24 inches (15 to 60 cm)) of block 12 . Additionally, each pair of side surfaces 28 a and 29 a, 28 b and 29 b, include a substantially vertical groove 34 therebetween that is configured to receive a portion of a lateral support beam 16 (see, for example, FIG. 11 ). While a pair of side grooves for each block is preferred, it is envisioned that one side surface be provided with a groove and the other side surface have a tongue configured to mate with the groove, thereby obviating the need for beams 16 . However, in order to maintain the vertically independent characteristics of columns 14 , the use of beams 16 is preferred.
[0116] Referring now to FIGS. 7 a and 7 b, another embodiment of the block of the present invention is depicted. The block 112 is generally panel-shaped and includes a front face 120 , a rear face 122 , a top surface 124 , a bottom surface 126 and pairs of side surfaces 128 a, 129 a, and 128 b, 129 b, respectively.
[0117] The front face 120 is spaced from the rear face 122 by a predetermined distance defining the thickness or depth 130 (generally about 1 to 4 inches (2.5 to 10.0 cm)) of the block 112 . As shown in FIG. 7 a, the front face 120 is formed to having a roughened or weathered surface. However, it is understood that the front face 120 could, be dressed, modified, or otherwise worked in any desired manner.
[0118] Vertically oriented splitting recesses may be provided on the front face of the block to enable the block to be fashioned into predetermined shapes. Here, the splitting recesses 121 are depicted as quartering the block 112 and forming front face segments 125 a, 125 b, 125 c, and 125 d. However, it is understood that the splitting recesses 121 may be located and oriented elsewhere on the block 112 . That is, the splitting recesses 121 could be off center, horizontal, diagonal, etc. Moreover, it is also understood that a block splitting recesses 121 may be omitted, if desired.
[0119] The front face 120 includes marginal areas 123 a, 123 b, 123 c, and 123 d. As may be expected, the number of marginal areas corresponds to the number of edges of the front face 120 . The marginal areas 123 a - d may be worked or modified, if desired, to produce different visual effects. In FIG. 7 a, the desired visual effect is for the marginal areas to simulate splitting recesses. Thus, the marginal areas 123 a - d are formed so that when blocks 112 are positioned in contact with each other in a wall structure 10 (See FIG. 3 , for example), the cross-sectional profiles of their marginal areas 123 a - d, when combined, simulate splitting recesses at the joints formed by the block. As depicted, the splitting recesses 121 have a cross-sectional profile that is somewhat circular, and the marginal areas 123 a - d have cross-sectional areas that are fluted or arced. As can be appreciated, the splitting recesses and marginal areas 123 a - d may be configured with other cross-sectional profiles, if desired. For example, a “V”-shaped cross-sectional profile.
[0120] Referring again to FIG. 7 a, the top surface 124 is spaced from the bottom surface 126 by a distance (taken along a “y” direction in a three-dimensional coordinate system relative to the block 112 ) to define the height 132 (about 6 to 12 inches (15 to 30 cm)) of the block 112 . When the blocks 112 are arranged vertically to form a column 14 (see, for example, FIGS. 4 and 5 ), the bottom surface 126 (not shown) of any block 112 other than the bottom block of a column 14 (See FIG. 5 ) rests on the top surface 124 of the block 112 therebelow. It is therefore preferred that the top surface 124 and the bottom surface 126 be configured to facilitate a stacking relationship between two blocks 112 . A stacking relationship is most easily achieved by making the top and bottom surfaces 124 , 126 substantially collateral, planar and relatively perpendicular to the rear face 122 and/or the front face 120 , as shown in FIGS. 4 and 5 . Alternatively, it is envisioned that the top surface 124 and the bottom surface 126 (see FIG. 7 b ) may be complementarily shaped, and not perpendicular to the rear face 122 and/or the front face 120 , as long as the upper and lower blocks 112 can be stacked in a vertical relationship. For example, the surfaces 124 , 126 (not shown) can be non-planar and/or irregular. Or, the surfaces 124 , 126 (not shown) can have compound curves or interlocking segments (not shown).
[0121] Referring to FIG. 7 b, the side surface pairs 128 a, 129 a and 128 b, 129 b, respectively, are preferably somewhat perpendicular to the rear face 122 and/or the front face 120 . The side surface 128 a is spaced from the side surface 128 b by a distance (taken along the “x” direction in a three-dimensional coordinate system relative to the block 112 ) to define the width 133 (6 to 24 inches (15 to 60 cm)) of the block 112 . Additionally, each pair of side surfaces 128 a, 129 a, 128 b and 129 b, include a substantially vertical groove 134 located therebetween that is configured to receive a portion of a lateral support beam (see, for example, the lateral support beam depicted in FIGS. 11 , and 23 - 36 ).
[0122] The block 112 is that it is additionally provided with one or more substantially vertical apertures or through holes 150 a, 150 b, and 150 c. As can be seen, apertures 150 a, 150 b, and 150 c, which are in substantial alignment with the grooves 134 located on either side of the block 112 . This enables for use with support beams 270 such as those shown in (See FIG. 12 ), to be used, if desired. The vertical apertures 150 a - c also allow a plurality of blocks 112 to be positioned in a running bond (again using support beams 270 such as those shown in FIG. 12 , for example). The aperture 150 b may be provided with a slot 152 , which that provides an opening to the rear face 122 . In addition, the block 112 may now be split into smaller predetermined sizes, with each smaller block (not shown) having a set of side grooves 134 . Although not depicted, it will be understood that apertures 150 a and 150 c may also be provided with slots (as with aperture 150 b ), if desired.
[0123] Another feature of block 112 is the provision of recesses 127 a and 127 b on the rear surface 122 adjacent the side surfaces 129 a and 129 b. The recesses come into play during, and aid in, the manufacturing of the block. After a large block (not shown) is molded and split into two smaller blocks and the smaller blocks are removed from the conveyor on which they rest by a pusher bar (not shown) that impacts the rear surfaces of the blocks and moves them in a desired direction. This works if the blocks are substantially parallel to the pusher bar. However, if the blocks are not substantially parallel to the pusher bar, the bar has a tendency to chip and break the side segments. The recesses provide clearance so that if the block is somewhat askew relative to the pusher bar, the bar will not contact the side segments and thereby reducing chipping and breakage.
[0124] FIG. 8 shows a preferred corner configuration using the blocks 12 of the present invention. The design of the block 12 lends itself to the formation of corners without the need for mortar, corner braces, or other supports. Two blocks 12 a and 12 b are simply aligned to form a corner butt joint 51 . Preferably, block 12 b is broken along its splitting recess to form a new split face, which roughly matches split front face of block 12 a. Holes 54 are drilled through the blocks 12 a and 12 b so that a fastener 56 may be inserted therein. Generally, the fastener may be any suitable fastener, and preferably, an appropriately sized pin, peg, or screw, and the like. Alternatively, glue, preferably construction mastic, may be applied instead of or, more preferably, in combination with fasteners to secure the blocks to each other.
[0125] Referring now to FIGS. 9 and 10 , another embodiment of a block 156 of the present invention is depicted. The block 156 is generally angularly-shaped and includes a front face 158 , a rear face 160 , a top surface 164 , a bottom surface 166 and pairs of side surfaces 168 a, 169 a, and 168 b, 169 b, respectively. As with the previously described blocks 112 , the side surfaces 168 a, 169 a, and 168 b, 169 b are provided with grooves 170 a and 170 b that are configured to receive portions of lateral support beams, and will not be discussed here in detail. An alternate embodiment of the block 156 ′ is illustrated in FIGS. 1-2 a. As shown in FIGS. 9-10 , front face 158 is formed with a roughened or weathered surface or facing segments 159 a - b and is provided with marginal areas 163 a - d. These features are not necessary to carry out the spirit of the invention, however. The front face 158 may be dressed, modified, or otherwise worked in any desired manner. The block 156 may also be provided with recesses 167 a and 167 b, located on the rear face segments 161 a and 161 b, adjacent the side surfaces 169 a and 169 b. As discussed previously, the recesses 167 a - b prevent and/or reduce chipping during the manufacturing process.
[0126] As depicted, the block 156 is configured so that the front face segments 159 a and 159 b, and the rear face segments 161 a and 161 b are oriented so that they intersect each other at a predetermined angle 172 . The angle of intersection 172 can vary from about 15 degrees to about 165 degrees. Preferably, though, the angle of intersection is about 90 degrees so that the block may be used to construct rectilinear structures. In that regard, it will be appreciated that the blocks 156 may be used with or without linearly shaped blocks to form columnar structures of varying shapes and sizes (see, for example FIG. 1 ). Moreover, it is envisioned that the blocks may be formed with more than two front and rear face segments 159 a - b, 161 a - b, and/or that the block could be formed in a generally arcuate shape.
[0127] Referring now to FIG. 11 , an embodiment of a beam of the present invention generally comprises an elongated spine or web and at least one rib, which is substantially coextensive therewith. More specifically, a preferred embodiment of beam 16 , as shown, includes a plurality of ribs that are arranged in a substantially coplanar and collateral relation. That is, there is a first pair of ribs 38 a, which are substantially coplanar and extend away from each other. And, there is a second pair of ribs 38 b, which are also substantially coplanar and extend away from each other. Note that the pairs of ribs 38 a and 38 b are in substantial collateral relation with each other and are spaced apart from each other by a distance defined by the web 36 . This configuration of two pairs of ribs 38 a and 38 b attached to each other by web 36 forms somewhat of an I-beam configuration. It is preferred that at least one set of ribs 38 a be resiliently deformable and, even more preferred, that they converge slightly towards and then diverge slightly away from the other ribs 38 b in a somewhat “V”-shaped configuration towards the ends of the ribs 38 . A “V”-shaped configuration is preferred because it allows a segment 35 of a block 12 to be gripped between the ribs 38 a - b (see, for example, FIGS. 23 and 24 ). As will be appreciated, in order for the desired amount of gripping force to occur, the distance or span 42 between a rib 38 b and the apex of the “V” of an unflexed rib 38 a should be slightly less than the thickness of segment 35 (see FIG. 24 ). It will also be appreciated that the distance or span 43 between the leading edge of flange 40 of the unflexed rib 38 a and the rib 38 b should be slightly greater than the thickness of segment 35 (See, again FIG. 24 ). Thus, when a beam 16 is attached to a block 12 the rib 38 a is deflected from its unstressed state to a stressed state and a segment 35 of a block may be gripped between ribs 38 a and 38 b. As depicted in FIG. 23 the ribs 38 a and 38 b are preferred because they prevent unwanted movement and misalignment between blocks 12 of a given column 14 and they are able to compensate for variations in dimensions that sometimes occur during manufacture of the blocks.
[0128] Beam 16 may be attached at its upper ends to a structure being skirted (see, for example, FIG. 1 ) if desired, preferably at or near the lowermost edge or bottom of the structure, and using conventional fastening techniques and technologies. Such attachments may be used in conjunction with or without a bracket 18 to provide support and stability to the independent columns 14 (see FIG. 5 ) by preventing them from leaning or falling forwardly or rearwardly. The beams aligns the blocks 12 of a given column), by preventing lateral movement therebetween (that is, movement along the “x” direction in a three-dimensional coordinate system relative to the blocks 12 ).
[0129] Another embodiment of a lateral support beam 116 is depicted in FIG. 11 a. Here, the beam 116 generally comprises a body having block-engaging portion and a bracket-engaging portion. More specifically, the beam 116 comprises a first web 180 and a second web 181 that are generally aligned with each other. Projecting from the webs 180 , 181 are pairs of ribs 182 a, 182 b, and 182 c. The first pair of ribs 182 a, which form the block-engaging portion, extend away from each other in a generally coplanar relation. The second pair of ribs 182 b is generally collaterally aligned with the first pair of ribs 182 a and is separated therefrom by a predetermined span 188 . The third pair of ribs 182 c is generally collaterally aligned with the second pair of ribs 182 b and is separated therefrom by a predetermined span 190 . The outer ends of ribs 182 a are provided with resilient flanges 184 that are configured and arranged such that the ribs 182 a are able to be received by the vertical grooves on the blocks. With this beam embodiment, segments of the sides of a block are not gripped between adjacent pairs of ribs. Rather, engagement with blocks is achieved through the first set of ribs 182 a that substantially span the depth of the vertical grooves of the blocks, where depth is taken along the “z” axis in the three dimensional coordinate system (see, for example, FIG. 7 a ). It will be appreciated that the block engaging portion, i.e., the first pair of ribs 182 a, need not be restricted to a flange configuration. A frictional engagement, for example, can be achieved with other configurations.
[0130] Alternative embodiments of support beams 270 , 287 and blocks 312 are illustrated in FIGS. 12, 13 and 27 . With regard to the support beam 270 depicted in FIG. 12 , support beam 270 comprises a pair of webs 272 , 274 , which are generally parallel to each other and that terminate in opposing ribs. A third web 276 extends from the surface formed by opposing ribs in general alignment with webs 272 , 274 and terminates in opposing ribs 278 c. The ends of opposing ribs 278 a and 278 b may be provided with flanges and coupling elements 280 , 282 , respectively. As will be appreciated, two webs 272 , 274 (versus a single web) increases the overall strength of the beam 270 so that the beam resists bending and warping more than beams that have only single webs that connect their opposing ribs.
[0131] The support beam 287 of FIG. 13 is similar to the support beam 270 of FIG. 12 . Instead of having opposed ribs that engage a block, however, the block engagement section 288 of the beam is configured so that it is able to substantially span the depths of the grooves of two opposing blocks, or the depth of the aperture 350 in the interior section of a block 312 (see FIG. 27 ) (where depth is taken along the “z” axis in the three dimensional coordinate system as shown in FIG. 7 a ). As depicted, the engagement section 288 of the support beam 287 is generally “T”-shaped and substantially spans the depth of the aperture 350 (i.e. see FIG. 27 ) where depth is taken along the “z” axis in the three dimensional coordinate system as shown in FIG. 7 a (see FIG. 45 , for example), and generally spans the width of the slot 352 of a block (see, FIG. 27 ). As shown, the engagement section 288 is hollow, however, it is understood that the engagement section 288 may be solid, if desired. The base of the “T”-shaped engagement section 288 is provided with a web 276 and a pair of opposing ribs 278 c to enable the support beam 287 to be connected to a bracket such as those depicted in FIGS. 44-45 . With regard to FIG. 27 , it will be appreciated that the depiction of the support beams 270 and 287 relative to the blocks 312 are for illustrative purposes only, and that they may be interchanged if desired.
[0132] A frictional engagement may be desired and this could be achieved with other configurations. For example, in FIG. 14 the block-engaging section 288 may take the form of generally planar opposing planar sections 192 each having resilient spurs 194 projecting therefrom. Or, as seen in FIG. 15 , the block-engaging section 288 may take the form of a preformed resilient body 196 having an aperture 198 . Note that in FIGS. 14 and 15 , the bracket-engaging portions 290 are shown in phantom.
[0133] With reference to FIG. 16 , the support beam 116 is similar to the support beam of prior embodiments in that it includes a web 510 from which a plurality of ribs 503 , 504 , 505 and 506 extend. In a departure from previous embodiments, the support beam 116 of this embodiment includes an extension 508 that terminates with an attachment member 512 . Preferably, the extension 508 is aligned with, and extends from the web 510 so as to position the attachment member 512 a predetermined distance from the plurality of ribs 503 , 504 , 505 and 506 . This arrangement serves several purposes. As explained above, not only does the extension 508 create spaces between a wall structure and a substructure that may be used as plenums, conduits, or for retaining insulative, fire-retardant or other building materials, but it also facilitates attachment of the support beam 116 to a substructure. Preferably, the attachment member 512 comprises feet 516 and 518 that extend laterally in opposite directions from the extension 508 to provide a point or points of connection which may be used with adhesive or fastening elements, such as nails or screws, in attaching a support beam to a substructure (see also, FIG. 29 ).
[0134] Referring now to FIG. 17 , the support beam 116 , again, has an extension 508 , which terminates in an attachment member 512 having feet 516 , 518 . However, in this embodiment, the extension 508 and the feet 516 , 518 are foreshortened. Note that the support beam 116 is not directly connected to a substructure but is operatively connected to a bracket 534 that is, in turn, operatively connected to a substructure. The bracket 534 includes a substructure engaging portion 536 , a span 538 and an attachment member with a support beam engaging portion 542 . The support beam engaging portion 542 is sized to be snuggly received and frictionally retained within a channel 530 or 532 formed by a rib and a foot 505 , 516 ; 506 , 518 , respectively, of the beam 116 . Note that the support beam 116 need not extend along the length of the bracket 534 , and more particularly, the support beam 116 need not be coextensive with the side of a block 112 (see FIG. 7 a ) to which it may be operatively connected. The reason for this is that a block need not be retained along its entire length of its grooves to be adequately retained as part of a wall structure. Instead, it is only necessary for a block to retained at several points. Thus, the support beams 116 may take the form of clips that attach to the bracket 534 , and a block 112 can be retained at a plurality of predetermined locations (i.e. such as upper and lower ends). It will be appreciated that such support beam clips may be used to operatively connect a pair of blocks to a support bracket by positioning the clips so that they span the interface between two adjacent blocks. It will also be appreciated that the support beam clip may be longer than a side of a block to which it is operatively connected so that it may operatively connect more than two blocks to a bracket.
[0135] The span 538 of the bracket 534 serves to position the support beam 116 a predetermined distance from a substructure while the substructure engaging portion 536 serves to attach the bracket 534 to a substructure. As with the aforementioned embodiment, the bracket 534 may be operatively connected to a substructure using a variety of fastening elements. It will be appreciated that both channels 530 , 532 of the support beam 116 of this embodiment may be used with oppositely facing brackets, if desired, to form a more robust connection between the wall structure and a substructure.
[0136] Referring now to FIG. 18 , the support beam 116 terminates at an attachment member 512 that includes two spaced apart resilient walls 550 , 552 having confronting arms 554 , 556 , which define a slot 558 and channel 560 , which are sized to admit and retain a second attachment member.
[0137] With this embodiment, the support beam 116 is not directly connected to a substructure but is operatively connected to a bracket 562 that is, in turn, operatively connected to a substructure (see, for example, FIG. 32 ). The bracket 562 includes substructure engaging portions 564 , 566 , a span 538 and a first attachment member 570 . Preferably, the first attachment member 570 is a dart-shaped head 572 having shoulders 574 , 576 that are configured to engage arms 554 , 556 of the support beam 116 in a constrained relation. That is, the attachment member 512 of the support beam is sized to slidingly receive the head 572 within a slot 558 and a channel 560 formed by the resilient walls 550 , 552 and their confronting arms 554 , 556 . Thus, the support beam 116 may be connected to a bracket 562 in a constrained manner. It will be appreciated that the support beam 116 can be operatively connected to the bracket 562 in several ways. For example, by positioning the bottom of the channel 560 and the slot 558 over the top of the dart shaped head 572 and the span 568 of bracket 562 and then sliding the support beam 116 down along the bracket 562 and interconnecting with an already positioned block, or sliding the support beam down along the bracket 562 and later interconnecting with a block, which is slid into position in a similar manner. Alternatively, a support beam 116 may be operatively connected to a bracket 562 by aligning the slot 558 of the attachment member 512 opposite the apex of the dart shaped head 572 and then pushing the support beam 116 towards the dart shaped head 572 until the arms 554 , 556 of the attachment member 512 engage the shoulders 574 , 576 of the dart shaped head 572 .
[0138] As will be appreciated, the support beam 116 of FIG. 18 need not extend along the length of the bracket 562 and, more particularly, the support beam need not be co-extensive with the side of a block to which it is operatively connected. The span 538 of bracket 562 serves to position the support beam 116 a predetermined distance from a substructure and the substructure engaging portion 564 , 566 serves to attach the bracket 562 onto a substructure. Bracket 562 may be operatively connected to a substructure using a variety of fastening elements 578 (see also, FIG. 32 ).
[0139] Referring now to FIG. 19 , the operative connection is reversed from that shown in FIG. 18 . That is, support beam 116 includes an extension that terminates in a first attachment member 570 having a head 594 with shoulders 596 , 598 . The bracket 580 now includes two spaced-apart resilient walls 582 , 584 having confronting arms 586 , 588 , which define a slot 590 and a channel 592 , which are sized to admit and retain the attachment member 594 in a constrained relation, as discussed above. As with the aforementioned embodiments, the support beam 116 need not extend along the length of the bracket 580 . The bracket may be operatively connected to a substructure using a variety of fastening elements.
[0140] Referring now to FIG. 20 , another preferred embodiment depicts a post 600 which has been provided with a plurality of connectors to enable the post 600 to support a plurality of wall structures. In this embodiment, the post 600 includes front and rear surfaces 602 , 604 and opposing sides, with a web 606 that extends from the front surface 602 , and an attachment bracket 612 that extends from the rear surface 604 . A pair of ribs 608 , 610 extend laterally in opposite directions from the web 606 in the same manner as the ribs 38 of support beam 16 in FIG. 11 , while the attachment bracket 612 includes a slot 614 and channel structure 616 similar to the slot 558 , 590 and channel 560 , 592 structures described and shown in FIGS. 18 and 19 , respectively. Thus, with this embodiment, blocks may be directly connected to the post 600 at side 602 or connected indirectly at side 604 via an appropriately configured support beam (such as beam 116 of FIG. 19 ).
[0141] Although not shown, other combinations of operative connections may also be used. For example, the post 600 may be provided with two direct connectors (webs with laterally extending ribs) or the post may be provided with two indirect connectors (attachment members, such as channels). As will be appreciated, the post 600 may be operatively connected to a substructure such as a footing or foundation, or be set into the ground using known techniques and technologies. While the post 600 is depicted as having a hollow cross-section, it is understood that the post may also be a solid in cross section or may have a reinforcing structure such as a pipe or a rod received therein.
[0142] With reference to FIG. 21 , the support beam 116 is similar to the support beam of prior embodiments, in that it includes a web 510 from which a plurality of ribs 503 , 504 , 505 and 506 extend. The support beam 116 includes an extension 508 that terminates with an attachment member 512 . Preferably, the extension 508 is aligned with, and extends from the web 510 so as to position the attachment member 512 a predetermined distance from the plurality of ribs 503 , 504 , 505 and 506 . In FIG. 21 , the attachment member 512 is depicted as feet 516 and 518 , however it is understood that the attachment member may take other forms. Note that ribs 503 , 504 , 505 and 506 are reversed relative to each other so that the pair of opposing ribs 505 and 506 are now forward, relative to the opposing pair of ribs 503 and 504 (similar to the rib arrangement as depicted in FIGS. 23 and 24 ). Note also, that the pair of forwardly facing opposing ribs 505 and 506 are somewhat thicker than the pair of opposing ribs 503 and 504 . This feature allows the support beam 116 to have a viewable surface 507 , which may form part of an observed wall structure (see FIG. 35 ).
[0143] Referring now to FIG. 22 , a partial horizontal section of the wall structure 10 of FIG. 4 is depicted. As shown, a beam 16 operatively connects two adjacent blocks 12 of adjacent columns 14 to each other. Here, the “V”-shaped ribs 38 a are positioned within grooves 34 of adjacent blocks 12 and ribs 38 b are positioned against the rear faces 22 of adjacent blocks 12 . In this configuration, the beam 16 remains hidden from view and provides support along several axes (taken along the “z” and “x” directions in a three-dimensional coordinate system relative to a block 12 ). With the beam 16 of this embodiment, the grooves 34 may be considerably larger than the thickness of the ribs 38 a, without affecting the gripping ability of the beam 16 . Thus, there may be quite a large space in front of the ribs 38 a. Note that the distance between side surfaces 29 a and 29 b of block 12 is less than the distance between side surfaces 28 a and 28 b of block 12 to allow the side surfaces 28 a, 28 b of adjacent blocks 12 to be brought into intimate contact with each other while providing enough space to accommodate the web 36 of the beam 16 (see FIGS. 24 and 24 a ). Note that a bracket 18 is shown (in dashed lines) as it would be positioned relative to an uppermost block 12 of a column 14 .
[0144] FIGS. 23 and 24 show a preferred beam arrangement in which the beam 16 shown in FIGS. 11 and 22 is reversed with respect to blocks 12 to which the beam is connected. That is, the ribs 38 b are positioned within opposing grooves 34 and ribs 38 a are positioned against the rear faces 22 of blocks 12 . This arrangement does not significantly change the function and gripping ability of the beam 16 as discussed above.
[0145] As with to the embodiment depicted in FIG. 22 , the distance between side surfaces 29 a and 29 b of the blocks is less than the distance between side surfaces 28 a and 28 b to allow side surfaces 28 a, 28 b of adjacent blocks 12 to be brought into intimate contact with each other while providing enough space to accommodate the web 36 of the beam 16 . Note that when two adjacent blocks 12 are brought into contact with each other, their corresponding margins 23 a and 23 b combine to form a profile that is substantially the same as the profile of a splitting recess 21 (as shown in FIGS. 22 and 24 ). It will be appreciated that the splitting recess 21 and may have other profiles, such as a “V”-shape and that the corresponding margins would be more beveled or chamfered.
[0146] Referring now to FIGS. 23, 23 a, 24 and 24 a, operatively connecting blocks together to form a wall structure 10 begins with connecting a block 12 to a beam 16 . As depicted in FIGS. 23 a and 24 a, the leading edge of flange 40 allows the rib 38 a to be displaced as it encounters the block segment 35 . As the beam 16 is connected to the block 12 , block segment 35 is gripped by ribs 38 a and 38 b.
[0147] In a preferred method to operatively connect a wall to a structure using the aforementioned bracket, a person would prepare or otherwise select an appropriate location in which to construct a wall. The construction would begin by placing a first block having opposing side grooves in a desired position and orientation. Then, a second, similar block would be placed directly on top of the first block so that the opposing side grooves of the first and second blocks are in vertical alignment with each other and the first and second blocks form a column. Next, the first and second blocks would be operatively connected to each other along one of their respective sides by inserting a rib of first support beam into the aligned grooves and seating it securely.
[0148] Next, a bracket is positioned so that its wall engaging portion is collaterally aligned and in contact with the support beam such that it extends therewith along the groove in the block. The structure engaging portion of the bracket is then brought into position for attachment to a structure by sliding or otherwise manipulating the bracket in a direction towards the point of attachment on the structure (this is generally above and co-planar with the wall). The bracket is than attached to the structure using conventional techniques and technologies. The rib of a second support beam is then inserted into the aligned grooves of the opposite sides of the blocks, and a second bracket is used to operatively connect this portion of the wall to a structure using the aforementioned steps.
[0149] A second column comprising similarly configured third and a fourth blocks may now be constructed. The operation is much the same, except now the third block is positioned so that one of its sides is adjacent to one of the sides of the first block and its groove engages at least one other rib of one of the already positioned support beams. The fourth block is then positioned on top of the third block in a similar manner. That is, the fourth block is positioned so that one of its sides is adjacent to one of the sides of the second block and its groove engages at least one other rib of one of the already positioned support beam and the wall engaging portion of the already installed bracket.
[0150] After the second column is erected, the third and fourth blocks would be operatively connected to each other along their respective free side by inserting at least one rib of a third support beam into their aligned vertical groove of the respective sides of the first and second blocks and seating them securely, and that support beam would be operatively connected to a support by yet another bracket. And so on. It will be appreciated that other methods of constructing a wall structure using the aforementioned components are possible.
[0151] FIG. 25 illustrates an alternative embodiment of a beam 16 having two ribs 38 a, 38 b but only one resiliently deformable rib 38 a. FIG. 26 shows yet another embodiment of a beam 16 comprising one pair of opposed ribs 38 b such that the support beam 16 is essentially an elongate spline. It should be understood that for purposes of clarity, the ribs 38 b as depicted in FIGS. 25 and 26 are substantially thinner than the grooves 34 in which they are positioned, and that in actuality ribs 38 a - b and grooves 34 would be configured to effectively maintain blocks 12 in a coplanar relation with little or no play.
[0152] Alternative embodiments of support beams and blocks are shown in FIG. 27 . As depicted in FIG. 27 , a support beam 270 may be operatively connected to one or more blocks 312 , at grooves 334 a and 334 b. Note that the blocks 312 include a front face 320 , a rear face 322 , a top surface 324 , a bottom surface (not shown), and side surfaces 328 a and 329 a, and 328 b and 329 b. The blocks 312 also include marginal areas 323 and notches 327 , which will not be discussed here in detail. As can be seen, the side surfaces 329 a and 329 b are foreshortened to accommodate the increased width of the support beam 270 . The support beam 270 may be operatively connected to a block 312 when the ribs 278 a and 278 b grip side segments 335 a, 335 b. The support beam 287 can be operatively connected to a block 312 by sliding a block engagement section 288 into the aperture 350 .
[0153] Another embodiment of a lateral support beam is depicted in FIG. 28 . Here, the beam 116 generally comprises a body having block-engaging portion and a bracket-engaging portion. More specifically, the beam 116 comprises a first web 180 and a second web 181 that are generally aligned with each other. Projecting from the webs 180 , 181 are pairs of ribs 182 a, 182 b, and 182 c. The first pair of ribs 182 a form block-engaging portions, which extend away from each other in a generally coplanar relation. The second pair of ribs 182 b is generally collaterally aligned with the first pair of ribs 182 a and is separated therefrom by a predetermined span 188 . The third pair of ribs 182 c is generally collaterally aligned with the second pair of ribs 182 b and is separated therefrom by a predetermined span 190 . The outer ends of ribs 182 a are provided with resilient flanges 184 that are configured and arranged such that the ribs 182 a are able to be received by the vertical grooves on the blocks of the present invention. With this embodiment, segments of the sides of a blocks re not gripped between adjacent pairs of ribs.
[0154] Now referring to FIG. 29 , a support beam 116 , similar to the support beam of prior embodiments, includes a web 500 from which a plurality of ribs 503 , 504 , 505 and 506 extend. The support beam 116 of this embodiment includes an extension 508 that terminates with an attachment member 512 . Preferably, the extension 508 is aligned with, and extends from the web 500 so as to position the attachment member 512 a predetermined distance from the plurality of ribs 503 , 504 , 505 , and 506 . The extension 508 not only creates spaces between a wall structure and a substructure that may be used as plenums, conduits, or for retaining insulative, fire-retardant or other building materials, and also facilitates attachment of the support beam 116 to a substructure “S” (partially shown). Preferably, the attachment member 512 comprises feet 516 , 518 that extend laterally in opposite directions from the extension 508 to provide a point or points of connection which may be used with adhesive or mechanical fastening elements, such as nails or screws 522 , in attaching a support beam to a substructure “S”.
[0155] FIG. 30 illustrates a partially assembled wall structure 410 comprising a plurality of blocks 412 retained in place by a plurality of vertically oriented, elongated support beams 416 that are operatively connected to a substructure “S” (shown in dashed lines). The support beams 416 allow the blocks 412 of adjacent horizontal courses to be substantially superposed one above the other and not laterally offset from each other in a bond pattern, as one may expect of such a wall structure. Thus, the wall structure 410 is comprised of a plurality of adjacent columns 414 a - d that may be operatively connected to each other in a serial fashion. Each block 412 of the wall structure 410 includes a front face 420 , a rear face 422 , a top surface 424 , a bottom surface 426 and opposing sides 427 a, 427 b. Each opposing side 427 a, 427 b includes opposing grooves 434 , 436 defined by plurality of outwardly extending fingers 428 a, 428 c and 428 b, 428 d, with outwardly facing surfaces 430 a, 430 c and 430 b, 430 d.
[0156] Preferably, the blocks 412 are symmetrically formed, so that either the front or rear face 420 , 422 , respectively, may face forwardly. This feature allows a block which has been damaged or had its surface otherwise altered to be easily removed and reinstalled by merely turning the block around (or over) so that other good or undamaged sides now being the viewable surface of the block. In other words, the blocks are reversible. The front and rear faces need not have the same surface treatment. That is, a block 412 may have a smooth front face and a roughened rear face 422 . Or, a block 412 may have roughened front face and a decorated or non-planar rear face. For example, in FIG. 30 , the lower most blocks 412 of column 414 c and column 414 d, respectively, have forwardly facing rear faces 422 while the remaining blocks in the partially assembled wall structure 410 have forwardly facing front faces. As depicted, the viewable front faces 420 of the blocks 412 of the wall structure 410 are smooth and the viewable rear faces 422 of the blocks of the wall structure 410 are roughened or otherwise decorated. Note that the leftmost beam 416 may be used to form the base and a cap of a horizontally oriented wall structure.
[0157] Referring now to FIG. 31 , a support beam 116 , has an extension 508 , which terminates in an attachment member 512 -with feet 516 , 518 . However, in this embodiment the extension 508 and the feet 516 , 518 are foreshortened. Note that the support beam 116 is not directly connected to a substructure “S” but is operatively connected to a bracket 534 that is, in turn, operatively connected to a substructure “S” (shown in dashed lines). The bracket 534 includes a substructure engaging portion 536 , a span 538 and an attachment member with a support beam engaging portion 542 . The support beam engagement portion 542 is sized to be snuggly received and frictionally retained within a channel 530 or 532 formed by a rib and a foot ( 505 , 516 ; 506 , 518 , respectively) of the beam 116 . Note that the support beam 116 need not extend along the length of the bracket 534 , and more particularly the support beam need not be coextensive with the side of a block to which it is operatively connected. The reason for this is that a block 112 need not be retained along its entire length of its grooves to be adequately retained as part of a wall structure. Instead, it is only necessary for a block to retained at several points. Thus, the support beams 116 may take the form of clips that attach to the bracket 534 , and a block 112 may be retained at a plurality of predetermined locations such as its upper and lower ends. It will be appreciated that such support beam clips may be used to operatively connect a pair of blocks to a support bracket 534 by positioning the clips so that they span the interface between two adjacent blocks. It will also be appreciated that the support beam clip may be longer than a side of a block to which it is operatively connected so that it may operatively connect more than two blocks to a bracket.
[0158] The span 538 of the bracket 534 serves to position the support beam 116 a predetermined distance from a substructure “S” while the substructure engaging portion 536 serves to attach the bracket 534 onto a substructure “S”. As with the aforementioned embodiment, the bracket 534 may be operatively connected to a substructure “S” using a variety of fastening elements. It will be appreciated that the support beam 116 of this embodiment may be used with oppositely facing brackets, if desired, to form a more robust connection between the wall structure and a substructure “S”.
[0159] Referring now to FIGS. 32 and 18 , the support beam 116 does not have an extension. Rather, as best shown in FIG. 18 , the beam 116 terminates at a first attachment member 512 that includes two spaced apart resilient walls 550 , 552 having confronting arms 554 , 556 , which define a slot 558 and channel 560 that are sized to admit and retain a second attachment member 570 .
[0160] With this embodiment, the support beam 116 is not directly connected to a substructure “S” but is operatively connected to a bracket 562 that is, in turn, operatively connected to a substructure “S” (shown in dashed lines). The bracket 562 includes substructure engaging portions 564 , 566 , a span 538 and an attachment member 570 . As best shown in FIG. 18 , the attachment member 570 is dart-shaped head 572 having shoulders 574 , 576 , which are configured to engage confronting arms 554 , 556 in a constrained relation. That is, the attachment member 570 of the support beam is sized to slidingly receive the dart shaped head 572 within a slot 558 and channel 560 formed by the resilient walls 550 , 552 and their confronting arms 554 , 556 . Thus, the support beam 116 may be connected to the bracket 562 in a constrained manner. It will be appreciated that the support beam 116 may be operatively connected to a bracket 562 in several ways. For example, by positioning the bottom of the channel 560 and the slot 558 over the dart shaped head 572 of the bracket 562 , the support beam 116 may be slid down along the bracket 562 to interconnect with an already positioned block 112 . Alternatively, the beam 116 may be slid down along the bracket 562 and later interconnecting with a block 112 , which is slid into position in a similar manner. Alternatively, a support beam 116 may be operatively connected to a bracket 562 by aligning the slot 558 of the attachment member 512 opposite the apex of the dart shaped head 572 and then pushing the support beam 116 towards the dart shaped head 572 until the confronting arms 554 , 556 of the attachment member 512 engage the shoulders 574 , 576 of the dart shaped head 572 .
[0161] The support beam 116 need not extend along the length of the bracket 562 , and, more particularly, the support beam need not be co-extensive with the side of a block to which it is operatively connected. The reasons for this have been discussed in conjunction with the description of FIG. 31 , and for purposes of brevity will not be repeated. The span 538 of the bracket 562 serves to position the support beam 116 a predetermined distance from a substructure “S” and the substructure engaging portion 564 , 566 serves to attach the bracket 562 to a substructure “S”.
[0162] Referring now to FIGS. 33 and 19 , the operative connection is reversed from FIG. 32 . That is, the support beam 116 includes an extension 508 that terminates in an attachment member 570 having a dart-shaped head 594 with shoulders 596 , 598 . The bracket 580 includes two spaced-apart resilient walls 582 , 584 having confronting arms 586 , 588 , which define a slot 590 and channel 592 that are sized to admit and retain the dart-shaped attachment member 594 in a constrained relation, as discussed above. As with the aforementioned embodiments, the support beam 116 need not extend along the length of the bracket 562 , and the bracket 562 may be operatively connected to a substructure “S” using a variety of fastening elements.
[0163] With reference to FIGS. 34 and 35 , support beam 116 depicted is similar to the support beam of prior embodiments in that it includes a web 510 from which a plurality of ribs 503 , 504 , 505 and 506 extend. In a departure from this previous embodiment, the support beam 116 includes an extension 500 that terminates with an attachment member 512 . Preferably, the extension 500 is aligned with, and extends from the web 510 so as to position the attachment member 512 is a predetermined distance from the plurality of ribs. Note that the ribs 503 , 504 , 505 and 506 are reversed relative to each other so that the pair of opposing ribs 505 and 506 are now forward relative to the opposing pair of ribs 503 and 504 . In FIG. 34 , the attachment member 512 is depicted as having feet 516 and 518 , however it is understood that the attachment member may take other forms such as those depicted in FIGS. 18-20 . Note also, that the pair of forwardly facing opposing ribs 505 , 506 are somewhat thicker than the pair of opposing ribs 503 , 504 . This feature allows the support beam 116 to have a viewable surface 507 , which may form part of an observed wall. As depicted in FIGS. 34 and 35 , ribs 505 and 506 may be coplanar or collateral relative to the viewable faces 320 , 322 of blocks in a wall structure.
[0164] Referring again to FIGS. 34 and 35 , the blocks 312 that are used with the aforementioned beam 116 are similar to the blocks 112 depicted in the wall construction 110 of FIG. 30 . That is, each block 312 has a front face 320 , a rear face 322 , a top surface, a bottom surface and opposing sides.
[0165] Each block 312 differs from the block 112 depicted in FIG. 30 in several respects. First, block 312 has only one pair of opposing fingers 328 a ′, 328 b ′ instead of the pair of opposing fingers depicted in FIG. 33 . Thus, each block 312 does not have a groove that obscures a support beam rib. Instead of a groove, each block 312 has opposing ledges 334 , 336 defined by pairs of side surfaces 330 a, 330 b, 330 c, 330 d and fingers 328 a ′, 328 b ′, respectively. Preferably, the thickness of the ledges 336 , 338 will be substantially the same as the thickness of opposing ribs 505 , 506 to enable the viewable surface of a wall structure to be substantially contiguous. However, it is understood that the thicknesses of the ledges 336 , 338 and/or opposing ribs 505 , 506 need not be substantially the same. For example, the thickness of the ribs 505 , 506 may be greater than the thickness of the ledges 336 , 338 of the blocks so that the viewable surface 507 of a support beam projects outwardly with respect to the viewable surface of the blocks of the wall structure (as in FIG. 35 ), or the thickness of the ribs 505 , 506 may be less than the thickness of the ledges 336 , 338 of the blocks so that the viewable surface 507 of the support beam is recessed with respect to the viewable surface.
[0166] Another difference between block 312 and block 112 is that the opposing laterally extending, aligned fingers 328 a ′, 328 b ′ are offset from the center plane of the block 312 . As seen in FIGS. 34 and 35 this allows blocks to be operatively connected to a support beam in several configurations. In FIG. 34 , for example, blocks 312 are operatively connected to a support beam so that front face 320 (left side) and rear face 322 (right side) are substantially flush with the viewable surface 507 of the support beam 116 . As with the aforementioned blocks of FIG. 30 , the front and rear faces may have the same surface or different surfaces. Here, the front face 320 on the left side of FIG. 34 is depicted as being smooth, while the rear face 322 on the left side of FIG. 34 is depicted as being roughened. The viewable surfaces on the right side of FIG. 34 are reversed. In FIG. 35 , the blocks 312 have been rotated so that when they are operatively connected to the support beam 116 they are set back from the viewable surface 507 . It will be appreciated that the blocks 312 need not be all coplanar or set back with respect to the viewable surface 507 of the support beam 116 . Combinations of setback blocks and coplanar blocks are possible to create a myriad of wall surfaces. It is contemplated that such combinations may be arranged into identifiable forms or patterns and may also be arranged to display alphanumeric characters and the like. Note that the viewable surface 507 may be provided with a textured or otherwise decorated surface, which matches the surfaces of adjacent blocks. Alternatively, as depicted in FIG. 34 , the forward facing surface of the support beam can be provided with a cap or strip 145 of material with a viewable surface 147 , which may be textured or otherwise decorated as desired and which may be affixed or attached to the viewable surface 147 in a conventional manner.
[0167] Referring now to FIG. 36 , another preferred embodiment depicts a post 600 , which has been provided with a plurality of connectors to enable the post to support a plurality of wall structures. In this embodiment, the post 600 includes opposing sides 602 , 604 from which extend a web 606 and a bracket 612 , respectively. A pair of ribs 608 , 610 extend laterally in opposite directions from the web 606 , while the bracket 612 includes the slot 614 and channel structure 616 similar to the slot and channel structures described and shown in FIG. 18 , respectively. Thus, with this embodiment, blocks may be directly connected to the post 600 at side 602 or connected indirectly at side 604 via an appropriately configured support beam.
[0168] Other combinations of operative connections may also be used. For example, the post 600 may be provided with two direct connectors (webs with laterally extending ribs) or the post may be provided with two indirect connectors (attachment members, such as channels). As will be appreciated, the post 600 may be operatively connected to a substructure such as a footing or foundation, or be set into the ground using known techniques and technologies. While the post 600 is depicted as having a hollow cross-section, it is understood that the post may also be a solid in cross-section or may have a reinforcing structure such as a pipe or a rod received therein (see, for example, FIG. 39 ).
[0169] FIGS. 37-37 b illustrate additional embodiments of the present invention. FIG. 37 shows a support beam 16 having a pair of leg structures 654 that are constructed and arranged to secure a wall comprising columns 14 of blocks 12 to an existing support structure 658 . The support structure 658 may be a building or any other type of structure that may support a wall structure 10 according to the present invention. Legs or leg portions 656 of the leg structures 654 extend rearwardly from the support beam 16 and are preferably secured to ribs 38 b thereof. The leg structures 654 may also be formed as part of the web 36 of the support beam 16 . The leg portions 656 have a foot 660 , which extends laterally therefrom to provide a point of connection for the support beam 16 to the existing support structure 658 . Nails, screws, or other appropriate fasteners 662 may be driven through the feet 660 of the support beam 16 and into the sheathing 664 of the typical wall of the wall of the existing structure 658 . The sheathing 664 is typically supported by a plurality of horizontal girts 666 . Once the support beam 16 has been secured to the existing structure 658 , blocks 12 are stacked between respective support beams 16 as illustrated in FIG. 37 such that ribs 38 a of the support beam 16 reside in grooves 34 in the sides of the blocks 12 .
[0170] In order to prevent the inflow of water into the wall structure 10 , it may be desirable to apply a bead of a waterproof material 670 , such as mastic or caulk, along the horizontal surfaces of the blocks 12 . The bead of waterproof material 670 forms a seal between the upper surface 24 of the lower block 12 upon which the waterproof material 670 has been applied and the lower surface 26 of the block 12 immediately above the lower block 12 . It will be appreciated that mastic or caulk may also be applied to the vertical side surfaces of the blocks (not shown).
[0171] Legs or leg portions 656 of support beam 16 preferably extend rearwardly from the ribs 38 b in a perpendicular relationship thereto. Similarly, it is preferred that the feet 660 of the support beam 16 extend laterally perpendicular to the leg portions 656 . The perpendicular relationship of the feet and legs to the remainder of the support beam 16 is the preferred embodiment thereof since the purpose of the leg portions 656 and the feet 660 to provide an offset for the wall structure from the existing structure 658 . This offset allows a wall structure 10 to be secured over uneven surfaces such as corrugated steel siding 668 , as illustrated in FIG. 37 . As can be seen, legs or leg portions 656 of support beam 16 are sufficiently long such that the support beam 16 clears ridge 673 of the steel siding 668 . As can be appreciated, steel siding 668 typically presents a plurality of vertically flat attachment surfaces. Where a wall structure 10 is to be applied to a wall of an existing structure 658 that is not vertically smooth, furring strips or blocking may be fastened to the wall of exterior of the existing structure 658 as needed. As support beams 16 provide no vertical support for the blocks 12 , the blocks must be provided with some sort of foundation. Examples of suitable foundation include, but are not limited to, a concrete pad or footing that is sunk into the ground, and a cantilever ledge or bracket which is securely affixed to the wall of the existing structure.
[0172] FIG. 37 a illustrates a support beam 16 having two pairs of ribs 38 a and 38 b separated by a web 36 and only a single leg structure 654 comprising a leg portion 656 and a foot 660 . The embodiment of FIG. 37 a is particularly useful when an obstruction, such as ridge 673 of steel siding 668 would prevent one of the leg structures 654 illustrated in FIG. 37 from securely contacting the wall of the structure 658 . Fasteners 662 are sufficient to provide the requisite lateral support for the wall structure 10 . The support beam 16 having only a single leg structure 654 may be rotated end-for-end depending on the offset location of an obstruction such as ridge 673 .
[0173] Preferably, the support beams of the present invention will be extruded or molded from a material such as a plastic, a fiber reinforced resin, or a metal such as aluminum. In addition to forming embodiments of support beams 16 having the respective profiles of the support beams illustrated in FIG. 37 a, it is possible that one leg structure 654 could be removed from a support beam 16 such as the support beam 16 of FIG. 37 having two leg structures 654 , thereby resulting in the support beam 16 embodiment illustrated in FIG. 37 a. However, where a single leg structure 654 would be sufficient to provide the needed lateral support for a wall structure 10 , it would be more economical to manufacture support 16 having only a single leg structure 654 . As used herein, the term “forward” means away from the center of the elevated structure (and along the “z” direction in a three-dimensional coordinate system relative to a block) and the term “rearward” means toward the center of the elevated structure (also along the “z” direction in a three-dimensional coordinate system relative to a block).
[0174] FIG. 37 b illustrates a support beam 16 that is constructed and arranged to provide lateral support to a wall structure 10 as described in conjunction with FIGS. 37 and 37 a. The main difference here being that the support beam 16 of FIG. 37 b has a pair of ribs 38 a and only a single rib 38 b extending from the web 36 . A leg structure 654 extends rearwardly from the rib 38 b preferably in a perpendicular relation thereto. While it is preferred that the leg or leg portion 656 and foot 660 be arranged at right angles to each other and to the ribs 38 b of the support beam 16 , these structures may be arranged at any angle to one another provided, of course, that there is a sufficient offset from the wall of the existing structure 658 to allow installation of the blocks 12 of the wall structure 10 and that the foot 660 of leg structure 654 may be securely fastened to an supporting structure 658 .
[0175] FIG. 38 illustrates a double-ended support beam 80 b, which is useful for constructing a dual wall structure 10 having a front face 74 and a rear face 76 . The space between the front and rear faces 74 , 76 of the wall structure 10 may remain hollow or may be filled. Each end of the double-ended support beam 80 b comprises a support beam or block engagement structure having a cross-sectional profile similar to the support beam illustrated in FIG. 11 arranged back-to-back in a spaced apart relation and connected by a spacer web 82 b. Spacer web 82 b is connected to the base pair of ribs 38 b of each of the support beam portions in a perpendicular fashion. In this manner, support beam 80 b couples dual walls of the wall structure 10 to provide mutual lateral support. Further support can be had by backfilling the space between the front and rear sides of the dual wall structure 10 with gravel, earth, sand, concrete or insulative material 79 . Preferably, it will be appreciated that a cap 81 , such may be placed over the top of the dual wall structure 10 to prevent the ingress of water, debris, or nuisance animals. It will also be appreciated that such a cap 81 may be secured to the dual wall structure by known technologies and techniques, if desired. See, for example, the use of adhesive material depicted in FIG. 37 .
[0176] FIG. 39 illustrates a single-sided wall structure 10 comprising columns 14 of blocks 12 supported by a post-like support beam 84 . Support beam 84 comprises a post 85 having extending therefrom a web 36 . A pair of ribs 38 a extend laterally from the web 36 in the same manner as the ribs 38 a of support beams 16 described in conjunction with FIG. 11 . As installed, post 85 is preferably rigidly seated in a footing or foundation set into the ground below the wall structure 10 . As can be appreciated, blocks 12 are stacked between respective post support beams 84 as described above. The post 85 preferably has a hollow cross-section. However, post 85 may also be solid in cross-section or be provided with a reinforcing structure such as a pipe or a rod received therein. An alternate embodiment for the post or support beam 84 involves securely seating a plurality of rods or members in footings or a foundation beneath the wall structure 10 and sliding the post or beam 84 of the type illustrated in FIG. 39 thereover. Blocks 12 would then disposed between respective pairs of post support beams 84 as described above.
[0177] Now turning to FIG. 40 , a wall structure 10 is depicted as it may be used in conjunction with an elevated structure “S.” As with the wall structure generally depicted in FIGS. 4 and 22 , this wall structure 10 is comprised of a plurality of blocks 12 arranged in columns 14 , having the columns 14 held in place by vertically oriented, lateral support beams 16 , and with each beam 16 operably connecting adjacent columns 14 together. The brackets 19 used in this embodiment, however, differ from the “U”-shaped brackets 18 of the previously described embodiment in several respects. First, the brackets 19 are shaped differently than the bracket 18 of FIGS. 4 and 22 . Instead of having an inverted “U”-shaped configuration as with bracket 18 , the bracket 19 of this embodiment has a single, downwardly extending portion. Another difference is that rather than positioning a portion of a block 12 within an opening 50 defined by a pair of walls 44 , 46 , the bracket 19 of the embodiment has a wall engaging portion 62 that extends downwardly into vertical grooves 34 at the sides of blocks 12 . Another difference between brackets 18 and 19 is that bracket 18 connects to a column 14 in a generally central location, whereas the brackets 19 of this embodiment connect at the sides of column 14 . As with the previously described brackets 18 , brackets 19 help to stabilize and prevent the wall structure 10 from tipping rearwardly or forwardly. The brackets 19 also prevent the structure from shifting from side to side.
[0178] For purposes of illustration, the size of the wall structure 10 of this embodiment has been limited three columns 14 and four courses, with the two uppermost blocks of the left column 14 removed to reveal the juxtaposition between the brackets 19 , beams 16 and blocks 12 . Note that the wall structure 10 depicted in this embodiment also includes a plurality of footings or support pads 80 a that are positioned beneath the columns 14 at the junction where they connect to the beams 16 . Preferably, each footing or support pad 80 a may be provided with a setting channel 82 a that is configured and arranged to receive the bottom edges of one or more columns of blocks in a constrained relation. Note that the footing or support pad 80 a for the middle and right columns 14 has been removed and replaced with an “L”-shaped support base or angle iron (see, for example, the support base in FIGS. 3 and 53 ) that spans the bottom of the middle and right columns 14 . This construction can be used when the use of individual, regularly spaced footings 80 a is not possible or desirable. Also note that the wall structure 10 is depicted as having a running bond on its three lowermost courses. As can be seen, the bottom and third courses of blocks do not have splitting recesses. They do, however, have their perimeter marginal areas 23 a - d worked. The second course of blocks, on the other hand, have splitting recesses 21 and have only their horizontal marginal areas worked. Thus, each column 14 will have blocks with alternating front faces. When the columns of blocks are positioned adjacent each other in the normal assembly procedure some of the blocks 12 will form tight joints 31 and some of the blocks will form joints that appear substantially thicker. Thus, from a distance, the wall structure 10 will give the impression that it was constructed of blocks and mortar in a conventional manner. It will be appreciated that the externally viewable surface of the wall structure depicted in FIG. 40 is merely one example of an externally viewable surface, and that many other externally viewable surfaces are possible.
[0179] Turning now to FIGS. 41-43 , a preferred embodiment of bracket 19 depicted in FIG. 40 will now be discussed. As can be seen in FIGS. 41 and 42 , the bracket 19 comprises a structure engaging portion 60 and a wall engaging portion 62 . The wall engaging portion 62 of the bracket 19 includes opposing surfaces 64 , 66 , which are arranged and configured to contact a portion of a beam 16 and a portion of a block, respectively. If desired, the wall engaging portion 62 may be provided with strengthening creases 67 . As will be appreciated, the wall engaging portion 62 of the bracket 19 has a width 77 and a length 78 whose dimensions correspond to the particular blocks that are being used to construct a wall, and will be discussed only in general terms. Thus, the width 77 may range from a distance roughly equivalent to the depth of a single groove 34 in one block, to a distance roughly equivalent to the depth of two grooves 34 of opposing blocks. The width may also be roughly equivalent to the width of the web 36 of the beam 16 so that the wall engaging portion of the bracket may be oriented transversely to the wall structure. The length 78 may also vary depending upon the requirements of the wall structure (not shown). A typical width and length for a wall engaging portion 62 may be on the order of about two inches by about four inches, and a typical width and length for a structure engaging portion 60 may be on the order of about two inches by about one-and-a-half inches. It will be appreciated that the bracket 19 may be formed from material that may be modified or otherwise altered to fit a particular application. Thus, for example, the width and/or length of the wall engaging portion may be cut-to-length length or otherwise tailored at a jobsite without appreciably delaying or hindering construction.
[0180] The structure engaging portion 60 of the bracket 19 also includes opposing surfaces 68 , 70 . However, in this embodiment, only opposing surface 68 is configured to contact a portion of a structure (See, FIGS. 40 and 42 ). As depicted, the structure engaging portion 60 is attached to a lower surface of a structure “S” by an upwardly extending fastener or fastening element 73 . It is understood, however, that the attachment surface of the structure can be an upper surface, in which case the opposing surface 70 would contact the surface of the structure “S” and the fastener would extend downwardly from surface 68 (shown in dashed lines). As shown in FIG. 42 , the structure engaging portion 60 and the wall engaging portion 62 are planar and substantially orthogonal with respect to each other. It is understood, however, that the wall engaging portion 62 and the structure engaging portion 60 need not be orthogonal to each other. They may be linearly aligned, for example. It is also envisioned that the wall and structure engaging portions may be formed in other configurations. For instance, either portion 60 , 62 may be formed with U-shaped profiles that enable the portions 60 , 62 to straddle sections of the structure and/or wall. That is the structure engaging portion may be formed so that it may straddle the bottom and side edges of a structure and the wall engaging portion may be formed to engage a wall structure at its front and/or rear surfaces. The structure engaging portion 60 is provided with an aperture 72 that may be used with a conventional fastener 73 . For purposes of this application, the term “fastening element” or “fastener” may include mechanical fasteners such as screws, nails, bolts, rivets, or their equivalents, and/or adhesives, weldments, or the like. Alternatively, the structure engaging portion 60 may be provided with an integral fastening element so that the portion 60 may be driven into or otherwise attached to a support.
[0181] Another embodiment of a bracket is depicted in FIGS. 44 and 45 . As can be seen, the bracket 200 generally comprises a structure engaging portion 202 and a support beam engaging portion 203 . More specifically, the structure engaging portion 202 comprises a first member 204 and a second member 206 , which are angled with respect to each other to form a generally “L”-shaped form. The first and second members may be provided with apertures 208 that permit attachment to a structure with fastening elements such as nail and threaded fasteners. It will be appreciated, though, that attachment may also be achieved with suitable adhesives used in lieu of or in addition to fastening elements. The support beam engaging portion 203 comprises a web 210 and a pair of legs 212 , 214 , which are angled with respect to the web 210 to form a generally “L”-shaped form. The web 210 includes an aperture 220 that is accessible through a slot 222 defined by edges 216 and 218 of legs 212 and 214 , respectively. The aperture 220 and slot 222 are configured to slidingly receive a pair of ribs and a portion of a web of a support beam. As depicted in FIGS. 44 , and 45 , when a support beam is attached to the bracket, the support beam is able to move in a constrained manner relative thereto. This feature allows, the bracket to be attached at different points along a structure as well as different points along a beam. Moreover, it allows a wall construction to be self-adjusting. An application of bracket 200 , a support beam 116 , and a plurality of brackets 112 as can be seen in FIG. 53 .
[0182] Another embodiment of a bracket is depicted in FIGS. 46 and 47 . The bracket 230 of this embodiment comprises a structure engaging portion 232 , a connecting web 234 , and a support beam engaging portion 235 that comprises a rib 236 and a coupling element 238 . The bracket 230 is configured and arranged to operatively connect a support beam (such as the support beams depicted in FIGS. 11 a, 28 , 44 , and 45 ) to a support. As with the previously described bracket embodiment ( 200 ), the structure engaging portion 232 may be provided with apertures 240 that permit the bracket to be attached to a structure with conventional fastening elements. Alternatively, the bracket may be attached to a support using other known technologies and techniques. When the bracket 230 is used to operatively connect a beam to a support, the coupling element 238 of the beam engaging portion 235 is slidingly retained between one of the coupling elements 186 and one of the pairs of ribs 182 a. Thus configured, a support beam is able to move in a constrained or sliding manner relative thereto. This feature allows the bracket to be attached at different points along a structure as well as along different points along a beam. The bracket also permits a wall structure to be self-adjusting.
[0183] Referring now to FIGS. 48 and 49 , an alternative embodiment of an attachment bracket 90 is depicted. Here, the bracket 90 is similar to earlier discussed bracket 18 (see FIGS. 4 and 22 ) in that it has opposing walls 92 , 94 that are connected to each other by a top wall or span 96 , and which retain a portion of a block in a constrained relation. However, in this embodiment, the shorter of the two walls 94 is provided with an arm 98 that is movably attached thereto by a connector 100 , such as a rivet. As depicted in FIG. 48 , the arm 98 is in a first position where it extends towards a block (not shown). In this position, the bracket 90 resembles bracket 18 (see FIG. 4 ) and may be attached at or near the underside of a structure in the usual manner, via the span 96 .
[0184] In situations where it is not possible to easily attach the bracket 90 to the underside of a structure, a user of the bracket 90 need only rotate the arm 98 to a second position so that it extends away from a block (not shown) as depicted in FIG. 49 . In this position, the bracket may be attached to a vertical surface via the arm by a conventional fastener, such as a nail or screw, which extends through an aperture 102 . Alternatively, the bracket may be secured to a vertical surface by a suitable adhesive. As will be appreciated, the bracket 90 may be oriented so that either one of the walls 92 , 94 may be in confronting relation with the front or rear face of a block.
[0185] FIGS. 50-52 illustrate brackets and beams as shown in FIGS. 2 and 2 a as they may be used in conjunction with blocks to form alternative structures. Starting with FIG. 50 , bracket 354 is depicted. The bracket 354 is similar to previously described bracket 200 shown in FIGS. 44 and 45 in that it generally comprises a structure engaging portion and a support beam engaging portion. However, there are differences. Instead of having a structure engaging portion that comprises a first member and a second member, structure engaging portion 356 of bracket 354 comprises a single or first member 357 . As depicted, the first member 357 is provided with an aperture 360 that facilitates attachment to a structure with fastening elements such as nails, threaded fasteners, or rivets. It will be appreciated, however, that an aperture or apertures need not be present in order to attach the bracket to a structure. The fastening element(s) may be driven through the first member, if desired. Additionally, it will also be appreciated that attachment may also be achieved with suitable adhesives, in lieu of, or in addition to, fastening elements. Continuing on, the support beam engaging portion 358 comprises a web 362 and a pair of legs 364 , 366 , which are angled with respect to the web to form a generally “L”-shaped form. The web 362 includes an aperture 368 that is accessible through a slot 370 defined by edges 372 and 374 of legs 366 and 364 , respectively. The aperture 368 and slot 370 are configured to slidingly receive a leg portion 732 b and foot 734 of a support beam 716 of FIGS. 51 and 52 .
[0186] Generally, the bracket of FIG. 50 may be used with beams and blocks as shown in FIGS. 51 and 52 to form wall structures similar to wall structures previously discussed. More specifically, support beam 716 , as shown, comprises an elongated spine or web 718 and plurality of ribs 720 and 722 , 724 and 726 , which are arranged in a substantially coplanar and collateral relation so that the first pair of ribs 720 , 722 , which are substantially coplanar, extend away from each other in a manner similar to other embodiments already described. As shown, a first pair of ribs 720 , 722 are designed to engage the grooves 728 of one or more blocks of a structure. As shown in FIG. 51 , the support beams 716 may be oriented in a generally vertical direction, or as in FIG. 52 , a generally horizontal direction. Note that in either orientation, the blocks would essentially be self-supporting.
[0187] In addition, the web also includes a second pair of ribs 724 , 726 which are also substantially coplanar and which extend away from each other. Note that the pairs of ribs 720 , 722 and 724 , 726 are in substantially collateral or parallel relation with respect to each other and are spaced apart from each other by a distance defined by the web 718 . The support beam 716 also includes a pair of pair of leg structures 730 having leg portions 732 a - b that are similar to the leg structures of FIG. 37 in that they extend rearwardly away from ribs 724 , 726 and which form a generally U-shaped channel therewith. The support beam differs, however, in that only one of the leg portions 732 b includes a foot 734 . As depicted, the foot 734 extends laterally away from the leg portion 732 b and is generally parallel with ribs 720 , 722 . As with the embodiment of FIGS. 2 and 2 a, the foot may be connected directly or indirectly to a support structure. However, as depicted, the beams of FIGS. 51 and 52 are operatively connected to a structure by a plurality of brackets 354 , which are attached to suitable structural members. With such an arrangement the beams, which are slidingly constrained by the brackets, permit blocks to move without destroying the integrity of the structure.
[0188] As shown in FIG. 53 , a bracket 200 is used as part of a wall system to operatively connect a support beam 116 to a structure “S”. Note that the lowermost course of blocks is supported by a horizontally oriented, elongated base, preferably in the form of an angle iron 83 , which can be used with one or more support pads or footings 80 a, if desired. The angle iron 83 includes an upper surface 86 , that is configured to receive one or more blocks thereon and a sidewall 88 that prevents the block(s) from being shifted backwards. Optionally, the upper surface and/or the sidewall of the angle iron 83 may be provided with adhesive material to enable the block(s) to be secured thereto, which increases the strength and stability of the wall structure. Often, a completed wall structure will terminate in an upper course of blocks that is offset from the structure “S”. In these situations, one or more capstones or sills 113 may be used to provide a finished look, with the sills being positioned upon the upper course of blocks. As will be understood, the sills may be attached to the upper course of blocks using known technologies and techniques, such as adhesives. Sometimes, there is a gap between a capstone or sill 113 and the structure “S”, through which moisture, debris, insects, etc. may pass. This gap can be effectively closed using a sealing element 250 as depicted in FIGS. 54 and 55 .
[0189] The sealing element 250 of the present invention generally comprises a body having a plurality of flexible, resilient strips that provide an effective seal between the sills or finish moldings and the structure. More specifically the sealing element 250 comprises a sealing panel 251 that is formed by first and second strips 252 and 254 and an attachment portion 255 that is formed by third and fourth strips 256 and 258 . The attachment portion 255 is operatively connected to the panel 251 such that the third and fourth strips extend therefrom in a generally radial relation. As can be seen in FIGS. 54 and 55 , the sealing element is in an unflexed state and the third and fourth strips 256 and 258 define an angle 262 , which can range from about 15 degrees to about 165 degrees. The preferred range of the angle however is in the range of about 45 degrees to about 75 degrees. The third and fourth strips 256 and 258 may include beads or wales 260 that enable the sealing element to anchor itself into position. In use, the third and fourth strips 256 and 258 of the attachment portion 255 are pinched together and inserted into the gap between the wall and a structure, as shown in FIGS. 53 and 56 . As the attachment portion 255 is seated, the first and second strips 252 , 254 of the panel 251 contact the surfaces of the sill 113 and the structure “S” and exert normal forces there against. Thus, effectively seals the gap. As will be appreciated, the sealing element is maintained in position by the beads 260 that, due to the resilient nature of the strips, tend to catch against irregularities in the surfaces of the sill and the structure “S” and resist movement. As will be appreciated, the sealing element 250 may be oriented so that the first and third strips 252 , 256 contact the sill 113 and the second and fourth strips 254 , 258 contact the structure “S”, if desired.
[0190] There may be times when it is not possible, practical, or desirable to use beams or the combination of beams and brackets, as previously described to operatively connect blocks to a structure. In such cases, blocks may be attached to a structure using only brackets. Generally, as shown in FIGS. 57-59 , each bracket comprises a structure engagement portion and a block engagement portion that are spaced from each other by a web. In one preferred embodiment, shown in FIG. 57 , the bracket 754 comprises a structure engagement portion 756 that is similar to previously described structure engagement portions in that it is configured and arranged to act as a point of attachment to a structure, and comprises a member 766 having an aperture 768 , with the aperture configured to be used in conjunction with a fastening element such as a nail, screw or rivet. The bracket also comprises a web 762 and a panel 760 , which collectively serve to connect the structure engagement portion 756 to a block engagement portion 758 , and which serve to position a block a predetermined distance from a structure to which it may be attached. While the structure engagement portion 756 and the web 762 form a generally 90 degree angle therebetween, it will be understood that the angle may be modified depending upon the configuration of the structure to which it is attached. Thus, for example, the angle could be acute or obtuse. The block engagement portion 758 , which is connected to the web, comprises a plurality of generally planar sections 759 a, 759 b, 759 c, 759 d, and which are configured to cooperatively engage portions of one or more blocks such that forward and rearward movement of the blocks relative to the structure, is limited. This is achieved by forming some sections so that they are substantially coplanar with each other and forming some sections so that they are substantially parallel to each other (when viewing the bracket on edge). Note that those sections that are coplanar with each other extend away from the web in opposite directions, while those sections that are parallel to each other and spaced from each other by a panel, need not be so restricted. Note also, that the sections are configured and arranged so that when viewed from front, the sections do not overlap or superimpose upon each other. As will be appreciated, this permits to bracket to be manufactured from material such as metal and formed into the desired configuration with a series of cuts and bends. It will be understood, however, that the bracket may be manufactured from different materials (eg. plastics) and formed using different techniques (eg. molding) without departing from the spirit and scope of the invention. In use, as shown in FIG. 60 (right side), the bracket 754 operatively connects two blocks to a structure “S”.
[0191] Alternative embodiments of bracket 754 are depicted in FIGS. 58 and 59 . As with the previously described bracket, these brackets 754 ′ and 754 ″, respectively, comprise a structure engagement portion, a web, and a block engagement portion. The structure engagement portions are similar to the structure engagement portion of FIG. 57 in that they are configured and arranged to act as a point of attachment to a structure, and comprises a member 766 ′, 766 ″ having an aperture 768 ′, 768 ″ respectively, with the aperture configured to be used in conjunction with a fastening element such as a nail, screw or rivet. Likewise, the brackets also comprise a web 762 ′, 762 ″ which serve to connect the structure engagement portion 756 ′, 756 ″ to a block engagement portion 758 ′, 758 ″, respectively, and which serve to position a block a predetermined distance from a structure to which it may be attached. In a departure from the web structure of FIG. 57 , the webs of FIGS. 58 and 59 include an additional aperture 764 ′, 764 ″ that is configured and arranged to act as a point of attachment to a structure (see, for example, the left side of FIG. 60 ). As with the previously describe embodiment of FIG. 57 , the angle formed by the structure engagement portion and the web (shown generally as 90 degrees) may be modified depending upon the configuration of the structure to which it is attached. The block engagement portions 758 ′, 758 ″, which are connected to respective webs, each comprise a plurality of sections 759 a ′ and 759 b ′, 759 a ″ and 759 b ″, which are configured to cooperatively engage portions of one or more blocks such that forward and rearward movement of the blocks relative to the structure, is limited. This is achieved by forming the sections so that they are generally coplanar to each other (when viewing the bracket on edge) and able to engage opposing surfaces in one or more blocks. A feature common to each of the sections 758 a ′ and 758 b ′, 758 a ″ and 758 b ″ is that they have a thickness 776 ′, 776 ″ that effectively spans the distance between the opposing surfaces into which they are positioned, such that forward and rearward movement of the blocks relative to the structure, is limited. In particular, the effective thickness of each section 776 ′, 776 ″ of bracket 754 ′, 754 ″ is achieved by forming creases 772 in each section to form darts 770 , whose ends define the extent of the effective thickness 776 ′. A strengthening rib 774 may be provided for each section, if desired. The effective thickness 776 ′ of the sections 770 of bracket 754 ′ is achieved by forming the sections so that they have high and low block contacting areas, preferably by curving the sections and more preferably by forming the sections into the shape of arcs. FIG. 60 is a plan view of the brackets of FIGS. 57 and 59 operatively connecting blocks of the present invention to a substructure.
[0192] It is to be understood that even though numerous characteristics and advantages of various embodiments of the present invention have been set forth in the foregoing description, together with details of the structure and function of various embodiments of the invention, this disclosure is illustrative only, and changes may be made in detail, especially in matters of structure and arrangement of parts within the principles of the present invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | The present invention relates to decorative and structural blocks designed to be installed as skirting structures for buildings, elevated structures and structural elements such as posts. More particularly, the present invention relates to a system that uses specifically designed and manufactured masonry blocks that are used in conjunction with specifically designed support beams and/or brackets to provide durable, attractive, easy to assemble surfaces or skirting structures. The blocks are shaped to be stacked in vertically independent, self-supporting columns, strengthened and linked together by specially shaped, lightweight, lateral support beams positioned between adjacent columns, and which may be attached directly or indirectly to a sub-structure. | 4 |
FIELD OF THE INVENTION
The field of this invention is tools run downhole preferably on cable and which operate with on board power to perform a downhole function and more particularly a downhole shifting tool.
BACKGROUND OF THE INVENTION
It is a common practice to plug wells and to have encroachment of water into the wellbore above the plug. FIG. 1 illustrates this phenomenon. It shows a wellbore 10 through formations 12 , 14 and 16 with a plug 18 in zone 16 . Water 20 has infiltrated as indicated by arrows 22 and brought sand 24 with it. There is not enough formation pressure to get the water 20 to the surface. As a result, the sand 24 simply settles on the plug 18 .
There are many techniques developed to remove debris from wellbores and a good survey article that reviews many of these procedures is SPE 113267 Published June 2008 by Li, Misselbrook and Seal entitled Sand Cleanout with Coiled Tubing: Choice of Process, Tools or Fluids? There are limits to which techniques can be used with low pressure formations. Techniques that involve pressurized fluid circulation present risk of fluid loss into a low pressure formation from simply the fluid column hydrostatic pressure that is created when the well is filled with fluid and circulated or jetted. The productivity of the formation can be adversely affected should such flow into the formation occur. As an alternative to liquid circulation, systems involving foam have been proposed with the idea being that the density of the foam is so low that fluid losses will not be an issue. Instead, the foam entrains the sand or debris and carries it to the surface without the creation of a hydrostatic head on the low pressure formation in the vicinity of the plug. The downside of this technique is the cost of the specialized foam equipment and the logistics of getting such equipment to the well site in remote locations.
Various techniques of capturing debris have been developed. Some involve chambers that have flapper type valves that allow liquid and sand to enter and then use gravity to allow the flapper to close trapping in the sand. The motive force can be a chamber under vacuum that is opened to the collection chamber downhole or the use of a reciprocating pump with a series of flapper type check valves. These systems can have operational issues with sand buildup on the seats for the flappers that keep them from sealing and as a result some of the captured sand simply escapes again. Some of these one shot systems that depend on a vacuum chamber to suck in water and sand into a containment chamber have been run in on wireline. Illustrative of some of these debris cleanup devices are U.S. Pat. No. 6,196,319 (wireline); U.S. Pat. No. 5,327,974 (tubing run); U.S. Pat. No. 5,318,128 (tubing run); U.S. Pat. No. 6,607,607 (coiled tubing); U.S. Pat. No. 4,671,359 (coiled tubing); U.S. Pat. No. 6,464,012 (wireline); U.S. Pat. No. 4,924,940 (rigid tubing) and U.S. Pat. No. 6,059,030 (rigid tubing).
The reciprocation debris collection systems also have the issue of a lack of continuous flow which promotes entrained sand to drop when flow is interrupted. Another issue with some tools for debris removal is a minimum diameter for these tools keeps them from being used in very small diameter wells. Proper positioning is also an issue. With tools that trap sand from flow entering at the lower end and run in on coiled tubing there is a possibility of forcing the lower end into the sand where the manner of kicking on the pump involves setting down weight such as in U.S. Pat. No. 6,059,030. On the other hand, especially with the one shot vacuum tools, being too high in the water and well above the sand line will result in minimal capture of sand.
What is needed is a debris removal tool that can be quickly deployed such as by slickline and can be made small enough to be useful in small diameter wells while at the same time using a debris removal technique that features effective capture of the sand and preferably a continuous fluid circulation while doing so. A modular design can help with carrying capacity in small wells and save trips to the surface to remove the captured sand. Other features that maintain fluid velocity to keep the sand entrained and further employ centrifugal force in aid of separating the sand from the circulating fluid are also potential features of the present invention. Those skilled in the art will have a better idea of the various aspects of the invention from a review of the detailed description of the preferred embodiment and the associated drawings, while recognizing that the full scope of the invention is determined by the appended claims.
One of the issues with introduction of bottom hole assemblies into a wellbore is how to advance the assembly when the well is deviated to the point where the force of gravity is insufficient to assure further progress downhole. Various types of propulsion devices have been devised but are either not suited for slickline application or not adapted to advance a bottom hole assembly through a deviated well. Some examples of such designs are U.S. Pat. Nos. 7,392,859; 7,325,606; 7,152,680; 7,121,343; 6,945,330; 6,189,621 and 6,397,946. US Publication 2009/0045975 shows a tractor that is driven on a slickline where the slickline itself has been advanced into a wellbore by the force of gravity from the weight of the bottom hole assembly.
SUMMARY OF THE INVENTION
A shifting tool is run on slickline and has an on board power supply. Rotary motion of the motor is converted to linear motion of the shifting tool using a ball screw device. The grip is obtained with longitudinal motion of a grip linkage and an on board jar then can do the shifting. Alternatively a linear motor can be used to extend and retract the grip assembly and shift using the jar tool. Optionally the tool can be anchored and linear motion from the on board power source operating a motor can do the shifting.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section view of a plugged well where the debris collection device will be deployed;
FIG. 2 is the view of FIG. 1 with the device lowered into position adjacent the debris to be removed;
FIG. 3 is a detailed view of the debris removal device shown in FIG. 2 ;
FIG. 4 is a lower end view of the device in FIG. 3 and illustrating the modular capability of the design;
FIG. 5 is another application of a tool run on slickline to cut tubulars;
FIG. 6 is another application of a tool to scrape tubulars without an anchor that is run on slickline;
FIG. 7 is an alternative embodiment of the tool of FIG. 6 showing an anchoring feature used without the counter-rotating scrapers in FIG. 6 ;
FIG. 8 is a section view showing a slickline run tool used for moving a downhole component;
FIG. 9 is an alternative embodiment to the tool in FIG. 8 using a linear motor to set a packer;
FIG. 10 is an alternative to FIG. 9 that incorporates hydrostatic pressure to set a packer;
FIG. 11 illustrates the problem with using slicklines when encountering a wellbore that is deviated;
FIG. 12 illustrates how tractors are used to overcome the problem illustrated in FIG. 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 2 shows the tool 26 lowered into the water 20 on a slickline or non-conductive cable 28 . The main features of the tool are a disconnect 30 at the lower end of the cable 28 and a control system 32 for turning the tool 26 on and off and for other purposes. A power supply, such as a battery 34 , powers a motor 36 , which in turn runs a pump 38 . The modular debris removal tool 40 is at the bottom of the assembly.
While a cable or slickline 28 is preferred because it is a low cost way to rapidly get the tool 26 into the water 20 , a wireline can also be used and surface power through the wireline can replace the onboard battery 34 . The control system can be configured in different ways. In one version it can be a time delay energized at the surface so that the tool 26 will have enough time to be lowered into the water 20 before motor 36 starts running. Another way to actuate the motor 36 is to use a switch that is responsive to being immersed in water to complete the power delivery circuit. This can be a float type switch akin to a commode fill up valve or it can use the presence of water or other well fluids to otherwise complete a circuit. Since it is generally known at what depth the plug 18 has been set, the tool 26 can be quickly lowered to the approximate vicinity and then its speed reduced to avoid getting the lower end buried in the sand 24 . The control system can also incorporate a flow switch to detect plugging in the debris tool 40 and shut the pump 38 to avoid ruining it or burning up the motor 36 if the pump 38 plugs up or stops turning for any reason. Other aspects of the control system 32 can include the ability to transmit electromagnetic or pressure wave signals through the wellbore or the slickline 28 such information such as the weight or volume of collected debris, for example.
Referring now to FIGS. 3 and 4 , the inner details of the debris removal tool 40 are illustrated. There is a tapered inlet 50 leading to a preferably centered lift tube 52 that defines an annular volume 54 around it. Tube 52 can have one or more centrifugal separators 56 inside whose purpose is to get the fluid stream spinning to get the solids to the inner wall using centrifugal force. Alternatively, the tube 52 itself can be a spiral so that flow through it at a high enough velocity to keep the solids entrained will also cause them to migrate to the inner wall until the exit ports 58 are reached. Some of the sand or other debris will fall down in the annular volume 54 where the fluid velocity is low or non-existent. As best shown in FIG. 3 , the fluid stream ultimately continues to a filter or screen 60 and into the suction of pump 38 . The pump discharge exits at ports 62 .
As shown in FIG. 4 the design can be modular so that tube 52 continues beyond partition 64 at thread 66 which defines a lowermost module. Thereafter, more modules can be added within the limits of the pump 38 to draw the required flow through tube 52 . Each module has exit ports 58 that lead to a discrete annular volume 54 associated with each module. Additional modules increase the debris retention capacity and reduce the number of trips out of the well to remove the desired amount of sand 24 .
Various options are contemplated. The tool 40 can be triggered to start when sensing the top of the layer of debris, or by depth in the well from known markers, or simply on a time delay basis. Movement uphole of a predetermined distance can shut the pump 38 off. This still allows the slickline operator to move up and down when reaching the debris so that he knows he's not stuck. The tool can include a vibrator to help fluidize the debris as an aid to getting it to move into the inlet 50 . The pump 38 can be employed to also create vibration by eccentric mounting of its impeller. The pump can also be a turbine style or a progressive cavity type pump.
The tool 40 has the ability to provide continuous circulation which not only improves its debris removal capabilities but can also assist when running in or pulling out of the hole to reduce chances of getting the tool stuck.
While the preferred tool is a debris catcher, other tools can be run in on cable or slickline and have an on board power source for accomplishing other downhole operations. FIG. 2 is intended to schematically illustrate other tools 40 that can accomplish other tasks downhole such as honing or light milling. To the extent a torque is applied by the tool to accomplish the task, a part of the tool can also include an anchor portion to engage a well tubular to resist the torque applied by the tool 40 . The slips or anchors that are used can be actuated with the on board power supply using a control system that for example can be responsive to a pattern of uphole and downhole movements of predetermined length to trigger the slips and start the tool.
FIG. 5 illustrates a tubular cutter 100 run in on slickline 102 . On top is a control package 104 that is equipped to selectively start the cutter 100 at a given location that can be based on a stored well profile in a processor that is part of package 104 . There can also be sensors that detect depth from markers in the well or there can more simply be a time delay with a surface estimation as to the depth needed for the cut. Sensors could be tactile feelers, spring loaded wheel counters or ultrasonic proximity sensors. A battery pack 106 supplies a motor 108 that turns a ball shaft 110 which in turn moves the hub 112 axially in opposed directions. Movement of hub 112 rotates arms 114 that have a grip assembly 116 at an outer end for contact with the tubular 118 that is to be cut. A second motor 120 also driven by the battery pack 106 powers a gearbox 122 to slow its output speed. The gearbox 122 is connected to rotatably mounted housing 124 using gear 126 . The gearbox 122 also turns ball screw 128 which drives housing 130 axially in opposed directions. Arms 132 and 134 link the housing 130 to the cutters 136 . As arms 132 and 134 get closer to each other the cutters 136 extend radially. Reversing the rotational direction of cutter motor 120 retracts the cutters 136 .
When the proper depth is reached and the anchor assemblies 116 get a firm grip on the tubular 118 to resist torque from cutting, the motor 120 is started to slowly extend the cutters 136 while the housing 124 is being driven by gear 126 . When the cutters 136 engage the tubular 118 the cutting action begins. As the housing 124 rotates to cut the blades are slowly advanced radially into the tubular 118 to increase the depth of the cut. Controls can be added to regulate the cutting action. They controls can be as simple as providing fixed speeds for the housing 124 rotation and the cutter 136 extension so that the radial force on the cutter 136 will not stall the motor 120 . Knowing the thickness of the tubular 118 the control package 104 can trigger the motor 120 to reverse when the cutters 136 have radially extended enough to cut through the tubular wall 118 . Alternatively, the amount of axial movement of the housing 130 can be measured or the number of turns of the ball screw 128 can be measured by the control package 104 to detect when the tubular 118 should be cut all the way through. Other options can involve a sensor on the cutter 136 that can optically determine that the tubular 118 has been cut clean through. Reversing rotation on motors 108 and 120 will allow the cutters 136 to retract and the anchors 116 to retract for a fast trip out of the well using the slickline 102 .
FIG. 6 illustrates a scraper tool 200 run on slickline 202 connected to a control package 204 that can in the same way as the package 104 discussed with regard to the FIG. 5 embodiment, selectively turn on the scraper 200 when the proper depth is reached. A battery pack 206 selectively powers the motor 208 . Motor shaft 210 is linked to drum 212 for tandem rotation. A gear assembly 214 drives drum 216 in the opposite direction as drum 212 . Each of the drums 212 and 216 have an array of flexible connectors 218 that each preferably have a ball 220 made of a hardened material such as carbide. There is a clearance around the extended balls 220 to the inner wall of the tubular 222 so that rotation can take place with side to side motion of the scraper 200 resulting in wall impacts on tubular 222 for the scraping action. There will be a minimal net torque force on the tool and it will not need to be anchored because the drums 212 and 216 rotate in opposite directions. In the alternative, there can be but a single drum 212 as shown in FIG. 7 . In that case the tool 200 needs to be stabilized against the torque from the scraping action. One way to anchor the tool is to use selectively extendable bow springs 224 that are preferably retracted for run in with slickline 202 so that the tool can progress rapidly to the location that needs to be scraped. Other types of driven extendable anchors could also be used and powered to extend and retract with the battery pack 206 . The scraper devices 220 can be materials for the made in a variety of shapes and include diamonds or other scraping action.
FIG. 8 shows a slickline 300 supporting a jar assembly 302 that is commonly employed with slicklines to use to release a tool that may get stuck in a wellbore and to indicate to the surface operator that the tool is in fact not stuck in its present location. The Jar assembly can also be used to shift a sleeve 310 when the shifting keys 322 are engaged to a profile 332 . If an anchor is provided, the jar assembly 302 can be omitted and the motor 314 will actuate the sleeve 310 . A sensor package 304 selectively completes a circuit powered by the batteries 306 to actuate the tool, which in this case is a sleeve shifting tool 308 . The sensor package 304 can respond to locating collars or other signal transmitting devices 305 that indicate the approximate position of the sleeve 310 to be shifted to open or close the port 312 . Alternatively the sensor package 304 can respond to a predetermined movement of the slickline 300 or the surrounding wellbore conditions or an electromagnetic or pressure wave, to name a few examples. The main purpose of the sensor package 304 is to preserve power in the batteries 306 by keeping electrical load off the battery when it is not needed. A motor 314 is powered by the batteries 306 and in turn rotates a ball screw 316 , which, depending on the direction of motor rotation, makes the nut 318 move down against the bias of spring 320 or up with an assist from the spring 320 if the motor direction is reversed or the power to it is simply cut off. Fully open and fully closed and positions in between are possible for the sleeve 310 using the motor 314 . The shifting keys 322 are supported by linkages 324 and 326 on opposed ends. As hub 328 moves toward hub 330 the shifting keys 322 move out radially and latch into a conforming pattern 322 in the shifting sleeve 310 . There can be more than one sleeve 310 in the string 334 and it is preferred that the shifting pattern in each sleeve 310 be identical so that in one pass with the slickline 300 multiple sleeves can be opened or closed as needed regardless of their inside diameter. While a ball screw mechanism is illustrated in FIG. 8 other techniques for motor drivers such as a linear motor can be used to function equally.
FIG. 9 shows using a slickline 400 conveyed motor to set a mechanical packer 403 . The tool 400 includes a disconnect 30 , a battery 34 , a control unit 401 and a motor unit 402 . The motor unit can be a linear motor, a motor with a power screw or any other similar arrangements. When motor is actuated, the center piston or power screw 408 which is connected to the packer mandrel 410 moves respectively to the housing 409 against which it is braced to set the packer 403 .
In another arrangement, as illustrated in FIG. 10 , a tool such as a packer or a bridge plug is set by a slickline conveyed setting tool 430 . The tool 430 also includes a disconnect 30 , a battery 34 , a control unit 401 and a motor unit 402 . The motor unit 402 also can be a linear motor, a motor with a power screw or other similar arrangements. The center piston or power screw 411 is connected to a piston 404 which seals off a series of ports 412 at run in position. When the motor is actuated, the center piston or power screw 411 moves and allow the ports 412 to be connected to chamber 413 . Hydrostatic pressure enters the chamber 413 , working against atmosphere chamber 414 , pushing down the setting piston 413 and moving an actuating rod 406 . A tool 407 thus is set.
FIG. 11 illustrates a deviated wellbore 500 and a slickline 502 supporting a bottom hole assembly that can include logging tools or other tools 504 . When the assembly 504 hits the deviation 506 , forward progress stops and the cable goes slack as a signal on the surface that there is a problem downhole. When this happens, different steps have been taken to reduce friction such as adding external rollers or other bearings or adding viscosity reducers into the well. These systems have had limited success especially when the deviation is severe limiting the usefulness of the weight of the bottom hole assembly to further advance downhole.
FIG. 12 schematically illustrates the slickline 502 and the bottom hole assembly 504 but this time there is a tractor 508 that is connected to the bottom hole assembly (BHA) by a hinge or swivel joint or another connection 510 . The tractor assembly 508 has onboard power that can drive wheels or tracks 512 selectively when the slickline 502 has a detected slack condition. Although the preferred location of the tractor assembly is ahead or downhole from the BHA 504 and on an end opposite from the slickline 502 placement of the tractor assembly 508 can also be on the uphole side of the BHA 504 . At that time the drive system schematically represented by the tracks 512 starts up and drives the BHA 504 to the desired destination or until the deviation becomes slight enough to allow the slack to leave the slickline 502 . If that happens the drive system 512 will shut down to conserve the power supply, which in the preferred embodiment will be onboard batteries. The connection 510 is articulated and is short enough to avoid binding in sharp turns but at the same time is flexible enough to allow the BHA 504 and the tractor 508 to go into different planes and to go over internal irregularities in the wellbore. It can be a plurality of ball and socket joints that can exhibit column strength in compression, which can occur when driving the BHA out of the wellbore as an assist to tension in the slickline. When coming out of the hole in the deviated section, the assembly 508 can be triggered to start so as to reduce the stress in the slickline 502 but to maintain a predetermined stress level to avoid overrunning the surface equipment and creating slack in the cable that can cause the cable 502 to ball up around the BHA 504 . Ideally, a slight tension in the slickline 502 is desired when coming out of the hole. The mechanism that actually does the driving can be retractable to give the assembly 508 a smooth exterior profile where the well is not substantially deviated so that maximum advantage of the available gravitational force can be taken when tripping in the hole and to minimize the chances to getting stuck when tripping out. Apart from wheels 512 or a track system other driving alternatives are envisioned such a spiral on the exterior of a drum whose center axis is aligned with the assembly 508 . Alternatively the tractor assembly can have a surrounding seal with an onboard pump that can pump fluid from one side of the seal to the opposite side of the seal and in so doing propel the assembly 508 in the desired direction. The drum can be solid or it can have articulated components to allow it to have a smaller diameter than the outer housing of the BHA 504 for when the driving is not required and a larger diameter to extend beyond the BHA 504 housing when it is required to drive the assembly 508 . The drum can be driven in opposed direction depending on whether the BHA 504 is being tripped into and out of the well. The assembly 510 could have some column strength so that when tripping out of the well it can be in compression to provide a push force to the BHA 504 uphole such as to try to break it free if it gets stuck on the trip out of the hole. This objective can be addressed with a series of articulated links with limited degree of freedom to allow for some column strength and yet enough flexibility to flex to allow the assembly 508 to be in a different plane than the BHA 504 . Such planes can intersect at up to 90 degrees. Different devices can be a part of the BHA 504 as discussed above. It should also be noted that relative rotation can be permitted between the assembly 508 and the BHA 504 which is permitted by the connector 510 . This feature allows the assembly to negotiate a change of plane with a change in the deviation in the wellbore more easily in a deviated portion where the assembly 508 is operational.
The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below: | A shifting tool is run on slickline and has an on board power supply. Rotary motion of the motor is converted to linear motion of the shifting tool using a ball screw device. The grip is obtained with longitudinal motion of a grip linkage and an on board jar then can do the shifting. Alternatively a linear motor can be used to extend and retract the grip assembly and shift using the jar tool. Optionally the tool can be anchored and linear motion from the on board power source operating a motor can do the shifting. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to an alignment device, and more particularly, to a device useful in constructing sheets or panels of pregrouted ceramic tiles.
In the past, the installation of ceramic tiles, for example, in the bathrooms or kitchens of conventional dwelling structures, was a time-consuming and expensive procedure. Each tile was individually set in grout mixed at the job site. Where plumbing fixtures extended through the area being tiled, each individual tile was cut and fit into place, a further time consuming procedure. In addition, setting tile and laying up masonary conventionally has been accomplished with cement mortars. Conventional mortars require prolonged periods to set properly. If water loss is too great with conventional mortars, the curing action is incomplete and the mortar is soft and chalky. These setting methods entail substantial materials and considerable labor for mixing and placing the mortar and placing the tiles.
More recently, systems have been developed which permit the installation of sheets or panels of pregrouted tiles. The pregrouted panels comprise a plurality of individual 4 × 4 inch tiles which are bonded to one another by a suitable adhesive grout. The panels are applied to a substrate, for example, gypsum wallboard, by using a suitable emulsion type adhesive. This type of construction method is particularly well adapted for gypsum wallboard substrates because water retention in the mortar no longer is a factor. Installation is simplified because single cuts are made in the tile panels for plumbing fixtures, for example, and the panels may be placed over the plumbing connections during panel installation.
A number of prior art systems are known for constructing pregrouted sheets or tile panels. For example, the U.S. Pat. to Fitzgerald, No. 3,239,981, issued Mar. 15, 1969, the U.S. Pat. to Watson, No. 3,291,676, issued Dec. 13, 1966, and the U.S. Pat. to Johnson, No. 3,359,354, issued Dec. 19, 1967, disclose particular methods for producing tile panels and illustrate various forms of prior art tile boards useful in the construction of the tile panels.
While these prior art devices and methods work well for their intended purpose, they present certain serious handicaps to an independent producer of tile panels. For example, the prior art in general discloses complicated methods and machinery for producing the panels. Generally, speaking, the methods and machinery also are intended to be utilized only with one manufacturer's ceramic tile. The invention disclosed hereinafter eliminates these prior art deficiencies by providing a low cost method and apparatus for producing tile panels. Because of its unique but simplified design, the tile board disclosed hereinafter is compatible with the ceramic tile produced by a variety of manufacturers.
One of the objects of this invention is to provide a low cost device for assembling sheets or panels of ceramic tile.
Another object of this invention is to provide a low cost method for producing pregrouted sheets of ceramic tile.
Another object of this invention is to provide a tile board useful in the construction of pregrouted ceramic tile sheets that is compatible with any one of the variety of different sizes or designs found in commercially available ceramic tiles.
Another object of this invention is to provide a tile board having a movable edge and means for manipulating the movable edge, the manipulating means also functioning cam fashion to guide the movable edge.
Other objects of this invention will be apparent to those skilled in the art in light of the following description and accompanying drawings.
SUMMARY OF THE INVENTION
In accordance with this invention, generally stated, a device useful in the manufacture of ceramic tile sheets is disclosed, having a generally rectangular, flat surface area bonded on three sides by a peripheral lip. One lip side is movably mounted to a backer-board structure, the outer boundary of which defines the generally rectangular, flat surface area. Means are provided for manipulating the movable edge by hand. The manipulating means also interacts with a portion of the backer board structure to act cam fashion, to guide the movable edge.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings,
FIG. 1 is a view in perspective of tile board of this invention;
FIG. 2 is a top plan view of the board of this invention, showing the movable edge in a first position;
FIG. 3 is a top plan view of the device of this invention showing the movable edge in a second illustrative position;
FIG. 4 is a sectional view, taken along the line 4--4 of FIG. 2;
FIG. 5 is a bottom plan view of the device shown in FIG. 1; and
FIG. 6 is an enlarged view of the dual function release and cam utilized with the board of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, reference numeral 1 indicates tile board of this invention. The board 1 includes a backer portion 2 and a rim portion 3 which extends about three edges of the backer portion 2, as later described in detail.
Backer portion 2 generally is rectangular in plan, having an upper surface 4 and a lower surface 5. Upper surface 4 is stepped along its right hand side, referenced to FIG. 1, so as to define a tile supporting area 6 and a lip supporting area 7. The backer portion 2 also has a pair of parallel grooves 8 and 9, respectively, extending through it, between the surfaces 4 and 5, along the edge interface of the areas 6 and 7. Each of the grooves 8 and 9 has an open end 10 and a closed bottom 11, which may be canted along the material thickness of the backer portion 2 to provide an attachment area 12.
The lip support area 7 has a channel 13 extending through it. The channel 13, in the embodiment illustrated, is positioned approximately equidistant from and between the grooves 8 and 9. The channel 13 has a first width 14 on the surface 4 side of the backer portion 2, and a second width 15 on the surface 5 side of the backer portion 2. The widths 14 and 15 are important in the operation of the board 1, and their interrelationship is discussed in more detail hereinafter.
The rim portion 3 extends about the perimeter of the tile support area 6 of the board 1. Rim portion 3 includes a lip 16 having a first non-movable part 17, a second non-movable part 18, and a movable straight edge part 19. The non-movable parts 17 and 18 are attached to the backer portion 2 by any convenient method. Conventional threaded fasteners work well, for example. The lip 16 extends above the outer boundary of the upper surface 4 for some predetermined distance H. The distance H may vary, but in general is chosen as to be sufficient to extend above the depth of a conventional ceramic tile, and usually is between one-sixteenth and one-eighth of an inch. The backer portion 2 may be constructed from any suitable material. Wood or fiberboard are acceptable. The lip 16 is preferably constructed from some type of plastic material.
The movable part 19 of the lip 16 is attached to a bar 20, which extends substantially along one dimension of the backer portion 2. The bar 20 may be constructed from a variety of suitable materials. The preferred embodiment utilizes aluminum stock. The bar 20 has a pair of openings 21 through it, which are utilized to mount a biasing means 22 to the bar 20. Biasing means 22 preferably is a pair of conventional coil compression springs 23, which are mounted between the bar 20 and attachment area 12 of the backer portion 2. The movable part 19 of the lip 16 is attached to the bar 20 by any conventional means. Again, threaded fasteners work well. The bar 20 is sized so that it may ride along the lip support area 7 of the backer portion 2. With the movable part 19 attached to the bar 20, part 19 completes the lip 16 in at least one position of the bar 20-part 19 combination.
The bar 20 has a follower 24 attached to one side of it. Follower 24, in the illustrated embodiment, is rectangular in plan and is intended to ride within the width 14 portion of the channel 13 in a free, slip fit. A hand grip 25 is attached outboard of the follower 24. Both the hand grip 25 and the follower 24 may be attached to the bar 20 by a threaded fastener 27. Hand grip 25 also preferably is rectangular in plan but is oversized with respect to the width 14 and undersized with respect to the width 15, thereby enabling it to move freely in the width 15 portion of the channel 13 in response to forces applied to it. The relatively large area provided by the width 15 permits easy outward movement of the bar 20, while a biasing means 22 returns the bar 20-part 19 combination to its initial position on release. For the purpose of this specification, the hand grip 25 and the follower 24 define a manipulative means 26.
Operation of the tile board 1 facilitates the manufacture of ceramic tile sheets. Individual ceramic tiles, conventionally 4 by 4 inches, are inserted face up along the upper surface 4 of the tile board 1. They may be placed as indicated in phantom lines in FIG. 2, preferably starting in the lower left-hand corner of the tile board 1, as referenced to FIG. 2. While either the size of the board or the size of the tile may vary, I find it convenient to construct a tile sheet by using 4 inch square tiles arranged so that the finished tile sheet is five tiles in length and four tiles in width, for a total of 20 tiles. Three rows of five tiles each are positioned inboard of the movable part 19. To place the 16th tile in sheet along the movable part 19 of the lip 16, the operator merely grips the hand grip 25 and draws the part 19 outwardly to the position shown in FIG. 3. When the 16th tile is in position, the operator may release the grip 25 and the biasing means 22 will bring the part 19 into abutment with the end tile of the row, aligning and holding all of the tiles in the row. Remaining tiles are positioned as necessary to form the sheet.
Ceramic tiles conventionally have a plurality of spacers formed along their edges, which spacers correctly position an individual tile with respect to the other adjacent tiles of the sheet. Commonly the spacers, not shown, are formed in pairs along each edge of an individual tile. In addition to positioning the tiles correctly, the spacers insure that a joint exists between contiguous tiles. The individual tiles are formed into a single sheet by inserting a suitable material along the narrow joints formed between the contiguous tiles by the spacers of the adjacent tile. A suitable grout is available from the Dow Chemical Company under the trade name Dow Corning 784. Dow Corning 784 is a silicone grout compound which preferably is cured by the application of heat and moisture. Other grouting compounds are compatible with the broader aspects of this invention. The grout may be applied by a gas powered caulking gun, or a conventional mechanical caulking gun may be utilized, if desired. In either case, only a narrow bead of grout enters the joint between adjacent tiles and both the front and rear faces of each individual tile remains free of material.
The board 1 of this invention is particularly well suited for the process of constructing tile sheets in that it enables a first operator to place the individual tiles on the board 1. Thereafter, the same operator may apply the grout, or the fiberboard 1 may be moved to a second station for grout application. In any case, after grout application, the boards 1 with their tile load in tact, are passed through a heat and moisture station for curing the particular grout utilized in conjunction with the tile sheet. Transfer between stations is facilitated because the movable part 19 of the lip 16 effectively locks and aligns the individual tiles against one another and the various components of the lip 16. Once cured, the individual tile pieces are attached to one another along the grout joint. After curing, the now integral tile sheet may be removed from the board 1 merely by moving the part 19 outwardly as shown in FIG. 3. Thereafter, tile sheet is allowed to slide from an upper edge 28 of the tile board 1. After removal, the board 1 may be cleaned, if necessary, and reused.
Numerous variations, within the scope of the appended claims, will be apparent to those skilled in the art in light of the foregoing description and accompanying drawings. Thus, the dimensions of the board 1 or the size tile used in conjunction with the board 1, may vary in other embodiments of this invention. While certain materials utilized in the construction of the board 1 were indicated as preferred, other substitute materials are compatible with the broader aspects of this invention. Likewise, while a dual pair of compression springs are shown and described for the biasing means 21, other biasing arrangements may be utilized. Trim shapes required for certain installations, such as caps and bullnose tiles, may be incorporated in the tile sheet, if desired. These variations are merely illustrative. | A device useful in the manufacture of ceramic tile sheets is provided, having a peripheral rim along three edges of a rectangular backer board structure. The fourth peripheral edge of the backer board structure is open to permit insertion of individual tile pieces and removal of an integral tile sheet. One of the closed edges is movably mounted to the backer board structure, and includes handle means for manipulating the movable edge of the device. The handle means also functions as an alignment means for the movable edge. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from U.S. provisional application 60/510,041, filed Oct. 9, 2003.
FIELD OF THE INVENTION
This invention relates to electrochemical machining (ECM), and more specifically, to trepan machining outside contours on long bars such as bars up to seven or more meters long. Such machined bars may be used, for example, as rotors in a progressive cavity device such as a progressive cavity motor or progressive cavity pump.
BACKGROUND OF THE INVENTION
U.S. Pat. Nos. 1,892,217 and 2,028,407, to R. J. L. Moineau, disclose a gear mechanism for use as a progressive cavity pump or motor. In a typical application of progressive cavity technology, the drilling of subterranean wells, a progressive cavity motor is used as a downhole motor to convert the energy of a flowing drilling fluid to mechanical power to rotate a drill bit.
In a progressive cavity pump or motor, both the stator and the rotor are formed with helical lobes. An interference fit between the external profile of the rotor and the internal profile of the stator provides a seal isolating the cavities of the pump or motor from adjoining cavities. The seal resists the fluid pressure which results from the mechanical pumping action, or from the conversion of fluid motion to mechanical energy in a motor.
Because of the requirement for an interference fit between the rotor and stator, one or both of these components must be covered with a resilient, or dimensionally forgiving, material, usually an elastomer, which also allows the pump or motor to pass or transfer abrasive particles and other objects carried along with the fluid. Historically, the resilient material has been provided on the interior of the stator. The rotor is coated with hard chromium to increase the wear resistance of its contacting surface.
In order to minimize friction where the rotor contacts the elastomer on the inside of the stator, the rotor must have a very highly polished surface. Currently a conventional milling process is used to generate the required outside profile along the length of the rotor. A polishing operation is then carried out to change the relatively rough surface resulting from the milling operation to an acceptable finish for chrome plating. Stainless steel alloys such as 17-4PH are often used to manufacture the rotors, because of their corrosion resistance, and their relatively easy machining.
The rotors of progressive cavity pumps typically have a bearing journal at one end, and therefore cannot be shaped by extrusion. The helical lobes of the rotor typically extend from a first end toward the second end, but stop short of the second end to allow for a bearing journal and attachment features. The rotor may be solid, or may have a hole bored partially or totally through its length. Rotors with more than one lobe have multiple concave areas that stop at some point along the length of the rotor, thus limiting the ways in which they can be manufactured.
Many other bar-like products also have external profiles that do not extend along their entire length. They have concave areas that also limit the method of manufacture. Thus this invention, while described in the context of the manufacture of a rotor for a progressive cavity fluid device, has potential applications in the manufacture of various other products.
BRIEF SUMMARY OF THE INVENTION
The apparatus in accordance with the invention comprises a cathodic tool having a through passage for receiving a workpiece. The passage has an entry opening and an exit opening, the entry opening corresponding in shape to, and being slightly larger than, the cross-section of the workpiece, and the exit opening corresponding in shape to, and being slightly larger than, the cross-section of the desired finished product. The cross-sectional shape of the through passage has a gradual transition from the shape of the entry opening to the shape of the exit opening, along the length of the through passage. A manifold, connected to the cathodic tool adjacent the exit opening, directs electrolyte through the through passage, about a workpiece moving through the through passage. A drive mechanism moves the workpiece through the passage and the manifold. Supports are provided for holding the workpiece as it moves through the cathodic tool, and an electric power supply is connected to the cathodic tool and connectible to the workpiece.
In a preferred embodiment of the invention, the above-mentioned manifold is a first manifold connected to the cathodic tool adjacent the exit opening, and a second manifold is connected to the cathodic tool adjacent the entry opening. The manifold adjacent the exit opening has a seal conforming to the desired cross-sectional shape of the finished product. The first manifold, which is located adjacent the exit opening of the cathodic tool, receives electrolyte from a supply, and directs the electrolyte into the through passage of the cathodic tool about the workpiece therein. A path is provided for circulating electrolyte from the second manifold to an electrolyte holding tank, from which it can be returned through the first manifold to the cathodic tool.
For producing a product having lobes, the opening of the through passage of the cathodic tool is circular, and the exit opening has a lobed cross-sectional shape. The through passage has lobes that gradually increase in size, proceeding in the direction from the entry opening to the exit opening.
For producing product having helical lobes, such as a rotor for a progressive cavity pump or motor, the drive mechanism includes a mechanism for rotating the workpiece about an axis along its length as the workpiece is moved through the passage of the cathodic tool, and the passage of the cathodic tool has lobes that both gradually increase in size, and twist about the axis of rotation of the workpiece, proceeding in the direction from the entry opening to the exit opening.
The electrochemical trepan machining of a workpiece in accordance with the invention is carried out by driving the workpiece through a cathodic tool having a through passage for receiving the workpiece, the passage having an entry opening and an exit opening, the entry opening corresponding in shape to, and being slightly larger than, the cross-section of the workpiece, and the exit opening corresponding in shape to, and being slightly larger than, the cross-section of the finished product. The cross-sectional shape of the through passage has a gradual transition from the shape of the entry opening to the shape of the exit opening, along the length of the through passage. Electrolyte is provided in the through passage of the cathodic tool, about the workpiece as the workpiece moves though said through passage, and an electric current is established through the electrolyte, between the workpiece and the cathodic tool, as the workpiece is driven through the cathodic tool.
Preferably, the electrolyte is caused to flow through the through passage, within a space between an interior wall of the cathodic tool and the workpiece.
In producing a product having an integral bearing journal, the workpiece initially has a circular, cylindrical cross-section, and the movement of the workpiece is stopped before the entire workpiece is driven into the cathodic tool, leaving a circular, cylindrical portion of the workpiece for use as a bearing journal.
In accordance with the invention, electrochemical machining (ECM) eliminates the need for milling, and eliminates, or at least significantly reduces, the need for polishing prior to chromium plating. A near reverse image of the desired outside profile is machined into the inside of a cathodic tool.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, in accordance with preferred and exemplary embodiments, together with further objects and advantages thereof, is more particularly described in the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is an isometric, schematic view of an ECM apparatus in accordance with a preferred embodiment of the invention;
FIG. 2 is an axial section through a cathodic tool and associated seals, showing the workpiece at its initial position, and FIG. 2(A) is an enlarged portion from FIG. 2 , showing details of a seal structure;
FIG. 3 is an axial sectional view through the cathodic tool and seals, illustrating a mid point of the machining process;
FIG. 4 is an axial section through the cathodic tool and seals, illustrating the workpiece at the final position of the machining process;
FIG. 5 is an isometric view of a the full length of a typical rotor for use in a progressive cavity pump or motor;
FIG. 6 is a detailed isometric view of an end portion of a typical rotor, showing the transition from a helical lobe profile to a bearing journal;
FIG. 7 is a schematic radial section of a typical rotor for a progressive cavity pump or motor;
FIG. 8 is a radial sectional view showing the rotor being formed as it passes out of an ECM cathodic tool;
FIG. 9 is a schematic, isometric, view of a typical cathodic tool for generating four straight, parallel lobes from a round bar, showing the cutting face profiles only, other features being suppressed for clarity; and
FIG. 10 is a schematic, isometric, view of a cathodic tool for generating the four helical lobes of a rotor for a progressive cavity pump or motor from a round bar, showing the cutting face profiles only, other features being suppressed for clarity.
DETAILED DESCRIPTION OF THE INVENTION
In the ECM apparatus 20 , illustrated in FIG. 1 , a workpiece 22 , in the form of long bar, is machined into a rotor for a progressive cavity pump. The workpiece is preferably machined from a stainless steel alloy such as 17-4PH.
The apparatus 20 is similar to the machine described in U.S. Pat. No. 6,143,407, the disclosure of which is here incorporated by reference. The machine of U.S. Pat. No. 6,143,407 is reconfigured to allow for the moving workpiece 22 to be connected to the positive side of a power supply 24 , so that it becomes an anode, while the negative side of the supply is connected to a stationary cathodic tool 26 . The cathodic tool must be held stationary, and adequate supports (not shown) must be provided to carry the workpiece 22 before and after it passes through the cathodic tool. The machine should be of a size sufficient to accommodate a workpiece about 7 meters or more in length. Both the moving workpiece and the fixed cathodic tool must be electrically insulated from machine frame to prevent short circuits.
The workpiece 22 , which has a high ratio of length to maximum cross section dimension, has its proximal end mounted in a drive 28 arranged to move along an axis extending lengthwise, and to rotate the workpiece about the axis, under computer control. The drive 28 should be capable of carrying an electric current up to about 30,000 Amperes to the workpiece while effecting simultaneous rotation and translation of the workpiece. The power supply voltage is typically a voltage up to about 25 volts DC. The distal end 32 of the workpiece extends into manifold 30 ( FIG. 2 ) of the cathodic tool 26 , which serves as the electrolyte outlet manifold, and is supported along its length by one or more suitable supports, such as support 31 , to prevent it from sagging.
The machining of a progressive cavity pump rotor, using the apparatus of FIG. 1 may be carried out using a voltage in the range from about 10 to 25 volts DC, typically 18 volts. The feed rate of the workpiece should be in the range of about 0.2 to 1 inch per minute, depending on the cross sectional area to be removed. A typical feed rate is 0.75 inch per minute. The current is approximately 10,000 Amperes for each cubic inch of material removed per minute. The capability of the power supply may vary from application to application as required.
A typical electrolyte is a water solution of sodium chloride (NaCl) at a concentration of 1.1 pounds gallon of water. In practice, the concentration may be varied from about 0.5 pounds per gallon to about 2.5 pounds per gallon of water. An alternate electrolyte composition can be a water solution of sodium nitrate (NaNO 3 ) at a concentration in the range from about 0.5 to about 3.0 pounds per gallon of water. Mixtures of NaNO 3 and NaCl may also be used, as can many other suitable electrolytes.
As shown in FIG. 2 , the electrolyte outlet manifold 30 is attached to a tapered cathodic electrode 34 , and is used to expel the electrolyte for the ECM process. The manifold 30 locates and centers the workpiece as it enters the cathodic tool, and provides a seal around the initial, unmachined, circular, cylindrical contour of the workpiece, while receiving electrolyte flowing out of the cathodic electrode. A blank 36 , having an external shape corresponding to that of the final machined rotor, is secured to the distal, or leading, end 32 of the workpiece 22 . This blank extends through the cathodic tool 34 , and through an electrolyte entry manifold 38 , attached to the end of the cathodic tool on the side opposite from manifold 30 . The blank 36 passes through suitably shaped seals in the exit manifold 38 , and prevents flow of electrolyte past the seals as the distal end 32 of the workpiece approaches the seals. The blank may be made of a suitable synthetic resin such as the acetal resin known by the trademark DELRIN, or PTFE. Alternatively, the blank may be a metal such as Niobium that has a breakdown potential far in excess of the breakdown potential for ordinary workpieces during the ECM process.
The electrolyte inlet manifold 38 is supplied with electrolyte from an electrolyte pump 40 , shown in FIG. 1 , which receives electrolyte from a holding tank 42 . Electrolyte is returned to the holding tank 42 from the electrolyte outlet manifold 30 through a pressure control valve 50 .
As shown in FIG. 2 , after passing through the inlet manifold 38 , the workpiece 22 moves, with electrolyte flowing over it, through the cathodic tool 34 . As shown in FIG. 10 , the cathodic tool 24 has a generally round entry opening 44 corresponding to the shape of the workpiece, and its interior gradually transforms to a four-lobed exit opening 46 , corresponding to the desired configuration of the rotor 47 , as shown in FIG. 7 . The profile of the exit opening 46 of the cathodic tool, as shown in FIG. 8 , is slightly larger than the desired cross section of the workpiece. In the case of a rotor for a progressive cavity pump, the interior surface of the cathodic tool has a twisted configuration as shown in FIG. 10 . However, for producing straight lobes or flutes, the shape of the interior of the cathodic tool can have the straight through configuration shown in FIG. 9 , where the interior surface 48 can be generated by straight lines intersecting a single point on a central axis. The cathodic tool is constructed from a conductive material such as a material consisting of 70% tungsten and 30% copper. The cathodic tool acts as a trepan tool used in milling and drilling operations except that no mechanical cutting action is required, and the shape of the product can have a complex contour, whereas only circular shapes can be produced with conventional trepan machining.
The electrolyte inlet manifold 38 , which is connected to the electrolyte pumping system, is required to seal on the finish-machined profile of the workpiece. The seals in manifold 38 are shaped to match the helical lobes of the product. As shown in FIG. 2A , these seals are provided with grooves, each having a cup type lip 51 , in which a compliant spring 53 is installed, to assist the internal pressure of the electrolyte in forcing contact between the seals and the profiled surface of the finished workpiece. Pressure and temperature of the electrolyte in the electrolyte recirculation path may be controlled by temperature and pressure transducers, pressure regulators and heat exchangers (not shown).
As the workpiece moves out of manifold 38 , it is cantilevered. If the workpiece were unsupported, its leverage would cause a large amount of stress on both manifolds. FIG. 1 illustrates supports 52 on the machine frame, which prevent the stress on the manifolds from becoming too large. The supports 52 carry the weight of the distal portion of the workpiece. These supports may either move with the workpiece, or may be made of a suitable material to avoid damage to the finish-machined profile of the workpiece. In a preferred embodiment, steel supports, having non-metallic wear plates for contact with the workpiece, are used. After completion of the electrochemical machining operation, the machined workpiece is backed out of the cathode assembly.
In an alternative embodiment of the invention electrolyte is caused to flow in the same direction in which the workpiece travels in the machining operation. In this case, electrolyte is pumped through manifold 30 , flows in the distal direction between the workpiece and the cathodic tool, and out through the manifold 38 for recirculation.
In some applications, another alternative is to allow the electrolyte to flow through the cathodic tool and exit without passing through an exit manifold. This may be required in cases where the profile of the finish machined workpiece has relatively sharp corners, or is otherwise shaped so that it does not provide a good sealing surface that can be sealed by seals in an exit manifold. A gravity drain system would then be required to return the electrolyte to the pumping system. The flow rates should be high enough to create a back pressure to force flow across the entire area, as shown in FIG. 7 , between the inside surface 46 of the cathode, and the outside profile of the workpiece.
Heat is generated because of the high electric current in the apparatus. The heat must be removed to maintain a stable system. As shown in FIG. 1 , a separate holding tank 54 and pump 56 are used to supply cool water to remove heat. Water is also pumped through the power supply 24 and the conductive cables that connect the power supply to the cathodic tool and the workpiece. Water is also used to cool the part holder 29 , shown in FIG. 4 . The holding tank 54 is maintained at a fixed temperature by using a temperature control system (not shown) and a heat exchanger (not shown) that isolates the temperature control system from the electrolyte.
The ECM process is one that uses an electrical potential to break down the water (H 2 O) into a hydroxide (OH − ) ion that joins with a metal ion to form a metal hydroxide such as Fe(OH) 2 . Hydrogen gas is formed in the process, and must be removed from the machining system to prevent gas bubbles from forming an electrically insulating obstruction to the process. Controlling the pressure of the electrolyte entering through the electrolyte inlet manifold, and the pressure at the electrolyte outlet manifold, allows for control of both the electrolyte flow rate, and the pressure within the ECM cell, to limit the formation of gas. Higher pressure in the outlet manifold also helps force electrolyte around contours that would otherwise cause cavitations in the electrolyte.
The apparatus is operated by a controller 58 , which performs multiple functions. The controller programs the translation and rotation of the workpiece to produce the helical shapes required in the case of a rotor having helical lobes for use in a progressive cavity fluid mechanism. The controller also maintains the proper voltage, taking into account the feed rate and the amount of material to be removed. It also controls proper timing of voltage changes. Other electrolyte functions such as the operation of pumps, pressure regulation, and temperature regulation, are also controlled by the controller.
The progress of a circular, cylindrical, workpiece through the cathodic electrode can be stopped at a point such that a short cylindrical portion is left at the proximal end of the workpiece, as shown in FIGS. 5 and 6 . The short cylindrical portion 60 , and the part 62 having helical lobes remain joined as a unitary element. The cylindrical portion can be ground and plated, and used as a bearing journal for the rotor.
Various modifications can be made to the apparatus and method described. For example, instead of pushing the workpiece through the cathodic tool, the workpiece may be pulled through the tool, by using a suitable attachment at the distal end of the workpiece. It may be desirable to pull rather than push the workpiece where the cross section of the workpiece is so weak that there is a risk of buckling.
While there have been described herein what are considered to be preferred and exemplary embodiments of the present invention, other modifications of the invention shall be apparent to those skilled in the art from the teachings herein, and it is, therefore, desired to be secured in the appended claims all such modifications as fall within the true spirit and scope of the invention.
Accordingly, what is desired to be secured by Letters Patent of the United States is the inventions as described and differentiated in the following claims. | An ECM apparatus includes a stationary cathode tool having a passage, and a drive mechanism for moving a bar-shaped workpiece through the passage of the cathode tool while simultaneously rotating the workpiece. Electrolyte flows, from a manifold on one end of the cathodic tool to a manifold at the other end, through the passage, between the wall of the passage and the workpiece. An electric current is simultaneously established in the electrolyte, between the wall of the passage and the workpiece. The internal shape of the cathodic tool wall has a gradual transition from a circular entry opening to a lobed exit opening, and lobes formed in the wall of the tool are shaped so that they twist in the direction of workpiece rotation, in order to form helical lobes in the workpiece. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to methods for processing an image signal for double or multiple exposure cameras in order to reduce fluorescent artifact effects.
BACKGROUND INFORMATION
[0002] Multi-exposure techniques are widely used for improving the dynamic range of video cameras. The dynamic range of a video signal generated by an image sensor is limited by its noise floor on the one hand and the saturation voltage on the other hand. For the lowest level in a typical scene, the signal to noise ratio (SNR) needs to be at least about 40 dB to have an acceptable quality. Therefore the total dynamic range should be 100 dB.
[0003] To achieve this, there is known the double exposure solution, where two pictures are taken shortly after one another: one with a short exposure time and one with a long exposure time. Combining the two can give a good SNR for the long exposed image in the dark part and can avoid saturation in the bright part for the short exposed image.
[0004] However, in artificial light sources, particularly fluorescents, light is modulated at twice the local mains frequency. If the integration time of the sensor is not a multiple of the period of the fluorescent light source, the amount of integrated light varies per field (frame), which creates a problem of flickers and changing colors.
[0005] The frequency of fluorescent light flicker is either 100 Hz or 120 Hz, according to national standards, and can vary up to 2%. To cope with this problem, there is usually provided either a manual switch or a flicker detection mechanism that sets the sensor integration time to an integer number of the fluorescence period (e.g. n/100 s or n/120 s respectively, depending on the national mains frequency, n=1,2,3, . . . ).
[0006] This special operation is a valid solution for single exposure time sensors, but leads to problems in connection with multiple exposure time sensors. If, for instance, the longer exposure time is chosen as 1/100 s, the shorter exposure (integration) time will be several times shorter than that of the longer exposure time (the exact relation depends on their ratio R) and will not be adequate for the operation under fluorescence light conditions.
[0007] International Patent Application WO 2007/038977 A1 discusses an image pickup apparatus comprising an image pickup arrangement for forming a plurality of image signals having different exposure conditions, a combining arrangement for combining said plurality of image signals to form a combined image signal having an extended dynamic range, further comprising display and/or a recording arrangement for displaying and/or recording said combined image signal, further comprising a function module correcting at least one of the image signals in order to achieve a smooth transition between the image signals at a transition point.
SUMMARY OF THE INVENTION
[0008] It is an object of this invention to improve performance of a double or multiple exposure camera in the presence of fluorescent light.
[0009] According to a first aspect of the exemplary embodiments and/or exemplary methods of the present invention there is provided a method for processing an image signal for double or multiple exposure cameras comprising the following steps:
a) determining whether fluorescent light is present, b) if so, ascertaining the period of the fluorescent light, c) forming a plurality of image signals having different exposure conditions with at least one image pickup sensor, such that at least a long exposure time is made equal to a multiple of the fluorescent light period, and a short exposure time is made equal to a fraction of the long exposure time, d) correcting at least part of the plurality of image signals with a correction function in order to obtain a corrected output signal, e) combining at least one of said plurality of image signals and said corrected output signal to form a combined image signal, and f) applying a gain factor G to the combined image signal, so that at least some image areas originating from the short exposure time are shifted out of a display range.
[0016] By applying a gain, problematic image parts which are, in the prior art, constructed from short exposure time, are essentially shifted out of the display range. At the same time, the lens is closed in such a way that same average light output is achieved as before the application of the gain.
[0017] To further improve the removal of the false colors, color saturation is reduced.
[0018] According to a further aspect of the exemplary embodiments and/or exemplary methods of the present invention, there is provided a method for processing an image signal for double exposure cameras comprising the following steps:
a) determining whether fluorescent light is present, b) if so, ascertaining the period and the phase of the fluorescent light period, c) forming a plurality of image signals having different exposure conditions with at least one image pickup sensor, such that at least a long exposure time is made equal to a multiple of the fluorescent light period, and a short exposure time is made equal to a fraction of the long exposure time, d) phase-locking the short exposure time to the period of the fluorescent light such that it essentially coincides with the maximum or the area around the maximum of the period of the fluorescent light, e) correcting at least part of the plurality of image signals with a correction function in order to obtain a corrected output signal, and f) combining at least one of said plurality of image signals and said corrected output signal to form a combined image signal.
[0025] Herein, essentially a fluorescent locking is performed so that the time, within which the short exposure integration is being performed, is positioned at the optimum moment within the fluorescent light period, i.e. at or around the peak (maximum) of the fluorescent light output.
[0026] For both aspects of the exemplary embodiments and/or exemplary methods of the present invention, it is advantageous to determine, whether fluorescent light is present, by monitoring color differences between long exposure times and short exposure times overtime. If color errors ascertained herein change over time, it is an indication that fluorescent light is present, and that the camera is not locked to the main frequency.
[0027] These measurements can not be performed over the saturated pixels originating from the long exposure, but only from intensity area where both long and short exposed pixels are not saturated.
[0028] According to a further aspect of the exemplary embodiments and/or exemplary methods of the present invention, an image pickup apparatus is provided for forming a plurality of image signals having different exposure conditions, comprising an arrangement for determining whether fluorescent light is present, an arrangement for combining a plurality of image signals to form a combined image signal, and further comprising an arrangement for processing the combination of plurality of image signals taking into account the determination, whether fluorescent light is present or not.
[0029] The accompanying drawings, which are incorporated in and constitute a part of the specification, show embodiments of the present invention and, together with the description, serve to explain the principles of the exemplary embodiments and/or exemplary methods of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 shows a graph for illustrating the influence of fluorescent light on the amount of light in a scene, over time.
[0031] FIG. 2 shows a graph similar to FIG. 1 , wherein a long exposure time is set to a multiple of the fluorescent light period.
[0032] FIG. 3 is a line graph showing image signals as a function of light level for two different exposure times.
[0033] FIG. 4 is a line graph showing image signals as a function of light level, the curve representing a longer exposure time having been processed by a multiplication (applying a factor smaller than 1).
[0034] FIG. 5 is a line graph illustrating application of a gain to the line graphs of FIG. 4 .
[0035] FIG. 6 shows line graphs showing color difference errors in a typical scene with a fluorescent light source.
[0036] FIG. 7 shows a line graph representing the influence of motion with respect to the line graph of FIG. 6 .
[0037] FIG. 8 shows the influence on the line graphs of FIG. 5 by other light sources.
[0038] FIG. 9 shows an exemplary embodiment of a measurement block for implementing the present invention.
DETAILED DESCRIPTION
[0039] In FIG. 1 , one can observe the influence of the fluorescent light on the amount of light in the scene. In case of a 50 Hz mains frequency, output light oscillates with 100 Hz frequency. If along integration time is not a multiple of the fluorescence period, amount of integrated light can vary per field due to a slow drift in the mains frequency. Here, TL and TS represent Long and Short exposure time periods interlinked with the ratio R between them. This is why the long integration time has to be set to be a multiple of the fluorescence period, for instance to 1/100 s in 50 Hz mains area and to 1/120 s in 60 Hz mains area, as in FIG. 2 . Frequency/phase of the mains does not influence the amount of the gathered light during the long exposure period. However, due to a slow drift in the mains frequency or a variable exposure time, the amount of gathered light from the short exposure period varies in time. This can lead to a light flicker and variable coloring due to various positions of long and short exposure times with respect to the oscillation period of the fluorescent light.
[0040] Although this provides a good solution for the Long exposure period, light gathered within Short exposure period is inevitably sampled at various position of the oscillation period of fluorescent light. Firstly, due to a slow frequency/phase drift, amount of light gathered within short exposure time period is variable and can be observed as the low-frequency flicker in brighter parts of the scene. Secondly, output of the fluorescent light tube is also not constant in color, but has different colors within the period. Depending on the type of fluorescent light, for instance, when switching on, fluorescent light is more red (period A in FIG. 2 ), in the peak of the period it is white (period B in FIG. 2 ) and at the end (switching of), it can be blue (period C in FIG. 2 ).
[0041] To solve for the problem of low-frequency intensity flicker and variable coloration present in the Short exposure periods two basic solutions are proposed:
[0042] Firstly, if fluorescent light is detected in a scene, the long exposure time is made equal to a multiple of fluorescence light period (for instance to 1/100 s or 1/120 s, depending on the mains frequency); by gain and color de-saturation, problematic image parts which are constructed from the short exposure time are as much as possible shifted out of the display range and their color saturation is reduced;
[0043] Secondly, if fluorescent light is detected in the scene, the longer exposure time is made equal to a multiple of the fluorescence light period (for instance to 1/100 s or 1/120 s, depending on the mains frequency). Essentially, a fluorescence locking is performed so that the time period within which the short exposure integration is being taken is positioned at the most optimal moment within the fluorescent light period, namely at the peak (maximum) of the fluorescent light output (case B in FIG. 2 ). Likewise, it is effected that light integrated during the short integration time is constant in time and has a correct color (not influenced by the fluorescence light output).
[0044] In FIGS. 3 to 5 , the following can be observed:
[0045] The line graph shown in FIG. 3 shows the functional relation between an input light level (x-axis) and the output signal (y-axis) of an image pickup sensor, especially a CCD-sensor, both of them in arbitrary units. Curve 1 represents the functional relation due to a short exposure time. Curve 2 represents the functional relation due to a long exposure time. Both curves show a linear part before getting distorted and going into saturation. FIG. 4 shows a similar graph after a processing step. During this process the values of the curve 2 are divided by the ratio of the exposure times applied. This results in the curve 2 . 1 which goes in saturation at rather low values of the light level. Curve 1 representing the functional relation between the input light level and output signal due to a short exposure time remains unchanged. The combination of the two images is achieved for example making use of the principles described in WO 2007/038977, which is hereby incorporated by reference.
[0046] Similar to the single exposure camera in the presence of fluorescent light, the long exposure time is, according to the exemplary embodiments and/or exemplary methods of the present invention, made equal to a multiple of fluorescence light period (for instance to 1/100 s or 1/120 s, depending on the mains frequency). Long and short exposed images can then be combined to a single image output.
[0047] As can be seen in FIG. 5 , gain (G) is applied to the combined signal so that image parts, where short exposed parts are used, are shifted out of the output range. Likewise, long exposed image parts (having the integration time of for instance 1/100 s or 1/120 s) will constitute the majority of the output signal. If some parts of the short exposure time are left in the scene, color reduction (fading) will be applied on those to remove false colors.
[0048] This operation can be performed when it is manually triggered by a user. Also, a fluorescence detector can be provided, and if fluorescent light is detected, previously described operation is performed. Such a fluorescent detector is also within the scope of the exemplary embodiments and/or exemplary methods of the present invention.
[0049] If during the normal camera operation the long exposure time is set to some value other than a multiple of the fluorescence period, the amount of integrated light can vary per field due to a slow drift in the mains frequency. This is even more visible for the short exposure time. However, even when the long exposure time is set to a multiple of the fluorescence period, short exposure time still displays the same problem and distorting color errors will be present. To detect if this is the case and if fluorescence light is present in the scene, the following approach is suggested:
[0050] The color differences between long and short exposures are measured every field or frame. The long exposure will be constant because it has 1/100 s (or 1/120 s) integration time which is equal to one 100 Hz (120 Hz) cycle of the fluorescent light source. The short exposure may contain large errors because it integrates only a small part (10 ms/R) of the 100 Hz fluorescent cycle. If the camera is not locked to the mains frequency the errors will change over time. Pixels in the long exposure that are saturated may not be taken in account.
[0051] Two measurement types are proposed, herein:
[0052] Firstly, the average values of long and short exposed pixels in several (n) intensity regions are accumulated. Differences between these measurements at various intensity levels will show periodic (sine-like) behavior in the presence of florescent light in that intensity range.
[0053] Furthermore, the color error measurement can be used to detect fluorescent light conditions and to adapt the dual exposure processing. It accumulates the difference between long and short exposed pixels within a certain level range. It also counts the number of pixels that are accumulated. This measurement is done separately for Cr and Cb lines of the complementary mosaic type of sensor. The accumulators and counters are stored and reset for every field/frame. If these measurements show periodic (sine-like) behavior, this indicates the presence of fluorescent light.
[0054] Examples of the color error measurements are shown in FIGS. 6 to 8 . The abscissa axis represents time scale.
[0055] FIG. 6 shows the color difference errors of the signals Cr and Cb in a typical scene with a fluorescent light source.
[0056] FIG. 7 shows the effect of motion in the observed scene on the signals Cr and Cb according to FIG. 6 : A noticeable disturbance of the measurement can be observed.
[0057] The measurement can also be disturbed by other light sources, as shown in FIG. 8 . The errors recorded in this figure are recorded under essentially the same conditions as in FIG. 7 , the only difference in the set-up being an active LCD screen visible in part of the scene, leading to the noise observable in this measurement.
[0058] A measurement block as shown in FIG. 9 can, according to an exemplary embodiment, be used as a fluorescent light detector. In an environment where fluorescent light is the dominating light source there will be differences in luminance and color between long and short exposure. The difference essentially depends on the exposure times and phase relation between exposure and mains frequency.
[0059] Accumulator/counter LN 0 900 and LN 1 910 calculate the differences in color between the short and long exposure. The differences are measured in a range that can be set with BASE and TOP registers 920 . If the Long Integration Image pixel is between BASE and TOP values en 1 is active. If the difference between long and short exposure is between −LIM_BASE and +LIM_TOP, en 2 will be active. Only color differences will be measured, so a differentiator and a pixel alternating sign multiplier are used as simple color separator. LN 0 measures one color (Cr or Cb), LN 1 the other (Cb or Cr). If both en 1 and en 2 are active then both pixels are accumulated and the counter is incremented. The accumulator/counter values are copied to the registers when at the end of the filed/frame.
[0060] The lower part of the mix measure block ( FIG. 9 ) measures Long Integration Image and Short Integration Image values in n programmable bin ranges 950 . If the Short Integration Image signal falls within one of the bin ranges set by BIN_x_TOP and BIN_x_BASE, (x=1 . . . n) the correct limits around Short Integration Image are selected set by LIM_x_BASE and LIM_x_TOP for the signal Long Integration Image to filter out extremes that could spoil the measurement. Such extremes can for instance occur in the presence of motion and/or light changes in the scene. Using LIM_x_BASE and LIM_x_TOP , as well as LIM_BASE and LIM_TOP, one can exclude the majority of these disturbances from the scene, since when Long and Short exposure signal are very different from each other, it is assumed that these differences originate from disturbances and not from fluorescent light. Likewise, measurement of these image parts can be disabled by setting the en_s, en 1 and en 2 to zero.
[0061] In addition, error signals should be filtered to remove all the spectral components that do not belong to the model of fluorescent light. If we assume that maximum deviation of the mains frequency from its nominal value is 1%, filters have to filter out all spectral components out of that range. Filter blocks (not shown in FIG. 9 ) can be also implemented in software.
[0062] Also, remainders of disturbances originating from the motion or other light changes in the scene are filtered out in the software part of the algorithm. All these measures are implemented for both the intensity as well as color error measurements.
[0063] An alternative/additional manner to skip measurements originating from motion or light change and not from the fluorescent light is to use an external signal that originates from different type of measurement and distinguishes between real light change and moving objects.
[0064] Pixels passing both tests enable summation of Short Integration Image and Long Integration Image and the counting of N over the field time. The accumulators are limited to prevent overflow. If one of the measurements hits the maximum, the corresponding bin width must be adapted.
[0065] For the n signals en_sx: en_sx=1 when BIN_x_BASE<sb<BIN_x_TOP.
[0066] When Short Integration Image pixel value falls into a bin, the second test is done where Long Integration Image pixel value should fall in a range around the Short Integration Image pixel value:
[0067] If en_sx=1, then the selector switches to: base=LIM_x_BASE and top=LIM_x_TOP, and when short−base<long<short+top, then en_s=1
[0068] If both tests en_s=1 and en_sx=1 then accumulator x is enabled.
[0069] The accumulators add pixel values belonging to the long integration time, short integration time and count the number when (en_sx=1 and en_s= 1 ) over a complete field/frame.
[0070] Finally, if these two measurement types as previously described show periodic (sine-like) behavior, this indicates the presence of florescent light sources in the scene. In case when camera mains locking is used, these measurement signals are likely to be constant values in time, and if they are constant non-zero in time, this is an indication of the presence of florescent light sources in the scene.
[0071] According to a further exemplary embodiment, fluorescence locking is performed so that the time within which the short exposure integration is taken is positioned at the most optimal moment within the fluorescent light period, namely at the peak (maximum) of the fluorescent light output (case B in FIG. 2 ); likewise, it is made sure that light integrated during the short integration time is constant in time and has a correct color (not influenced by the fluorescence light output). To achieve this, (color) errors between long and short exposure time are observed and used as a control signal to drive the Phase Locked Loop such that it assures the correct phase (read-out moment) of the short exposure time with respect to the fluorescent lighting. When the correct read-out moment is selected for the short exposure time, color errors are either constant or do not exist: they do not show oscillatory (periodic) behavior.
[0072] Input for the PLL can be for instance one or more of the (color) error signals or some combination of them. The current scheme not only compensates for the phase difference between the optimal read moment and the current read moment of the short integration image, but also for the frequency difference of the actual and ideal mains lock frequencies. Namely, due to a frequency drift of mains (usually up to 1% of a nominal value), sampled light in the short exposure time changes the color temperature and dominant color content in time, which is also prevented in the scheme as now proposed.
[0073] The way that fluorescent locking control may be achieved is by changing the camera frequency so that it runs on the same current mains frequency (which is used for driving the fluorescent light sources) and that its phase is adjusted such that the short integration image is positioned at the peak (maximum) of the fluorescent light output (case B in FIG. 2 ). When multi-phase fluorescent light is present in the scene, the camera will lock to the phase that gives the majority output signal. Usually, all mains phases run synchronously with each other and if the camera locks to one of them, mutual relation will be maintained. This means that light sources having the phase other than one the camera is locked to will have a constant phase relationship and will be producing constant light output/color. | Methods are described for processing an image signal for double or multiple exposure cameras in order to reduce fluorescent artifact effects. | 7 |
ORIGIN OF THE INVENTION
The invention described herein was made in the performance of official duties by an employee of the Department of the Navy and may be manufactured, used, licensed by or for the Government for any governmental purpose without payment of any royalties thereon.
FIELD OF THE INVENTION
The present invention relates generally to gun receivers and actions and more particularly to pneumatically or hydraulically-controlled and/or triggered receivers and actions.
BACKGROUND OF THE INVENTION
During the qualification of energetic materials (i.e., explosives, propellants, gas generants, pyrotechnics) for various types of ammunition (e.g., bombs, warheads, rockets, power devices), various methods are employed to characterize the reaction violence of the energetic material to such unplanned-for stimuli as dropping or enemy fire. In one test to characterize impact sensitivity, a universal receiver fitted with a standard test barrel is employed to fire a sample of energetic material with a known velocity at a nearby steel target plate. The impact of the energetic material sample upon the plate, which is usually recorded via high-speed cinematography, results in a violent reaction of the material, the degree or extent of which is used as a guide for further material development. Because of the close proximity of the target, the violent reaction and the potential for high-velocity flying debris, the operator is remotely located during gun firing. However, current devices require the operator to provide hands-on arming and safing of the test gun assembly.
The arming/safing procedure requires the operator to connect a device for pulling the sear and for moving the cocking piece from the SAFE position to the ARM position, or in the event of a misfire, from the FIRE position to the SAFE position. These hands-on procedures subject the operator to a potential injury in the event of accidental firing of the test assembly due to either mechanical defect or operator procedural error. Because the projectiles are developmental energetic materials whose sensitivities may not be fully understood, electrically-actuated solenoids or other electrical safe/arm devices are unsuitable, as any stray electrical currents may initiate the projectile material in the presence of the operator. Additionally, although the high-speed cameras are physically isolated from the test assembly, they are electrically controlled. Spurious electrical noise emanating from an electrical safe/arm device might cause the cameras or other data-recording devices to operate at an inopportune moment, thereby causing valuable data to be lost.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a safe/arm/firing mechanism suitable for use with highly energetic material.
It is another object of the invention to provide a safe/arm/firing mechanism for a universal receiver having a remote operating mechanism.
It is yet another object of the invention to provide a safe/arm/firing mechanism having an electrically non-conducting connection to its actuating power source.
In accordance with the foregoing and other objects, a universal receiver having pneumatic safe/arm/firing mechanism is provided. The universal receiver and safe/arm/firing mechanism in one embodiment, is attached to a 12-gauge shotgun barrel. The receiver assembly comprises a receiver shell having a barrel clampnut on one end and a breech plug on the opposite end. The breech plug contains a striker assembly which is controlled by a pneumatically-operated sear and safetied by a pneumatically-operated safety bar mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing objects and other advantages of the present invention will be more fully understood from the following detailed description and reference to the appended drawings wherein:
FIG. 1 is a cross-sectional view of the universal receiver assembly showing the receiver in either the SAFE or ARMED mode with striker cocked;
FIG. 2 is a schematic view of the integrated control assembly for the sear and safety cylinders; and
FIG. 3 is a cross sectional view of the multi-port control valve showing the physical structure of the valve.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, the pneumatic safe/arm/firing mechanism of the present invention, designated generally by the reference numeral 10, is shown attached to a universal receiver assembly 12. The receiver assembly 12 is attached to a 12-gauge shotgun barrel 14.
The universal receiver assembly 12 is a conventional and known receiver assembly comprising a receiver shell 15 having a female-threaded end 151 and a female-threaded end 152. A barrel clampnut 141 is screwed into the receiver shell 15 at end 151 and secures the barrel 14 inside the receiver shell. A cartridge 153 is shown for reference.
A breech plug assembly 13 is threaded into receiver shell end 152 and contains the striker and cocking piece 131. The striker and cocking piece 131 is shown in the armed and safe position with the firing pin 132 retracted away from the cartridge 153, firing spring 154 compressed, and sear 161 engaging the striker and cocking piece 131. The striker and cocking piece 131 has a cocking handle 133 attached to a striker shaft 135 which has a collar 137 affixed to engage the firing spring 154. Mounting plate 16 is attached to the receiver shell 15 using bolts 162.
The mounting plate 16 provides a surface for attachment of the sear operating cylinder 163, the safety retract assembly 166 containing the safety retract cylinder 165, and the multi-port pneumatic control valve 167. Multi-port pneumatic control valve 167 is supplied with low-pressure air (less than 100 psig) from tank 171 which is remotely mounted to avoid any damage by explosive debris. Non-conducting valve supply line 172 is routed to a pneumatic quick-disconnect fitting 174 on the side of mounting plate 16. Said fitting serves as a hard-attach point for the supply line and as an optional pneumatic safety disconnect. Plate 16 is drilled to provide a passage for the low pressure air to the pneumatic control valve 167. Connection of this passage to the pneumatic control valve 167 is by standard pneumatic fittings and tubing. A two-position shut-off valve 173 allows remote operation of the air pressure reaching the multi-port control valve 167. When valve 173 is in the shut-off position, low pressure air otherwise trapped within valve supply line 172 is vented to the atmosphere. Said valve 173 is equipped with a pneumatic quick-disconnect fitting 175 located inside a locked box 176. As a safety measure, the system operator retains the key to box 176 on his person at all times such that connection of the valve supply line 172 to the valve 173 can be accomplished only when the box 176 has been opened by said operator.
With no air pressure applied, the safety bar 181 is extended to the safe position by safety return spring 182. With air pressure applied, control valve 167 directs air pressure through supply line 184 to safety retract cylinder 185. As the safety bar 181 reaches the fully retracted position, the adjustable snubber 187 engages switch 188 on control valve 167, thereby re-directing air flow to pneumatic sear operating cylinder 163. The entire sear assembly 164 comprises the operating cylinder 163, the sear 161 and the sear spring 160.
The multi-port control valve 167 shuttle can be switched only at the extremes of travel of the safety bar and safety retract cylinder. This feature is critical to the safety of the design. That is, the gun cannot fire once the safety bar is blocking the striker. Furthermore, the fully-retracted position of the safety bar is the major qualifying/enabling criterion for disengagement of the sear. Moreover, should the safe/arm/fire mechanism have to function safely in a difficult environment (e.g., high vibration), an alternative embodiment, designed to ensure that the valve shuttle is bi-stable, has mechanical detents incorporated in the shuttle. Operation of the control valve 167 may be seen in FIG. 2, wherein a diagram shows the functional relationships between the safety retract cylinder 185 and the control valve 167. Air pressure is supplied to control valve 167 at the inlet port 201. With the safety bar in the extended (safe) position, air flow is directed as shown by the solid lines, low pressure air via line 203 to the safety retract cylinder 185 through integrated check and needle valve 205 and check valve 212 and further to line 207. In this flow direction most of the motive air is directed through the check valve 212. Line 207 extends from the control valve 167 to safety retract cylinder 185 as depicted (the actual connection of the line is not shown in order to maintain the clarity of the drawing).
At the same time that air is directed to the safety retract cylinder 185, the sear retract cylinder (not shown in the diagram) is vented to atmospheric pressure via line 209. This venting insures that no air pressure is applied to the sear until full retraction of the safety retract bar and that any residual pressure in the sear cylinder is vented.
As the safety retract cylinder reaches the retracted position, the mechanical connection 210 causes control valve 167 to switch to the sear retract position with air flow as shown by the dotted lines. Low pressure air in the safety retract cylinder is slowly vented through adjustable restriction 205 and further through line 214 to atmospheric pressure (ATM). Adjustment of metered restriction 205 permits tailoring the extension time of safety retract cylinder 185 and safety bar 181. In this flow direction, all of the exhaust from line 207 must flow through the metered restriction 205 because the check valve 212 closes in this direction of flow. It is the adjustment feature of metered restriction 205 (in concert with the spring rate, k, of the safety return spring 182) that permits tailoring the extension time of safety retract cylinder 185 and safety bar 181 (which are slaved together). Thus, proper adjustment of metered restriction 205 ensures that when firing is intended, the striker 131 can fall and fire the cartridge 153 before the safety bar 181 can intercept it. As the safety retract cylinder is gradually extended, under the net influence of the safety return spring 182 and the controlled exhaust flow through metered restriction 205, the control valve 167 which is shifted only at the extremes of travel of the safety bar and safety retract cylinder, remains in the position shown by the dotted lines. Low pressure air is directed via line 216, thereby retracting the sear and firing the cartridge. Also shown is a vent 220 for relieving pressure on the non-working side of the safety retract cylinder.
Referring now to FIG. 3, a representation of the physical structure of the control valve 167 is shown. Valve shuttle 301 is shown in the extended position, thereby connecting air-in port 303 to safety retract port 305. At the same time, the sear retract cylinder is vented through sear retract port 307 to atmospheric pressure port 309. This valve position matches the position shown in FIG. 2 with solid lines. When the safety retract cylinder approaches the limit of its travel, the mechanical interconnect moves the valve shuttle to the right, thereby venting the safety retract cylinder to atmospheric pressure and applying low pressure air to the sear retract cylinder. The safety bar extends under spring pressure to the safe position, but is restricted by the restrictor valve so that the sear retraction and gun firing is complete well before safety bar extension is complete. At the sound of the shot (or from instrumentation data indicating the shot has been delivered), the position of valve 173 is changed. This removes motive air from port 303 of the control valve and vents line 172 to the atmosphere. Under the net influence of its return spring 182, the safety bar 181 extends. Again, to ensure that the gun striker 131 falls before the safety bar can extend, intercept the cocking piece 133, and thereby prevent gun firing, the flow of air in the exhaust direction (i.e., from the safety bar retract cylinder 185 to the atmosphere) is metered through the adjustable restriction 205 so as to retard the extension of the bar. This permits sufficient time for striker fall to occur. With the striker in the `fired` position, the safety bar clears the cocking piece and extends fully. In this position, the control valve shuttle 301 is shifted to the initial position shown in FIG. 3, and the system is again at rest.
The advantages and features of the invention are numerous. The pneumatic system allows safing and arming of the system without the dangers of inadvertent firing due to stray or induced electrical currents. Similarly, the pneumatic sear retraction mechanism allows firing of the system without electrical devices. Additionally, the air system is remotely located so that any ricocheted or flying debris cannot damage the air pressure tank. Further, in the event of any malfunction in the system or a misfire, either the safety bar or sear cylinder will be vented to atmospheric pressure, thereby allowing extension under spring pressure. These advanced safety features are necessary to insure operator safety when firing explosive projectiles in the typical short range test setups.
Although the invention has been described relative to a specific embodiment thereof, there are numerous variations and modifications that will be readily apparent to those skilled in the art in the light of the above teachings. For example, the invention herein is specifically designed to operate while isolated within a bombproof structure. Because of the action of the projectile exploding within the structure, camera coverage of the operation of the safe/arm/firing device is not practical. However, the pneumatic operation of the device allows monitoring directly by use of fluidic sensors or further safing is desired. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described. | A universal receiver having a pneumatic safe/arm/firing mechanism is provd. The receiver comprises a receiver shell with a threaded barrel clampnut on one end and a threaded breech plug assembly on the opposite end. The breech plug assembly includes a cocking and striker piece and a pneumatically-operated sear. A separate pneumatically-operated safety bar interlocks with the cocking and striker piece to prevent inadvertent firing. A multi-port pneumatic valve is connected to sequentially operate the safety bar retractor followed by the sear retraction, thereby firing the gun. | 5 |
TECHNICAL FIELD
The present invention relates to a system and a process for producing higher silanes useful in engineered silicon materials including semiconductors.
BACKGROUND OF THE INVENTION
Silicon semiconductor devices have become nearly ubiquitous in society. They can be found in portable devices such as MP3 players, watches, cell phones, etc. They can be found in most vehicles. They can be found in the workplace in computers, PDAs, telephone systems, elevators, and in numerous other products. They can also be found in homes in microwaves, TVs, radios, refrigerators, toys, just to name a few. The ever increasing presence of silicon chips makes it increasingly important to find new ways to manufacture silicon chips for less.
Currently monosilane is used in the manufacture of silicon chips and generally in making materials having films of polycrystalline silicon, epitaxial silicon or amorphous silicon. The monosilane is decomposed at very high temperatures. Because higher silanes including disilane and trisilane are more easily decomposed than monosilane and are low in loss by evaporation during film formation, it is possible to attain a decrease in the film forming temperature, an improvement in the film forming rate and an increase in the formed film yield by using higher silanes. Thus a need exists to manufacture higher silanes cheaply and in large amounts.
Higher silanes can be manufactured by pyrolysis. However at the high temperatures used for pyrolysis much of the monosilane is converted into elemental silicon, a useless byproduct. Hence, a need exists for a method of making higher silanes with less waste.
The manufacture of higher silanes by pyrolysis also creates undesirable other silanes. Silicon chip manufacturing requires a very high purity feed. Removing large quantities of impurities wastes reactants and desired products and requires expensive purification. This wastes starting material and requires additional purification. Thus, a need exists for a method creating less impurities.
SUMMARY OF THE INVENTION
In accordance with the present invention, novel methods are provided for making disilane, trisilane, and other higher silanes. In accordance with one aspect of the invention, a method is provided for making a higher or higher than higher silane from a lower silane, including, but not limited to making disilane from monosilane, trisilane from disilane, and trisilane from monosilane. The method includes heating a first lower silane containing stream so that the stream is in a first reaction temperature range while avoiding exposing the stream to a temperature greater than about 20° C. more than the maximum temperature of the first reaction temperature range. Preferably the stream is not exposed to a temperature greater than about 10° C. more than the maximum temperature of the first reaction temperature range. Preferably the lower silane containing stream is at a pressure in excess of atmospheric pressure and contains less than 20% by volume non-reacting diluents such as hydrogen. Preferably when making trisilane from disilane, the first reaction temperature range is within from about 250° C. to about 450° C. Preferably when making disilane from monosilane, the first reaction temperature range is within from about 350° C. to about 550° C.
Next the heated first lower silane containing stream within the reaction temperature range is introduced into the first reaction zone where it is maintained within the reaction temperature range to form a higher silane reaction product. Preferably the first reaction zone has an average residence time of about 15 seconds to about 60 seconds. Preferably less than 20%, more preferably less than 10%, even more preferably less than 6%, and most preferably less than 3% of the lower silane is converted to the higher silane in each pass through the first reaction zone. The first reaction zone is a volume maintained within the reaction temperature range. It may include a catalyst. A first gaseous mixture containing the lower silane and the higher silane formed in the first reaction zone exits the first reaction zone.
In a first embodiment, the first gaseous mixture is purified to produce the higher silane. In a second embodiment, the first gaseous mixture is used to make a higher than higher silane. In the first embodiment, the first gaseous mixture is separated into a first higher silane containing stream having a relatively high concentration of the higher silane and a second lower silane containing stream having a relatively high concentration of the lower silane. Preferably, the higher silane containing stream is separated from any higher than higher silane impurities to purify the higher silane containing stream.
The second lower silane containing stream is heated so that the second stream is in a first reaction temperature range while avoiding exposing the second stream to a temperature greater than about 20° C. more than the maximum temperature of the first reaction temperature range and is introduced into the first reaction zone. Preferably, the second lower silane containing stream and the first lower silane containing stream are combined before they are heated to a temperature within the reaction temperature range.
In the second embodiment, the first gaseous mixture and a second higher silane containing stream having a relatively higher concentration of the higher silane than the first gaseous mixture are introduced into a second reaction zone to form a higher than higher silane. The first gaseous mixture and the higher silane stream can be mixed together before introduction into the second reaction zone.
A second gaseous mixture exits the second reaction zone. It contains the lower silane, the higher silane, and a higher than higher silane. It is separated into a third lower silane containing stream having a relatively high amount of the lower silane, into the higher silane containing stream, and into a higher than higher silane containing stream having a relatively high amount of the higher than higher silane. Preferably the higher than higher silane containing stream undergoes an additional separation to remove impurities.
The third lower silane containing stream is heated so that the third stream is in a first reaction temperature range while avoiding exposing the third stream to a temperature greater than about 20° C. more than the maximum temperature of the first reaction temperature range and is introduced into the first reaction zone. Preferably the third lower silane containing stream is not exposed to a reaction temperature greater than about 10° C. more than the maximum temperature of the first reaction temperature range.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a process flow diagram for making disilane and higher silanes.
FIG. 2 is a process flow diagram for making trisilane and higher silanes.
DETAILED DESCRIPTION OF THE INVENTION
The invention may have 1, 2, or more reaction zones. In one embodiment, there is one reaction zone as shown in FIG. 1 . A single reaction zone process is most useful for making a higher silane from a lower silane, for example, disilane from monosilane, trisilane from disilane, tetrasilane from trisilane, etc. A first lower silane containing stream 120 is introduced into a preheater 100 . Preheater 100 heats lower silane containing stream 120 to a temperature within the first reaction temperature range.
Preferably, preheater 100 heats the first lower silane containing stream 120 rapidly, more preferably in less than 20 seconds, even more preferably in less than 10 seconds, even more preferably in less than 6 seconds, and most preferably less than 1 second. Preheater 100 could heat this rapidly by exposing first lower silane containing stream 120 to hot wall temperatures. However, this would encourage the thermal decomposition of the silanes and the formation of undesirable higher than higher silanes. Consequently, the wall surface exposed to the lower silane containing stream should have a temperature not more than about 25° C. more than the maximum temperature of the first reaction temperature range, preferably not more than about 20° C., more preferably not more than about 15° C., and most preferably not more than about 10° C.
Preheater 100 has a conventional design. It consists of a metal pipe wrapped in electrical resistance heaters, and in insulation. First lower silane containing stream 120 flows inside the pipe. Temperature probes can be provided to modulate the power output of the heaters to ensure that lower silane stream 120 is not exposed to overly hot temperatures. In order to heat quickly, the pipe preferably has a relatively small diameter.
Preheater 100 heats first lower silane containing stream 120 to form a heated lower silane containing stream 122 , which is introduced into a first reactor or first reaction zone 102 . First reaction zone 102 is designed to maintain the temperature of heated lower silane containing stream 122 within the reaction temperature range. The lower limit of the first reaction temperature range is the minimum temperature below which the reaction for making the higher silane does not appreciably occur. The upper limit is the maximum temperature to which lower silane containing stream 120 and heated lower silane containing stream 122 are heated. Preferably, if the lower silane is monosilane and the higher silane is disilane, the first reaction temperature range is within from about 350° C. to about 550° C., more preferably from about 400° C. to about 500° C., even more preferably from about 425° C. to about 475° C., and most preferably from about 440° C. to about 460° C. Preferably, if the lower silane is disilane and the higher silane is trisilane, the first reaction temperature range is within from about 250° C. to about 450° C., more preferably from about 280° C. to about 400° C., even more preferably from about 305° C. to about 375° C., and most preferably from about 330° C. to about 350° C.
First reaction zone 102 can be a pipe wrapped in electrical resistance heaters and insulation like the preheater. However, because the heat transfer requirements for first reaction zone 102 is much less than preheater 100 , the electrical resistance heaters can have a lower power output and the diameter of first reaction zone 102 can be larger. For convenience, first reaction zone 102 and preheater 100 are separate. However, they can in fact be part of the same piece of equipment.
Preferably, the residence time within first reaction zone 102 is relatively short, preferably less than about 5 minutes, more preferably less than about 2 minutes, and most preferably, between about 15 seconds and about 60 seconds. The low residence time tends to reduce the conversion rate per pass, but boosts the overall output of the higher silane as it reduces the amount of higher silane that decomposes and the formation of undesirable higher than higher silanes. Preferably, the conversion rate per pass is less than 20%, more preferably less than 10%, even more preferably less than 6%, and most preferably less than 3%.
A first gaseous mixture 124 exits first reaction zone 102 . Gaseous mixture 124 contains predominantly lower silane, some higher silane, and smaller amounts of higher than higher silanes. It may also contain hydrogen and lower than lower silanes. Gaseous mixture 124 is introduced into a distillation tower 104 . Distillation tower 104 has a condenser 112 that uses liquid nitrogen to condense and separate gaseous mixture 124 into an overhead stream 130 containing relatively high amounts of hydrogen and/or lower than lower silanes, a higher silane containing stream 132 containing relatively high amounts of the higher silane, and a second lower silane containing stream 126 that is recycled back to preheater 100 . Overhead stream 130 exits the system. Higher silane containing stream 132 is collected in the pot 108 of distillation column 104 so that it can be further purified by distillation to remove undesirable higher than higher silanes after the reaction process has been shut down.
In a second embodiment, the process has two reaction zones as shown in FIG. 2 . The process is particularly well suited for making a higher than higher silane from a lower silane, for example, trisilane from monosilane, tetrasilane from disilane, etc. The process has a preheater 100 a and a first reaction zone 102 a . If the process is used to make trisilane from monosilane, preheater 100 a , first reaction zone 102 a , lower silane containing stream 120 a , and heated lower silane stream 122 a can be the same as preheater 100 , first reaction zone 102 , lower silane containing stream 120 , and heated lower silane stream 122 for making disilane from monosilane in the first embodiment. The first gaseous mixture 124 a exiting first reaction zone 102 a is introduced into a second reaction zone 110 and mixed with a second higher silane containing stream 134 . Alternatively first gaseous mixture 124 a can be mixed with second higher silane containing stream 134 before being introduced into second reaction zone 110 .
Preferably, second higher silane containing stream 134 is at a temperature and is of a flow rate so that first gaseous mixture 124 a is cooled to a temperature within a second temperature range better suited for converting higher silane into a higher than higher silane. If the higher than higher silane is trisilane and the higher silane is disilane, preferably the second reaction temperature range is within from about 250° C. to about 450° C., more preferably from about 280° C. to about 400° C., even more preferably from about 305° C. to about 375° C., and most preferably from about 330° C. to about 350° C.
Because the temperatures conducive to creating a higher than higher silane are conducive to creating undesirable higher than higher than higher silanes, it is desirable to minimize the amount of time in the second reaction temperature range. In fact, it is believed that it might be desirable that second higher silane containing stream 134 is at a temperature and is of a flow rate so that first gaseous mixture 124 a is cooled down to a temperature below 350° C. and preferably below 300° C. when streams 134 and 124 a are completely mixed together. It is also believed that it may be preferable that the mixing occur rapidly. By designing the system so that streams 134 and 124 a rapidly mix to achieve a temperature below 350° C. and preferably below 300° C., there is very little time for reactions consuming higher than higher silanes.
Second reaction zone 110 can be similar to first reaction zone 102 a in design. A second gaseous mixture 136 exits second reaction zone 110 and is introduced into distillation column 104 a.
Distillation column 104 a has four outputs. The first output is an overhead stream 130 a containing predominantly hydrogen and a lower than lower silane. Overhead stream 130 a exits the system. A higher than higher silane containing stream 132 a having relatively high amounts of the higher than higher silane is another output. It is allowed to collect into the pot 108 a of distillation column 104 a for distillation to remove impurities such as the higher silane and any higher than higher than higher silanes after reaction zones 102 a and 110 have been shut down. A third output is a third lower silane containing stream 140 having relatively high amounts of the lower silane. Third lower silane containing stream 140 is recycled back to preheater 100 a . A fourth output is a second higher silane containing stream 134 having relatively large amounts of the higher silane. It is introduced to second reaction zone 110 or mixed with first gaseous mixture 124 a before introduction to second reaction zone 110 . Second higher silane containing stream 134 may be further cooled or heated prior to its introduction into second reaction zone 110 or mixture with the first gaseous mixture 124 a.
In general for both embodiments, the pressure of lower silane containing streams 120 and 120 a and the pressure of first gaseous mixture 124 and 124 a can be any pressure as long as the reactants are gaseous. Preferably, the pressure is more than atmospheric. Increasing the pressure above atmospheric allows for smaller equipment and it makes any distillations or condensations easier to perform.
Preferably reaction zones 102 , 102 a , and 110 , and preheaters 100 and 100 a are designed to operate in plug flow. More preferably, preheaters 100 and 100 a are designed to operate in highly turbulent flow to provide high heat transfer rates. Such high heat transfer rates are not necessary for reaction zones 102 , 102 a and 110 . Flow rates and pipe diameters for reaction zones and preheaters should be sized accordingly. In addition, baffles and distribution plates may be used to prevent uneven flow distributions and channeling. Maldistribution may create hot spots thereby resulting in the decomposition of silane.
Hydrogen is believed to limit the decomposition of silane because it is a byproduct of that decomposition. However, in general for both embodiments, the concentration of non-reacting diluents, such as hydrogen, in lower silane containing streams 120 and 120 a can be less than 20% by volume, and can be less than about 10%. This allows for smaller equipment sizes and increases the efficiency of separations. In particular, reducing the concentration of diluent greatly reduces the size of condensers 112 and 112 a . Because of the low residence times in first reaction zone 102 and 102 a and the gentle heating of lower silane containing stream 120 and 120 a , having low concentrations of diluents does not result in excessive decomposition of silanes into silica and hydrogen. On the other hand, it may be desirable to have concentrations of diluents higher than 20% when condenser size is less important.
In accordance with the present invention, disilane, trisilane, and higher silanes can be produced cheaply and abundantly from a lower silane such as monosilane. The use of a preheater, not exposing the process streams to overly hot temperatures, and minimizing the residence time minimizes the creation of undesirable silane impurities and minimizes the decomposition of reactants and products into elemental silicon. In the two reactor zone process, the mixing of the first gaseous mixture 124 a and the second higher silane containing stream 134 rapidly quenches the hot gaseous mixture achieving control over the residence time at higher temperatures minimizing waste and impurities.
Example 1
Approximately 16 kg/hr of disilane at 30 psia was fed to a pre-heater where it was heated to 350° C. The preheater was constructed of approximately 30 feet of ⅜″ diameter 316 stainless steel tubing. The first reactor has a volume of about 50 L and had a length to diameter ratio of approximately 5:1. The reactor was held at 350° C. Byproduct silane and any hydrogen was removed as an overhead stream. The outlet gas from the reactor was composed of 4.1% monosilane, 93.5% disilane, 2.17% trisilane, and 0.15% tetrasilane. No higher silanes or hydrogen were detected.
Example 2
The conditions were the same as example 1 except an 8 L reactor was used. The outlet gas from the reactor was composed of 2.124% monosilane, 96.67% disilane, 1.138% trisilane, and 0.07% tetrasilane. No higher silanes or hydrogen were detected.
Example 3
The equipment was the same as example 2. 2.5 kg/hr of monosilane was heated to 460° C. Silane was not purged in the overhead. The outlet gas from the reactor was composed of 98.33% monosilane, 1.414% disilane, 0.236% trisilane, and 0.019% tetrasilane. No higher silanes or hydrogen were detected.
Example 4
The conditions were the same as example 3 except 3.4 kg/hr of monosilane was heated to 440° C. The outlet gas from the reactor was composed of 99.63% monosilane, 0.341% disilane, and 0.027% trisilane. No higher silanes or hydrogen were detected. | A method for making a higher silane from a lower silane comprises heating a lower silane containing stream without exposing it to temperatures more than 20° C. more than the maximum temperature of a first reaction temperature range. The heated lower silane containing stream is introduced into a first reaction zone and allowed to react. The method further comprises mixing a first gaseous mixture from the first reaction zone with a higher silane containing stream and introducing the mixed streams into a second reaction zone operating within a second reaction temperature range. A second gaseous mixture exiting the second reaction zone is separated into various streams. One stream containing unreacted lower silanes is recycled to an earlier heating step and first reaction zone. The higher silane containing stream is mixed with the first gaseous mixture. Average residence time is low to prevent decomposition and formation of undesired silane byproducts. | 8 |
FIELD OF THE INVENTION
The present invention relates to a throttle body valve structure employed to control or meter the flow of air into, for example, a manifold/carburetor arrangement furnishing air to a carburetor designed to combine said air with a suitable fuel and deliver same to an internal combustion engine.
BACKGROUND AND SUMMARY OF THE INVENTION
Traditionally, throttle body valve structures have utilized an internal circular butterfly type valving arrangement for increasing or decreasing the flow of air to a manifold/carburetor arrangement. Controlling the precise amount of air and fuel to the manifold/carburetor is important to the fuel efficiency of an engine. In a fuel injection system of an internal combustion engine, the incoming air is regulated by the throttle body valve which is connected by a linkage to the accelerator pedal. As the accelerator pedal is depressed, the valve is opened allowing air to enter the intake.
Throttle body valve assemblies are traditionally fabricated of metal due to the requirements for strength, durability, dimensional tolerance, machinability, and other advantages inherent in the use of metal. A perceived drawback, however, is that the use of fabricated metals necessarily affect the weight of the overall assembly.
Further, with regard to conventional butterfly valving arrangements, such valving arrangements generally necessitate internal valving components utilizing mounting pins and springs for operation of the butterfly member. These components can become fouled and damaged due to the vulnerable, internal positioning of the components.
Accordingly, it is desirable in the art of fuel intake systems to provide a lightweight, throttle body assembly capable of improved operation in the control of the air flow to the manifold and/or the carburetor.
It is also desirable in the art of valves to provide a valve with an unobstructed internal throat.
It is further desirable to provide a valve capable of improved metering of the air or fluid passing therethrough.
It is further desirable to provide an all-plastic throttle body valve in order to obtain a reduction in weight in comparison with conventional metal throttle body valve assemblies.
Converting a throttle body valve from metal to plastic presents a possible problem due to the dimensioning required in the throat bore to ensure a closed throttle. Due to the variability of the injection molding process, as well as material sensitivity (to the environment), a direct material exchange is not feasible. Thus, in order to produce a plastic throttle body valve that functions well, an alternative design that is less sensitive to molding operations and the environment is provided.
The throttle body valve according to the present invention includes a valve body including an interior passageway connecting an inlet and an outlet of the valve body. The valve body includes an arcuate sliding surface through which the inlet is provided, and a closure member pivotally attached to the valve body for selectively opening and closing the inlet. The present invention is advantageous in that there is no obstruction in the air stream when the throttle body valve is wide open.
Further applicability of the scope of the present invention will become apparent from the detailed description given hereinafter. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings wherein:
FIG. 1 is a perspective view of a throttle body valve according to the present invention, wherein the throttle body valve is shown in a fully opened position;
FIG. 2 is a perspective view of the throttle body valve according to the present invention, wherein the throttle body valve is in a fully closed position;
FIG. 3 is a perspective view of a valve body for use in a throttle body valve assembly according to the present invention;
FIG. 4 is a perspective view of an arcuate closure member according to a second embodiment of the present invention;
FIG. 5 is a perspective view of an arcuate closure member according to a third embodiment of the present invention wherein a slide plate is provided for obtaining a sealed relationship with the arcuate sliding surface of the valve body;
FIG. 6 is a cross-sectional view of the arcuate closure member shown in FIG. 5, illustrating a spring for biasing the slide plate toward the arcuate sliding surface of the valve body; and
FIG. 7 is a schematic view of an air induction system having a plastic throttle body valve in combination with a fuel introduction apparatus for use with an internal combustion engine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1-3, a throttle body valve assembly 10 will be described according to a first embodiment of the present invention. Valve assembly 10 includes a valve body 12 including an interior passageway 14 connecting an inlet 16 and an outlet 18, as shown in FIG. 3. An arcuate closure member 20 is pivotally attached to valve body 12 and is provided for selectively covering air inlet 16 for increasing or decreasing air flow through internal passage way 14. Valve body 12 is provided with an exterior arcuate sliding surface 22 against which closure member 20 is in sliding engagement. Arcuate surface 22 is provided with a stop surface or flange 24 adjacent to a first edge 16a of air inlet 16. Arcuate surface 22 extends from stop surface 24 to a position beyond a second edge 16b of air inlet 16, such that arcuate surface 22 is generally in sliding contact with closure member 20 when closure member 20 is in its fully open position, as shown in FIG. 1. Thus, arcuate surface 22 preferably is in direct contact with the arcuate closure member 20 during a full range of movement from a fully closed position, as shown in FIG. 2, to a fully open position, as shown in FIG. 1. Arcuate surface 22 can also be provided with a stop surface for stopping the movement of the closure member in the fully open position.
Closure member 20 which is pivotally mounted to valve body 12 by pivot bosses 28 extending from opposite sides of valve body 12 is provided with an arcuate sealing portion 30 and first and second arm portions 32 extending generally transversely therefrom. The arms 32 are provided with pivot openings 34 which receive the pivot bosses 28 thereby allowing for pivotal movement to selectively open and close the inlet 16. The curvature of arcuate sealing portion 30 generally corresponds with the curvature of arcuate surface 22 to assist in selectively sealing the inlet.
A seal groove 38 is provided about the periphery of air inlet 16. A circular seal 40 is generally provided in seal groove 38. The seal 40 is preferably formed from a material such as polytetrafluoroethylene, graphite, or a lubricant impregnated engineering material, for example so that the seal does not unduly restrict the desired movement of the closure member. Seal 40 is particularly effective for sealing air leaks between the arcuate sealing portion 30 and arcuate surface 22. Seal 40 also allows the valve assembly 10 to be manufactured with less restrictive molding tolerances.
Arcuate surface 22 preferably includes reinforcing ribs 44 which provide structural strength to arcuate surface 22 and valve body 12. Valve body 12 is provided with a flange 46 which facilitates fastening valve assembly 10 to the desired surface such as a manifold or carburetor for example. Flange 46 is provided with a plurality of bolt holes 48 for receiving bolts 50 for securely fastening valve assembly 10 to a manifold or carburetor.
To activate the valve assembly 10, a cable or motor generally acting through another mechanism, rotates closure member 20 about arcuate surface 22 to cover air inlet 16 as desired.
The valve body 12 and closure member 20 are preferably made from an engineering plastic material having suitable performance properties such as desirable heat stability and dimensional stability. Illustrative materials are nylon (polyamide), a polybutylene terephthalate (PBT) or a PBT and acrylonitrile styrene acrylate (ASA) blend, ABS polymer (acrylonitrile-butadiene-styrene), and polycarbonate. Such materials may also be reinforced with glass and/or mineral fibers or particles. Especially preferred materials are ULTRAMID ® A3HG7 BIk Q17 20560 nylon, ULTRAMID ® A3WG7 BIk 23210 nylon, ULTRAMID ® B3WG7 BIk 564 BGVW nylon and ULTRADUR ® S 4090 G6 polybutylene terephthalate, commercially from BASF Corporation of Wyandotte, Mich.
Referring to FIG. 4, a second embodiment of the present invention is provided with an expansion joint 60 in each of the arms 32a of closure member 20a. A pair of springs 62 are provided on each arm 32a and are attached to the fastening members 64. Expansion joint 60 divides the arms 32a into two segments, namely a first segment 66 which includes a pivot opening 34a and a second segment 68 which is connected to arcuate portion 70 of closure member 20a, Springs 62 are provided for biasing the second segments 68 of arms 32a toward the first segments 66 as well as biasing arcuate portion 70 in a direction toward arcuate surface 22 of valve body 12. The biasing force provided by springs 62 ensures a sealing fit between portion 70 of arcuate closure member 20a and arcuate surface 22.
A third embodiment of the arcuate closure member 20b is shown in FIGS. 5 and 6. Closure member 20b is provided with an arcuate slide plate 80 which provides a sealing portion, disposed between arms 32b and radially inward from arcuate portion 82 which is connected to arms 32b. A retaining flange 84 is provided along an edge of arcuate portion 82 in order to maintain slide plate 80 in a proper position with respect to arcuate portion 82. A plurality of retaining pins 86 are provided for supporting slide plate 80 in a radially inward direction. (Alternatively, slide plate 80 could be integrally formed with pins extending laterally therefrom which are received in corresponding grooves in arms 32b.) Slide plate 80 is provided with a beveled surface 88 along at least one edge thereof to facilitate a sliding relationship between slide plate 80 and circular seal 40. Furthermore, slide plate 80 is provided with a spring seat 90 and arcuate portion 82 is provided with a spring seat 92 for supporting a spring 94 therebetween. Spring 94 biases slide plate 80 in a radially inward direction so as to provide a sealing contact between slide plate 80 and arcuate surface 22 of valve body 12. It is recognized that springs other than the spring 94 shown in FIG. 6 could be used for biasing slide plate 80 in the radially inward direction. Furthermore, a plurality of springs may be desirable for providing a proper biasing force against slide plate 80.
With reference to FIG. 7, a first embodiment of the valve assembly 10 according to the present invention is illustrated in an air/fuel introduction system for use with an internal combustion engine. It should be noted however that valve assembly 10 is provided for purposes of illustration only since other assemblies provided herein are also applicable.
The air/fuel introduction system generally includes an air induction system 100 which is provided with air passages 102, 104, respectively, leading to and extending from valve assembly 10. A fuel introduction apparatus 108 is provided for introducing fuel to the air passing through air induction system 100. The mixed air and fuel are then introduced to engine cylinders 110 via intake valve 112. The combusted air is exhausted through exhaust valve 114. It should be noted that the valve assembly 10 can be utilized with any known fuel introduction apparatus. For example, and without intending to be limiting, fuel introduction apparatus generally include carburetors, fuel injectors, and throttle body fuel injectors which are all well known in the art. The valve assembly 10 is provided within a housing 118 which covers valve assembly 10 and provides a sealed connection with air passages 102, 104.
The location of fuel introduction apparatus 108 will vary depending upon the type of apparatus used. For example, for a throttle body fuel injection system, the injectors would generally be located adjacent to the valve assembly 10. With a fuel injection system, the injector would typically be connected directly to engine cylinders 110 for introducing fuel directly therein. Finally, a carburetor would be located in between valve assembly 10 and engine cylinders 110. Typically, an air intake manifold is provided for distributing air or an air fuel mixture to the individual cylinders of an engine.
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 plastic throttle body valve including a valve body having an interior passage way connecting an inlet and an outlet of the valve body. The valve body includes an arcuate surface through which the inlet is provided, and a closure member pivotally attached to the valve body for selectively opening and closing the inlet. The valve has the advantage that there is no obstruction in the air stream when the valve is wide open. | 5 |
This is a Divisional of application Ser. No. 08/664,442 filed Jun. 21, 1996 now abandoned.
This invention relates to composite framing members, more specifically to studs and tracks, joists and bands, headers, and rafters formed from wood and metal composites.
BACKGROUND AND PRIOR ART
Residential and light commercial construction generally use wood as the primary building material for studs, plates, joists, headers and trusses. However, all-wood construction has problems. The rapidly rising cost of raw wood supplies has in effect substantially raised the cost of these members. Further, the quality of available framing lumber continues to decline. Finally, wood is flammable and susceptible to insects and rot.
Due to these problems, many builders have been switching to using all steel framing. The costs between using wood or steel framing is getting closer. In January 1990, the cost of framing lumber was about $225 per thousand board feet, peaking to highs of $500 in both January, 1993 and January 1994. Since June 1995, the framing lumber composite price has been rising from $300 per thousand board feet Estimates from the AISI and NAHB Research Center state at a framing lumber cost of $340 to $385, there would be no difference between the cost of framing a house in steel as compared in wood. Thus, the break-even point between wood and steel framing is at about $360 per thousand board feet of framing lumber, and the lumber price has exceeded that point several times in recent years by as much as 40%, giving steel a competitive advantage.
Recycling has additionally helped the cost of steel to remain on a stable or downward trend. Steel costs have varied little in recent years. Traditionally variations can be correlated to steel demand by the automobile industry when demand is high, steel usually increases slightly in price. Consequently, the use of metal framing in residential and light commercial construction is increasing, a trend recognized and encouraged by the American Iron and Steel Institute (AISI).
All steel studs, tracks and trusses are being manufactured by Tri-Chord, HL Stud Corporation, Truswall Systems, Techbuilt Manufacturing, Knudson Manufacturing, John McDonald, and MiTek Ultra-Span Systems.
A problem with using all steel framing is its high thermal conductivity, leading to thermal bridging, "ghosting", and greater potential for water vapor condensation on interior wall surfaces. "Ghosting" is when an unsightly streak of dust accumulates on the interior wallboard, where the steel studs lie behind, due to an acceleration of dust particles toward the colder surface. Another problem of using all steel framing is the increased energy use for space conditioning (heating and cooling). Metal used for exterior framing members allows greater conduction heat transfer between the outside and inside surfaces of a wall, roof or floor. In colder climates, this increased conduction can cause condensation in interior surfaces, contributing to material degradation and mold and mildew growth. Metal framing also decreases the effectiveness of insulation installed in the cavity between the metal framing due to increased three dimensional thermal shorting effects. Higher sound transmission is another disadvantage of metal framing since sound conductivity is greater in metal than in wood. Electricians have more difficulty working with all steel framing when running holes for wiring since metal is more difficult to drill than wood, and grommets or conduits must be used to protect the wire.
U.S. Pat. No. 5,285,615 to Gilmour describes a thermal metallic building stud. However, the Gilmour member is entirely formed from metal. In Gilmour, the thermal conductivity is only partially reduced by having raised dimples on the ends contacting other building materials.
U.S. Pat. No. 3,960,637 to Ostrow describes impractical wood and metal composites. Ostrow requires each end flange have tapered channels, the end flanges being formed from extruded aluminum, molded plastic and fiberglass. Ends of the vertical wood web must be fit and pressed into a tapered channel. Besides the difficulty of aligning these parts together, other inherent problems exist. Extruding the channel flanges from aluminum or using molds, cuts and rolling to create the channelled plastic and fiberglass end flanges is expensive to manufacture. To stabilize the structures, Ostrow describes additional labor and manufacturing costs of gluing members together and sandwiching mounting blocks on the outsides of each channel.
Other metal and wood framing member patents of related but less significant interest include: U.S. Pat. Nos. 5,452,556 to Taylor; 5,440,848 to Deffet; 5,072,547 to DiFazio; 4,875,316 to Johnston; 4,301,635 to Neufeld; 4,274,241 to Lindal; 4,031,686 to Sanford; and 3,531,901 to Meechan.
SUMMARY OF THE INVENTION
The first objective of the present invention is to provide a metal/wood composite wall stud that increases the total thermal resistance of a typical steel framed insulated wall section by some 43percent and would eliminate interior condensation and "ghosting" for all but the coldest regions of the United States.
The second object of this invention is to provide a wood and metal composite framing combinations that achieve a resource efficient and economic construction framing member. Metal is used for its high strength, and potentially lower cost and resource efficiency through recycling. Wood is used primarily for its lower thermal conductivity and for its availability as a renewable resource, and for its workability.
The third object of this invention is to provide a wood and metal composite framing members that allows electricians to be able to route wires through walls in the same way they are accustomed to doing with solid framing lumber.
The fourth object of his invention is to provide a wood and metal composite framing member that would be easy to manufacture.
The fifth object of this invention is to provide a wood and metal composite framing member that has low sound conductivity compared to prior art steel framing members.
The sixth object of this invention is to provide a wood and metal composite framing member that has reduced effects from flammability compared to all wood members.
The invention includes J-shaped, L-shaped, triangular shaped cross-sectional metal forms (plate legs) connected by a wood midsections, whereby the wood is fastened to the metal by machine pressing of the metal to wood, similar to the common truss plate, or by nails, staples, screws, or other mechanical fastening means, or by adhesive glue. The outward faces of the metal members are pre-formed with four longitudinal ridges such that the contact surface area to applied sheathings is reduced by about 90%.
Metal and wood composites are used to create framing members (studs and tracks, joists and bands, headers, rafters, and the like) for light-weight construction. Metal is utilized for its high strength, resistance to rot and insects, cost stability, and potentially lower cost through recycling. Wood is used primarily for its lower thermal conductivity, and availability. The metal components form the primary structure while wood, either solid or other engineered wood, provides some structure and a thermal break. The metal used can be steel of approximately 18 to approximately 22 gauge.
Metal/wood composite framing members can be used in place of conventional wood framing members such as: 2×4 and 2×6 wall studs, and 2×8, 2×10, 2×12 and other dimensions of roof rafters, floor joists and headers. The novel framing members can be used to replace conventional light-gauge steel framing to reduce thermal transmittance and sound transmission.
Further objects and advantages of this invention will be apparent from the following detailed description of a presently preferred embodiment which is illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1A is a perspective isometric view of a first preferred embodiment metal/wood stud.
FIG. 1B is a cross-sectional view of the embodiment of FIG. 1A along arrow AA.
FIG. 2A is a perspective isometric view of a second preferred embodiment metal/wood stud.
FIG. 2B is a cross-sectional view of the embodiment of FIG. 2A along arrow BB.
FIG. 3A is a perspective isometric view of a third preferred embodiment metal/wood stud.
FIG. 3B is a cross-sectional view of the embodiment of FIG. 3A along arrow CC.
FIG. 4A is a perspective isometric view of a fourth preferred embodiment metal/wood joist, rafter and header.
FIG. 4B is a cross-sectional view of the embodiment of FIG. 4A along arrow DD.
FIG. 5A is a top perspective view of a fifth embodiment track for metal/wood stud systems.
FIG. 5B is a bottom perspective view of the embodiment of FIG. 5A along arrow E1.
FIG. 5C is a cross-sectional view of the embodiment of FIG. 5B along arrow EE.
FIG. 6A is a perspective view of a sixth preferred embodiment metal/wood band.
FIG. 6B is a cross-sectional view of the embodiment of FIG. 6A along arrow FF.
FIG. 7 is a cross-sectional view a framing system utilizing the embodiments of FIGS. 1A-6B.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Before explaining the disclosed embodiment of the present invention in detail it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
The preferred method of calculating thermal transmittance for building assemblies with integral steel is the zone method published by the American Society of Heating Refrigeration and Air-Conditioning Engineers (ASHRAE). A recent study by the National Association of Home Builders Research Center and Oak Ridge National Laboratory verified the usefulness of the zone method for calculating thermal transmittance for light gauge steel walls.
Thermal transmittance calculations were completed using the zone method for the metal/wood stud invention embodiments. Table 1 shows a comparison of thermal transmittance (given as total R-value) for nine wall configurations. The first wall listed is a conventional 2×4 wood frame wall with 1/2" plywood sheathing and R-11 fiberglass cavity insulation. The total wall R-value is 13.2 hr-F-ft 2 /Btu. the second and third walls listed are conventional metal stud walls, one with 1/2" plywood sheathing (R-7.9) and the other with 1/2" extruded polystyrene sheathing (R-11.4). With conventional metal studs, high resistivity insulated sheathing is necessary to limit the large loss of total thermal resistance when low resistivity sheathings are used. In some cases, it is not desirable to use the non-structural insulated sheathing, such as when brick ties are needed, or when higher racking resistance is needed.
In comparison, the metal/wood stud walls corresponding to those described in the subject invention has a 43 per cent greater total R-value than the conventional metal stud wall when using plywood sheathing. Thermal performance of the metal/wood stud wall with plywood sheathing is nearly the same as the conventional wall with 1/2" extruded polystyrene (XPS insulated sheathing). Where non-structural sheathing is acceptable, fiber board sheathing, which is much less expensive than plywood, further increases the total R-value of the metal/wood stud wall.
TABLE 1__________________________________________________________________________COMPARISON OF THERMAL TRANSIT TRANSMITTANCE FOR CONVENTIONALMETAL STUD WALL AND NOVEL METAL/WOOD STUD WALL Stud Size Stud Spacing Cavity Exterior TotalDescription Inch Inch O.C. Insulation Sheathing R-Value__________________________________________________________________________ Conventional metal stud.* 1.625 × 3.625 24 R-11 1/2" plywood 7.9 Conventional metal stud.* 1.625 × 3.625 24 R-11 1/2" XPS 11.4 Novel metal/wood stud, 1.5 × 3.5 24 R-11 1/2" plywood 11.3 Novel metal/wood stud 1.5 × 3.5 24 R-13 1/2" plywood 12.8 Novel metal/wood stud 1.5 × 3.5 24 R-15 1/2" plywood 14.2 Novel metal/wood stud 1.5 × 3.5 24 R-11 1/2" fiber board 12.1 Novel metal/wood stud 1.5 × 3.5 24 R-13 1/2" fiber board 13.6 Novel metal/wood stud 1.5 × 3.5 24 R-15 1/2" fiber board 15.0__________________________________________________________________________ *Conventional metal stud values from "Thermodesign Guide for Exterior Walls, American Iron and Steel Institute, Washington, D.C., Pub. No. RG9405, Jan. 1995 Comparison of vertical, transverse, and racking load capacities of 2 × 4 wood stud, metal stud, and subject invention wood/metal composite stud. Structural analysis by Kim McLeod, P.E. Of Keymark Enterprises, Boulder, Colorado.
Summary calculation results compared the allowable axial load for stud elements subjected to combined loading with axial and bending components. The three elements analyzed were a conventional 2×4 wood, a conventional 20 gauge steel stud, and the present invention metal/wood composite stud. All elements were 8' tall, and spaced 16" O.C. Wind (transverse) load at 110 mph. Table 2 shows that the metal/wood composite section can support 54% more weight than the metal stud, and 250% more weight than the wood stud. This gives the opportunity for further cost optimization by increasing the spacing which would reduce the number of studs required, or for reducing the amount of steel used in the composite section.
TABLE 2______________________________________STRUCTURAL CALCULATION RESULTSFOR NOVEL METAL/WOOD STUDAllowable Axial 2×4 3.5" 20 Gauge 3.5" Metal/WoodLoad Wood Stud Metal Stud Composite Section______________________________________8' tall stud 551 lb 894 lb 1378 lb16" O.C.110 mph wind______________________________________
FIG. 1A is a perspective isometric view of a first preferred embodiment metal/wood stud 100. FIG. 1B is a cross-sectional view of the embodiment 100 of FIG. 1A along arrow AA. Referring to FIGS. 1A-1B, embodiment 100 includes metal forms 110, 120 such as but not limited to 20 gauge steel has been cold-formed in a roll press into a cross-sectional channel J-shape. Each form 110, 120 includes steel web portions 112, 122 that have staggered rows of cutout portions 115, 125 which are of a pressed tooth type triangular shape. Web portions 112, 122 are perpendicular to flanges 116, 126 which include approximately 4 rows of raised V-shaped grooves 117, 127 running longitudinally along the exterior of the flanges 116, 126. Flange returns 118, 128 are perpendicular to flanges 116, 126. Teeth 115, 125 can be hydraulically pressed adjacent the top and bottom rear side 152 of central web board 150. Central web board 150 can be solid wood, OSB, (oriented strand board) plywood and the like, having a thickness of approximately 1/2 an inch. Alternatively, web portions 112, 122 of forms 110, 120 can be fastened to the central web board 150 by nails, screws, staples and the like, or adhesively glued. A finished metal/wood stud 100 can have a length, L1, of approximately 8 feet or longer, height H1 of approximately 3.5 to 5.5 inches, width W1 of approximately 1.5 inches. Web portions 112, 122 can have a height, h1 of approximately 1.125 inches, front plate height, h2 of approximately 0.75 inches, raised grooves R1, of approximately 0.125 inches. A spacing, x1 of approximately 0.125 inches separates each flange 116, 126 from the top and bottom of central web board 150.
FIG. 2A is a perspective view of a second preferred embodiment metal/wood stud 200. FIG. 2B is a cross-sectional view of the embodiment 200 of FIG. 2A along arrow BB. Referring to FIGS. 2A-2B, embodiment 200 includes metal forms 210, 220 such as but not limited to 20 gauge steel that has been roll pressed into a cross-sectional channel right-triangular-shape. Each form 210, 220 includes outer web portions 212, 222 that have staggered rows of cut-out portions 213, 223 which are of a pressed tooth type triangular shape. Outer web portions 212, 222 are perpendicular to flanges 214, 224 which include approximately 4 rows of raised V-shaped grooves 215, 225 running longitudinally along their exterior surface. Flange returns 216, 226 are approximately 45 degrees to flanges 214, 224, and are connected to inner web portions 218, 228 each having staggered rows of cut-out portions 219, 229 which also are of the pressed tooth type triangular shape. Teeth 213, 219 and 223, 229 can be firmly pressed adjacent the top and bottom of central web board 250. Central web board 250 can be solid wood, OSB, plywood and the like, having a thickness of approximately 1/2 an inch. Alternatively, web portions 212, 218, 222, 228 can be fastened to the central web board 250 by nails, screws, staples and the like. Outer web portions 212, 222 can have a height, B1 of approximately 1.1625 inches, flanges 214, 224 can have a width, B2 of approximately 1.5 inches, flange returns 216, 226 can have a height, B3 of approximately 0.925 inches and inner web portions 218, 228 can have a height, B4 of approximately 1 inch. A finished metal/wood stud 200 can have the remaining dimensions and spacings similar to the embodiment 100 previously described, except height, B5 can be approximately 5.5 to approximately 7.25 inches.
FIG. 3A is a perspective isometric view of a third preferred embodiment metal/wood stud 300. FIG. 3B is a cross-sectional view of the embodiment 300 of FIG. 3A along arrow CC. Referring to FIGS. 3A-3B, embodiment 300 includes metal forms 310, 320 such as but not limited to 20 gauge steel has been roll pressed into a cross-sectional channel triangular-shape with parallel plates on the apex of the triangle. Each form 310, 320 includes metal web portions 312, 322, 318, 328 that have staggered rows of cut-out portions 313, 323, 319, 329 which are of a pressed tooth type triangular shape. Web portions 312, 322, 318, 328 attach to 45 degree flange returns 314, 324 which are attached to respective flanges 315, 325 which include approximately 4rows of raised V-shaped grooves 316, 326 running longitudinally along their exterior surface. Teeth 313, 319 and 323, 329 can be pressed adjacent the top and bottom of central web board 350. Central web board 350 can be solid wood, OSB, plywood and the like, having a thickness of approximately 1/2 an inch. Alternatively, metal web portions 312, 318, 322, 328 can be fastened to the central web board 350 by nails, screws, staples and the like. Metal web portions 312, 318, 322, 328 can have a height, C1 of approximately 0.875 inches, flanges 315, 325 can have a width, C2 of approximately 1.5 inches, flange returns 314, 317, 324, 327 can have a height, C3 of approximately 0.4625 inches. A finished metal/wood stud 300 can have remaining dimensions and spacings similar to the embodiment 200 previously described.
FIG. 4A is a perspective isometric view of a fourth preferred embodiment 400 useful as a metal/wood joist, rafter and header. FIG. 4B is a cross-sectional view of the embodiment 400 of FIG. 4A along arrow DD. Referring to FIGS. 4A-4B, embodiment 400 includes metal forms 410, 420 such as but not limited to 20 gauge steel has been roll pressed into a cross-sectional channel triangular-shape with parallel plates on the apex of the triangle. Each form 410, 420 includes metal web portions 412, 422, 418, 428 that have staggered rows of cut-out portions 413, 423, 419, 429 which are of a pressed tooth type triangular shape. Metal web portions 412, 422, 418, 428 attach to 45 degree flange returns 414, 424, 417, 427 which are attached to respective flanges 415, 425 which include approximately 4 rows of raised V-shaped grooves 416, 426 running longitudinally along their exterior surface. Teeth 413, 419 and 423, 429 can be pressed adjacent the top and bottom portions of central web boards 452, 454. A central metal plate 460 has left facing tooth rows 463 and right facing tooth rows 465 for connecting to adjacent respective web boards 452, 454. Plate 460 has a spacing above and below to separate such from flanges 415, 425. Central web boards 452, 454 can be solid wood, OSB, plywood and the like, having a thickness of approximately 0.375 inches. Alternatively, metal web portions 412, 418, 422, 428 can be fastened to the central web boards 452, 454 by nails, screws, staples and the like. Metal web portions 412, 418, 422, 428 can have a height, D1 of approximately 1.0188 inches, flanges 415, 425 can have a width, D2 of approximately 1.5 inches, flange returns 414, 417, 424, 427 can have a height, D3 of approximately 0.3188 inches. A finished embodiment 400 can have practically any length, L2 to serve as a floor joist, rafter or header, width D2 can be approximately 1.5 inches and height D4, can be approximately 5.5 inches or more.
FIG. 5A is a top perspective view of a fifth embodiment track 500 for metal/wood stud and track systems. FIG. 5B is a bottom perspective view of the embodiment 500 of FIG. 5A along arrow E1. FIG. 5C is a cross-sectional view of the embodiment 500 of FIG. 5B along arrow EE. Referring to FIGS. 5A-5C, embodiment 500 includes metal forms 510, 520 each having a generally L-shaped cross-section. Forms 510, 520 each include flanges 512, 522 approximately 1.125 inches in height perpendicular to metal web portions 514, 524, which are approximately 1.1625 inches in length. Metal web portions 514, 524 have tooth shaped triangular cut-outs 515, 525, which are pressed into sides of center-web-board 550. A spacing E2 of approximately 0.125 inches separates the ends of center-web-board 550 from flanges 512, 522, respectively. A finished embodiment 500 can have remaining dimensions and spacings similar to the embodiments 100, 200, and 300 above.
FIG. 6A is a perspective view of a sixth preferred embodiment metal/wood joists and bands 600. FIG. 6B is a cross-sectional view of the embodiment 600 of FIG. 6A along arrow FF. Referring to FIGS. 6A-6B, embodiment 600 includes top metal form 610 having a T-cross-sectional shape and lower metal form 620 having a straight line cross-sectional shape. Form 610 includes metal web portion 612, having a length, F1 of approximately 1.0375 inches having tooth shaped triangular cut-outs 613 which are pressed into upper end sides of wood center web board 650. Form 610 further includes an upright leg 614 having a length F2 of approximately 1.3 inches, perpendicular to a third leg 616, having a length, F3 of approximately 1.25 inches, which abuts against and overlaps top end 652 of centerboard 650. Lower metal form 620 has a metal web portion 622 having tooth shaped triangular cut-outs 623 which are pressed into upper end sides of wood center board 650, and a continuous extended plate 624. The continuous width F4, of metal plate 622, 624 is approximately 1.75 inches, with plate 624 extending a length F5 of approximately 0.75 inches from the lower end 654 of center-web-board 650 having thickness of approximately 0.5 inches. A finished embodiment 600 can have a width F6 and length L3 similar to embodiment 400.
FIG. 7 is a cross-sectional view a framing system 700 utilizing the embodiments of FIGS. 1A-6B. Embodiment 700 can be a two story building having a metal/wood bottom track 500 attached at floor 702 by conventional fasteners such as nails, screws, bolts and the like. Vertically oriented metal/wood studs 100/200/300 can be attached to floor and ceiling tracks 500 by steel framing screws 715 and the like. A metal/wood band 600 attaches first floor ceiling track 500 to metal/wood floor joist 400 and subfloor 710, which has conventional steel framing flathead type screws 716 and the like. The second floor has a similar arrangement with rafters 400 attached at conventional angles to upper metal/wood top track 500.
A cost of a metal/wood composite stud such as those described in the previous embodiment 100 is estimated to be $4.24. The lowest cost of conventional 20 gauge steel studs is $2.52 each, however, to obtain the same thermal performance, an insulated sheathing is required which raises the cost to $4.55 per stud. The metal/wood framing member's invention is directly cost effective compared to the conventional metal stud. In addition, structural calculations show that the metal/wood stud configuration can support 54% more weight at the same 8' wall height, 16" O.C. spacing, and 110 mph wind load. This give opportunity for further cost optimization by increasing the spacing which would reduce the number of studs required. For example, a 2000 square foot house framed 16" O.C. will have about 168 conventional steel exterior wall studs, the same house framed 24" O.C. with the stronger metal/wood composite exterior wall studs will use only 107 studs. With 61 fewer exterior wall studs required, the builder can save about $270.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended. For the claims, the invention will be described as having all metal portions including the forms to be referred to as flanges, and all mid wood portions will be referred to as wood web members. | Metal and wood composites are used to create framing members (studs and tracks, joists and bands, rafters, headers and the like.) for lightweight construction. Metal is utilized for its high strength, resistance to rot and insects, cost stability, and potentially lower cost through recycling. Metal that can be used includes roll formed steel approximately 18-22 gauge. Wood is used primarily for its lower thermal conductivity, and availability. The metal components form the primary structure while wood, either solid or other engineered wood, provides some structure and a thermal break. The invention connects J-shaped or triangular shaped metal forms to wood sections. The metal flange ends can have various J, C, L, right triangular, triangular, T and straight line cross-sectional shapes. The wood is fastened to the metal by machine pressing of the metal to wood. Alternatively the fastening includes nails, staples, screws, and the like, and also by adhesive glue. The outward faces of the metal members are pre-formed with four longitudinal ridges such that the contact surface area to applied sheathings is reduced by about 90%. | 4 |
TECHNICAL FIELD OF THE INVENTION
[0001] This invention relates, in general, to controlling the production of fluids from a well that traverses a hydrocarbon bearing subterranean formation and, in particular, to an apparatus for controlling the inflow of production fluids from the subterranean well that is adjustable over the life of the well.
BACKGROUND OF THE INVENTION
[0002] Without limiting the scope of the present invention, its background will be described with reference to producing fluid from a subterranean formation, as an example.
[0003] During the completion of a well that traverses a hydrocarbon bearing subterranean formation, production tubing and various equipment are installed in the well to enable safe and efficient production of the formation fluids. For example, to prevent the production of particulate material from an unconsolidated or loosely consolidated subterranean formation, certain completions include one or more sand control screens positioned proximate the desired production intervals. In other completions, to control the flow rate of production fluids into the production tubing, it is common practice to install one or more fluid flow control devices within the tubing string.
[0004] Recently, attempts have been made to utilize fluid flow control devices within completions requiring sand control. While certain benefits have been achieved through the use of such devices, many of these devices are complicated to operate and have suffered from poor reliability. In addition, it has been found that during the life of the well, as the formation depletes and reservoir pressure decreases, the flow control characteristics of many such fluid flow control devices may not remain suitable for achieving the desired production goals, particularly in long horizontal intervals.
[0005] Accordingly, need has arisen for a fluid flow control device for controlling the inflow of formation fluids in a completion requiring sand control. A need has also arisen for such a fluid flow control device that is reliable in a variety of flow conditions. Further, a need has arisen for such a fluid flow control device that can be used throughout the life of the well.
SUMMARY OF THE INVENTION
[0006] The present invention disclosed herein comprises a fluid flow control apparatus for controlling the inflow of formation fluids. The fluid flow control apparatus of the present invention is reliable in a variety of flow conditions. In addition, the fluid flow control apparatus of the present invention can be used throughout the life of the well and may be used in conjunction with a filter medium to serve as a sand control screen with flow control capabilities.
[0007] In one aspect, the present invention is directed to a sand control screen that is positionable within a wellbore. The sand control screen includes a base pipe having at least one opening that allows fluid flow between an exterior of the base pipe and an interior flow path of the base pipe. A filter medium is positioned exteriorly of the base pipe. An actuatable device is operably associated with the at least one opening. The actuatable device is operable to initially prevent fluid flow through the at least one opening and is actuatable to allow fluid flow through the at least one opening. In one embodiment, the actuatable device is a pressure actuated device that is actuated responsive to an increase in pressure to a predetermined level in the interior flow path. For example, the pressure actuated device may be a rupture disk.
[0008] In another aspect, the present invention is directed to a sand control screen that includes a base pipe having at least one opening that allows fluid flow between an exterior of the base pipe and an interior flow path of the base pipe. A filter medium is positioned exteriorly of the base pipe. A flow restricting device is disposed in a fluid flow path between the filter medium and the at least one opening. An actuatable device is operably associated with the at least one opening. In this embodiment, the flow restricting device is operable to create a pressure drop in fluids flowing therethrough. In addition, the actuatable device is operable to initially prevent fluid flow through the at least one opening and is actuatable to allow fluid flow through the at least one opening.
[0009] In yet another aspect, the present invention is directed to a sand control screen that includes a base pipe having at least one opening that allows fluid flow between an exterior of the base pipe and an interior flow path of the base pipe. A filter medium is positioned exteriorly of the base pipe. A one way valve is disposed in a fluid flow path between the filter medium and the at least one opening. An actuatable device is operably associated with the at least one opening. In this embodiment, the one way valve is operable to allow fluid flow in a downstream direction from the filter medium to the at least one opening and to prevent fluid flow in an upstream direction from the at least one opening to the filter medium. In addition, the actuatable device is operable to initially prevent fluid flow through the at least one opening and is actuatable to allow fluid flow through the at least one opening.
[0010] In a further aspect, the present invention is directed to a sand control screen that includes a base pipe having at least one opening that allows fluid flow between an exterior of the base pipe and an interior flow path of the base pipe. A filter medium is positioned exteriorly of the base pipe. A flow restricting device and a one way valve are disposed in a fluid flow path between the filter medium and the at least one opening. An actuatable device is operably associated with the at least one opening. In this embodiment, the flow restricting device is operable to create a pressure drop in fluids flowing therethrough, the one way valve is operable to allow fluid flow in a downstream direction from the filter medium to the at least one opening and prevent fluid flow in an upstream direction from the at least one opening to the filter medium and the actuatable device is operable to initially prevent fluid flow through the at least one opening and is actuatable to allow fluid flow through the at least one opening. Also in this embodiment, the flow restricting device may be upstream or downstream of the one way valve or the flow restricting device and the one way valve may be integrally formed.
[0011] In another aspect, the present invention is directed to a flow control apparatus for controlling the inflow of production fluids from a subterranean well. The flow control apparatus includes a tubular member having a plurality of openings that allow fluid flow between an exterior of the tubular member and an interior flow path of the tubular member. The flow control apparatus also includes a multi-stage flow restricting section that is operably positioned in a fluid flow path between a fluid source disposed exteriorly of the tubular member and the interior flow path. The flow restricting section includes a plurality of flow restricting devices each of which is operable to create a pressure drop and each of which is associated with one of the openings creating a plurality of flow paths between the fluid source and the interior flow path via the respective openings. Actuatable devices are operably associated with at least some of the openings.
[0012] Each of the acutatable devices initially prevents fluid flow through the associated opening and is actuatable to allow fluid flow through the associated opening to sequentially reduce the pressure drop experienced be fluids flowing from the fluid source to the interior flow path.
[0013] In one embodiment of the fluid flow control apparatus, at least some of the flow restricting devices include one way valve capabilities to prevent fluid flow from the flow restricting section to the fluid source. In another embodiment, the fluid flow control apparatus includes a filter medium disposed exteriorly of the tubular member between the fluid source and the multi-stage flow restricting section.
[0014] In yet another aspect, the present invention is directed to a sand control screen that includes a base pipe having first and second openings that allow fluid flow between an exterior of the base pipe and an interior flow path of the base pipe. A filter medium and a flow restricting section are disposed exteriorly of the base pipe. The flow restricting section including first and second flow restricting devices that respectively create first and second pressure drops in fluids flowing therethrough. The first flow restricting device provides a first flow path between the filter medium and the interior flow path via the first opening. The first and second flow restricting devices provide a second flow path between the filter medium and the interior flow path via the second opening. An actuatable device is operably associated with the first opening. The actuatable device is operable to initially prevent fluid flow through the first opening and is actuatable to allow fluid flow through the first opening. In this manner, fluid flow through the flow restricting section is adjustable from the second flow path to the first flow path which reduces the pressure drop associated with fluid flow through the flow restricting section.
[0015] In one embodiment of the sand control screen, an actuatable device operably associated with the second opening initially prevents fluid flow through the second opening and is actuatable to allow fluid flow through the second opening. Additionally or alternatively, a one way valve may be associated with one or both of the flow restricting devices to prevent fluid flow from the flow restricting section to the filter medium.
[0016] In a further aspect, the present invention is directed to a sand control screen that includes a base pipe having first, second and third openings that allow fluid flow between an exterior of the base pipe and an interior flow path of the base pipe. A filter medium and a flow restricting section are disposed exteriorly of the base pipe. The flow restricting section including first, second and third flow restricting devices that respectively create first, second and third pressure drops in fluids flowing therethrough. The first flow restricting device provides a first flow path between the filter medium and the interior flow path via the first opening. The first and second flow restricting devices provide a second flow path between the filter medium and the interior flow path via the second opening. The first, second and third flow restricting devices provide a third flow path between the filter medium and the interior flow path via the third opening. First and second actuatable devices are operably associated with the first and second openings. The first and second actuatable devices are operable to initially prevent fluid flow through the first and second opening, respectively and are actuatable to allow fluid flow through the first and second openings, respectively. The second actuatable device may be a pressure actuated device that is actuated responsive to an increase in pressure to a first predetermined level in the interior flow path. The first actuatable device may also be a pressure actuated device that is actuated responsive to an increase in pressure to a second and higher predetermined level in the interior flow path. In this manner, fluid flow through the flow restricting section is adjustable from the third flow path to the second flow path and then to the first flow path, thereby progressively reducing the pressure drop associated with fluid flow through the flow restricting section.
[0017] In one embodiment, each of the flow restricting devices also has a one way valve associated therewith that prevents fluid flow from the flow restricting section to the filter medium. Also in this embodiment, the base pipe may include a fourth opening that allows fluid flow between the exterior of the base pipe and the interior flow path of the base pipe and provides a fourth flow path that bypasses the first, second and third flow restricting devices. In this configuration, an actuatable device is operably associated with the fourth opening that is operable to initially prevent fluid flow through the fourth opening and is actuatable to allow fluid flow through the fourth opening, thereby bypassing the first, second and third flow restricting devices.
[0018] In another aspect, the present invention is directed to a one way valve that includes a substantially tubular outer housing and a ball cage disposed within the outer housing. The ball cage has a substantially tubular member that defines an internal flow passageway. An annular flange extends radially outwardly from the tubular member and has a plurality of passageways extending longitudinally therethrough. An annular retainer flange extends radially outwardly from the tubular member. A plurality of longitudinally extending tracks disposed relative to an outer surface of the tubular member and extend between the annular flange and the annular retainer flange. A plurality of balls are disposed within an annular region defined by the outer housing, the outer surface of tubular member, the annular flange and the annular retainer flange. Each of the balls corresponds with one of the tracks such that the balls are allowed to travel longitudinally within the tracks but are prevented from traveling circumferentially within the annular region outside of the corresponding tracks.
[0019] In one configuration, the balls are remote from the passageways to allow fluid flow through the one way valve in a first direction. In another configuration, the balls seat relative to the passageways to prevent fluid flow through the one way valve in a second direction.
[0020] In one embodiment, each of the tracks has a substantially uniform circumferential width along its longitudinal length. In another embodiment, each of the tracks has a greater circumferential width proximate the annular retainer flange as compared to its circumferential width proximate the annular flange.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
[0022] FIG. 1 is a schematic illustration of a well system operating a plurality of fluid flow control devices according to the present invention;
[0023] FIG. 2 is side view partially in quarter section of a fluid flow control device according to the present invention;
[0024] FIG. 3 is side view partially in quarter section of a fluid flow control device according to the present invention;
[0025] FIG. 4 is side view partially in quarter section of a fluid flow control device according to the present invention;
[0026] FIG. 5 is side view partially in quarter section of a fluid flow control device according to the present invention;
[0027] FIG. 6 is side view partially in quarter section of a fluid flow control device according to the present invention;
[0028] FIG. 7 is side view partially in quarter section of a fluid flow control device according to the present invention;
[0029] FIG. 8 is side view partially in quarter section of a fluid flow control device according to the present invention;
[0030] FIG. 9 is side view partially in quarter section of a fluid flow control device according to the present invention;
[0031] FIGS. 10A-E are cross sectional views of various embodiment of flow restricting devices for use in a fluid flow control device according to the present invention;
[0032] FIGS. 11A-F are cross sectional views of various embodiments of one way valves for use in a fluid flow control device according to the present invention;
[0033] FIGS. 12A-C are views of one embodiment of an annular one way valve having a plurality of flow paths therethrough that may be used in a fluid flow control device according to the present invention; and
[0034] FIGS. 13A-C are views of another embodiment of an annular one way valve having a plurality of flow paths therethrough that may be used in a fluid flow control device according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the present invention.
[0036] Referring initially to FIG. 1 , therein is depicted a well system including a plurality of fluid flow control devices embodying principles of the present invention that is schematically illustrated and generally designated 10 . In the illustrated embodiment, a wellbore 12 extends through the various earth strata. Wellbore 12 has a substantially vertical section 14 , the upper portion of which has installed therein a casing string 16 .
[0037] Wellbore 12 also has a substantially horizontal section 18 that extends through a hydrocarbon bearing subterranean formation 20 . As illustrated, substantially horizontal section 18 of wellbore 12 is open hole.
[0038] Positioned within wellbore 12 and extending from the surface is a tubing string 22 . Tubing string 22 provides a conduit for formation fluids to travel from formation 20 to the surface. Positioned within tubing string 22 is a seal assembly 24 and a plurality of fluid flow control devices 26 . Through use of the fluid flow control devices 26 of the present invention, control over the flow rate and composition of the produced fluids is enabled. For example, by choking production from the entire producing interval, a more uniform production profile from the entire interval is achievable. Specifically, if production from formation 20 were allowed without downhole choking, a majority of the production into tubing string 22 would come from the portion of formation 20 near the heel of the well with little contribution from the portion of formation 20 near the toe of the well. This scenario can result in premature water encroachment as the desired fluids from the portion of formation 20 near the heel depletes.
[0039] By incorporating one or more fluid restricting devices in each fluid flow control device 26 of the present invention, a more uniform production profile along the entire length of substantially horizontal section 18 can be achieved. In addition, in those embodiments having more than one fluid restricting device in series within each fluid flow control device 26 , the uniform production profile can be maintained for the life of the well as the pressure drop associated with fluid flow control devices 26 can be adjusted over time.
[0040] In the illustrated embodiment, each of the fluid flow control devices 26 provides not only fluid flow control capability but also sand control capability. The sand control screen elements or filter media associated with fluid flow control devices 26 are designed to allow fluids to flow therethrough but prevent particulate matter of sufficient size from flowing therethrough. The exact design of the screen element associated with fluid flow control devices 26 is not critical to the present invention as long as it is suitably designed for the characteristics of the formation fluids and any treatment operations to be performed. For example, the sand control screen may utilize a nonperforated base pipe having a wire wrapped around a plurality of ribs positioned circumferentially around the base pipe that provide stand off between the base pipe and the wire wrap. Alternatively, a fluid-porous, particulate restricting, metal material such as a plurality of layers of a wire mesh that are sintered together to form a fluid porous wire mesh screen could be used as the filter medium. As illustrated, a protective outer shroud having a plurality of perforations therethrough may be positioned around the exterior of the filter medium.
[0041] Even though FIG. 1 depicts the fluid flow control devices of the present invention in an open hole environment, it should be understood by those skilled in the art that the fluid flow control devices of the present invention are equally well suited for use in cased wells. Also, even though FIG. 1 depicts a string of fluid flow control devices, it should be understood by those skilled in the art that the fluid flow control devices of the present invention are equally well suited for use in wells that are divided into a plurality of intervals using packers or other sealing devices between adjacent fluid flow control devices or groups of fluid flow control devices.
[0042] In addition, even though FIG. 1 depicts the fluid flow control devices of the present invention in a horizontal section of the wellbore, it should be understood by those skilled in the art that the fluid flow control devices of the present invention are equally well suited for use in deviated or vertical wellbores. Accordingly, it should be understood by those skilled in the art that the use of directional terms such as above, below, upper, lower, upward, downward and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure. Further, even though FIG. 1 depicts the fluid flow control devices of the present invention as including sand control screen elements, it should be understood by those skilled in the art that the fluid flow control devices of the present invention are equally well suited for use in completions that do not require sand control.
[0043] Referring next to FIG. 2 , therein is depicted a fluid flow control device according to the present invention that is representatively illustrated and generally designated 100 . Fluid flow control device 100 may be suitably coupled to other similar fluid flow control devices, seal assemblies, production tubulars or other downhole tools to form a tubing string as described above. Fluid flow control device 100 includes a sand control screen section 102 and a flow restrictor section 104 . Sand control screen section 102 includes a suitable sand control screen element or filter medium, such as a wire wrap screen, a woven wire mesh screen or the like, designed to allow fluids to flow therethrough but prevent particulate matter of sufficient size from flowing therethrough. In the illustrated embodiment, a protective outer shroud 106 having a plurality of perforations 108 is positioned around the exterior of the filter medium.
[0044] Flow restrictor section 104 is configured in series with sand control screen section 102 such that production fluid must pass through sand control screen section 102 prior to entering flow restrictor section 104 . Flow restrictor section 104 includes an outer housing 110 . Outer housing 110 defines an annular chamber 112 with base pipe 118 . Base pipe 118 includes an opening 120 that allow fluid flow between the exterior of base pipe 118 and an interior flow path 122 within base pipe 118 . An actuatable device 124 is disposed within opening 120 .
[0045] In operation, fluid flow control device 100 is installed within the well with actuatable device 124 in its unactuated configuration. In this configuration, no fluid is able to flow through fluid flow control device 100 . In certain embodiments, actuatable device 124 may be a pressure actuated device that is actuated responsive to an increase in pressure to a predetermined level in interior flow path 122 . For example, actuatable device 124 may be a rupture or burst disk that provides for one-time-use. In this case, a membrane of the rupture disk is engineered to fail at a fixed pressure such that exposing the membrane to such a pressure opens a passageway through the rupture disk. Use of such a rupture disk enables a single opening event and does not allow for resealing. It should be noted, however, by those skilled in the art that other types of actuatable devices may alternatively be used, such devices including, but not limited to, valves, sliding sleeves, removable plugs and the like. In addition, other methods of actuating a device or otherwise establishing communication through the base pipe can be used including, but not limited to, hydraulic control systems, electrical actuators, punch tools and the like. Once actuatable device 124 has been actuated, fluid flow through opening 120 and therefore fluid flow control device 100 is allowed. Accordingly, fluid flow control device 100 may be operated from a no flow configuration to a flow enabled configuration by actuating actuatable device 124 .
[0046] Referring next to FIG. 3 , therein is depicted a fluid flow control device according to the present invention that is representatively illustrated and generally designated 200 . Fluid flow control device 200 may be suitably coupled to other similar fluid flow control devices, seal assemblies, production tubulars or other downhole tools to form a tubing string as described above. Fluid flow control device 200 includes a sand control screen section 202 and a flow restrictor section 204 . Sand control screen section 202 includes a suitable sand control screen element or filter medium. In the illustrated embodiment, a protective outer shroud 206 having a plurality of perforations 208 is positioned around the exterior of the filter medium.
[0047] Flow restrictor section 204 is configured in series with sand control screen section 202 such that production fluid must pass through sand control screen section 202 prior to entering flow restrictor section 204 . Flow restrictor section 204 includes an outer housing 210 . Outer housing 210 defines an annular chamber 212 with base pipe 218 . Base pipe 218 includes an opening 220 that allows fluid flow between the exterior of base pipe 218 and an interior flow path 222 within base pipe 218 . An actuatable device 224 is disposed within opening 220 . A flow restricting device 226 is also disposed with annular chamber 212 . Flow restricting device 226 includes a flow passageway 228 that creates a pressure drop in fluids that pass therethrough.
[0048] In operation, fluid flow control device 200 is installed within the well with actuatable device 224 in its unactuated configuration. In this configuration, no fluid is able to flow through fluid flow control device 200 . Once actuatable device 224 has been actuated, fluid flow through opening 220 and therefore fluid flow control device 200 is allowed. In this embodiment, the fluid flowing from sand control screen section 202 to interior flow path 222 via opening 220 must pass through flow passageway 228 of flow restricting device 226 . Flow passageway 228 is engineered to create a desired pressure drop in the fluids passing therethrough which also controls the flow rate at a given reservoir pressure. As discussed above, when a string of fluid flow control devices 200 extends from the heel to the toe of the well, establishing a suitable pressure drop in all such fluid flow control devices 200 will help to equalize the production profile along the length of the interval.
[0049] Even though flow restricting device 226 has been depicted with a tubular flow passageway 228 , those skilled in the art with recognize that other types of flow restricting devices could alternative be used. For example, in addition to tubular flow passageways, as best seen in FIG. 10C , other suitable flow restricting devices include orifice plates, as best seen in FIG. 10A , nozzles, as best seen in FIG. 10B , coiled tubulars, as best seen in FIG. 10D , helical passageways, as best seen in FIG. 10E and the like may be used.
[0050] Referring next to FIG. 4 , therein is depicted a fluid flow control device according to the present invention that is representatively illustrated and generally designated 300 . Fluid flow control device 300 may be suitably coupled to other similar fluid flow control devices, seal assemblies, production tubulars or other downhole tools to form a tubing string as described above. Fluid flow control device 300 includes a sand control screen section 302 and a flow restrictor section 304 . Sand control screen section 302 includes a suitable sand control screen element or filter medium. In the illustrated embodiment, a protective outer shroud 306 having a plurality of perforations 308 is positioned around the exterior of the filter medium.
[0051] Flow restrictor section 304 is configured in series with sand control screen section 302 such that production fluid must pass through sand control screen section 302 prior to entering flow restrictor section 304 . Flow restrictor section 304 includes an outer housing 310 . Outer housing 310 defines an annular chamber 312 with base pipe 318 . Base pipe 318 includes an opening 320 that allows fluid flow between the exterior of base pipe 318 and an interior flow path 322 within base pipe 318 . An actuatable device 324 is disposed within opening 320 . A one way valve is disposed with annular chamber 312 . One way valve 326 prevents fluid loss into the formation when pressure within interior flow path 322 exceeds that of the formation, for example when pressure is used to actuate actuatable device 324 .
[0052] In operation, fluid flow control device 300 is installed within the well with actuatable device 324 in its unactuated configuration. In this configuration, no fluid is able to flow through fluid flow control device 300 . Once actuatable device 324 has been actuated, fluid flow through opening 320 is allowed. In this embodiment, the fluid flow from interior flow path 322 to the formation is prevented by one way valve 326 . This prevents fluid loss when pressure is used to actuate similar actuatable devices in this or other fluid flow control devices. When the actuation pressure is released, fluid flow from the formation to interior flow path 322 through one way valve 326 is allowed.
[0053] As should be understood by those skilled in the art a variety of different one way valve configurations may be suitable used in the flow restrictor section of the fluid flow control devices of the present invention. For example, a spring biased annular sleeve, as best seen in FIG. 11A , a spring biased ball and seat, as best seen in FIG. 11B , a pivoting gate, as best seen in FIG. 11C , a spring biased poppet and seat, as best seen in FIG. 11D , a resilient member that radially flexes, as best seen in FIG. 11E , a plurality of floating balls in an annular race and circumferentially spaced apart seats, as best seen in FIG. 11F and the like may be used. In addition, it should be understood by those skilled in the art that a one way valve could alternative be positioned in series with the actuatable device within the base pipe.
[0054] Referring next to FIG. 5 , therein is depicted a fluid flow control device according to the present invention that is representatively illustrated and generally designated 400 . Fluid flow control device 400 may be suitably coupled to other similar fluid flow control devices, seal assemblies, production tubulars or other downhole tools to form a tubing string as described above. Fluid flow control device 400 includes a sand control screen section 402 and a flow restrictor section 404 . Sand control screen section 402 includes a suitable sand control screen element or filter medium. In the illustrated embodiment, a protective outer shroud 406 having a plurality of perforations 408 is positioned around the exterior of the filter medium.
[0055] Flow restrictor section 404 is configured in series with sand control screen section 402 such that production fluid must pass through sand control screen section 402 prior to entering flow restrictor section 404 . Flow restrictor section 404 includes an outer housing 410 . Outer housing 410 defines an annular chamber 412 with base pipe 418 . Base pipe 418 includes an opening 420 that allows fluid flow between the exterior of base pipe 418 and an interior flow path 422 within base pipe 418 . An actuatable device 424 is disposed within opening 420 . A flow restricting device 426 is disposed with annular chamber 412 . Flow restricting device 426 includes a flow passageway 428 that creates a pressure drop in fluids that pass therethrough. A one way valve 430 is disposed downstream of flow restricting device 426 within annular chamber 412 . One way valve 430 prevents fluid loss into the formation when pressure within interior flow path 422 exceeds that of the formation, for example when pressure is used to actuate actuatable device 424 and other similar devices.
[0056] In operation, fluid flow control device 400 is installed within the well with actuatable device 424 in its unactuated configuration. In this configuration, no fluid is able to flow through fluid flow control device 400 . Once actuatable device 424 has been actuated, fluid flow through opening 420 is allowed. In this embodiment, fluid loss from flow path 422 to the formation is prevented by one way valve 430 . Fluid production from the formation to interior flow path 422 via opening 420 is allowed. This fluid flow must pass through flow passageway 428 of flow restricting device 426 which is engineered to create a desired pressure drop in the fluids passing therethrough which also controls the flow rate therethrough at a given reservoir pressure. As discussed above, when a string of fluid flow control devices 400 extends from the heel to the toe of the well, establishing a suitable pressure drop in all of such fluid flow control devices 400 will help to equalize the production profile along the length of the interval.
[0057] Referring next to FIG. 6 , therein is depicted a fluid flow control device according to the present invention that is representatively illustrated and generally designated 500 . Fluid flow control device 500 may be suitably coupled to other similar fluid flow control devices, seal assemblies, production tubulars or other downhole tools to form a tubing string as described above. Fluid flow control device 500 includes a sand control screen section 502 and a flow restrictor section 504 . Sand control screen section 502 includes a suitable sand control screen element or filter medium. In the illustrated embodiment, a protective outer shroud 506 having a plurality of perforations 508 is positioned around the exterior of the filter medium.
[0058] Flow restrictor section 504 is configured in series with sand control screen section 502 such that production fluid must pass through sand control screen section 502 prior to entering flow restrictor section 504 . Flow restrictor section 504 includes an outer housing 510 . Outer housing 510 defines an annular chamber 512 with base pipe 518 . Base pipe 518 includes an opening 520 that allows fluid flow between the exterior of base pipe 518 and an interior flow path 522 within base pipe 518 . An actuatable device 524 is disposed within opening 520 . A flow restricting device 526 is disposed with annular chamber 512 . Flow restricting device 526 includes a flow passageway 528 that creates a pressure drop in fluids that pass therethrough. A one way valve 530 is disposed upstream of flow restricting device 526 within annular chamber 512 . One way valve 530 prevents fluid loss into the formation when pressure within interior flow path 522 exceeds that of the formation, for example when pressure is used to actuate actuatable device 524 and other similar devices.
[0059] In operation, fluid flow control device 500 is installed within the well with actuatable device 524 in its unactuated configuration. In this configuration, no fluid is able to flow through fluid flow control device 500 . Once actuatable device 524 has been actuated, fluid flow through opening 520 is allowed. In this embodiment, fluid loss from flow path 522 to the formation is prevented by one way valve 530 . Fluid production from the formation to interior flow path 522 via opening 520 is allowed. This fluid flow must pass through flow passageway 528 of flow restricting device 526 which is engineered to create a desired pressure drop in the fluids passing therethrough which also controls the flow rate therethrough at a given reservoir pressure. As discussed above, when a string of fluid flow control devices 500 extends from the heel to the toe of the well, establishing a suitable pressure drop in all of such fluid flow control devices 500 will help to equalize the production profile along the length of the interval.
[0060] Referring next to FIG. 7 , therein is depicted a fluid flow control device according to the present invention that is representatively illustrated and generally designated 600 . Fluid flow control device 600 may be suitably coupled to other similar fluid flow control devices, seal assemblies, production tubulars or other downhole tools to form a tubing string as described above. Fluid flow control device 600 includes a sand control screen section 602 and a flow restrictor section 604 . Sand control screen section 602 includes a suitable sand control screen element or filter medium. In the illustrated embodiment, a protective outer shroud 606 having a plurality of perforations 608 is positioned around the exterior of the filter medium.
[0061] Flow restrictor section 604 is configured in series with sand control screen section 602 such that production fluid must pass through sand control screen section 602 prior to entering flow restrictor section 604 . Flow restrictor section 604 includes an outer housing 610 . Outer housing 610 defines an annular chamber 612 with base pipe 618 . Base pipe 618 includes an opening 620 that allows fluid flow between the exterior of base pipe 618 and an interior flow path 622 within base pipe 618 . An actuatable device 624 is disposed within opening 620 . A flow restricting device 626 is disposed with annular chamber 612 . Flow restricting device 626 includes a flow passageway 628 that creates a pressure drop in fluids that pass therethrough. Flow restricting device 626 also includes an integral one way valve 630 . One way valve 630 prevents fluid loss into the formation when pressure within interior flow path 622 exceeds that of the formation, for example when pressure is used to actuate actuatable device 624 and other similar devices.
[0062] In operation, fluid flow control device 600 is installed within the well with actuatable device 624 in its unactuated configuration. In this configuration, no fluid is able to flow through fluid flow control device 600 . Once actuatable device 624 has been actuated, fluid flow through opening 620 is allowed. In this embodiment, fluid loss from flow path 622 to the formation is prevented by one way valve 630 . Fluid production from the formation to interior flow path 622 via opening 620 is allowed. This fluid flow must pass through flow passageway 628 of flow restricting device 626 which is engineered to create a desired pressure drop in the fluids passing therethrough which also controls the flow rate therethrough at a given reservoir pressure. As discussed above, when a string of fluid flow control devices 600 extends from the heel to the toe of the well, establishing a suitable pressure drop in all of such fluid flow control devices 600 will help to equalize the production profile along the length of the interval.
[0063] Referring next to FIG. 8 , therein is depicted a fluid flow control device according to the present invention that is representatively illustrated and generally designated 700 . Fluid flow control device 700 may be suitably coupled to other similar fluid flow control devices, seal assemblies, production tubulars or other downhole tools to form a tubing string as described above. Fluid flow control device 700 includes a sand control screen section 702 and a flow restrictor section 704 . Sand control screen section 702 includes a suitable sand control screen element or filter medium. In the illustrated embodiment, a protective outer shroud 706 having a plurality of perforations 708 is positioned around the exterior of the filter medium.
[0064] Flow restrictor section 704 is configured in series with sand control screen section 702 such that production fluid must pass through sand control screen section 702 prior to entering flow restrictor section 704 . Flow restrictor section 704 includes an outer housing 710 . Outer housing 710 defines an annular chamber 712 with base pipe 718 . Base pipe 718 includes an opening 720 and an opening 722 that allow fluid flow between the exterior of base pipe 718 and an interior flow path 724 within base pipe 718 . An actuatable device 726 is disposed within opening 720 and an actuatable device 728 is disposed within opening 722 . A flow restricting device 730 is disposed with annular chamber 712 . Flow restricting device 730 includes a flow passageway 732 that creates a pressure drop in fluids that pass therethrough. In addition, a flow restricting device 734 is disposed with annular chamber 712 . Flow restricting device 734 includes a flow passageway 736 that creates a pressure drop in fluids that pass therethrough.
[0065] In certain operations, fluid flow control device 700 is installed within the well with actuatable devices 726 and 728 in their unactuated configurations. In this configuration, no fluid is able to flow through fluid flow control device 700 . Thereafter, actuatable device 726 may be actuated downhole to establish fluid communication therethrough. Alternatively, fluid flow control device 700 may be installed within the well with actuatable device 726 removed or otherwise disabled. In either installed configuration, once fluid flow through opening 720 is enabled, the fluid flowing from sand control screen section 702 to interior flow path 724 via opening 720 must pass through flow restricting device 734 and flow restricting device 730 . Each of flow restricting device 734 and flow restricting device 730 is engineered to create a desired pressure drop in the fluids passing therethrough, which also controls the flow rate therethrough at a given reservoir pressure. As discussed above, when a string of fluid flow control devices 700 extends from the heel to the toe of the well, establishing a suitable pressure drop in all of such fluid flow control devices 700 will help to equalize the production profile along the length of the interval.
[0066] As the reservoir becomes depleted and the reservoir pressure declines, the pressure drop created by flow restricting device 734 together with flow restricting device 730 may no longer be desirable. In the present embodiment, the pressure drop associated with fluid flow control device 700 can be adjusted to enhance the ultimate recovery from the reservoir. Specifically, when it is desired to reduced the pressure drop through fluid flow control device 700 , actuatable device 728 may be actuated downhole to establish fluid communication through opening 722 . In this configuration, the fluid flowing from sand control screen section 702 to interior flow path 724 now passes through flow restricting device 734 and opening 722 bypassing flow restricting device 730 and the pressure drop associated therewith. Accordingly, this embodiment allows for the reduction in the pressure drop experienced by fluids passing therethrough by establishing a fluid pathway that bypasses flow restricting device 730 .
[0067] Referring next to FIG. 9 , therein is depicted a fluid flow control device according to the present invention that is representatively illustrated and generally designated 800 . Fluid flow control device 800 may be suitably coupled to other similar fluid flow control devices, seal assemblies, production tubulars or other downhole tools to form a tubing string as described above. Fluid flow control device 800 includes a sand control screen section 802 and a flow restrictor section 804 . Sand control screen section 802 includes a suitable sand control screen element or filter medium. In the illustrated embodiment, a protective outer shroud 806 having a plurality of perforations 808 is positioned around the exterior of the filter medium.
[0068] Flow restrictor section 804 is configured in series with sand control screen section 802 such that production fluid must pass through sand control screen section 802 prior to entering flow restrictor section 804 . Flow restrictor section 804 includes an outer housing 810 . Outer housing 810 defines an annular chamber 812 with base pipe 818 . Base pipe 818 includes a plurality of openings 820 , 822 , 824 , 826 that allow fluid flow between the exterior of base pipe 818 and an interior flow path 828 within base pipe 818 . Each of opening 820 , 822 , 824 , 826 has an actuatable device 830 , 832 , 834 , 836 respectively disposed therein. A flow restricting device 838 is disposed with annular chamber 812 . Flow restricting device 838 includes a flow passageway 840 that creates a pressure drop in fluids that pass therethrough and an integral one way valve 842 that prevents fluid loss into the formation. In addition, a flow restricting device 844 is disposed with annular chamber 812 . Flow restricting device 844 includes a flow passageway 846 that creates a pressure drop in fluids that pass therethrough and an integral one way valve 848 that prevents fluid loss into the formation. Further, a flow restricting device 850 is disposed with annular chamber 812 . Flow restricting device 850 includes a flow passageway 852 that creates a pressure drop in fluids that pass therethrough and an integral one way valve 854 that prevents fluid loss into the formation.
[0069] In certain operations, fluid flow control device 800 is installed within the well with each of actuatable devices 830 , 832 , 834 , 836 in their unactuated configuration. In this configuration, no fluid is able to flow through fluid flow control device 800 . Alternatively, fluid flow control device 800 may be installed within the well with actuatable device 830 removed or otherwise disabled. In either installed configuration, once fluid flow through opening 820 is enabled, the fluid flowing from sand control screen section 802 to interior flow path 828 via opening 820 must pass through each of flow restricting devices 838 , 844 , 850 , each of which is engineered to create a desired pressure drop in the fluids passing therethrough and control the flow rate therethrough at a given reservoir pressure. As discussed above, when a string of fluid flow control devices 800 extends from the heel to the toe of the well, establishing a suitable pressure drop in all of such fluid flow control devices 800 will help to equalize the production profile along the length of the interval.
[0070] As the reservoir becomes depleted and the reservoir pressure declines, the pressure drop created by flow restricting devices 838 , 844 , 850 may no longer be desirable. In the present embodiment, the pressure drop associated with fluid flow control device 800 can be adjusted. Specifically, when it is desired to reduced the pressure drop through fluid flow control device 800 , actuatable device 832 may be actuated downhole to establish fluid communication through opening 822 . This actuation may be achieved by pressuring up interior flow path 828 to a predetermined first level. During this pressuring up phase, fluid loss into the formation is prevented by one way valve 842 .
[0071] Once communication through opening 822 is established, the fluid flowing from sand control screen section 802 to interior flow path 828 now passes through flow restricting devices 844 , 850 and opening 822 bypassing flow restricting device 838 and the pressure drop associated therewith. Accordingly, this embodiment allows for the reduction in the pressure drop experienced by fluids passing therethrough by establishing a fluid pathway that bypasses flow restricting device 838 .
[0072] As the reservoir becomes further depleted, the pressure drop created by flow restricting devices 844 , 850 may no longer be desirable. In the present embodiment, the pressure drop associated with fluid flow control device 800 can be again adjusted. Specifically, when it is desired to reduced the pressure drop through fluid flow control device 800 , actuatable device 834 may be actuated downhole to establish fluid communication through opening 824 . This actuation may be achieved by pressuring up interior flow path 828 to a predetermined second level that is higher than the first level. During this pressuring up phase, fluid loss into the formation is prevented by one way valve 848 .
[0073] Once communication through opening 824 is established, the fluid flowing from sand control screen section 802 to interior flow path 828 now passes through flow restricting device 850 and opening 824 bypassing flow restricting devices 838 , 844 and the pressure drops associated therewith. Accordingly, this embodiment allows for the reduction in the pressure drop experienced by fluids passing therethrough by establishing a fluid pathway that bypasses flow restricting devices 838 , 844 .
[0074] As the reservoir becomes even further depleted, the pressure drop created by flow restricting device 850 may no longer be desirable. In the present embodiment, the pressure drop associated with fluid flow control device 800 can be further adjusted. Specifically, when it is desired to reduced the pressure drop through fluid flow control device 800 , actuatable device 836 may be actuated downhole to establish fluid communication through opening 826 . This actuation may be achieved by pressuring up interior flow path 828 to a predetermined third level that is higher than the second level. During this pressuring up phase, fluid loss into the formation is prevented by one way valve 854 .
[0075] Once communication through opening 826 is established, the fluid flowing from sand control screen section 802 to interior flow path 828 now passes through opening 826 bypassing all of the flow restricting devices and the pressure drops associated therewith. Accordingly, this embodiment allows for the progressive reduction in the pressure drop experienced by fluids passing therethrough by establishing fluid pathways that sequentially bypass additional ones of the flow restricting devices.
[0076] Referring now to FIGS. 12A-C , therein are depicted various views of an annular one way valve having a plurality of flow paths therethrough that is generally designated 900 . Annular one way valve 900 may be used in any of the above described fluid flow control devices in conjunction with or as an alternative to any of the one way valves described above such as the one way valves depicted in FIGS. 11A-F . Annular one way valve 900 include a ball cage 902 that is disposed within an outer housing 904 such as the outer housings of the fluid flow control devices described above. Ball cage 902 includes a substantially tubular member 906 that, along with other portions of the base pipe described above, defines an internal flow passageway 908 . Ball cage 902 includes a radially outwardly extending annular flange 910 having a plurality of passageways 912 extending longitudinally therethrough. As illustrated, there are eight passageways 912 , only some of which are visible in the various views. It should be understood by those skilled in the art that other numbers of passageways both greater than and less than eight could alternatively be used.
[0077] Formed within the outer surface of tubular member 906 are a plurality of longitudinally extending slots 914 . Each slot 914 circumferentially corresponds to one of the passageways 912 . Ball cage 902 includes a radially outwardly extending annular retainer flange 916 having a plurality of notches 918 formed therein. Each notch 918 circumferentially corresponds to one of the slots 914 . Together, corresponding notches 918 and slots 914 form tracks 920 . Disposed within each of the tracks 920 is a ball 922 . When ball cage 902 is disposed within housing 904 as depicted in FIG. 12A , each ball 922 is retained within its corresponding track 920 such that the balls are allowed to travel longitudinally within annular region 924 but are prevented from traveling circumferentially within annular region 924 beyond the width of the corresponding track 920 . Accordingly, a corresponding one-to-one relationship is created between balls 922 and passageways 912 .
[0078] In operation, balls 922 move within tracks 920 in response to pressure difference between passageways 912 and annular passageway 926 that is selectively in fluid communication with internal flow passageway 908 . For example, fluid communication between annular passageway 926 and internal flow passageway 908 may be prevented in a manner similar to that described above with reference to actuatable devices disposed within openings of a base pipe, such as actuatable device 324 within opening 320 of base pipe 318 . Likewise, fluid communication between annular passageway 926 and internal flow passageway 908 may be allowed by actuating such an actuatable device. When annular passageway 926 is in fluid communication with internal flow passageway 908 and the pressure in internal flow passageway 908 is less than the pressure at passageways 912 , fluid flow through one way valve 900 from upstream of passageways 912 to internal flow passageway 908 is allowed as balls 922 are remote from passageways 912 . When annular passageway 926 is in fluid communication with internal flow passageway 908 and the pressure in internal flow passageway 908 is greater than the pressure at passageways 912 , fluid flow through one way valve 900 toward passageways 912 from internal flow passageway 908 is disallowed as balls 922 seat within passageways 912 . Accordingly, one way valve 900 provides reliable flow control by selective allowing and preventing fluid flow therethrough which, when used within one of the fluid flow control devices described above, prevents fluid loss into a formation from internal flow passageway 908 but allows production from the formation into internal flow passageway 908 .
[0079] Even though tracks 920 have been depicted as being formed by slots 914 within the outer surface of tubular member 906 and notches 918 in annular retainer flange 916 , it should be understood by those skilled in the art that tracks 920 can take other configurations, such configuration also being considered within the scope of the present invention. For example, radially outwardly extending longitudinal rails or other structures attached to the outer surface of tubular member 906 may be used to form tracks 920 above the outer surface of tubular member 906 such that corresponding balls 922 are prevented from traveling circumferentially within annular region 924 beyond the rails.
[0080] Referring now to FIGS. 13A-C , therein are depicted various views of an annular one way valve having a plurality of flow paths therethrough that is generally designated 950 . Annular one way valve 950 may be used in any of the above described fluid flow control devices in conjunction with or as an alternative to any of the one way valves described above such as the one way valves depicted in FIGS. 11A-F . Annular one way valve 950 include a ball cage 952 that is disposed within an outer housing 954 such as the outer housings of the fluid flow control devices described above. Ball cage 952 includes a substantially tubular member 956 that, along with other portions of the base pipe described above, defines an internal flow passageway 958 . Ball cage 952 includes a radially outwardly extending annular flange 960 having a plurality of passageways 962 extending longitudinally therethrough. As illustrated, there are eight passageways 962 , only some of which are visible in the various views. It should be understood by those skilled in the art that other numbers of passageways both greater than and less than eight could alternatively be used.
[0081] Formed within the outer surface of tubular member 956 are a plurality of longitudinally extending slots 964 . Each slot 964 circumferentially corresponds to one of the passageways 962 . Ball cage 952 includes a radially outwardly extending annular retainer flange 966 having a plurality of notches 968 formed therein. Each notch 968 circumferentially corresponds to one of the slots 964 . Together, corresponding notches 968 and slots 964 form tracks 970 . Disposed within each of the tracks 970 is a ball 972 . When ball cage 952 is disposed within housing 954 as depicted in FIG. 13A , each ball 972 is retained within its corresponding track 970 such that the balls are allowed to travel longitudinally within annular region 974 but prevented from traveling circumferentially within annular region 974 beyond the width of the corresponding track 970 . Accordingly, a corresponding one-to-one relationship is created between balls 972 and passageways 962 .
[0082] In operation, balls 972 move within tracks 970 in response to pressure difference between passageways 962 and an annular passageway 976 that is selectively in fluid communication with internal flow passageway 958 . For example, fluid communication between annular passageway 976 and internal flow passageway 958 may be prevented in a manner similar to that described above with reference to actuatable devices disposed within openings of a base pipe, such as actuatable device 324 within opening 320 of base pipe 318 . Likewise, fluid communication between annular passageway 976 and internal flow passageway 958 may be allowed by actuating such an actuatable device. When annular passageway 976 is in fluid communication with internal flow passageway 958 and the pressure in internal flow passageway 958 is less than the pressure at passageways 962 , fluid flow through one way valve 950 from upstream of passageways 962 to internal flow passageway 958 is allowed as balls 972 are remote from passageways 962 . In this embodiment, tracks 970 allow balls 972 to move a limited circumferentially distance which reduces the flow restriction through one way valve 950 as compared to one way valve 900 described above as balls 972 are no longer in the direct flowpath of fluids flowing therethrough. Likewise, allowing such limited circumferentially travel of balls 972 within tracks 970 reduces erosion of balls 972 which could otherwise reduce the sealing capability of balls 972 . When annular passageway 976 is in fluid communication with internal flow passageway 958 and the pressure in internal flow passageway 958 is greater than the pressure at passageways 962 , fluid flow through one way valve 950 toward passageways 962 from internal flow passageway 958 is disallowed as balls 972 seat within passageways 962 . Accordingly, one way valve 950 provides reliable flow control by selective allowing and preventing fluid flow therethrough which, when used within one of the fluid flow control devices described above, prevents fluid loss into a formation from internal flow passageway 958 but allows production from the formation into internal flow passageway 958 .
[0083] Even though tracks 970 have been depicted as being formed by slots 964 within the outer surface of tubular member 956 and notches 968 in annular retainer flange 966 , it should be understood by those skilled in the art that tracks 970 can take other configurations, such configuration also being considered within the scope of the present invention. For example, radially outwardly extending longitudinal rails or other structures attached to the outer surface of tubular member 956 may be used to form tracks 970 above the outer surface of tubular member 956 such that corresponding balls 972 are prevented from traveling circumferentially within annular region 974 beyond the rails.
[0084] While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments. | A flow control apparatus ( 800 ) includes a tubular member ( 818 ) having a plurality of openings ( 820, 822, 824, 826 ) that allow fluid flow between an exterior and an interior flow path ( 828 ) of the tubular member ( 818 ) and a multi-stage flow restricting section ( 804 ) operably positioned in a fluid flow path between a fluid source disposed exteriorly of the tubular member ( 818 ) and the interior flow path ( 828 ). The flow restricting section ( 804 ) including a plurality of flow restricting devices ( 838, 844, 850 ) each operable to create a pressure drop. Actuatable devices ( 830, 832, 834, 836 ) operably associated with the openings ( 820, 822, 824, 826 ) are sequentially actuatable to allow fluid flow through the associated openings ( 820, 822, 824, 826 ), thereby sequentially reducing the pressure drop experienced by fluids flowing from the fluid source to the interior flow path ( 828 ). | 4 |
CROSS REFERENCE TO RELATED APPLICATION(S)
This Utility Patent Application claims the benefit of the filing date of Application No. DE 101 59 851.3, filed Dec. 6, 2001, and International Application No. PCT/EP02/12966, filed Nov. 20, 2002, both of which are herein incorporated by reference.
BACKGROUND
Some circuit arrangements are compact modules for power-electronic installations, in which different power components are connected up to form standardized subunits. In this case, parallel circuits of two or more transistors or diodes are produced in order to increase the maximum current-carrying capacity of the circuit.
FIG. 1 illustrates an example of a power module for switching large currents according to the prior art, and the electrical equivalent circuit diagram is shown in FIG. 2 . Such an arrangement is disclosed for example in EP 0 427 143 B1 or EP 0 277 546 A1. In the case of the circuit illustrated, two semiconductor switching elements, in particular power IGBT, are present, which are in each case integrated in a semiconductor body 120 , 122 and arranged on a carrying plate 160 . The carrying plate 160 is usually constructed in two layers with a carrier 160 b and a rear side metallization 160 a.
A top side, or at least part of the surface of the semiconductor bodies 120 , 122 forms terminals 121 , 123 —in the present case the emitter or source terminals E—of the components. The gate terminals G are not illustrated separately in FIG. 1 ; they may be situated in a region of the surfaces which is insulated from the emitter or source terminals. The collector or drain terminals of the transistors integrated in the semiconductor bodies 120 , 122 are usually formed by rear sides of the semiconductor bodies, which, in the case illustrated, are conductively connected to one another by a busbar 110 to which the semiconductor bodies are applied.
The terminals 121 , 123 are connected by means of bonding wires 140 , 142 , of which a plurality are provided per device in order to increase the current-carrying capacity, to a common line, in the present case a busbar 130 , which can be connected to a circuit potential.
The carrying plate 160 with the busbars 110 , 130 may be designed as DCB substrate (DCB=direct copper bonding). The busbars 110 , 130 are copper regions or copper islands on a ceramic substrate as carrier 40 a . The rear side metallization is likewise composed of copper.
When the parallel-connected emitter-collector paths or drain-source paths (in series with a load) are connected to a supply voltage, high-frequency oscillations which lead to electromagnetic interference emissions arise both when the transistors are switched on, that is to say driven into the on state, and when the transistors are switched off, that is to say driven into the off state. Such oscillations are reported, for example, in Y. Takahashi, K. Yoshikawa, T. Koga, M. Soutome, T. Takano, H. Kirihata, Y. Seki: “Ultra high power 2.5 kV–1800 A Power Pack IGBT, Proceedings of ISPSD, 1997, 233–236 or B. Gutsmann, P. Mourick, D. Silber: “Explanation of IGBT Tail Current Oscillations by a Novel ‘Plasma Extraction Transit Time’ Mechanism”, 31 st European Solid-State Device Research Conference ESSDERC, Sep. 11–13, 2001, 255–258.
SUMMARY
One embodiment of the present invention provides a circuit arrangement having at least two semiconductor components each having terminals. At least one terminal of one semiconductor component is electrically conductively connected to a terminal of the other semiconductor component such that the occurrence of high-frequency oscillations during the switching-on or switching-off operation is prevented, or said oscillations are at least greatly attenuated, in the semiconductor components.
In the case of the circuit arrangement according to one embodiment of the invention, an eddy current attenuation structure is provided above the arrangement in a manner spaced apart from the semiconductor components, which structure is of plate-type, lattice-type, frame-type or loop-type design.
The high-frequency oscillations occurring during the switching operations should result from resonant circuits which are formed by junction capacitances C 10 , C 20 of the transistor T 10 , T 20 and line inductances LP, as is illustrated in FIG. 2 on the basis of a parallel circuit of two transistors.
The high-frequency oscillations arising during the switching operations in the semiconductor components and the leads thereof induce eddy currents in the attenuation structure according to one embodiment of the invention. The attenuation structure has a suitable resistance, which results in ohmic losses which react upon the resonant circuit and attenuate the high-frequency oscillations.
In this case, a sheet resistance of the attenuation structure, which is in one embodiment formed flat, is large enough to bring about ohmic losses in the case of the induced eddy currents, but small enough to actually enable eddy currents to arise. If the attenuation structure has an excessively large resistance, no eddy currents arise and the attenuation structure is ineffectual. The attenuation structure is likewise ineffectual in the case where it has an excessively small resistance, so that ohmic losses scarcely arise. The resistance value of the attenuation structure for which an optimum attenuation is brought about can be determined by measurements or simulations depending on the precise construction of the circuit arrangement and the number of semiconductor components used.
The eddy current attenuation structure is, in particular, arranged above bonding wires via which the semiconductor components are electrically conductively connected to one another—in particular via a current-conducting rail. These bonding wires provide for particularly good coupling of the high-frequency oscillations into the attenuation structure, which bring about eddy currents there.
Preventing, or at least attenuating, high-frequency oscillations during the switching operations is furthermore achieved by means of a circuit arrangement according to an embodiment of the invention where provision is made for providing, in addition to an existing electrically conductive connection between the semiconductor components, a high-impedance line connection. In one embodiment a bonding wire, which directly connects the two semiconductor components to one another, is provided.
This direct connection influences the inductance and the resistance of the parasitic resonant circuit. In this case, the resistance can be set depending on the frequency of the oscillations that occur such that particularly high losses occur within a desired frequency range and lead to an attenuation of the high-frequency oscillation.
The attenuation structure above the circuit arrangement and the high-impedance direct connection (“direct bonding”) are used jointly.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification. The drawings illustrate the embodiments of the present invention and together with the description serve to explain the principles of the invention. Other embodiments of the present invention and many of the intended advantages of the present invention will be readily appreciated as they become better understood by reference to the following detailed description. The elements of the drawings are not necessarily to scale relative to each other. Like reference numerals designate corresponding similar parts.
FIG. 1 illustrates a circuit arrangement according to the prior art.
FIG. 2 illustrates an equivalent circuit diagram of the circuit arrangement according to FIG. 1 .
FIG. 3 illustrates an exemplary embodiment of a circuit arrangement according to the invention with a plate-type attenuation structure.
FIG. 4 illustrates an exemplary embodiment of a circuit arrangement according to the invention with a frame-type attenuation structure.
FIG. 5 illustrates a lattice-type attenuation structure in plan view.
FIG. 6 illustrates series resistance ( FIG. 6 a ) an inductance ( FIG. 6 b ) of a parasitic resonant circuit in the case of a circuit arrangement with an eddy current attenuation structure depending on the distance between the attenuation structure and the semiconductor components for varying sheet resistances.
FIG. 7 illustrates an exemplary embodiment of a circuit arrangement according to the invention with a high-impedance direct connection.
FIG. 8 illustrates series resistance ( FIG. 8 a ) and inductance ( FIG. 8 b ) of a parasitic resonant circuit in the case of a circuit arrangement with direct connection depending on the conductivity of the direct connection at a selected frequency (550 MHz).
FIG. 9 illustrates series resistance ( FIG. 9 a ) and inductance ( FIG. 9 b ) of a parasitic resonant circuit in the case of a circuit arrangement with direct connection depending on the frequency at a selected specific conductivity (3.7·10 9 pS/μm).
FIG. 10 illustrates a further exemplary embodiment of a circuit arrangement according to the invention with a plate-type attenuation structure.
DETAILED DESCRIPTION
In the following Detailed Description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the Figure(s) being described. Because components of embodiments of the present invention can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.
FIG. 3 illustrates a perspective view of an exemplary embodiment of a circuit arrangement according to one embodiment of the invention. In the example illustrated, two semiconductor components are provided, which are in each case integrated in a semiconductor body 20 , 22 . Said semiconductor components are power diodes or power transistors, for example. The semiconductor bodies 20 , 22 are applied to a carrier arrangement 60 with a carrier plate 60 a , 60 b.
In the case of the components, one terminal of the semiconductor components, for example, the emitter or source terminal in the case of transistors, is formed by the top side 21 , 23 of the semiconductor components 20 , 22 . These terminals 21 , 23 of the semiconductor components are electrically conductively connected to one another. For example, said terminals 21 , 23 are in each case connected by means of line connections 40 , 42 , for example bonding wires, to a current-conducting rail 30 which is applied on the carrier plate 60 a , 60 b and is part of the carrier arrangement. In order to increase the current-carrying capacity or in order to reduce the nonreactive resistance between the terminals 21 and 23 and the busbar 30 , a plurality of bonding wires 40 , 42 in each case are provided per terminal 21 , 23 .
The semiconductor bodies 21 , 22 are applied to a further busbar 10 of the carrier arrangement 60 , said busbar being insulated from the busbar 30 . Said busbar 10 electrically conductively connects together the rear sides, which, in the case of power transistors, usually form the collector or drain terminals thereof. The carrying plate is designed in particular as a DCB substrate (DCB=direct copper bonding) having copper islands spaced apart from one another on an insulating carrier 60 b , usually a ceramic. In this case, the busbars 10 , 30 are respectively formed by one of the copper islands.
The bonding wires 40 , 42 and the busbars 10 , 30 form a conductor loop which connects the components 20 , 22 and to which the plate-type attenuation structure 50 is arranged essentially parallel.
If the components are driven such that they change from an on to an off state or from an off to an on state then high-frequency oscillations may occur on account of parasitic effects.
In order to prevent or at least attenuate these high-frequency oscillations, according to one embodiment of the invention, a plate-type attenuation structure 50 is provided above the arrangement with the semiconductor components 20 , 22 and the bonding wires 40 , 42 , which attenuation structure is not electrically conductively connected to the semiconductor components 20 , 22 and the bonding wires 40 , 42 . Said plate-type attenuation structure 50 is electrically conductive and has a sheet resistance that depends on the further properties of the circuit arrangement, as will be explained in more detail below.
The high-frequency oscillations arising during the switching operations produce eddy currents in the plate-type attenuation structure 50 , the resistance of this structure being chosen in such a way that, on account of these induced eddy currents, ohmic losses maximally arise in the structure 50 in order to attenuate the high-frequency oscillations in this way.
FIG. 4 illustrates a further exemplary embodiment of a circuit arrangement according to one embodiment the invention, which differs from that shown in FIG. 3 by the fact that an attenuation structure 52 is provided above the semiconductor components 20 , 22 , which attenuation structure is essentially designed as a flat frame. In this attenuation structure 52 , too, eddy currents are induced by high-frequency oscillations arising during the switching operations. Said high-frequency oscillations are emitted in particular by the bonding wires 40 , 42 , which act as antennas in this regard.
FIG. 5 illustrates a plan view of a further embodiment of a possible attenuation structure which can be used according to one embodiment of the attenuation structures 50 , 52 in accordance with FIGS. 3 and 4 . This attenuation structure 54 is designed as a flat lattice-type element.
A customary value for the minimum distance between the bonding wires at their point that projects the furthest from the semiconductor bodies 20 , 22 and the attenuation structure 50 , 52 , 54 is 0.1 mm to 5 mm.
The carrier plate—preferably designed as a DCB substrate—in accordance with FIGS. 2 and 3 is formed in two layers with an insulating layer 60 b , for example, a ceramic, on which the busbars 10 , 30 are arranged, and a rear side metallization 60 a , for example, made of copper.
Eddy currents are likewise induced in said rear side metallization, but they do not contribute to a sufficient attenuation of the oscillation owing to the usually small electrical resistance of the rear side metallization.
In the case of a further embodiment illustrated in FIG. 10 , provision is made for forming an attenuation structure 62 instead of a low-impedance rear side metallization below the insulating layer 60 b . The attenuation structures arranged above the components 20 , 22 , as are illustrated, for example in FIGS. 3 and 4 , can then be dispensed with, if appropriate.
The attenuation structures are preferably composed of a material which has the desired high electrical resistance for attenuating the eddy currents. This material may be formed as homogeneous material or else as inhomogeneous material. The inhomogeneous material preferably has regions (islands) having a low electrical resistance between which high-impedance regions are arranged.
FIG. 6 illustrates the influence of a plate-type attenuation structure on the series resistance and the series inductance of a parasitic resonant circuit depending on the distance between the plate-type attenuation structure and the bonding wires for different sheet resistances of the plate-type attenuation structure.
The dashed lines (at the bottom in FIG. 6 a and at the top in FIG. 6 b ) show the value for the series resistance and the series inductance without any attenuation structure, which amounts to approximately 0.075 Ω and 5.35 nH, respectively, in the case of the simulated model on which the curve profiles are based.
FIGS. 6 a and 6 b furthermore illustrate the profiles of the series resistance and of the series inductance depending on the distance between the plate-type attenuation structure and the bonding wires for attenuation structures having different sheet resistivities. The different resistivities illustrated amount to 0.17·10 −3 ohm/square for copper and furthermore 1 ohm/square, 2 ohm/square, 3 ohm/square, 5 ohm/square and 20 ohm/square. The sheet resistivity results from the resistivity of the respective material divided by the thickness of the plate-type attenuation structure used, which amounts to 100 μm in the present case, so that the sheet resistivity (resistivity per square) for copper results from the quotient of 1.7·10 −8 Ω/m (resistivity) and the thickness 100 μm.
It is evident that an attenuation structure made of copper leads the series resistance of the parasitic resonant circuit virtually unchanged and is thus approximately ineffectual with regard to the attenuation.
Generally, it is evident that the attenuation structure is all the more ineffectual, the smaller the distance between the attenuation structure and the bonding wires. This result is not surprising since the field strength decreases with increasing distance from the bonding wires, as a result of which the intensity of the eddy currents induced in the attenuation structure and thus the influence of the attenuation structure on the high-frequency oscillations also decrease.
FIG. 6 a also illustrates that the effect of the attenuation structure on the series resistance initially increases as the sheet resistivity of the material used for the attenuation structure increases, and, after reaching a maximum, decreases again for further increasing values. In the case of the exemplary embodiment illustrated in FIG. 6 a , materials having a sheet resistivity of 2 to 3 ohms/square bring about the greatest increase in the series resistance of the parasitic resonant circuit and thus the largest effect with regard to the attenuation of the high-frequency oscillations occurring in the resonant circuit. The curve in accordance with FIG. 6 a was determined at a resonant circuit frequency of 250 MHz.
The optimum sheet resistivity for the material of the attenuation structure for a given semiconductor circuit arrangement having two or more components, in particular power transistors connected in parallel, can be determined by recording a simulation curve of the type illustrated in FIG. 6 a , the material which contributes most to the increase in the series resistance of the parasitic resonant circuit being preferred in one embodiment.
If consideration is given to the profile of the series inductance in FIG. 6 b depending on the distance between the upper plate and the bonding wires, then it is noticeable that the attenuation structure reduces the series inductance of the parasitic resonant circuit, this effect decreasing with increasing distance between the attenuation structure and the bonding wires. It holds true with regard to the series inductance that the attenuation structure reduces the series inductance to a greater extent, the lower the sheet resistivity of the material used for the attenuation structure.
FIG. 7 illustrates a further embodiment of a circuit arrangement having two semiconductor components 20 , 22 , the terminals 21 , 23 of which are connected to one another via bonding wires 40 , 42 and a busbar 30 . This embodiment of the circuit arrangement differs from the circuit arrangements illustrated in FIGS. 3 to 5 and described above by virtue of the fact that, instead of the plate- or frame-type attenuation structure, a high-impedance line connection 70 is provided, which electrically conductively connects the terminals 21 , 23 of the semiconductor components 20 , 22 to one another in addition to the already present electrically conductive connection via the bonding wires 40 , 42 and the busbar 30 . In this case, the line connection 70 is formed in particular as a bonding wire.
In one embodiment, the electrical resistance of the material used for this bonding wire 70 amounts to between 100 and 10,000 times the electrical resistance of aluminium.
By means of this high-impedance bonding wire 70 in comparison with customary bonding wires, the inductance of the parasitic resonant circuit, which is critically formed by the bonding wires 40 , 42 and the busbar 30 between the terminals 21 and 23 of the components 20 , 22 is influenced in such a way that the series resistance of the parasitic resonant circuit is particularly high for a specific frequency or a specific frequency range, as a result of which the losses of the resonant circuit are particularly high for these frequencies, which leads to a great attenuation of high-frequency oscillations having frequencies in this frequency range, as is explained below with reference to FIG. 8 a.
FIG. 8 a illustrates the profile of the series resistance of the parasitic resonant circuit for a given frequency of 550 MHz, which represents a customary value for the high-frequency oscillations occurring during the switching operations, for different values of the conductivity of the bonding wire 70 (connecting bond) that directly connect the components 20 , 22 . In this case, the series resistance rises up to a maximum proceeding from low conductivities for the bonding wire 70 in order then to decrease again for further increasing conductivities of the bonding wire 70 . In the example illustrated, a conductivity of the bonding wire 70 of 3.7·10 9 pS/μm is optimal with regard to the attenuation of a high-frequency oscillation with a frequency of 550 MHz, since the series resistance assumes its maximum value for this conductivity value. For comparison, the series resistance when using a bonding wire 17 made of aluminium is illustrated in FIG. 8 a and is represented by the value on the far right in FIG. 8 a.
FIG. 8 b illustrates the influence of the conductivity of the connecting bond on the series inductance of the parasitic resonant circuit, which makes it clear that the series inductance decreases as the conductivity of the connecting bond increases, and falls particularly steeply in the region in which the series resistance reaches its maximum, in order then to decrease only little as the conductivity of the connecting bond 10 increases. The value for the series inductance when using aluminium as connecting bond is also highlighted for comparison in FIG. 8 b.
Finally, FIGS. 9 a and 9 b illustrate the dependence of the series resistance and the series inductance on the frequency for a connecting bond 70 having a conductivity of 3.7·10 9 pS/μm in comparison with an arrangement without a high-impedance connecting bond. It becomes clear that the series resistance increases to a particularly great extent as the frequency of the oscillations increases, given the presence of such a bonding wire, and that, by contrast, the series inductance decreases to a particularly great extent as the frequency of the oscillations increases.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof. | The present invention relates to a circuit assembly with at least two semiconductor components, each having terminals, whereby at least one terminal of the first semiconductor component is connected to a terminal of the other semiconductor component in an electrically conductive manner. The circuit assembly damps high-frequency oscillations that occur during switching operations. An eddy-current damping structure is provided above said assembly at a distance from the semiconductor components or said semiconductor components are directly connected to each other by means of a high-resistance wire connection in addition to the existent electroconductive connection. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to trailer apparatus, and more particularly pertains to a new and improved emergency axle apparatus wherein the same is arranged for temporary securement to a trailer for support of the trailer to permit temporary transport thereof.
2. Description of the Prior Art
The breakage and associated breakdown of conventional trailer apparatus, particularly such as boat trailers and the like that are loaded, requires the elaborate and expensive unloading of such trailer structure permitting the transport of the trailer for subsequent repair. The instant invention attempts to overcome deficiencies of the prior art by providing for an axle structure arranged for temporary securement to a trailer to accommodate support and transport of the trailer for subsequent repair.
U.S. Pat. No. 3,995,856 to Ronne; U.S. Pat. No. 4,871,183 to Moss; U.S. Pat. No. 4,087,008 to Silva, Jr.; and U.S. Pat. No. 3,613,921 to Ryden are examples of tow dollies for wheeled vehicles as utilized in the prior art to permit the transport of disabled trailers and the like.
As such, it may be appreciated that there continues to be a need for a new and improved emergency axle apparatus as set forth by the instant invention which addresses both the problems of ease of use as well as effectiveness in construction to accommodate the transport of a trailer structure for repair and in this respect, the present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
In view of the prior art, the present invention provides an emergency axle apparatus wherein the same sets forth an axle structure arranged for the temporary mounting to an existing trailer structure for the transport of the trailer structure for repair.
To attain this, the present invention provides an elongate axle beam with an associated first end and intermediate flange members arranged to support an axle and associated trailer to substitute support for the trailer to accommodate conditions such as a broken axle, spindle, or defective wheel. The axle beam includes a second end flange having a spindle supporting a wheel rotatably thereto.
My invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed and it is distinguished from the prior art in this particular combination of all of its structures for the functions specified.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. 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.
It is another object of the present invention to provide a new and improved emergency axle apparatus which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved emergency axle apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved emergency axle apparatus which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such emergency axle apparatus economically available to the buying public.
These together with other 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 had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an isometric illustration of the instant invention.
FIG. 2 is an isometric illustration in exploded view of the spindle structure of the invention.
FIG. 3 is an enlarged isometric illustration of a support flange as utilized by the invention.
FIG. 4 is an isometric illustration of the invention in use.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 to 4 thereof, a new and improved emergency axle apparatus embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, the emergency axle apparatus 10 of the instant invention essentially comprises an elongate axle beam 11 longitudinally aligned, having a first end 12 spaced from a second end 13. A second end flange 14 includes a spindle 17 orthogonally mounted thereto, wherein the spindle is oriented in a parallel spaced relationship relative to the axle beam 11 projecting forwardly of the second end. A first end flange 15 is orthogonally mounted to the axle beam 11 at the first end 12, with a plurality of identical intermediate flanges 16 mounted along the axle beam 11 in a parallel relationship relative to one another. The first end flange 15 and the intermediate flanges 16 are coextensive relative to one another and include a flange first side edge 18 spaced from a flange second side edge 19, with a flange top edge 20. A flange top side edge opening 21 is directed into the flange from the top side edge 20 between the first and second side edges 18 and 19. Each opening 21 includes an opening floor 22 at a lower end of the opening spaced from the top side edge 20. The floor 22 includes a plurality of floor projections 23 arranged to engage in a frictional relationship with an existing trailer axle of a trailer requiring temporary transport, in a manner as illustrated in FIG. 4. The spindle 17 is defined along a spindle axis 17a that is arranged to orthogonally and medially intersect or be arranged below each of the openings 21 to properly orient the spindle 17 in a relationship to align the apparatus 10 in a manner as to minimize tilting of the trailer when the axle beam 11 is mounted to the existing trailer axle, in a manner as illustrated in the FIG. 4.
The first side edge 18 of the first end flange 15 and the intermediate flanges 16 has a first side edge slot 24 that is canted upwardly from the first side edge 18 towards the floor 22, but spaced from the floor 22. The second side edge 19 of each of the flanges 15 and 16 has a second side edge flange 25 orthogonally mounted to the second side edge, with the second side edge flange 25 including an internally threaded bore 26. A threaded adjuster rod 27 is threadedly received within the threaded bore 26, with the threaded adjuster rod having a lock nut mounted thereon to selectively and fixedly secure the adjuster rod 27 relative to the threaded bore 26. A flexible chain 29 is mounted to an upper distal end of the adjuster rod 27, wherein one of the chain links of the flexible chain 29 is received within the associated first side edge slot 24 to permit the looping of the chain 29 of each of the flanges 15 and 16 over a trailer axle in permitting subsequent tightening of the chain about the trailer axle to secure the axle beam 11, in a manner as illustrated in FIG. 4.
The FIG. 2 illustrates that the spindle 17 is provided with a spindle flange 30 rotatably mounted about the spindle 17 utilizing a spindle flange bearing 31 receiving the spindle 17 therethrough. A retainer nut 32 is mounted to the spindle to capture the spindle flange relative to the spindle 17. A wheel member 33 is mounted to the spindle flange 30 to provide for rotation of the wheel member 33 for ease of transport of a trailer to be transported.
As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure, and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | An elongate axle beam with an associated first end and intermediate flange members are arranged to support an axle and associated trailer to substitute support for the trailer to accommodate conditions such as a broken axle, spindle, or defective wheel. The axle beam includes a second end flange having a spindle supporting a wheel rotatably thereto. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a Continuation-in-part of co-pending U.S. application Ser. No. 10/150,057 filed May 17, 2002, now U.S. Pat. No. 6,751,896, which is a Continuation-in-part of copending U.S. application Ser. No. 09/624,099 filed Jul. 24, 2000, now U.S. Pat. No. 6,430,849 .
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention generally relates to a material handling apparatus and, in a preferred embodiment thereof, more particularly relates to an excavating apparatus, representatively a tracked excavator, having operatively attached to the stick portion of its boom a specially designed combination bucket and breaker structure which uniquely permits the excavator operator to selectively carry out either digging or refusal material breaking tasks without having to change out equipment on the stick.
[0004] 2. Description of Related Art
[0005] Large scale earth excavation operations are typically performed using a powered excavating apparatus, such as a tracked excavator, having an articulated, hydraulically pivotable boom structure with an elongated, pivotal outer end portion commonly referred to as a “stick”. Secured to the outer end of the stick is an excavating bucket which is hydraulically pivotable relative to the stick between “closed” and “open” positions. By pivotally manipulating the stick, with the bucket swung to a selected operating position, the excavator operator uses the bucket to forcibly dig into the ground, scoop up a quantity of dirt, and move the scooped up dirt quantity to another location, such as into the bed of an appropriately positioned dump truck.
[0006] A common occurrence during this conventional digging operation is that the bucket strikes refusal material (in excavation parlance, a material which “refuses” to be dug up) such as rock which simply cannot be broken and scooped up by the bucket. When this occurs it is typical practice to stop the digging operation, remove the bucket from the stick, and install a hydraulically operated “breaker” on the outer end of the stick in place of the removed bucket. The breaker has, on its outer end, an oscillating tool portion which rapidly hammers the refusal material in a manner breaking it up into portions which can be subsequently dug up. After the breaker has been utilized to break up the refusal material, the operator removes the breaker from the stick, replaces the breaker with the previously removed bucket, and resumes the digging operation with the bucket.
[0007] While this procedure is easy to describe, it is a difficult, laborious and time-consuming task for the operator to actually carry out due to the great size and weight of both the bucket and breaker which must be attached to and then removed from the stick , and the necessity for the operator to climb into and out of the high cab area of the excavator (often in inclement weather) to effect each bucket and breaker changeout on the stick. This sequence of bucket/breaker/bucket changeout, of course, must be laboriously repeated each time a significant refusal area is encountered in the overall digging process.
[0008] A previously utilized alternative to this single excavator sequence is to simply provide two excavators for each digging project—one excavator having a bucket attached to its boom stick, and the second excavator having a breaker attached to its boom stick. When the bucket-equipped excavator encounters refusal material during the digging process, it is simply moved away from the digging site, and the operator climbs down from the bucket-equipped excavator, walks over to and climbs up into the breaker-equipped excavator, drives the breaker-equipped excavator to the digging site, and breaks up the encountered refusal material. Reversing the process, the operator then switches to the bucket-equipped excavator and resumes the digging process to scoop up the now broken-up refusal material.
[0009] While this digging/breaking technique is easier on the operator, it is necessary to dedicate two large and costly excavators to a given digging task, thereby substantially increasing the total cost of a given excavation task. A modification of this technique is to use two operators—one to operate the bucket-equipped excavator, and one to operate the breaker-equipped excavator. This, of course, undesirably increases both the manpower and equipment cost for a given excavation project.
[0010] Another attempt to solve this problem is disclosed in U.S. Pat. No. 6,085,446 and U.S. Pat. No. 4,100,688 for an excavating machine having a motorized milling tool attached to the back of the bucket. A primary disadvantage of these devices is complexity, cost, and reliability. Another disadvantage is the weight that must be continuously carried by the bucket. The additional weight substantially reduces the carrying capacity and mobility of the bucket. Another disadvantage to the device of U.S. Pat. No. 6,085,446 is that the back of the bucket cannot be used to smooth or pad the soil, as is a well-known practice in the industry. Another disadvantage is that surface rock is not subject to an overburden pressure, so it generally fails faster under compression and impact forces than by the shearing forces of a scrapping and gouging rotary drilling tool.
[0011] Another attempt to solve this problem is disclosed in U.S. Pat. No. 4,070,772 for an excavating machine having a hydraulic breaker housed inside, or on top of, the boom stick. A primary disadvantage of this device is that it is extremely complex and expensive. Another disadvantage of this device is that it cannot be retrofit to existing excavators. Another disadvantage of this device is that the size of the breaker is limited. Another disadvantage of this device is that the bucket must be fully stowed to access the breaker and vice versa, making simultaneous operation impractical.
[0012] A more recent attempt to solve this problem is disclosed in U.S. Pat. No. 5,689,905 for another excavating machine having a hydraulic breaker housed inside, or on top of, the boom stick. In this device, the chisel portion of the breaker is removed when not in use. A primary disadvantage of this device is that it fails to permit immediate, unassisted switching from breaker to bucket, and thus simultaneous operation is impossible. Another disadvantage of this device is that it requires manual handling of the extremely heavy chisel tool each time the operator desires to convert to a breaker or bucket operation. Another disadvantage of this device is that it is extremely complex and expensive. Another disadvantage of this device is that it cannot be retrofit to existing excavators.
[0013] As can be readily appreciated from the foregoing, a need exists for an improved technique for carrying out the requisite digging and refusal material-breaking portions of an overall excavation operation in a manner eliminating or at least substantially eliminating the above-mentioned problems, limitations and disadvantages commonly associated with conventional digging and breaking operations. It is to this need that the present invention is directed.
SUMMARY OF THE INVENTION
[0014] In carrying out principles of the present invention, in accordance with a preferred embodiment thereof, an excavating machine, representatively a tracked excavator, is provided with a specially designed pivotable boom stick assembly that includes a boom stick having first and second excavating tools secured thereto for movement relative to the boom stick. Illustratively, the first excavating tool is an excavating bucket secured to the boom stick for pivotal movement relative thereto between a first position and a second position, and the second tool is a breaker secured to the boom stick for pivotal movement relative thereto between a stowed position and an operative position.
[0015] A hydraulically operable drive apparatus is interconnected between the boom stick and the bucket and breaker and is useable to pivotally move the bucket between its first and second positions, and to pivotally move the breaker between its stowed and operative positions. Representatively, the drive apparatus includes a plurality of hydraulic cylinder assemblies operatively interconnected between the boom stick and the bucket and breaker.
[0016] The bucket, when the breaker is in its stowed position, is movable by the drive apparatus to the second bucket position and is useable in conjunction with the boom stick, and independently of the breaker, to perform a digging operation. The breaker, when the bucket is in its first position, is movable by the drive apparatus to the breaker's operative position and is useable in conjunction with the boom stick, and independently of the bucket, to perform a breaking operation. Accordingly, the excavating machine may be advantageously utilized to perform both digging and breaking operations without equipment changeout on the boom stick.
[0017] Another advantage of the present invention is that the bucket can be operated without fully stowing the breaker. Likewise, the breaker may be operated without the necessity to fully extend the bucket. This increases the efficiency of the excavation process by providing immediate access to each of the tools, without delay. Another advantage of this capability is that it further increases the efficiency of the excavation process by rendering the bucket available to frequently scrape away the freshly generated cuttings so the breaker tool is always exposed to fresh refusal material, avoiding operation against previously generated cuttings. Another advantage of this capability is that by avoiding operation against previously generated cuttings, the breaker tool will last longer.
[0018] In an illustrated preferred embodiment thereof, the excavating machine is also provided with control circuitry coupled to the drive apparatus and useable to operate it. Representatively, the control circuitry includes a hydraulic flow circuit in which the drive apparatus is interposed; a flow controller operative to electively reverse the direction of hydraulic fluid flow through a portion of the hydraulic flow circuit; a diverting valve apparatus interconnected in the hydraulic flow circuit and operable to selectively route hydraulic fluid through the hydraulic flow circuit to (1) a first portion of the drive apparatus associated with the bucket, or (2) a second portion of the drive apparatus associated with the breaker; and a switch structure useable to selectively operate the diverting valve apparatus.
[0019] In another illustrated preferred embodiment of the present invention, a breaker and deployment system is disclosed, having a mounting bracket attached to the underside and lower end of the boom stick. A breaker is pivotally attached to a first pivot on the bracket. In the preferred embodiment, the first pivot is bifurcated. A hydraulic cylinder is pivotally attached at a second pivot on the bracket, in close proximity to the first pivot. The hydraulic cylinder is pivotally attached to the breaker at a third pivot. This embodiment has the advantage of requiring only one hydraulic cylinder. This embodiment has the additional advantage of using a much shorter hydraulic cylinder. This embodiment has the additional advantage of rapid deployment and retraction of the breaker. This embodiment has the additional advantage of a more stable and durable assembly during use. This embodiment has the additional advantage of being much easier and faster to install or remove. This embodiment has the additional advantages of being less expensive to manufacture, install, and service. This embodiment has the additional advantage of resulting in an increased range of motion of the deployed tool. This embodiment has the additional advantage of providing protection for the hydraulic cylinder when the tool is deployed and operational. This embodiment has the additional advantage of resulting in a less obstructive configuration of the hydraulic cylinder in relation to the boom stick when deployed.
[0020] In another illustrated preferred embodiment of the present invention, a bracket is attached to the inside and lower end of the boom stick. A breaker is pivotally attached to a first pivot on the bracket. A latch-lock assembly is mounted to, and between, the boom stick and the breaker. This embodiment has the advantage of preventing undesired, partial deployment of the breaker from the vibration and impact forces encountered during operation of the bucket. In a preferred embodiment, the latch-lock assembly comprises a slide latch located in a guide box attached to the boom stick for latching engagement with a strike attached to the breaker assembly. In another preferred embodiment, the latch-lock assembly comprises a ball latch attached to the boom stick for latching engagement with a strike ball attached to the breaker assembly.
[0021] In another illustrated preferred embodiment of the present invention, a shock absorbing retraction stop is attached to the boom stick. This prevents damage to the breaker and the boom stick when the breaker is in the stowed position, encountering vibration and impact forces during operation of the bucket.
[0022] In another illustrated preferred embodiment of the present invention, a bracket is attached to the underside and lower end of the boom stick. A breaker is pivotally attached to a first pivot on the bracket. Deployment of the breaker is made by the force of gravity acting on the breaker, upon release of the latch-lock assembly. In this embodiment, a controllable hydraulic cylinder is unnecessary to forcibly move the breaker. The breaker may be stowed by retracting the bucket into the breaker, thus forcing it upwards and against the boom stick until the latch-lock assembly can be engaged to secure the breaker in place. This embodiment has the advantage of being easily retrofit onto excavating machines without modification of the hydraulic system. An additional advantage of this embodiment is the lower cost of materials and installation. Optional to this embodiment, an uncontrolled hydraulic or pneumatic cylinder may be used to prevent free fall of the breaker upon release of the latch-lock. An advantage of this embodiment is increased safety.
[0023] In another illustrated preferred embodiment of the present invention, a bracket is attached to the underside and lower end of the boom stick. An extension stop is attached to the bracket, engageable with the breaker. One advantage of this embodiment is that it adds to the operator's control of the breaker tool. Another advantage of this embodiment is that the extension stop transmits a component of the impact force from the breaker directly to the boom stick, which reduces the reaction forces on the hydraulic cylinder, thus extending the life of the hydraulic cylinder. Another advantage of this embodiment is that the extension stop prevents over-extension of the breaker away from the boom stick, which has been shown to result in damage to the hydraulic cylinder used to deploy the breaker. Another advantage of this embodiment is that it is also useful in the gravity deployment embodiment disclosed above and elsewhere herein, to prevent excessive movement of the breaker during operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] [0024]FIGS. 1 and 2 are simplified, somewhat schematic side elevational views of a representative excavating machine illustrating the variable positioning available for a bucket and breaker simultaneously carried by the stick portion of its boom.
[0025] [0025]FIGS. 3A and 3B are schematic diagrams of a specially designed hydraulic and electrical circuit used to control the pivotal orientations of the bucket and breaker relative to the boom stick.
[0026] [0026]FIGS. 4, 5 and 6 are simplified, somewhat schematic side elevational views of a representative excavating machine, fitted with a preferred embodiment of a breaker and deployment system of the present invention. These figures illustrate the deployment of the breaker from the stowed position.
[0027] [0027]FIG. 7 is an isometric view of a preferred embodiment of a breaker portion of the breaker and deployment system of the present invention.
[0028] [0028]FIG. 8 is an exploded view of a preferred embodiment of a breaker portion of the breaker and deployment system of the present invention.
[0029] [0029]FIG. 9 is a top view of a preferred embodiment of the bracket of the present invention.
[0030] [0030]FIG. 10 is a side view of a preferred embodiment of the bracket of the present invention.
[0031] [0031]FIG. 11 is an isometric view of a preferred embodiment of the bracket of the present invention.
[0032] [0032]FIG. 12 is a side-sectional view of a preferred embodiment of the breaker and deployment system of the present invention.
[0033] [0033]FIG. 13 is a side-sectional view of a preferred embodiment of the breaker and deployment system of FIG. 12, showing the breaker fully deployed.
[0034] [0034]FIG. 14 is a bottom sectional view of a preferred embodiment of the breaker and deployment system of the present invention
[0035] [0035]FIG. 15 is a side view of the preferred embodiment of the breaker and deployment system shown attached to the boom stick of an excavating machine, with a breaker assembly in the fully retracted and latched closed.
[0036] [0036]FIG. 16 is a side view of the preferred embodiment of the breaker system of FIG. 15, with the breaker system unlatched and in a fully extended and stopped position.
[0037] [0037]FIG. 17 is an isometric view of the preferred embodiment of the breaker system of FIGS. 15 and 16, with the breaker system shown in a fully extended and stopped position.
[0038] [0038]FIG. 18 is an isometric view of the preferred embodiment of the breaker system of FIG. 17, disclosing an alternative latch-lock assembly.
[0039] [0039]FIG. 19 is a side view of a preferred embodiment of a gravity deployment system of the present invention, showing the breaker on an excavating machine in the extended position.
[0040] [0040]FIG. 20 is a side view of the preferred embodiment of the gravity deployment system of FIG. 19, showing the relationship between the bucket, the breaker, and the boom stick, as the bucket is retracted to retract the gravity deployed breaker.
[0041] [0041]FIG. 21 is a side view of the preferred embodiment of the gravity deployment system of FIGS. 19 and 20, showing complete retraction and latching of the breaker by retraction of the bucket.
[0042] [0042]FIG. 22 is a partial perspective view of an alternative embodiment of the present invention in which a hydraulic rotary actuator is employed to move the breaker assembly relative to the boom stick.
[0043] [0043]FIG. 23 is an isometric section view of the rotary actuator of the embodiment of FIGS. 22, and 23 through 25 .
[0044] [0044]FIG. 24 is an side view of the alternative embodiment of FIG. 22.
[0045] [0045]FIG. 25 is a top view of the alternative embodiment of FIGS. 22 and 23.
[0046] [0046]FIG. 26 is a partial section view of an alternative bracket assembly for securing the breaker assembly to the boom stick.
[0047] [0047]FIG. 27 is a left-side view of a portion of the alternative bracket assembly of FIG. 26.
[0048] [0048]FIG. 28 is an end section view of the portion of the alternative bracket assembly of FIGS. 26 and 27.
DETAILED DESCRIPTION OF THE INVENTION
[0049] Illustrated in simplified form in FIGS. 1 and 2 is an earth excavating machine which is representatively in the form of a tracked excavator 10 having a body portion 12 supported atop a wheeled drive track section 14 and having an operator cab area 16 at its front or left end. While a tracked excavator has been illustrated, it will be readily appreciated by those of skill in this particular art that the principles of the present invention, as later described herein, are equally applicable to other types of earth excavating machines including, but not limited to, a wheeled excavator and a rubber-tired backhoe. It is further understood that the invention may assume various orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in appended claims. Hence specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
[0050] A conventional articulated boom structure 18 projects forwardly from excavator body portion 12 and includes an elongated base portion 20 and a stick portion 22 . The right or inner end of boom base portion 20 is pivotally secured to body portion 12 , adjacent the front end thereof, and boom base portion 20 is pivotable in a vertical plane, toward and away from the ground, by means of hydraulic cylinder assemblies 24 (only one of which is visible in FIGS. 1 and 2) disposed on opposite sides of boom base portion 20 and interconnected between a pivot location (not visible) on excavator body portion 12 and a pivot location 26 on boom base portion 20 .
[0051] Upper end 22 a of boom stick 22 is connected to the left or outer end of boom base portion 20 , at pivot location 28 , and is forcibly pivotable in a vertical plane about pivot location 28 , toward and away from the front end of the excavator body 12 , by means of a hydraulic cylinder assembly 30 operatively interconnected between a pivot location 32 on boom base portion 20 and a pivot location 34 on the upper end 22 a of boom stick 22 .
[0052] A conventional excavating bucket 36 is pivotally secured to lower end 22 b of stick 22 , at pivot location 38 , and is further secured to the lower end of stick 22 by a conventional pivotal drive bar linkage 40 , 42 . A hydraulic cylinder assembly 44 is pivotally interconnected between a pivot location 46 on upper end 22 a of stick 22 and a pivot location 48 on drive bar linkage 40 , 42 . The hydraulic cylinder assembly 44 may be utilized to pivot bucket 36 relative to lower end 22 b of stick, in a vertical plane toward and away from the front end of excavator body 12 , between (1) a solid line, fully open position (see FIGS. 1 and 2) in which bucket 36 is disposed on the front side of stick 22 with its open side facing generally downwardly, and (2) a dotted line, fully closed position 36 b (see FIG. 1) in which bucket 36 is disposed on the right side of stick 22 with its open side facing generally upwardly. And, of course, bucket 36 may be pivoted to a selected dotted line operating position 36 a (see FIG. 1) somewhere between these two pivotal limit positions.
[0053] According to a key aspect of the present invention, a breaker 50 is mounted on stick 22 in addition to excavating bucket 36 . In a manner subsequently described herein, this permits the same powered excavating apparatus 10 to uniquely perform both digging and breaking operations without the previous necessity of having to perform repeated tool changeouts on stick 22 or having to provide two separate powered excavating machines—one to dig and one to break.
[0054] Breaker 50 has a body section 52 with inner and outer ends 52 a and 52 b . Carried on the outer end 52 b is an elongated, longitudinally reciprocable breaking tool 54 which is forcibly reciprocated in response to selective transmittal to breaker 50 of pressurized hydraulic fluid via suitable hydraulic lines (not shown). Inner breaker body end 52 a is pivotally connected, at pivot location 56 , to a suitable bracket 58 anchored to lower stick end 22 b and projecting outwardly from its rear side. Outer breaker body end 52 b is pivotally connected, at pivot location 60 , to the rod ends of a pair of hydraulic cylinder assemblies 62 (only one of which is visible in FIGS. 1 and 2) pivotally connected at their opposite ends to upper stick end 22 a at pivot location 64 .
[0055] Hydraulic cylinder assemblies 62 are selectively operable, as later described herein, to forcibly pivot breaker 50 between (1) a solid line stowed or fully open position (see FIGS. 1 and 2) in which breaker body 52 extends upwardly along and generally parallel to the inner side of stick 22 , with reciprocable breaker tool 54 positioned adjacent upper stick end 22 a , and (2) a dotted line fully closed operational position 50 a (see FIG. 2) in which the breaker body extends downwardly beyond lower stick end 22 b , at an obtuse angle to the length of stick 22 , with reciprocable breaker tool 54 pointing downwardly as viewed in FIG. 2. Of course, breaker 50 may also be positioned at any selected pivotal orientation between these two illustrated pivotal limit positions.
[0056] As can be seen by comparing FIGS. 1 and 2, with breaker 50 in its solid line stowed orientation (see FIGS. 1 and 2), bucket 36 may be freely pivoted between its solid and dotted line limit positions 36 and 36 b (see FIG. 1), and used in digging operations, without interference from stowed breaker 50 . Similarly, with bucket 36 in its fully open solid line pivotal orientation (see FIGS. 1 and 2), breaker 50 can be swung downwardly from its solid line stowed orientation (see FIGS. 1 and 2) to a selected dotted line operating orientation (see FIG. 2), and used to break up refusal material, without interference from bucket 36 . Thus, either bucket 36 or breaker 50 may be used independently of the other without the necessity of excavation equipment changeout on boom stick 22 .
[0057] The present invention thus provides an excavating machine or apparatus having a uniquely operative boom stick assembly 66 (see FIGS. 1 and 2) which includes stick 22 , two independently operable excavation tools (representatively, excavating bucket 36 and breaker 50 ) each carried on the stick 22 for movement relative thereto between first and second limit positions, and drive apparatus (representatively the hydraulic cylinder assemblies 44 , 62 ) interconnected between stick 22 and bucket 36 and breaker 50 and operable to variably position them relative to stick 22 .
[0058] Using the representative excavating machine 10 , a typical digging and breaking operation can be carried out as follows. With breaker 50 in its solid line stowed orientation (see FIGS. 1 and 2), and bucket 36 pivoted to a suitable operational orientation (for example, the dotted line orientation 36 a shown in FIG. 1), the operator carries out a digging operation in a conventional manner. When refusal material, such as rock, is encountered and cannot be scooped up with bucket 36 , the operator simply pivots bucket 36 back to its fully open, solid line position (see FIGS. 1 and 2), pivots breaker 50 away from its solid line stowed orientation (see FIGS. 1 and 2) to a selected operational orientation (for example, the dotted line orientation 50 a shown in FIG. 2), and hydraulically operates breaker 50 to break up the refusal material.
[0059] After this breaking task is completed, the operator simply pivots deployed breaker 50 back to its solid line, stowed orientation (see FIG. 2), pivots bucket 36 away from its solid line fully open orientation (see FIG. 1) to a selected dotted line orientation, scoops up the now broken refusal material, and resumes the digging operation using bucket 36 . Accordingly, both the digging and breaking portions of an overall excavation task may be performed by the machine operator without leaving cab area 16 or having to effect an equipment changeout on stick 22 .
[0060] Schematically depicted in FIGS. 3A and 3B is a specially designed hydraulic/electric circuit 70 used to selectively pivot bucket 36 and breaker 50 between their previously described limit positions relative to stick 22 . Circuit 70 includes bucket hydraulic cylinder assembly 44 ; breaker hydraulic cylinder assemblies 62 ; a manually operable hydraulic bucket/breaker pivotal position controller 72 ; a pair of solenoid operated hydraulic diverter valves 74 , 76 ; and an electrical bucket/breaker selector switch 78 .
[0061] Hydraulic cylinder assemblies 44 and 62 are of conventional construction, with each of them having a hollow cylinder 80 , a piston 82 reciprocally mounted in the cylinder 80 , and a rod 84 drivably connected to piston 82 and extending outwardly through an end of cylinder 80 . Hydraulic bucket/breaker position controller 72 is appropriately positioned in cab area 16 and has a control member 86 that may be manually moved in the indicated “close” and “open” directions. Similarly, electrical bucket/breaker selector switch 78 is appropriately positioned in cab area 16 and has a switch member 88 that may be manually toggled to either a “breaker” position or a “bucket” position. Each of the hydraulic diverter valves 74 , 76 has, from left to right as viewed in FIGS. 3A and 3B, a dead end port 90 , a through-flow passage 92 , an interconnected pair of turnaround ports 94 , and a dead end port 96 . Additionally, each valve 74 , 76 has an electrical solenoid portion 98 operative as later described herein to shift the porting in its associated valve as schematically indicated by the arrows 100 in FIG. 3B.
[0062] DC electrical power supply lines 102 , 104 are connected to the input side of bucket/breaker selector switch 78 , and DC electrical control output lines 106 , 108 are interconnected between the output side of switch 78 and valve solenoids 98 . With selector switch member 88 toggled to its “bucket” position, no electrical power is supplied to solenoids 98 , and ports and passages 90 , 92 , 94 , 96 of hydraulic diverter valves 74 , 76 are in their FIG. 3A orientations relative to the balance of schematically depicted circuit 70 . When selector switch member 88 is toggled to its “breaker” position, DC electrical power is transmitted to the solenoids 98 via electrical lines 106 and 108 to thereby shift the valve porting leftwardly relative to the balance of circuit 70 as schematically indicated by arrows 100 in FIG. 3B.
[0063] With electrical switch member 88 in its “bucket” position, hydraulic cylinder assemblies 44 and 62 , hydraulic position control 72 , and hydraulic diverter valves 74 and 76 are hydraulically interconnected as follows as viewed in the schematic FIG. 3A circuit diagram.
[0064] Main hydraulic power lines 110 , 112 are connected to the bottom side of position controller 72 ; hydraulic line 114 is interconnected between the right end of position controller 72 and through-flow passage 92 of diverter valve 76 ; hydraulic line 116 is interconnected between through-flow passage 92 of diverter valve 76 and the upper end of cylinder portion 82 of bucket hydraulic cylinder assembly 44 ; hydraulic line 118 is interconnected between the lower end of cylinder portion 82 of bucket hydraulic cylinder assembly 44 and through-flow passage 92 of diverter valve 74 ; and hydraulic line 120 is interconnected between through-flow passage 92 of diverter valve 74 and the left end of position controller 72 . Hydraulic line 122 is interconnected between dead end port 90 of diverter valve 76 and the upper ends of cylinder portions 80 of breaker hydraulic cylinder assemblies 62 ; and hydraulic line 124 is interconnected between dead end port 90 of diverter valve 74 and the lower ends of cylinder portions 80 of breaker hydraulic cylinder assemblies 62 .
[0065] Referring to FIG. 3A, with electrical selector switch member 88 toggled to its “bucket” position, position controller 72 is useable to control the pivotal orientation of bucket 36 relative to stick 22 (see FIG. 1) when breaker 50 is in its solid line stowed orientation. For example, when hydraulic control member 86 is moved toward the “open” position, hydraulic fluid is sequentially flowed (as indicated in the arrowed hydraulic portion of circuit 70 in FIG. 3A) through hydraulic lines 112 and 114 , through-flow passage 92 of diverter valve 76 , hydraulic line 116 , the interior of cylinder portion 80 of bucket hydraulic cylinder assembly 44 , hydraulic line 118 , through-flow passage 92 of diverter valve 74 , and hydraulic lines 120 and 110 . This hydraulic flow retracts rod 84 of bucket hydraulic cylinder assembly 44 to thereby pivot bucket 36 in a clockwise direction away from its fully closed orientation 36 b in FIG. 1. Conversely, when position control member 86 is shifted in a “close” direction, the hydraulic flow through this arrowed hydraulic portion of circuit 70 is reversed, thereby forcibly extending rod 84 of bucket hydraulic cylinder assembly 44 and pivoting bucket 36 in a counterclockwise direction toward its fully closed dotted line orientation 36 b shown in FIG. 1.
[0066] Turning now to FIG. 3B, when it is desired to use breaker 50 instead of bucket 36 , bucket 36 is pivoted to its fully open solid line position shown in FIG. 1, and electrical bucket/breaker switch member 88 is toggled to its “breaker” position to thereby supply electrical power, via leads 106 and 108 , to solenoids 98 of hydraulic diverter valves 74 , 76 . This, in turn, causes the porting of valves 74 , 76 to shift leftwardly (as viewed in FIG. 3B) as schematically indicated by arrows 100 . After such port shifting (see FIG. 3B), hydraulic lines 120 , 124 are coupled as shown to interconnected turnaround ports 94 in valve 74 , and hydraulic lines 114 , 122 are coupled to the interconnected turnaround ports 94 in valve 76 .
[0067] Next, hydraulic control member 86 is moved in its “close” direction. In response, hydraulic fluid is sequentially flowed (as indicated in the arrowed hydraulic portion of the circuit 70 in FIG. 3B) through hydraulic lines 110 and 120 , interconnected turnaround ports 94 in diverter valve 74 , hydraulic line 124 , the interiors of cylinder portions 80 of breaker hydraulic cylinder assemblies 62 , hydraulic line 122 , interconnected turnaround ports 94 in diverter valve 76 , and hydraulic lines 114 and 112 . This hydraulic flow forcibly extends rod portions 84 of breaker hydraulic cylinder assemblies 62 to thereby forcibly pivot the stowed breaker 50 (see FIG. 2) downwardly to a selected operating orientation such as dotted line position 50 a in FIG. 2. The now operationally positioned breaker 50 may be hydraulically operated, to cause the reciprocation of its tool portion 54 , using a conventional hydraulic breaker control (not shown) suitably disposed in cab area 16 of representative excavating apparatus 10 . After breaker 50 has been used, the circuit 70 can be utilized to swing breaker 50 back up to its stowed orientation and then swing bucket 36 back down to a selected operational orientation thereof.
[0068] As will be readily appreciated by those of skill in this particular art, excavation apparatus 10 may be easily retrofit to provide it with both digging and breaking capabilities as previously described herein by simply connecting breaker 50 and its associated hydraulic drive cylinder apparatus 62 to stick 22 , and modifying the existing bucket positional control circuitry (for example, as shown in FIGS. 3A and 3B) to add positional control capabilities for added breaker 50 . In this regard it should be noted that position controller 72 shown in the circuit diagrams of FIGS. 3A and 3B may be existing bucket position controller. With the simple addition of diverter valves 74 and 76 , bucket/breaker selector switch 78 , and additional hydraulic lines, the operator can select and independently control both bucket 36 and breaker 50 .
[0069] A variety of modifications may be made to the illustrated embodiment of the present invention without departing from the principles of such invention. For example, as previously mentioned, aspects of the invention can be advantageously utilized on a variety of types of excavating machines other than the representatively illustrated tracked excavator 10 . Additionally, while hydraulic/electric circuit 70 permits the selected positional control of either bucket 36 or breaker 50 , other types of control circuitry may be alternatively utilized, if desired, including separate hydraulic circuits for bucket and breaker. Moreover, while the independently utilizable tools mounted on stick 22 are representatively an excavating bucket and a breaker, other independently utilizable excavating tools could be mounted on stick in place of the illustrated bucket and breaker. Also, while the illustrated bucket and breaker are shown as being pivotally mounted to stick, the particular independently operable tools selected for mounting on stick could have alternate positional movements, such as translation, relative to boom stick on which they are mounted.
[0070] [0070]FIG. 4 discloses earth-excavating machine 10 of FIG. 1 and FIG. 2, fitted with a preferred embodiment of an alternative and preferred breaker and deployment system 200 which is unique, and has numerous advantages. In this embodiment, a hydraulic breaker assembly 201 is mounted on boom stick 22 in addition to excavating bucket 36 . A unitary bracket 202 is rigidly attached to stick 22 by welding or other means of secure attachment. Breaker assembly 201 is pivotally attached to bracket 202 . A single hydraulic cylinder assembly 204 is pivotally attached at one end to bracket 202 . Hydraulic cylinder assembly 204 is pivotally attached at its other end to breaker assembly 201 . Thus, bracket 202 supports the entire deployment system of breaker assembly 201 . The principle of the hydraulic operative control of breaker and deployment system 200 is identical to that disclosed above, except that single hydraulic cylinder 204 is operated for deployment and retraction of breaker assembly 201 .
[0071] [0071]FIG. 5 illustrates earth excavating machine 10 fitted with breaker and deployment system 200 as in FIG. 4. In this figure, breaker assembly 201 is shown released and in a partially deployed position.
[0072] [0072]FIG. 6 illustrates earth excavating machine 10 fitted with breaker and deployment system 200 as in FIG. 4. In this figure, breaker assembly 201 is shown released and in a fully extended position. In this embodiment, breaker assembly 201 may be selectively positioned in any orientation between (and including) the fully deployed and fully retracted positions.
[0073] [0073]FIG. 7 is an isometric view of a preferred embodiment of breaker assembly 201 of the present invention. In this embodiment, breaker assembly 201 has a left body section 206 and an opposite right body section 208 . Breaker assembly 201 has an inner end 210 and an opposite outer end 212 . An optional cover plate 214 is attached between left body section 206 and right body section 208 , over outer end 212 . A conventional breaker tool 216 is secured between left body section 206 and right body section 208 . Cover plate 214 has an opening 218 , through which breaker tool 216 extends. Breaker tool 216 has an internal hydraulically operated cylinder 220 (not shown). A longitudinally reciprocating tool 222 is removably connectable to breaker tool 216 . Reciprocating tool 222 forcibly reciprocates in response to selective transmittal of pressurized hydraulic fluid via suitable hydraulic lines (not shown) to internal hydraulic cylinder 220 of breaker tool 216 .
[0074] [0074]FIG. 8 is an exploded view of another preferred embodiment of breaker assembly 201 . In this embodiment, a gripping structure 224 is located on breaker tool 216 . A pair of lower lock plates 226 secures the outer end 212 of breaker tool 216 between left body section 206 and right body section 208 . In another preferred embodiment, each lower lock plate 226 has a surface structure 228 for secured engagement with gripping structure 224 of breaker tool 216 . Left body section 206 , right body section 208 , and lower lock plates 226 , have matching hole patterns 230 receivable of a plurality of mechanical fastener assemblies 232 .
[0075] A pair of upper lock plates 236 secures the inner end 210 of breaker tool 216 between left body section 206 and right body section 208 . Left body section 206 , right body section 208 , and upper lock plates 236 , have matching hole patterns 230 receivable of a plurality of mechanical fastener assemblies 232 . In an alternative and equivalent embodiment (not shown) left body section 206 and right body section 208 are manufactured with the functional equivalent of lower lock plates 226 and upper lock plates 236 formed integrally on their inside surfaces.
[0076] Still referring to FIG. 8, left body section 206 has a first socket 238 and right body section 208 has a matching first socket 240 located near inner end 210 of breaker assembly 201 . First sockets 238 and 240 are pivotally connectable to bracket 202 .
[0077] Left body section 206 has a third socket 242 and right body section 208 has a matching third socket 244 . A third pivot bushing 246 is attached in and between third sockets 242 and 244 . Pivot bushing 246 is pivotally connectable to hydraulic cylinder assembly 204 .
[0078] [0078]FIG. 9 is a top view of a preferred embodiment of bracket 202 of the present invention. FIG. 10 is a side view of bracket 202 , and FIG. 9 is an isometric view of bracket 202 . Referring to FIG. 9, bracket 202 has a low-end 250 and an opposite high-end 252 . Bracket 202 has a base 254 . In a preferred embodiment, a slotted portion 256 is located on base 254 at each of a low-end 250 and an opposite high-end 252 .
[0079] As best seen in FIG. 11, a left bracket side 258 and a right bracket side 260 extend upward from base 254 in substantially parallel relation to each other. Referring to FIG. 9, left bracket side 258 and right bracket side 260 each have a first socket 262 in substantial centerline alignment with each other. First socket 262 is located on high-end 252 of bracket 202 . Left bracket side 258 and right bracket side 260 each have a second socket 264 in substantial centerline alignment with each other. Second socket 264 is located on low-end 250 of bracket 202 .
[0080] In a preferred embodiment, bracket 202 has a bifurcated pivot means for pivotal attachment of breaker assembly 201 to bracket 202 . In the embodiment disclosed in FIGS. 9, 10, and 11 , the bifurcated pivot means comprises a left bushing 268 extending out of first socket 262 of left bracket side 258 , and a right bushing 270 extending out of first socket 262 of right bracket side 260 . It will be known by one of ordinary skill in the art, that there are other ways to achieve the disclosed configuration of bushings 268 and 270 extending from sides 258 and 260 , without the necessity for first sockets 262 , such as by external welding, casting of the bracket, and other means.
[0081] In a preferred embodiment, best seen in FIG. 14, left bushing 268 and right bushing 270 are removably located in respective first sockets 262 . In this embodiment, an optional bushing stop 272 is attached to the inside wall of each of left bracket side 258 and right bracket side 260 . Also in this embodiment, each of left bushing 268 and right bushing 270 have an internal thread 271 to facilitate removal. Looking to FIG. 14, a removable bushing cap 273 may be attached, as by bolts or other means, to each of first socket 238 and 240 of left body section 206 and right body section 208 respectively. The removability of left bushing 268 and right bushing 270 permits easy removal of breaker assembly 201 without disassembly or removal of bracket 202 .
[0082] In a less preferred embodiment, a first pivot bar 275 (not shown) extends through and between first socket 238 of left bracket side 258 and first socket 240 of right bracket side 260 . While simpler in design, this configuration lacks a significant advantage of the disclosed bifurcated pivot means. As shown in greater detail below, the use of non-bifurcated pivot bar 274 presents a potential interfering obstacle for hydraulic cylinder assembly 204 when breaker assembly 201 is retracted.
[0083] Referring again to FIG. 9, a pivot bar 274 extends through and between second socket 264 of left bracket side 258 and second socket 264 of right bracket side 260 . Pivot bar 274 provides pivotal connection of hydraulic cylinder assembly 204 to bracket 202 .
[0084] In the preferred embodiment, left bushing 268 and right bushing 270 are located in closer proximity to high-end 252 than is pivot bar 274 . Pivot bar 274 is located in closer proximity to base 254 than are left bushing 268 and right bushing 270 .
[0085] In another preferred embodiment, an extension stop means limits the maximum extension of breaker assembly 201 . In a preferred embodiment, the extension stop means is a mechanical interference between breaker assembly 201 and mounting plate 202 . In FIGS. 9, 10, and 11 , the extension stop means disclosed comprises a pair of extension stops 276 , attached, one each, to left bracket side 258 and right bracket side 260 . In an equivalent alternative embodiment not shown, extension stops 276 are attached to base 254 . One of ordinary skill in the art will understand that a variety of modifications may be made to the illustrated embodiment of the present invention without departing from the principles of such invention. For example, a single extension stop may by used.
[0086] [0086]FIG. 12 is a cross-sectional side view of a preferred embodiment of the breaker and deployment system 200 of the present invention. In this view it can be seen that breaker assembly 201 is pivotally attached to bracket 202 , hydraulic cylinder assembly 204 is pivotally attached at one end to bracket 202 , and hydraulic cylinder assembly 204 is pivotally attached at its other end to breaker assembly 201 . Thus configured, a triangular relationship is formed between bushing 270 , pivot bar 274 , and pivot bushing 246 . Operation (expansion) of hydraulic cylinder assembly 204 increases the length of one side of the triangle, causing angular rotation of breaker assembly 201 around bushing 270 (and bushing 268 , not shown) and coincident deployment of breaker assembly 201 into operative position.
[0087] [0087]FIG. 13 is a side-sectional view of a preferred embodiment of the breaker and deployment system of FIG. 12, showing the breaker fully deployed. In FIG. 13, the benefit of the bifurcated pivot means is clearly shown. In FIG. 13, breaker assembly 201 has been deployed to a point by which hydraulic cylinder 204 is aligned between the inside of left bushing 268 (not shown) and the inside of right bushing 270 , as shown by the position of bushing stop 272 . This positions reciprocating tool 222 closer to the vertical position, allowing the operator of excavating machine 10 to operate the tool at greater subsurface depths, and thus dramatically enhance the value of the breaker and deployment system.
[0088] In another embodiment of the present invention, a method of “Su per-deployment” is disclosed. By this method, breaker assembly 201 may be deployed past the deployment angle permitted by full extension of hydraulic cylinder 204 . To accomplish this, the operator takes the following steps:
[0089] 1. Fully extend hydraulic cylinder 204 ;
[0090] 2. momentarily disengages the power to hydraulic cylinder 204 ;
[0091] 3. allow gravity to urge rotation of breaker assembly 201 a few degrees further;
[0092] 4. initiate retraction of hydraulic cylinder 204 , further extending the angular deployment of breaker assembly 201 .
[0093] In this manner, the maximum deployment angle achieved is only limited by eventual mechanical interference with boom stick 22 , or selective placement of extension stops 276 .
[0094] [0094]FIG. 14 is a sectional view of breaker and deployment system 200 of a preferred embodiment with the section taken as shown in FIG. 12. In FIG. 14, the benefit of the bifurcated pivot means is again shown. In this figure, it is seen that left first socket 238 of left body section 206 is pivotally attached to left bushing 268 of mounting plate 202 . Right first socket 240 of right body section 208 is pivotally attached to right bushing 270 of mounting plate 202 . Thus attached, it can be seen that there is clearance between the inside of left bushing 268 and the inside of right bushing 270 such that hydraulic cylinder assembly 204 can rotate freely to a position between them without mechanical interference. This permits a greater angular deployment, and thus convenient utilization of breaker assembly 201 .
[0095] [0095]FIG. 15 is a side view of a preferred embodiment of breaker and deployment system 200 attached to boom stick 22 of excavating machine 10 , with breaker assembly 201 in the fully retracted position. A shock absorbing retraction stop 280 is attached between boom stick 22 and breaker assembly 201 . Retraction stop 280 prevents damage to breaker assembly 201 , hydraulic cylinder 204 , and boom stick 22 when breaker 201 is in the stowed position, encountering vibration and impact forces during operation of bucket 36 . In the embodiment shown, retraction stop 280 is attached to boom stick 22 . In an alternative and equivalent embodiment, not shown, retraction stop 280 is attached to breaker assembly 201 .
[0096] Also disclosed in FIG. 15, a latch-lock assembly 282 is mounted to, and between, boom stick 22 and breaker assembly 201 . Latch-lock assembly 282 secures breaker and deployment system 200 in the retracted position, preventing undesired partial deployment of breaker assembly 201 from the vibration and impact forces encountered during operation of bucket 36 . As shown, latch-lock assembly includes a strike 284 located on breaker assembly 201 . In the preferred embodiment, latch-lock 282 is operable from within cab 16 of excavating machine 10 . Operation of latch-lock assembly 282 may be electrically, manually, pneumatically, or hydraulically.
[0097] [0097]FIG. 16 is a side view of a preferred embodiment of breaker and deployment system 200 attached to boom stick 22 of excavating machine 10 , with breaker assembly 201 in the fully extended and stopped position. In this view, extension stop 276 has engaged left body section 206 , preventing further angular rotation (extension) of breaker assembly 201 . In the preferred embodiment, a second extension stop 276 has simultaneously engaged right body section 208 on the opposite side, and not visible in this view.
[0098] [0098]FIG. 17 is an isometric view of the preferred embodiment of breaker and deployment system 200 of FIG. 16, with breaker and deployment system 200 shown in a fully extended and stopped position. In this view, it can be seen there is clearance between the inside of left bushing 268 and the inside of right bushing 270 such that hydraulic cylinder assembly 204 can rotate freely to a position between them without mechanical interference. This permits a greater angular deployment, and thus convenient utilization of breaker assembly 201 .
[0099] Also seen in FIG. 17, is further detail of a preferred embodiment of latch-lock assembly 282 . In this embodiment, latch assembly 282 has a guide box 286 attached to the underside of boom stick 22 . A slide latch 288 is slidably located within guide box 286 . A control piston 290 is electrically, manually, pneumatically, or hydraulically operated from within cab 16 of excavating machine 10 to alternately move slide latch 288 between an engagement and release position with strike 284 . In a preferred embodiment, strike 284 has a beveled face 292 for contact engagement with slide latch 288 . In another preferred embodiment, guide box 286 has a reinforcement plate 294 to prevent deformation of guide box 286 and undesired release of breaker assembly 201 .
[0100] [0100]FIG. 18 is an isometric view of the preferred embodiment of the breaker system of FIGS. 15-17, with the breaker system shown in a fully extended and stopped position, and disclosing an alternative latch-lock assembly 300 . In this embodiment, a strike ball 302 is located on breaker assembly 201 . In a preferred embodiment, strike ball 302 is welded or otherwise attached to the end of hydraulic cylinder 204 . A ball latch 304 is attached to boom stick 22 . Ball latch 304 is releasably operated by arm 306 . Release 308 actuates arm 306 and is electrically, manually, pneumatically, or hydraulically operated from within cab 16 of excavating machine 10 . A spring 310 (not shown) located within ball latch 304 urges ball latch 304 closed, and receivable of strike ball 302 upon subsequent retraction of breaker assembly 201 .
[0101] [0101]FIGS. 19, 20 and 21 are side views of a preferred embodiment of an alternative gravity deployment system, showing the relationship between bucket 36 , breaker assembly 201 , and boom stick 22 . In this embodiment, bucket 36 is retracted to retract the gravity deployed breaker assembly 201 . The advantage of this embodiment is that it can be incorporated onto excavating machine 10 without a requirement for hydraulic cylinder 204 or hydraulic/electric circuit 70 to selectively pivot bucket 36 and breaker assembly 201 . FIG. 21 is a side view of the preferred embodiment of the gravity deployment system of FIGS. 19 and 20, showing complete retraction and latching of breaker assembly 201 by retraction of bucket 36 .
[0102] [0102]FIGS. 22, 23, and 24 are isometric, side, and top views, respectively, of an alternative embodiment of the present invention that replaces the hydraulic cylinder assembly 204 (illustrated in FIGS. 12 through 21) with a compact and more efficient rotary actuator assembly 400 . Rotary actuator assembly 400 comprises a hydraulically actuated rotary actuator 402 disposed between boom stick 22 and breaker assembly 201 to cause pivotal movement between the two. Rotary actuators of the helical, sliding spline variety are readily commercially available, such as those sold by Helac® Corporation, located at 225 Battersby Avenue, Enumclaw, Wash. 98022, U.S.A.
[0103] Referring to FIG. 25, a section view of hydraulic rotary actuator 402 is illustrated. As seen in this view, a generally cylindrical housing 404 contains a piston 406 which translates longitudinally back-and-forth within housing 404 in response to the application of hydraulic pressure from one side of piston 406 . Piston 406 engages a first helically splined shaft 408 that rotates responsive to the translation of piston 406 in housing 404 . Helically splined shaft 408 in turn engages a second helically splined shaft 410 (with splines pitched in the opposite direction), on an output shaft 412 of actuator 402 .
[0104] The angular position of output shaft 412 is fixed by stopping flow of fluid into and out of cylindrical housing 404 . This stops piston 406 from moving and prevents output shaft 412 from rotating. The direction of rotation of output shaft 412 can be changed by supplying hydraulic pressure to the opposite side of piston 406 , causing the piston and output shaft 412 to reverse direction.
[0105] Referring back to FIG. 22, in the preferred embodiment, actuator 402 is welded to pillow blocks 414 , which are secured by bolts 418 or other mechanical fastening means to boom stick 22 . Thus, rotary actuator 402 is fixed relative to boom stick 22 . Output shaft 412 extending from the end of rotary actuator 402 may be secured by a generally symmetrical bolt pattern 418 to breaker assembly 201 . Thus, when hydraulic pressure is supplied through one or the other of ports 409 , the output shaft 412 (and breaker assembly 201 ) rotate relative to housing 404 (and boom stick 22 ).
[0106] As shown, hydraulic pressure acting on piston 406 is converted into rotary motion of output shaft 412 capable of moving breaker assembly 201 relative to boom stick 22 . This provides a compact, yet high-torque, rotary actuator 402 capable of replacing either of hydraulic cylinder assemblies 62 or 204 , shown in other embodiments, while using a smaller volume of fluid.
[0107] [0107]FIGS. 26 through 28 illustrate an alternative embodiment of bracket assembly 202 employed to secure breaker assembly 201 to boom stick 22 (not shown). In some respects, bracket assembly 202 is similar to that illustrated in FIGS. 9 through 11 and 14 , and corresponding reference numerals are used where the components are identical. Referring to FIGS. 26 and 27, in this embodiment, a pair of threaded bolts 501 (each having a flat portion 503 milled in its end) is received in corresponding threaded sockets 505 formed in each bracket side 258 , 260 . A set screw 507 and corresponding bore 509 is positioned in each bracket side 258 , 260 to intersect sockets 505 , thereby bearing on flat portions 503 of bolts 501 and preventing inadvertent rotation of bolts 501 and removal from sockets 505 .
[0108] As seen in FIG. 26, breaker assembly 201 has a left body section 206 and an opposite right body section 208 . Left body section 206 has a first socket 238 and right body section 208 has a matching first socket 240 (not shown). First sockets 238 and 240 are pivotally connectable to bracket 202 . As best seen in FIG. 28, a circular reinforcing boss 511 is provided around each of first sockets 238 and 240 , through which bolts 501 extend. As best seen in FIG. 28, a zerk or grease fitting 513 is provided on each boss 511 . A bore 517 extends through each boss 511 through which grease is injected to lubricate bolts 501 and the surfaces around them. Inserting grease through zerk or grease fitting 513 reduces the friction between bracket 202 and breaker assembly 201 , reducing the hydraulic horsepower needed for deployment and retraction and improving overall operability of breaker and deployment system 200 .
[0109] As shown in FIG. 28, bolts 501 extend through boss 511 and breaker sections 206 , 208 (only one side of the assembly is illustrated) and into threaded socket 505 in bracket sides 258 , 260 . In the preferred embodiment, a metallic washer 515 is placed around each bolt 501 between breaker sections 206 , 208 and bracket sides 258 , 260 . Bolts 501 are secured against unthreading rotation within threaded sockets 505 by set screws 507 in set screw sockets 509 . Set screw sockets 509 intersect threaded sockets 505 and allow set screws 507 to engage flats 503 of bolts 501 . The bracket assembly is otherwise similar to that shown above and serves to provide a pivoting joint between boom stick 22 and breaker assembly 201 . This alternative bracket assembly is more quickly and easily disassembled than that shown above, permitting faster interchange of breaker assemblies 201 , if necessary.
[0110] In a less preferred embodiment, flats 503 are not included, and set screws 507 bear directly on the threaded portion of bolts 501 and achieve a similar, though less secure result. Again, zerk or grease fitting 513 and its associated bore 517 permit lubrication of the pivot joint formed by the assembly.
[0111] The foregoing detailed description is to be clearly understood as being given by way of illustration and example, the spirit and scope of the present invention being limited solely by the appended claims. | An excavating machine, representatively a tracked excavator has a boom stick portion on which both an excavating bucket and a hydraulic breaker are mounted for hydraulically driven pivotal movement between first and second limit positions. The bucket may be operated independently of the breaker for digging operations. Similarly, the breaker may be operated independently of the bucket for refusal material-breaking operations. The same excavating machine may now use the bucket and breaker in a rapid and continuous exchange to permit frequent removal of small quantities of broken refuse material with the bucket, exposing the bucket and breaker to fresh refuse material. A lubricatable attachment system is disclosed for improved breaker system connectivity that permits quick installation and removal of the breaker. An alternative deployment system is disclosed having a rotary actuator for efficient and rapid deployment without the need for an additional hydraulic cylinder. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to an air throttle valve for controlling the air flowing through an internal combustion engine, such as a spark ignited or compression ignition internal combustion engine.
Throttle valves have been used with internal combustion engines for well over a century. Most commonly used throttle valves include a round or oval plate, usually made of brass or aluminum. The throttle plate extends through a slotted, or slab cut, rotatable shaft which passes through the walls of an air passage. Typically, the air passage may be incorporated in a device such as a throttle body for use within a fuel injected engine; alternatively, the air passage may be incorporated into the housing of a mixing device such as a carburetor. Throttle devices with oval plates rely upon a nearly line-on-line contact between the majority of the throttle blade periphery and the throttle housing to achieve a near-zero or low airflow condition corresponding to engine idle operation. However, to avoid sticking of the throttle plate it is necessary to maintain a clearance between the throttle plate and the bore within which the plate is housed. Unfortunately, it is very difficult to achieve a precise low flow condition with conventional valve geometry, because air leakage through the clearance regions causes widely varying airflow.
A throttle valve assembly according to present invention solves problems inherent with known throttle valves by providing a throttle plate having a spherical section which rides directly upon the throttle bore, so as to provide superior sealing of the throttle plate in the bore. Because the spherical section throttle plate has only a single defining dimension, the orientation issues arising with other plate geometries are avoided.
SUMMARY OF THE INVENTION
A throttle valve for internal combustion engine includes a generally cylindrical valve housing having inside diameter and a throttle plate pivotally mounted within the valve housing. The throttle plate includes a valve disc having an outer rim shaped as a spherical segment, with the valve disc having an outside diameter proximate the inner diameter of the valve housing. Pivots extend through apertures formed in the valve housing and into contact with the valve disc. The present throttle valve further includes a sensor for determining the rotational position of the throttle plate and a motor assembly for positioning a throttle plate. In a preferred embodiment, the throttle plate and the generally cylindrical valve housing may be formed from the same type of powdered metal, such as powdered iron, or other types of powdered or other metals known to those skilled in the art and suggested by this disclosure. The valve disc and valve housing may advantageously be coated with a manganese phosphate finish which impedes corrosion while serving as a break-in coating of the parts.
In order to operate the present assembly efficiently, the motor assembly may include a motor connected with a double or triple reduction gear train.
According to another aspect of the present invention, valve disc used in the present throttle body includes a ring-shaped structure surrounding a thinner circular core. The ring-shaped structure has an outer diameter shaped as a spherical segment, which allows the present valve disc to rotate within the throttle valve body or housing without binding or sticking.
According to another aspect of the present invention, the valve body or housing may be formed as a two piece assembly by separating a preform along fracture path extending through pivot apertures formed in the preform.
According to another aspect of the present invention, the valve disc may have integral and unitary pivots or, alternatively, the valve disk may have trunnions for accepting pivots inserted inwardly through apertures formed in the valve housing.
It is an advantage of a system according to the present invention that airflow to an engine may be very precisely controlled, notwithstanding the presence of contamination of the throttle bore, or extreme thermal gradients.
It is a further advantage of a system according to the present invention that the present throttle system may be manufactured without a need for excessive hand fitting of throttle valve discs within throttle valve bores.
It is a further advantage of a system according to the present invention that the throttle body and throttle valve may be constructed of the same material, so as to avoid problems with uneven thermal growth of the components.
It is a further advantage of a system according to the present invention that the present throttle valve assembly is more compact than known throttle valves, and is therefore useful for technical applications including not only main air throttles, but also manifold control valves and other air-routing and controlling applications. For this reason, as used herein, the terms “throttle valve” and “throttle system” refer to all of the previously enumerated types of air valves.
It is a further advantage of a system according to the present invention that the present throttle valve assembly is more resistant to damage from thermal excursions, such as those experienced either during backfire events or with engines operated with high exhaust gas recirculation (EGR) rates.
Other advantages, as well as features and objects of the present invention, will become apparent to the reader of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an assembled throttle valve according to the present invention.
FIG. 2 is an exploded perspective view of the throttle valve shown in FIG. 1 .
FIG. 3 is an exploded view of a portion of a second type of throttle valve according to the present invention.
FIG. 4 is an end elevation of a throttle plate according to one aspect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIGS. 1 and 2 , valve assembly 10 has valve housing 14 , with inside diameter 18 . Bearing races 42 ( FIG. 2 ) provide housings for a plurality of bearing balls 46 which allow stub shafts 50 to pivot with respect to valve housing 14 . Throttle position sensor 24 and housing 82 , which mounts throttle positioning motor 78 , are located on opposite sides of valve housing 14 . As shown in FIG. 3 , each stub shaft 50 accommodates additional hardware. In one case, rotor 32 , including brushes 33 of throttle position sensor 24 , is locked to one of stub shafts 50 . On the opposite side of valve assembly 10 , stub shaft 50 is locked to gear 78 , which is mounted within housing 82 and ultimately driven by motor 78 .
Valve assembly 10 is useful for employment with a drive-by-wire system in which the control of an engine throttle is achieved solely by means of electronics, as opposed to a more conventional mechanical cable assembly. Because valve housing 14 is generally cylindrical, the housing may be mounted conveniently in an air induction system or, even in an air inlet manifold, without the need for additional threaded fasteners.
FIGS. 1 and 2 also show throttle plate, or valve disc, 22 , which has an outer rim illustrated as a ring-shaped structure, 26 , which surrounds circular core 30 . This construction is shown more particularly in section in FIG. 4 . Rim 26 is shaped as a spherical segment having an outside diameter which is slightly less than the inside diameter 18 of valve housing 14 . Because outer rim 26 of throttle plate 22 is shaped as a spherical segment, throttle plate 22 is resistant to becoming corked or stuck in the closed position within valve housing 14 , as sometimes occurs with known throttle plates.
Throttle plate 22 has two trunnions, 34 , formed integrally with ring-shaped structure 26 and circular core 30 . As shown in FIG. 4 , each of trunnions 34 has a female spline, 38 , formed therein, which matches and is engaged by splines 52 formed at the inboard end of each of stub shafts 50 . Acting together, female spline 38 , and male spline 52 assure that throttle plate 22 is not free to rotate except as driven by motor 78 and gear train 66 . Each of trunnions 34 has an outer surface, 39 , which contacts the inner diameter 18 of housing 14 . Because surfaces 39 are spherical segments having the same radius of curvature as the outermost surface of ring-shaped structure 26 , surfaces 39 may ride freely upon inner diameter 18 , while at the same time providing optimal airflow control, particularly at the idle airflow position. Throttle plate 22 has three locating depressions 36 formed therein. Depressions 36 provide a convenient structure for mounting throttle plate 22 in a machine tool during manufacturing of the throttle plate.
Throttle disc 22 and valve housing 14 may advantageously be coated with a manganese phosphate finish which impedes corrosion, while serving as a break-in coating for these parts. The manganese phosphate coating also serves as an abradable seal between disc 22 and inner diameter 18 of housing 14 .
FIG. 3 illustrates a second embodiment of a throttle valve assembly according to present invention in which throttle plate 22 has integral stub shafts 56 , which are cast in place with the balance of throttle plate 22 . In order to permit mounting of throttle plate 22 within housing 82 upon pivot apertures 86 , housing 82 is formed as a two-piece assembly manufactured by separating a preform along fracture paths extending within shoulders 90 and through pivot apertures 86 Housing 82 is assembled by means of retainers 57 and snap rings 58 , which fit about shoulders 90 . Bearings 48 are provided to allow pivoting action of throttle plate 22 within housing 82 . Torsion spring 88 urges throttle plate 22 to its idle airflow position. Either one or two such torsion springs would be employed with the embodiment of FIGS. 1 and 2 .
Notwithstanding that ball bearings 46 and 48 are shown with the various embodiments of the present invention, other types of antifriction bearings, or even plain bearing elements, could be used to practice present invention.
The inventors of the present throttle valve determined that the valve may be advantageously constructed from powdered metal such as ferrous or non-ferrous metals, or alternatively, other metallic or non-metallic composites or die or pressure-cast metals known to those skilled in the art and suggested by this disclosure. One advantageous combination is powdered iron, used for both throttle plate 22 as well as for housings 14 and 82 . Forming throttle plate 22 and housings 14 and 82 from the same material will avoid problems due to differential thermal expansion, while allowing the spherical outer surface of throttle plate 22 to be finished by grinding to a very fine surface detail, including the outboard-most surfaces, 39 , of trunnions 34 . In this manner, the outer portions of trunnions 34 will remain in contact with valve housing 14 when valve disk 22 is rotated by the throttle operator, in this case motor 78 and gear train 66 .
Although the present invention has been described in connection with particular embodiments thereof, it is to be understood that various modifications, alterations, and adaptations may be made by those skilled in the art without departing from the spirit and scope of the invention set forth in the following claims. | A throttle valve for an internal combustion engine includes a cylindrical valve housing and a spherical segment valve disc mounted within the valve housing. The spherical segment valve disc seals with the valve housing without the need for abutting interference between the valve disc or throttle plate and the valve housing. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to communication systems.
BACKGROUND OF THE INVENTION
[0002] Wireless data traffic has increased greatly in recent years, forcing wireless service providers (WSPs) to upgrade their networks. One problem is that the capacity of wireless networks must currently be upgraded according to peak cell utilization, rather than average cell utilization. For example, typical wireless networks operate at roughly 30% of capacity. Capital expense costs for WSPs could be reduced if these utilization peaks were smoothed.
[0003] A possible solution to smoothing peaks in cell utilization would be to allocate less cell capacity to users who have less need for bandwidth. However, there are currently no mechanisms in place for a WSP to learn of the bandwidth needs of individual users.
[0004] The best existing solution to the problem is for the WSP to engineer the system to limit overloads by controlling call admissions, cell balancing and capacity engineering. Assigning certain types of traffic, such as voice or video, to a higher priority QoS and/or guaranteeing its bit rate can also help mitigate the ill effects of congestion for that traffic. However, giving certain types of traffic high priority does not help in reducing peak utilization. Furthermore, prioritizing traffic based on its type does not necessarily serve the needs of the WSP's users. For example, a user about to board a flight may want a movie download to proceed as quickly as possible, but the download will only receive best effort treatment. Another user may care only that the movie downloads within two or three hours, and in this case even normal, best effort treatment is not required.
[0005] Therefore, a need exists for a way of providing more optimal data traffic utilization in wireless communication systems.
BRIEF SUMMARY OF THE INVENTION
[0006] An exemplary embodiment provides for a WSP to offer lower-speed wireless data at a discount to users when cell utilization is high. The price can be set dynamically depending on the level of cell utilization. Users could then decide whether to accept the discount depending on their data needs. For example, this provides a method by which the WSP can learn of the users' requirements.
[0007] In accordance with an exemplary embodiment, a user utilizes an application on their mobile unit to query the WSP at any time for discounts. The WSP preferably responds with a discount rate, a data bit rate, plus a time period over which the discount rate is valid. The user can then ignore this discount offer, or accept by responding to the WSP. If the offer is accepted, the user's data traffic is carried at the offered bit rate over the time window, and the price of the data during this period is set according to the offer.
[0008] Discounts preferably take the form of a reduction in how bits sent or received are counted against the user's monthly data quota. For example, the discount for a lowered bit rate might be 0.5, meaning that every bit sent or received by a user is counted as only half a bit.
[0009] The incentive to agree to a lower bit rate may be an offer of additional bits to be added to the users monthly quota or an offer of free or reduced price bits at a time of lesser network utilization.
[0010] The WSP may also send discount advertisements to opted-in users as well, possibly sometime in advance of the period for which the discount is applicable. The same procedure as stated above is then applied if the user accepts the offer.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] FIG. 1 depicts the functional architecture of a communication network in accordance with an exemplary embodiment of the present invention.
[0012] FIG. 2 depicts a call flow diagram in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] FIG. 1 depicts the functional architecture of communication network 100 in accordance with an exemplary embodiment of the present invention. Communication network 100 preferably includes wireless network 101 and mobile unit 103 . Communication network can be any suitable wireless network.
[0014] Wireless network 101 preferably includes base station 105 , wireless service provider (WSP) server 111 , prediction server 121 , and charging system 131 .
[0015] Base station 105 is a wireless communications station installed at a fixed location and used to communicate with mobile units and network elements located within wireless network 101 . Although only one base station (base station 105 ) is depicted in FIG. 1 for clarity, it should be understood that a typical wireless network includes a plurality of base stations.
[0016] WSP server 111 is preferably responsible for receiving user requests, for sending offers in response to these requests, and for receiving user acceptances of offers.
[0017] Prediction server 121 is preferably responsible for predicting utilization levels of cells in the WSP network.
[0018] Charging system 131 is a server that provides processing of information relating to charging mobile unit 103 for data used.
[0019] Mobile unit 103 is a mobile unit that can communicate with wireless network 101 . Mobile unit 103 can be, for example, a smart phone or tablet. Mobile Unit 103 preferably includes a user client application 113 .
[0020] User client application 113 preferably utilizes a “RESTful” API, typically implemented as messages in the XML format over the HTTP protocol used for web traffic.
[0021] FIG. 2 depicts a call flow diagram 200 in accordance with an exemplary embodiment of the present invention.
[0022] User client application 113 sends Request Discount message 201 to WSP Server 111 . Request Discount message preferably includes an identification of mobile unit 103 .
[0023] WSP Server 111 sends Request Prediction of Cell Utilization message 202 to Prediction Server 121 .
[0024] Prediction Server 121 sends Prediction message 203 to WSP Server 111 .
[0025] WSP Server 111 computes ( 204 ) the terms of any discount offer. Upon receiving the request, WSP Server 111 computes the elements of the offer, preferably based on user information and predicated cell utilization, which is obtained from Prediction Server 121 . In accordance with an exemplary embodiment, the elements of the offer include a discount rate, a data rate, and an offered time period.
[0026] WSP Server 111 sends Discount Offer message 205 to User client application 113 . Discount Offer message 205 preferably includes a digital signature so that a user could not “spoof” the WSP Network 111 by accepting a discount never actually offered by WSP Network 111 .
[0027] If the user wants to accept the offer sent in Discount Offer message 205 , User client application 113 sends Accept Offer message 206 to WSP Server 111 . WSP Server 111 would then implement the reduced bandwidth rate, preferably using mechanisms that are available at the cell site. In an exemplary embodiment, this is accomplished by limiting total traffic throughput. In an alternate exemplary embodiment, this is accomplished via reducing the priority through QoS settings. In addition, both of these can be used in conjunction. WSP Network 111 can alternately offload mobile unit 103 to an alternative access network, not shown. Additionally, a user that accepts an offer is preferably able to terminate the terms of the offer at any time during the period of the offer.
[0028] In response to receiving Accept Offer message 206 , WSP Server 111 sends Set Discounted Charging Level message 207 to Charging System 131 . In addition, WSP Server 111 preferably updates the billing system on the way bits are counted towards the user's monthly quota in accordance with the offer.
[0029] WSP Server 111 sends Set Bit Rate for User Cell message 208 to base station 105 , which implements the bit rate discounted offered to and accepted by mobile unit 103 . In an exemplary embodiment, wireless network 101 is an LTE network and the mechanism for bit-rate control comprises reducing the amount of user traffic allowed for best effort flows through the eNodeB by lowering the user's UE-AMBR setting. This could also be accomplished by lowering settings and limiting bandwidth for the user in the packet gateway, such as via APN-AMBR.
[0030] In a further exemplary embodiment, wireless network 101 is an LTE network and the mechanism for bit-rate control comprises establishing a guaranteed bit rate (GBR) bearer to a very low value that will carry all of the user traffic, effectively reducing the user's rate proportionally compared to best effort users. In a further exemplary embodiment, wireless network 101 is an LTE network and the mechanism for bit-rate control comprises assigning discount traffic to a QCI (QoS) value that has a lower priority than standard best effort. For example, discount users would be assigned the lowest QCI value of 9. In a further exemplary embodiment, users can be offloaded to a slower network, such as CDMA or W-CDMA.
[0031] An exemplary embodiment of the present invention thereby provides for reduced peak cell utilization, thereby reducing WSP capital expenditure. In accordance with an exemplary embodiment, a user can transmit more data each month without any perceived loss of utility. This facilitates users getting more value from their monthly data quota. Furthermore, user satisfaction is increased for all of the WSP's users, because wireless data performance decreases at times of high utilization. This increased user satisfaction is in turn a benefit to the WSP, for example in retaining customers.
[0032] While this invention has been described in terms of certain examples thereof, it is not intended that it be limited to the above description, but rather only to the extent set forth in the claims that follow. | A method for offering wireless data at a discounted rate is provided. A wireless service provider is queried to discover discounted data transfer rates. A discount rate proposal is sent to the querying mobile user. The discount rate proposal includes a discount rate, a data bit rate, and an offered time period. If the mobile unit accepts the discount rate proposal, user data is carried at the data bit rate during the offered time period priced at the discount rate. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional of U.S. application Ser. No. 09/878,802 entitled AQUEOUS SUSPENSIONS OF PENTABROMOBENZYL ACRYLATE, filed Jun. 11, 2001, which claims foreign priority on Israeli Application No. 136725, filed on Jun. 12, 2000, the disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to novel compositions of matter that are aqueous suspensions of pentabromobenzyl acrylate (PBBMA) and to a process for making them.
BACKGROUND OF THE INVENTION
[0003] Pentabromobenzyl acrylate (PBBMA) is an acrylic monomer, which is useful in many applications, especially but not exclusively, in the field of fire retardants for plastic compositions. It can be polymerized easily by known techniques such as bulk polymerization, solution polymerization etc., or by mechanical compounding or extrusion. In mechanical compounding or extrusion, it may be grafted onto existing polymer backbones, or added to unsaturated loci on polymers.
[0004] All these properties render PBBMA a particularly useful tool in the hands of experienced compounders. However, it has been impossible, so far, to carry out aqueous manipulations with PBBMA, in spite of their desirability, because, on the one hand, PBBMA is insoluble in water, and on the other hand, because of its high bromine content, it has a high specific gravity, about 2.7,—and therefore does not lend itself to the preparation and use of aqueous suspensions.
[0005] It is a purpose of this invention to provide stable dispersions or suspensions of PBBMA, which are new compositions of matter. Dispersions and suspensions are to be considered synonyms, as used herein.
[0006] It is another purpose of this invention to provide such dispersions or suspensions that are aqueous dispersions or suspensions.
[0007] It is a further purpose of this invention to provide a process for preparing such suspensions.
[0008] It is a further purpose of this invention to provide suspensions of PBBMA for particular applications in industry.
[0009] It is a still further purpose of this invention to provide suspensions of PBBMA together with additional compounds, such as synergists for increasing the fire-retarding efficiency of compositions obtained from PBBMA.
[0010] It is a still further purpose of this invention to provide processes comprising the polymerization and/or copolymerization of PBBMA for the production of particular products.
[0011] Other purposes and advantages of the invention will appear as the description proceeds.
SUMMARY OF THE INVENTION
[0012] The suspension of PBBMA, according to the invention, is characterized in that it comprises PBBMA in the form of finely ground particles, having a size smaller than 50 μm and preferably smaller than 10 □m and more preferably from 0.3 □m to 10 μm, and contains suspending agents chosen from among xanthene gums, anionic or nonionic purified, sodium modified montmorilonite, naphthalene sulfonic acid-formaldehyde condensate sodium salt, sodium or calcium or ammonium salts of sulfonated lignin, acrylic acids/acrylic acids ester copolymer neutralized-sodium polycarboxyl, and wetting agents chosen from among alkyl ether, alkylaryl ether, fatty acid diester and sorbitan monoester types, polyoxyethylene (POE) compounds. The POE compounds are preferably chosen from among:
POE allyl ethers N—5; 10; 20; POE lauryl ethers N—5; 10; 20; POE acetylphenyl ethers N—3; 5; 10; 20; POE nonylphenyl ethers N—3; 4; 5; 6; 7; 10; 12; 15; 20; POE dinonylphenyl ethers N—5; 10; 20; POE oleate—N—9, 18, 36; Sorbitan monooleate N—3; 5; 10; 20.
[0020] Alkyl naphthalene sulfonates or their sodium salts.
[0021] N is the number of ethylene oxide units.
[0022] Said suspension is typically, though not necessarily, an aqueous one.
[0023] The suspension according to the invention may also include nonionic or anionic surface active agents or wetting agents, which can be chosen by persons skilled in the art. For example, nonionic agents may be polyoxyethylene (POE) alkyl ether type, preferably NP-6 (Nonylphenol ethoxylate, 6 ethyleneoxide units) Anionic agents may be free acids or organic phosphate esters or the dioctyl ester of sodium sulfosuccinic acid. It may, also, include other additives which function both as dispersing agents and suspending agents commonly used by skilled persons like sodium or calcium or ammonium salts of sulfonated lignin, acrylic acids/acrylic acids ester copolymer neutralized-sodium polycarboxyl, preferably naphthalene sulfonic acid-formaldehyde condensate sodium salt. The suspension according to the invention may also include defoaming or antifoaming agents, which can be chosen by persons skilled in the art. For example, emulsion of mineral oils or emulsion of natural oils or preferably emulsion of silicon oils like AF-52™.
[0024] The invention further comprises a method of preparing a suspension of PBBMA, which comprises grinding the PBBMA together with wetting agent and preferably also dispersing agent to the desired particle size adding it to the suspending medium, consisting of water containing suspension stabilizing agents, with slow stirring, preferably at 40 to 400 rpm. Grinding is preferably carried out with simultaneous cooling. The order of the addition of the wetting agents, the dispersing agents and the suspending agents is important.
[0025] Preserving or stabilizing agents such as Formaldehyde, and preferably a mixture of methyl and propyl hydroxy benzoates, can also be added to the suspension.
[0026] Typical size distributions of PBBMA both before grinding and as they are when present in suspensions according to the invention, are listed hereinafter. “D” indicates the diameter of the particles in μm and S.A. indicates the surface area in square meters per gram. “v” designates volume and 0.25 means 25% by volume.
D (v, 0.1) D (v, 0.5) D (v, 0.9) Specific S.A. PBBMA before 2.40 19.34 58.20 0.3623 grinding PBBMA in 0.36 1.54 6.62 2.2554 suspension
[0027] In an embodiment of the process of the invention, wherein suspensions of PBBMA and additional compounds—such as fire-retardant synergists, e.g. fire-retardant antimony oxide (AO), the process comprises preparing a suspension of the additional compound in a way similar to the preparation of the PBBMA suspension, and then mixing the two suspensions, preferably by adding the suspension of the additional compound to a slowly stirred suspension of PBBMA, and continuing stirring until a homogeneous, mixed suspension is obtained.
[0028] The suspensions, in particular the aqueous suspensions, of the invention are stable. When stored at room temperature, they are stable for at least two weeks and preferably at least one month. Their stability may be higher, e.g. three months or more. If they have to be stored at high temperature, they should pass the “Tropical Storage Test”, at 54° C., viz. be stable under such Test for at least one week.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0029] The following examples are intended to illustrate the invention, but are not binding or limitative.
EXAMPLE 1
Preparation of a Suspension of PBBMA
[0030] A glass bead wet mill equipped with cooling jacket and continuous feed by a peristaltic pump, was utilized for grinding. PBBMA (750 gr) was mixed with water (240 ml), NP-6 (Nonylphenol ethoxylate) (1 ml) and Darvan#1 (Naphtalenesulfonic acid formaldehyde condensate, sodium salt) (30 gr). The mixture was fed into the grinding beads mill over a period of 25 min. The resulting slurry was stirred gently, mechanical blade stirrer, 40-60 rpm, and 10 ml of 1.5% Rhodopol 23, Xanthan Gum (CAS N o 11138-66-2) in water with preserving agents, 1% Methyl Paraben, methyl-4-hydroxybenzoate, CAS N o 99-76-3 and 0.5% Propyl Paraben, propyl-4-hydroxybenzoate, CAS N o 94-13-3, were added.
EXAMPLE 2
Preparation of a PBBMA-AO Suspension
[0031] A suspension of Antimony Oxide was prepared as follows. To a 3-liter round bottom flask, fitted with a mechanical stirrer, were added water (240 ml), NP-6 (1 ml) (Nonylphenol ethoxylate), and Darvan #1 (Naphtalenesulfonic acid formaldehyde condensate, sodium salt) (30 g). Finely ground antimony oxide, Ultrafine grade with typical average particle size of 0.2 μm-0.4 μm. (AO, 750 g) was slowly added under fast stirring, 400-600 rpm. The stirrer was slowed, 50-150 rpm and a 1.5% solution of Rhodopol 23 Xanthan Gum (CAS N o 11138-66-2) with preserving agents—1% Methyl Paraben, methyl-4-hydroxybenzoate, (CAS N o 99-76-3) and 0.5% Propyl Paraben, propyl-4-hydroxybenzoate, (CAS N o 94-13-3) were added (115 ml).
[0032] The mixed PBBMA-AO suspension was prepared as follows. To a slowly stirred, 40 rpm, suspension of PBBMA (750 ml) at 25° C.-30° C., obtained as described in Example 1, was added the AO suspension (250 ml) as described above. After five minutes, stirring was stopped, yielding a homogeneous mixture.
EXAMPLE 3
Preparation of a PBBMA-Styrene-Butylacrylate Terpolymer Latex
[0033] In a 0.5 L 4 necked round bottom flask fitted with mechanical stirrer, reflux condenser, thermometer, dropping funnel and Nitrogen inlet were charged 1.4 gr SDS (Sodium Dodecyl Sulfate) and 100 mL of water. The flask was immersed in an oil bath and heated to 70° C. with continuous stirring, 250 rpm, Nitrogen was introduced under the surface of the liquid. After 1 hr. the nitrogen inlet was raised above the surface of the liquid and 0.15 gr of K 2 S 2 O 8 were added. Five minutes later a solution of 15 gr Styrene and 15 gr Butylacrylate was added dropwise over 30 min. The emulsion pre-polymerization was continued for another 90 min. after which 6 gr of a PBBMA suspension (˜60% solids) were added dropwise over 70 min. The polymerization was continued overnight.
[0034] A stable latex (stable for more than two month) was obtained.
[0035] The terpolymer isolated from this emulsion was characterized. The bromine content was 7% and the glass transition temperature was 18.8° C.
EXAMPLE 4
Preparation of a PBBMA-Styrene-Acrylonitrile Terpolymer
[0036] In a 0.5 L 4 necked round bottom flask fitted with mechanical stirrer, reflux condenser, thermometer, dropping funnel and Nitrogen inlet were charged 1.4 gr SDS (Sodium Dodecyl Sulfate) and 100 mL of water. The flask was immersed in an oil bath and heated to 70° C. with continous stirring, 250 rpm, Nitrogen was introduced under the surface of the liquid. After 1 hr. the nitrogen inlet was raised above the surface of the liquid and 0.15 gr of K 2 S 2 O 8 were added. Five minutes later a solution of 18.2 gr Styrene and 5.8 gr Acylonitrile was added dropwise over 30 min. The emulsion pre-polymerization was continued for another 20 min. after which 8.5 gr of a PBBMA suspension (˜60% solids) were added dropwise over 40 min. A second portion of 0.15 gr of K 2 S 2 O 8 was added 3 hr. after the addition of the suspension was finished. The polymerization was continued overnight.
[0037] A stable latex (stable for at least one month) was obtained.
[0038] The terpolymer isolated from this emulsion was characterized. The bromine content was 12.5%, the nitrogen content was 5% and the glass transition temperature was 107° C. The molecular weight depends on the polymerization conditions. In this particular case a Weight Average Molecular Weight, Mw, of 1.2*10 6 and Number Average Molecular Weight, Mn, of 422,000, was determined (in Dimethylformamide solution, calibrated with Polystyrene standards).
[0039] The suspensions of the invention are useful for a number of applications, and the way in which they are used and the resulting products, are also part of the invention.
[0040] Fire Retardants are commonly used in carpet-backings. However, the fire retardants of the prior art are not bound to the carpet, and are susceptible to removal by dry cleaning. According to the invention, the aqueous suspension of PBBMA is applied to the reverse side of the carpets and is polymerized by heating at temperatures above 130° C. This results in a coating of PBBMA polymer, which is bound to the carpet.
[0041] In the prior art, fire retardants are used in the textile industry. However, they generally produce light scattering, because they are used in powder form. According to the invention, the aqueous solution of PBBMA, optionally with complementary components, is applied to textile materials and penetrates into the fibers, and then polymerization is effected by heating at temperatures above 130° C., thus polymerizing PBBMA and binding the resulting polymers to the fibers. Addition of free radical initiating catalysts, the conventional polymerization catalysts such as organic peroxides, e.g., benzoylperoxide, or other free radical producing catalysts, e.g., azobisisobutyronitrile, will shorten polymerization time.
[0042] The PBBMA suspensions of the invention can be used to copolymerize PBBMA with other monomers or grafted to polymers, in order to produce adhesives, which are also fire-retardants or other types of surface modifiers and binding promoters.
[0043] Likewise, the suspensions of the invention can be used to copolymerize PBBMA with other (meth)acrylate derivatives, such as butyl acrylate, methyl methacrylate or other monomers, to produce transparent plastics of predetermined refraction indices.
[0044] Double layered particles can also be produced, according to the invention, by adding another monomer, e.g. another (meth)acrylic derivative, to the PBBMA suspensions under polymerization conditions, to produce very stable latexes. An example of such other monomers can be, for instance, aliphatic (meth)acrylates or hydroxyethyl acrylate.
[0045] The novel products obtained according to the invention, and the processes for their production, are also part of the invention.
[0046] While examples of the invention have been described for purposes of illustration, it will be apparent that many modifications, variations and adaptations can be carried out by persons skilled in the art, without exceeding the scope of the claims. | Suspensions of PBBMA, characterized in that they comprise PBBMA in the form of finely ground particles and contain suspending agents chosen from among xanthene gums, anionic or nonionic purified, sodium modified montmorilonite, naphthalene sulfonic acid-formaldehyde condensate sodium salt, sodium or calcium or ammonium salts of sulfonated lignin, acrylic acids/acrylic acids ester copolymer neutralized-sodium polycarboxyl, and wetting agents chosen from among alkyl ether, alkylaryl ether, fatty acid diester and sorbitan monoester types, polyoxyethylene (POE) compounds. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an operation unit structured by unitizing a throttle operating lever of an engine and a start switch which can be applied to various working devices provided with an engine as a source of power and a self starter such as a trimmer, a chain saw, a rotation saw or the like, or a power spreader, various farm working machines or the like, and more particularly to an operation unit of an engine which eliminates an erroneous operation of the start switch based on a simple mechanism.
2. Description of the Related Art
An engine provided with a self-starter actuates a start motor by operating a start switch, and starts the engine based on the actuation. A rotation speed of the engine is controlled by operating a throttle lever so as to control an opening degree of a throttle valve via a control wire. When the rotation speed of the engine reaches a predetermined rotation speed, a clutch within a clutch housing engages so as to start an actuation of a rotary blade or the like. When stopping the rotation of the engine, an engine stop switch is turned on. In conventional, the start switch and the engine stop switch are independently provided, however, for example, according to a switch apparatus described in Japanese Utility Model Application Publication (JP-Y) No. 1-22194, a single movable contact having three contact points is provided, the contact is structured such that a pressure button rotating an operation knob and actuating a start switch provided within the operation knob is pressure actuated to a terminal side, an engine stop switch is changed between a stop position and a working position based on the rotating operation of the knob, and the start switch and the stop switch are composed such that an OFF state, that is, a stop state of the engine is maintained even if the pressure button is pushed at a time when the stop switch is at the stop position, and the engine is started by pushing the pressure button only when the stop switch is at the working position.
Further, for example, according to Japanese Utility Model Application Publication (JP-Y) No. 7-5233, an apparatus is structured by a throttle operating lever, a start and stop operating lever, one control wire in which one end is coupled to the throttle operating lever, and an interlocking mechanism controlling an opening degree of the throttle valve, an actuation of a start switch actuating a start motor and an actuation of an engine stop switch interlocking with a working state of the control wire. Further, a start safety lock lever is arranged near the throttle operating lever. The throttle operating lever, the start and stop operating lever and the start safety lock lever are arranged in a handy operating portion intensively.
In the engine control apparatus according to JP-Y No. 7-5233, the opening degree of the throttle valve of the engine is controlled from an idle position to a full-open position based on the operation of the throttle operating lever. The start and stop operating lever is at a reference position which can be freely operated by the throttle operating lever, is moved to a stop position locking to the start safety lock lever so as to stop the engine, and is moved further to a start position after releasing the lock by the start safety lock lever so as to start the engine. Further, the one control wire is actuated in correspondence to an operated state of the throttle operating lever and the start and stop operating lever, and the interlocking mechanism controls the opening degree of the throttle valve, the actuation of the start switch actuating the start motor and the actuation of the engine stop switch stopping the engine, interlocking with the working state of the control wire.
According to the engine control apparatus, when operating the throttle operating lever and the start and stop operating lever in accordance with a required procedure, the working state is transmitted to the interlocking mechanism via the one control wire, the opening degree of the throttle valve, the actuation of the start switch and the actuation of the engine stop switch are controlled by the interlocking mechanism in correspondence to the working state, and the engine is controlled to a desired start or stop state, or a desired rotation speed. Further, since the throttle operating lever and the start and stop operating lever are provided in the operating portion in the working machine, and the interlocking mechanism, the start switch and the engine stop switch are provided in the prime mover portion, it is possible to control all of the engine start and stop and the rotation speed by the handy portion. Accordingly, an operability is excellent, an electric wiring to the start switch and the engine stop switch can be simplified, and a connecting line connecting the operating portion and the prime mover portion can be constituted only of the one control wire so as to improve an outer appearance.
Meantime, the composite switch apparatus disclosed in JP-Y No. 1-22194 mentioned above is structured such that the start switch of the self-starter and the engine stop switch are integrally installed and composed, however, the start switch is turned on by pushing the start button, for example, unless the operating knob for the engine stop switch is rotated to the stop position, so that the engine rotation starts. Accordingly, it is required to make certain of the fact that the operating knob is not at the stop position every time when it is intended to start the engine. Further, according to JP-Y No. 1-22194 at this time, there is no description which directly associates the operation of the throttle operating lever operating so as to open and close the throttle valve of the engine with the composite switch apparatus as far as it is determined based on the drawings thereof. Accordingly, even if the throttle operating lever is in the operated state, the working device such as the rotary blade or the like is actuated by pushing the start button as mentioned above.
On the other hand, according to the engine control apparatus described in JP-Y No. 7-5233 mentioned above, there is no risk that the working device or the like is erroneously actuated as far as the throttle operating lever and the start and stop operating lever is not erroneously operated. However, its mechanism and operating procedures are extremely complicated and troublesome, an accuracy of parts is required, and it is troublesome to maintain the parts. Further, the erroneous operation tends to be generated in the throttle operating lever and the start and stop operating lever, it is hard to simply start and stop the engine itself, and a smooth operation is expected only by persons of experience in the art.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an operation unit which can securely avoid an erroneous operation and an erroneous actuation tending to be generated between the start switch of the self-starter and the throttle operating lever as mentioned above, and in which the start switch and the throttle operating lever are integrally installed, with an extremely simple structure.
The object can be achieved by a basic structure of the present invention, that is, an operation unit starting an engine via a start motor and controlling an engine rotation, comprising: an engine operation box storing therein a control operation portion controlling an opening degree of a throttle valve of the engine and a start switch terminal connected to an inner side of a drive circuit of the start motor starting the engine; a throttle operating lever provided in an outer portion of the engine operation box and operating the control operation portion so as to control the opening degree of the throttle valve from an idle position to a full-open position; and a start switch connecting and disconnecting the start switch terminal, wherein the throttle operating lever has a switch shielding portion which enables to operate the start switch without an interference between the throttle operating lever and an operating portion of the start switch at a time when the throttle operating lever is at an idle position, and disables to operate the start switch by shielding at least a part of the operating portion of the start switch by means of a part of the throttle operating lever at a time when the throttle operating lever is operated so as to be apart from the idle position.
Further, in accordance with a preferable aspect, the throttle operating lever is rotatably supported to the operation box around one end portion thereof serving as a rotation center, has the switch shielding portion in a rotation end portion, and is structured such that the switch shielding portion rotates between the idle position on the operation box and an upper position of a portion in which the start switch is provided.
In general, the engine start by a self-starter drives the start motor for starting the engine by operating the start switch in the case that the opening degree of the throttle valve is equal to or less than a predetermined opening degree. The engine is started by a rotational drive of the start motor. At this time, since the engine is rotated at a lower speed than a predetermined speed, a clutch is not connected to the working devices, and the engine continues rotating without actuating the working devices. In this case, if the opening degree of the throttle valve is opened to the idling opening degree or more by operating the throttle operating lever, the engine rotation is increased to a rotation speed at which the engine rotation is automatically connected to the working devices by means of the actuation of the clutch, and the actuation of the working devices is started.
However, if the start switch is carelessly turned on, for example, in a state in which the throttle valve is opened to the opening degree equal to or more than the predetermined opening degree by erroneously operating the throttle operating lever before operating the start switch, the engine immediately starts high speed rotation, thereby actuating the working devices from the beginning of the engine start, for example, via a centrifugal clutch or the like. Accordingly, an excessive danger is generated.
On the contrary, in accordance with the basic structure of the present invention, since the throttle operating lever does not interfere with the start switch at a time when the throttle operating lever is at the idle position, it is possible to operate the start switch, and if the switch is turned on in this state, the start motor is driven and can start the engine. At this time, since the engine speed does not reach the predetermined rotation speed, the engine rotation is not connected to the actuation of the working devices. Further, in the case of erroneously operating the throttle operating lever so as to move the lever to the position apart from the idle position before turning on the start switch, a part of the throttle operating lever covers and shields a part of an operation surface of the start switch from the above in the present invention. Accordingly, it is impossible to touch the operation surface of the start switch by a finger even if it is intended to turn on the start switch, so that it is impossible to turn on the start switch. Therefore, since an operator takes note of operating the throttle lever, the operator returns the throttle operating lever to the idle position and thereafter operates the start switch again so as to start the engine.
In other words, according to the present invention, the throttle operating lever interrupts until the throttle operating lever is returned to the idle position, so that it is impossible to operate the start switch. Further, in this case, if the start switch is provided with an engine stop switch portion, the engine is not ignited even by operating the start switch and it is impossible to start the engine, by operating the engine stop switch portion, for example, in a stop switch structure provided with the same structure as JP-Y No.1-22194 mentioned above, by rotating an operation knob for the stop switch portion to the stop position. Further, even if the engine is under operation, it is possible to immediately stop the engine on the ground by rotating the engine stop switch portion to the stop position.
Further, as in the preferable embodiment mentioned above, if the shielding portion is provided in a part of the throttle operating lever rotating around one end serving as the rotation center in the switch box, the start switch is placed on a rotation locus thereof, and the shielding portion is formed in such a shape and at such a position that the shielding portion always covers the upper surface of the operation surface of the start switch when the shielding portion existing at a reference position (an idle position) is moved, the shielding portion shields the operation surface of the start switch at the same time of rotating the throttle operating lever. Accordingly, it is possible to securely disenable to operate the start switch, and it is possible to prevent the engine and the working devices from being carelessly actuated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a bush cutter to which the present invention is applied, as seen from a back surface side;
FIG. 2 is a perspective view showing an outer appearance in the case that a throttle operating lever of an operation unit of an engine corresponding to a typical embodiment of the present invention is at an idle position;
FIG. 3 is a plan view of the operation unit as seen from a start switch side in the case that the lever is at the idle position;
FIG. 4 is a perspective view showing an outer appearance in the case that the throttle operating lever of the operation unit is apart from the idle position;
FIG. 5 is a top elevational view of the operation unit as seen from the start switch side in the case that the lever is apart from the idle position;
FIG. 6 is a perspective view of an entire showing one example of a start switch attached to the unit; and
FIG. 7 is a cross sectional view showing an example of an internal structure of the start switch.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A description of a preferable embodiment in accordance with the present invention will be specifically given below based on an illustrated embodiment.
FIG. 1 is a bush cutter provided with a self-starter corresponding to a typical embodiment in which an operation unit according to the present invention is attached to a handle portion.
The bush cutter 1 mentioned above is provided with an engine portion 2 , a long lever 3 corresponding to a long operation lever, and a rotary blade 4 . A long driven shaft (not shown) constituted of a metal rod is inserted into the long lever 3 , and a base end portion of the long lever 3 is coupled to the rotary blade 4 via a gear housing 5 . A bevel gear mechanism (not shown) is arranged in an inner portion of the gear housing 5 . On the other hand, a base end portion of the long lever 3 is coupled to the engine portion 2 via a clutch housing (not shown). Further, a grip 6 doubling as a suspended portion suspended to a part of a harness (not shown) is attached to a position adjacent to the clutch housing in a base end portion of the long lever 3 . Further, an operating handle 7 of the bush cutter 1 is fixedly provided in adjacent to a rotary blade side corresponding to a front side of the grip 6 doubling as the suspended portion. A main body of a self-starter 8 is fixedly provided in a back face of the engine portion 2 . In this case, reference numeral 9 in the drawing denotes a dustproof member.
The operating handle 7 is extended to right and left sides with respect to the long lever 3 , and is constituted of a pipe member in which an apical end portion is raised up to an obliquely upper side, and operation grip portions 7 a ′ and 7 b ′ made of hard rubber or the like are fixedly provided in apical ends of left and right handles 7 a and 7 b . In accordance with an illustrated embodiment, an operation unit 10 of an engine according to the present invention is attached to an upper end of the right operation grip 7 b ′. Operating members such as a throttle operating lever 11 , a start switch 14 and the like are attached to the operation unit 10 . The operating members are respectively coupled to the engine portion 2 and a start motor (not shown) placed in the self-starter 8 , via a throttle wire and a lead wire which are not illustrated, and various operations at a time of starting the engine and after starting the engine can be executed by the operating members arranged in the operation unit 10 .
FIGS. 2 to 5 show the operation unit 10 corresponding to a typical embodiment in accordance with the present invention. The operation unit 10 according to the present embodiment is assembled in a single box 12 . Based on FIGS. 2 and 4 , the box 12 is formed in a hollow rectangular shape having an upper wall portion 12 a formed in a circular arc shape so as to extend along a rotation of a throttle operating lever 11 , first to fourth side wall portions 12 b to 12 e in four sides of the upper wall portion 12 a , and a lower wall portion 12 f . In an inner portion of the box 12 , there are interiorly provided a part of a throttle wire (not shown) controlling an opening degree of a throttle valve of an engine (not shown) in correspondence to a rotating operation amount of the throttle operating lever 11 , and a switching terminal (not shown) starting and stopping a start motor (not shown) provided in the self-starter 8 by a switching operation of the start switch 14 .
A half portion of a second side wall portion 12 c of the upper wall portion 12 a is formed as a depressed portion 12 a ′ open to an upper portion of the second side wall portion 12 c , and a bottom surface of the depressed portion 12 a ′ is formed as a horizontal surface. The start switch 14 is attached to the depressed portion 12 a ′. A depth of the depressed portion 12 a ′ is set approximately equal to a height of an outer exposed position of the start switch 14 , and an upper surface of the start switch 14 forms an upper surface position of the upper wall portion 12 a of the box 12 . Further, insertion and attachment holes 12 c ′ and 12 e ′ for the operation lever 3 having an approximately equal shape as an outer diameter of the operation lever 3 of the bush cutter 1 are respectively formed in a penetrating manner in center portions of the second and fourth side wall portions 12 c and 12 e arranged so as to face to each other in the box 12 . As mentioned above, in order to firmly fix and integrate in a state in which the operation lever 3 is inserted to the insertion and attachment holes 12 c ′ and 12 e ′, it is preferable to divide the box 12 into two pieces, employ a boss connection structure and fasten by a bolt or the like. Further, a throttle wire drawing port 12 c ′ (not shown) is formed in a corner portion of the second side wall portion 12 b of the box 12 close to the third side wall portion 12 c to which the throttle operating lever 11 is supported.
The throttle operating lever 11 and the start switch 14 are arranged in the upper wall portion 12 a and the third side wall portion 12 d of the box 12 . The throttle operation lever 11 forms an L-shaped lever constituted by a first lever portion 11 a in which one end portion is formed in an approximately center portion of the third side wall portion 12 d of the box 12 and the other end portion has a length reaching the circular arc shaped upper wall portion 12 a , and a second lever portion 11 b which is bent approximately at 90 degree in the other end portion of the first lever portion 11 a and extends to a portion near an opposite edge portion to the upper wall portion 12 a . In accordance with an illustrated embodiment, a base end portion of rotation of the first lever portion 11 a arranged approximately in the center portion of the third side wall portion 12 d is formed as a flanged disc 11 c as shown in FIGS. 2 and 4 , and a bolt insertion hole to which the bolt 13 is inserted is formed in a center thereof. Further, a substantial oval plate portion 11 d whose center is deflected toward a side of the second side wall portion 12 c of the box 12 is formed in an apical end portion of rotation of the second lever portion 11 b . The bolt 13 fastens an end supporting member of the unshown throttle wire disposed in the box and the throttle operating lever 11 via an unshown nut so as to be rotatable interposing the box.
FIGS. 6 and 7 show an example of the start switch 14 . The start switch 14 has similar appearance to a capped tube body having an open lower surface, a pressure portion 15 serving as a second box, an engine stop switch portion 16 and a cylindrical base portion 17 are sequentially arranged in a pressing direction, and a compression spring 18 and a pin-shaped terminal member 19 are arranged in series in hollow portions thereof.
The pressure portion 15 is formed in a cap shape having a peripheral wall portion 15 b serving as an attachment portion extended toward the pressing direction from a peripheral edge of a disc portion 15 a , and an end portion of the peripheral wall portion 15 b is bent to an inner side so as to be fixed to the engine stop switch portion 16 so as to be slidable and rotatable. The engine stop switch portion 16 is structured such that a peripheral surface thereof is constituted of a hollow body in which a large-diameter portion 16 a and a small-diameter portion 16 b are coupled via a step in a direction of a center line, a rotation knob 16 c is protruded from a part of the large-diameter portion 16 a , and an indication projection 16 d is provided in a protruding manner in an opposite side to the rotation knob 16 c . On and off positions by the engine stop switch portion 16 are expressed on a leading end rotation circumference of the indication projection 16 d in the attachment portion 15 b of the start switch 14 . The cylindrical base portion 17 supports a lower face outer peripheral edge portion of the large-diameter portion 16 a of the engine stop switch portion 16 from a lower side so as to be slidable and rotatable. The cylindrical base portion 17 is fixedly provided so as to be fitted to the attachment portion 15 b of the second box 15 . A plurality of arm portions 17 b extending in a radial pattern to an inner peripheral surface of a lower end portion of the cylindrical base portion 17 are integrally formed in the cylindrical base portion 17 , while arranging a cylindrical thread portion 17 a screwing and supporting the pin-shaped terminal member 19 in a center in the lower end opening surface of the cylindrical base portion 17 .
The pin-shaped terminal member 19 is screwed into the cylindrical thread portion 17 a , and an upper end thereof is protruded to an upper side from an upper end of the cylindrical thread portion 17 a . Further, a lower end of the pin-shaped terminal member 19 is protruded to a lower side from a lower end of the cylindrical thread portion 17 a . Although an illustration is omitted, to a lower end portion of the pin-shaped terminal member 19 , an end portion of a lead wire (not shown) extending from the start motor (not shown) and a contact terminal (not shown) are attached to the inner portion of the box 12 as already described, and a part of the contact terminal and the pin-shaped terminal member 19 are connected via a short lead wire. A retainer 20 supporting an upper end of the compression spring 18 is attached to the disc portion 15 a of the cap-shaped pressure portion 15 , an upper end of the compression spring 18 is fixed to the retainer 20 , and a lower end of the compression spring 18 is loaded and fixed to a flange portion 17 c formed in a peripheral surface of an upper end portion of the cylindrical thread portion 17 a.
The compression spring 18 comprises a small-diameter spiral portion 18 a and a large-diameter spiral portion 18 b , an upper end of the small-diameter spiral portion 18 a is fixed to the retainer 20 arranged in the cap-shaped pressure portion 15 , and a lower end of the large-diameter spiral portion 18 b is fixed to the flange portion 17 c of the cylindrical thread portion 17 a . An inner diameter of the small-diameter spiral portion 18 a is set to be smaller than a diameter of the pin-shaped terminal member 19 , and an inner diameter of the large-diameter spiral portion 18 b is set to be larger than the diameter of the pin-shaped terminal member 19 . An end portion of another lead wire extending from the start motor (not shown) is firmly coupled to the large-diameter portion 18 b of the compression spring.
In accordance with the start switch 14 having the structure mentioned above, the cap-shaped pressure portion 15 and the engine stop switch portion 16 are normally at upper positions due to a spring force of the compression spring 18 , and are moved to a lower side together with the retainer 20 by pressing the cap-shaped pressure portion 15 against the spring force of the compression spring 18 . When the start switch 14 is in the normal state, an upper end portion of the pin-shaped terminal member 19 inserted into the inner portion of the compression spring 18 exists in an inner portion of the large-diameter spiral portion 18 b of the compression spring 18 in a non-contact state, and does not reach the small-diameter spiral portion 18 a . In this case, when pushing the cap-shaped pressure portion 15 , the compression spring 18 is compressed and the small-diameter spiral portion 18 a is moved in the pushing direction. By this movement, the upper end portion of the pin-shaped terminal member 19 is brought into contact with the small-diameter spiral portion 18 a and a passage for the start motor is to be conductive, and the start motor (not shown) is activated.
On the other hand, the engine stop switch portion 16 is guided by a lower end edge of the cap-shaped pressure portion 15 around a center axis line of the start switch 14 so as to be independently rotated, by operating the rotation knob 16 c . By the rotation, an ignition coil of an ignition circuit becomes in a connection state or a disconnection state, and set a spark plug to an ignition fire state or an extinguished fire state. Under the ignition fire state, the apical end of the indication projection 16 d of the engine stop switch portion 16 indicates an indication position ON expressed in the start switch attachment portion 15 b , as shown in FIG. 6 , and under the extinguished fire state, the apical end of the indication projection 16 d indicates an indication position OFF.
Further, the engine operation unit 10 according to the embodiment 1 of the present invention provided with the structure mentioned above is fixedly provided, for example, in any (the right operation grip portion 7 b ′ in the illustrated embodiment) of the operation grip portions 7 a ′ and 7 b ′ arranged in a apical end portion of the operation handle 7 a and 7 b of the bush cutter 1 , as already mentioned. When it is intended to start the engine, if the engine stop switch portion 16 is at the OFF position, the engine is not started even by pushing the start switch 14 . If the indication projection 16 d indicates the ON position by rotating the engine stop switch portion 16 , it is possible to start the engine by pushing the start switch 14 . However, in accordance with the present embodiment, even if the indication projection 16 d indicates the ON position, the engine is not always started only by pushing the start switch 14 .
In other words, according to the present embodiment, if it is intended to push the start switch 14 at a time when the throttle operation lever 11 is at the idle position, it is possible to push the start switch 14 and it is possible to start the engine because the substantially oval plate portion 11 d formed in the apical end portion of the rotatable throttle operating lever 11 do not exist above the start switch 14 . Accordingly, in the case that the throttle operating lever 11 is apart from the idle position so as to be at the position opening the throttle valve, the substantial oval plate portion 11 d of the throttle operating lever 11 covers the cap-shaped pressure portion 15 of the start switch 14 , so that it is impossible to push the cap-shaped pressure portion 15 . As a result, the start motor can not be driven until the throttle operating lever 11 is returned to the idle position, and the engine can not be rotated. Accordingly, it is possible to prevent the rotary blade 4 from being carelessly actuated.
In the case of pushing the start switch 14 after confirming that the throttle operating lever 11 is at the idle position, the start motor is driven so as to start the engine. After the engine start is confirmed, the pushing operation of the start switch 14 is released. Therefore, the start switch 14 is disconnected and the start motor is stopped, however, the engine continues an idling rotation.
In this case, when rotating the throttle operating lever 11 in a counterclockwise direction in FIG. 2 from the idle position, the throttle wire is drawn to the inner portion of the box 12 in correspondence to the rotation amount of the throttle operating lever 11 via the wire drawing portion 12 b ′ of the box 12 , which increases the opening degree of the throttle valve (not shown) so as to increase the rotation speed of the engine and rotates the rotary blade 4 . In the case that the work is finished and the engine is stopped, the engine is immediately stopped by operating the operation knob 16 c of the engine stop switch portion 16 such that the indication protruding portion 16 d indicates the OFF position.
As is understood from the description mentioned above, according to the operation unit of the engine based on the present invention, since the throttle operating lever and the start switch including the engine stop switch are installed within the case so as to be unitized, it is not necessary that the throttle operating lever, the engine stop switch and the start switch are provided in the machine body in a separated manner, and the unit can be attached intensively in the handy handle portion. Accordingly, it is possible to easily carry out the operation itself of the working devices. Further, particularly, in accordance with the present invention, since the start switch is effective only when the throttle operating lever is at the idle position, the engine is not started even if the start switch is operated in the state in which the throttle operating lever is moved, so that it is possible to securely eliminate the erroneous actuation caused by the erroneous operation without paying any specific attention, and it is possible to secure a further safety.
In this case, the present invention is not limited to the embodiment mentioned above, but, for example, it goes without saying that the shape and the structure of the throttle operating lever and the start switch can be variously changed, and the interlocking mechanism between the throttle operating lever and the throttle wire or the like can be appropriately changed within the scope of claims. For example, in the case that the pressure portion 15 exists in the side wall portion 12 d , the oval plate portion 11 d may be arranged in the first lever portion 11 a. | An operation unit is provided with an engine operation box storing a control operation portion controlling an opening degree of a throttle valve and a start switch terminal connected to a start motor; a throttle operating lever for controlling the opening degree from an idle position to a full-open position; and a start switch connecting and disconnecting the start switch terminal, wherein the throttle operating lever has a switch shielding portion which enables to operate the start switch without an interference between the throttle operating lever and an operating portion of the start switch when the throttle operating lever is at an idle position, and disables to operate the start switch by shielding at least a part of the operating portion of the start switch by means of a part of the throttle operating lever when the throttle operating lever is operated to be apart from the idle position. | 5 |
FIELD OF THE INVENTION
The present invention pertains to a sewing machine with an adjusting device for adjusting hem projection length sensors that can be moved relative to a cutting device including a first sensor provided for sending a signal to initiate a cutting process for a front hem projection length and a second sensor of which is provided for sending a signal for bringing about a cutting process for a rear hem projection length.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 3,329,113 discloses a device with a cutting device and with sensors, whose distance from the cutting device is variable. The cutting device is activated by a signal of the sensor that is the front sensor in the direction of feed for a first cutting process. The first cutting process cuts through a connection means for a plurality of fabric parts, at a distance from the front edge of the respective fabric. This distance depends on the distance between this sensor and the cutting device. The cutting device is activated by a signal of the rear sensor for another cutting process, by which the connection means is cut through at a distance from the rear edge of the fabric, which distance depends on the distance between this sensor and the cutting device.
On a fabric that has hem projection lengths relative to its front and rear edges, the hem projection lengths can be shortened to a predeterminable length by this device. If the hem projection lengths are to be folded over at the respective fabric edge and they are to be pushed into the associated part of the hem, at least this part of the hem must not have a seam connection with the rest of the fabric part. However, the above mentioned U.S. Pat. No. 3,329,113 does not indicate how the seam formation could be limited to the middle part of the hem.
A device with a stitch counter is described in U.S. Pat. No. 4,276,837; this stitch counter is switched on as soon as the distance between the rear edge of the fabric and the stitch formation site, which distance is indicated by a sensor, drops below a predetermined value, and it remains in operation until it reaches a predeterminable end value. A feed distance for the fabric, which is obtained from the predetermined distance from the stitch formation site minus the width of a seamless rear fabric edge, is associated with this end value. Seam formation is terminated when the end value is reached.
Although the width of the seamless rear fabric edge can be preselected by this device by presetting the end value, it is necessary to reset the stitch counter if the fabric has hem projection lengths, and the width of the seamless rear fabric edge is to be adjusted to the rear hem projection length each time the length of this hem projection length changes. Since the above mentioned U.S. Pat. No. 4,276,837 contains no data on this, it can be assumed that the resetting must be performed by the operator.
Contrary to the seamless rear fabric edge, the formation of a similar front fabric edge is not possible with this device.
SUMMARY AND OBJECTS OF THE INVENTION
It is a primary object of the present invention to provide an adjusting device by which the length of the respective hem projection length and the width of an associated seamless fabric edge can be adjusted depending on one another, with a minimum of operator effort, for processing a fabric provided with hem projection lengths both at its beginning and at its end.
According to the invention, a sewing machine is provided including a first sensor provided for sending a signal for initiating a cutting process for a front hem projection length and a second sensor for sending a signal for initiating a cutting process for a rear hem projection length and adjusting means for adjusting the position of the first sensor and second sensor relative to a cutting device. A stop is provided including means for moving the stop in a feed direction for positioning a front edge of the fabric to be sewn for presetting a width of a seamless front edge of the fabric being sewn. A distance of the stop from a stitch formation site is used for predetermining a position of the hem projection length sensors. A position of the stop is used to dimension a seamless rear edge of fabric being sewn, which edge joins an end of the seam in such a way that a residual seam length, formed from a difference between the fabric end length and the width of the seamless front fabric edge, can be preset by said adjusting means for stopping a needle bar in a top reversal position when said residual seam length is reached. A measuring device is provided for measuring feed distances of the fabric being sewn. A forward sensor, located in front of the stitch formation site, is provided for activating the measuring device. The forward sensor provides an indication of the fact that the actual fabric end length has dropped below a predeterminable fabric end length.
If the fabric is to have a seamless front edge between its front edge and the beginning of the seam to be formed, the stop is positioned at a distance from the stitch formation site that corresponds to the desired width of the fabric edge, behind the stitch formation site in the direction of feed. Therefore, when the front edge of the fabric is placed against the stop, the site of the fabric at which the first stitch of the seam to be formed is made will be located beneath the needle.
Since the distance between the hem projection length sensors and the cutting device is set depending on the position of the stop in relation to the stitch formation site, it is ensured that the length of the hem projection length at the front edge of the fabric, hereinafter called front hem projection length for short, is always adjusted to the width of the seamless front edge of the fabric, on the one hand, and, on the other hand, there is a constant length ratio between the front hem projection length and that at the rear edge of the fabric (rear hem projection length), and the same length is preferably selected for both hem projection lengths.
To obtain the same ratio between the length of the hem projection length and the width of the seamless fabric edge at the rear edge of the fabric as at the front edge of the fabric, the constant fabric end length, which is consequently known prior to the beginning of a sewing process, is reduced by a distance, whose amount depends on the distance between the stop and the stitch formation site, by utilizing the length ratio of the two hem projection lengths.
Consequently, a plurality of adjustment processes are performed by the adjusting device automatically by only one presetting being performed by the operator, namely, by, presetting the position of the stop. As a result, a hem can be sewn onto a fabric such that the respective hem projection length can be pushed over its entire length into the associated part of the hem when the front hem projection length is folded over at the front edge of the fabric and the rear hem projection length is folded over at the rear edge of the fabric.
If the distance between the two hem projection length sensors is selected to be such that it corresponds to the length of the two hem projection lengths, the width of the seamless front fabric edge that is needed to form the residual seam length can be determined by the measuring device based on a measuring process initiated by a signal from the first hem projection length sensor (which determines the dimension of the seamless front fabric edge) and the measuring process can be concluded by a signal sent by the second hem projection length sensor. It is now possible to dispense with a device by which a value associated with the position of the stop can be preset for the measuring device.
The measuring device may include a counting device for stitch formation cycles performed during the measuring process. The feed distance passed over by the fabric being sewn corresponds to the product of the count value of the counting device and the stitch length. Such a stitch length may be preselectable on a stitch length mechanism. This arrangement provides a variant of the adjusting device, with which a particularly accurate dimensioning of the residual seam length is possible.
Unlike in the case of the seamless front fabric edge, which can be predetermined via the stop with high accuracy, the width of the seamless rear fabric edge depends on the sewing conditions, e.g., the stitch formation frequency. If a particularly accurate dimensioning of the width of the latter fabric edge is desired, the sewing conditions must be taken into account. This can be done by associating a memory for correction values with the adjusting device.
A variant of the adjusting device according to the present invention may be provided wherein the hem projection length sensors can be moved by a drive mechanism. The drive mechanism is controlled in terms of direction and amount as a function of a preset position of the stop, while maintaining a constant distance ratio from the cutting device, in relation to the cutting device. This arrangement is advantageous if the length ratio between the front and rear hem projection lengths is to be independent of the absolute length of the front hem projection length.
The cutting device is preferably arranged centrally between forward hem projection length sensor and the rear hem projection length sensor. The hem projection length sensors are moved by the drive mechanism by equal distances and in opposite directions.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a perspective view of a sewing machine for feeding a hem and for sewing it to a cut part,
FIG. 2 is a schematic perspective view of a needle bar and stitch length mechanism drive of the sewing machine;
FIG. 3 is a schematic circuit diagram of a control device for the sewing machine; and
FIG. 4 is a schematic view showing a hem connected to a fabric according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings and in particular FIG. 4, the invention is provided for connecting a fabric part or cut part workpiece Z to a hem B. In the connected state, the hem B is folded in its middle and is connected to the fabric Z along a seam 200. The invention provides a sewing machine for accurately providing a front hem projection length 210 by a cutting process and by also providing a rear hem projection length 220 by a further cutting process. A seamless front edge 230 is preferably provided (for example such that the hem projection length may be folded over at a front fabric edge 240 and such that the projection length 210 may be pushed into the associated part of the hem). A seamless rear edge 250 may also be provided (the distance from the end of the seam 200 to the rear fabric edge 260).
FIG. 1 shows a sewing machine whose housing 1 is formed by a base plate 2, a stand 3, an arm 4, and a head 5. A main shaft 6 (FIG. 2), which carries a pulse disk 7 of a pulse generator 8, is mounted in the arm 4. An opening 9, toward which a photodiode 10 of the pulse generator 8 is directed, is provided on the pulse disk 7. After passage through the opening 9, the light beams reach a photodetector 12. The photodiode 10, as well as the photodetector 12, designed as a phototransistor (FIG. 3), are connected to the positive pole of a stabilized power source and grounded via a resistor 13 each.
As is shown in FIG. 2, a cam 14, which is surrounded by a cam rod 15, is attached to the main shaft 6. The free end of the cam rod 15 is hinged to the web part 16 of a fork-shaped, two-armed lever 17, which is pivotably mounted in the housing 1 by means of a pivot pin 18, and has driven arms 19. The lever 17 forms part of a switching device 20 known from U.S. Pat. No. 4,569,297, which provides the possibility of switching off the needle bars 21 of the sewing machine in their top reversal position by single-acting cylinders 22, actuated by a pressure medium, whose piston rods 23 are connected to the switching device 20, being activated to withdraw their piston rods 23. Due to the release of the pressure in the cylinders 22, the piston rods 23 will again return into their starting position under the effect of a compression spring each arranged in the cylinder 22. The needle bars 21, each of which carries a needle 24, are now again switched on. The top reversal position of the needle bars 21 is now indicated via the pulse generator 8, because the opening 9 in the pulse disk 7 will then be located in the path of light between the photodiode 10 and the photodetector 12.
A presser foot device 25 is arranged in the head 5 of the sewing machine. This presser foot device 25 has a single-acting, pressure medium-actuated cylinder 26, whose piston rod 27 is connected to the presser bar 29, to which the presser foot 30 is attached, via a connection element 28.
As is shown in FIG. 1, another, single-acting, pressure medium-actuated cylinder 31, which is mounted displaceably in horizontally extending guide rails 32 and is connected via a spindle 33 to an actuating drive 34 formed by a stepping motor, is provided on the front side of the head of the sewing machine. A stop 36 for the fabric to be sewn, which stop can be lowered onto the base plate 2, is attached to the piston rod 35 of the cylinder 31. In addition, a strip 37, which carries a photodiode 38 in front of the needles 24 in the direction of feed and photodiodes 39 and 40 arranged at different distances from the needles 24, behind the needles 24, is also arranged on the front side of the head.
A sensor 41, which is aligned with the photodiode 38, is stationarily arranged in the base plate 2, and two hem projection length sensors 42 and 43, of which the hem projection length sensor 42 is aligned with the photodiode 39, and of which the hem projection length sensor 43 is aligned with the photodiode 40, are arranged movably in the base plate 2. The hem projection length sensor 42 is arranged on a spindle 44, whose threads have the same pitch as the threads of a spindle 45 housing the hem projection length sensor 43, but is provided with threads extending in the opposite pitch direction. Both the spindles 44 and 45 are connected to a common drive mechanism 46 in the form of a stepping motor 47.
The photodiodes 38 through 40, as well as the sensors 41 through 43, designed as phototransistors (FIG. 3), are connected to the positive pole of a stabilized power source, and are grounded via a respective resistor 48.
The sewing machine has a cutting device 50 (FIG. 1) with a movable blade 51, which is accommodated, like a stationary blade 52, in the base plate 2. The movable blade 51 is connected to a drive 53.
The sewing machine is provided with a hem feed means 54. This has folding plates 55 and 56 for folding the hem B and a guide plate 57 for a cut part Z, to which the hem is to be sewn. To feed the fabric to be sewn, which is formed by the cut part and the hem, the sewing machine has a feed dog 58, which extends through slots of a needle plate 59 housed by the base plate 2. The needle plate 59 is provided with passage openings 61 (FIG. 2) for the needles 24 at the stitch formation site 60.
As is shown in FIG. 2, the feed dog 58 is arranged on a feed dog support 62, whose fork-shaped end 63 surrounds a cam 65 attached to a shaft 64, and the shaft 64 imparts one stroke movement per stitch formation cycle to the feed dog 58. The other end of the feed dog support 62 pivotably acts on a pin 66 of a rocker 67. The rocker 67 has a fork-shaped design with arms 68 and is nonrotatably arranged on a shaft 70, which imparts one feed movement per stitch formation cycle to the feed dog 58.
Two cams 74 and 75 are nonrotatably mounted on a stitch length mechanism drive shaft 71, which is driven in a ratio of 1:1 to the main shaft 6. A cam rod 76 surrounding the cam 74 is hinged at its opposite end to a rocker 77 attached to the shaft 64. A second cam rod 78 surrounding the cam 75 is hinged on a pin 80, on which a connecting rod 81, which is connected by means of a pin 82 to a crank 83 attached to the shaft 70, is mounted. Next to the cam rod 78, a connecting rod 84, which surrounds a pin 86 carried by a crank 85, acts on the pin 80. The effective length of the connecting rod 81 is equal to that of the connecting rod 84, so that the shaft 70 remains immobile despite the cam rod 78 moving if the pins 82 and 86 are aligned.
To change the movement of the cam rod 78 acting on the shaft 70, the crank 85 is clamped on an adjusting shaft 87. The adjusting shaft 87 carries a second crank 88, on the free end of which a tension spring 90 attached to the housing 1 acts, and which is connected via a tie rod 91 to one end of an oscillating lever 92, which is attached to a shaft 93 mounted in the housing 1. The free end of the oscillating lever 92 has a spherical projection 94, which is arranged rotatably between side walls of an adjusting groove 95 of an adjusting wheel 96 that is arranged rotatably on an axle that is integral with the housing. The elements 80 through 96 form a stitch length mechanism 97, and the stitch length is set in the known manner by rotating the adjusting wheel 96.
The rotation position of the adjusting wheel 96 is monitored by a sensor device 98, which has a photodiode 100 on one side of the adjusting wheel 96, and a photodetector 101 on the other side of the adjusting wheel 96. The adjusting wheel 96 is provided with an opening 102, which is located in the path of the light of the sensor device 98 and is much narrower in the rotation position of the adjusting wheel 96 that is associated with "zero" stitch length than would be necessary for the passage of the total amount of light beams emitted from the photodiode 100. The opening continuously becomes wider in the direction of rotation corresponding to the increase in stitch length, until it reaches a width sufficient for the passage of all the light beams emitted by the photodiode 100 in the rotation position of the adjusting wheel 96 that is associated with the maximum stitch length. As a result, the photodetector 101, which is designed as a phototransistor (FIG. 3) and is connected, just as the photodiode 100, to the positive pole of a stabilized power source, and is grounded, just as the latter, via a respective resistor 103, acts as a stitch length monitor 104, because a light intensity received by the photodetector 101 is associated with each rotation position of the adjusting wheel 96.
As is shown in a simplified embodiment in FIG. 3, the sewing machine is provided with a control device 105. The control device 105 has an input device 106, which converts analog signals received at the inputs IE 1 through IE 5 into digital signals, and amplifies them. The sensor 41 is connected to the input IE 1 of the input device 106; the photodetector 101 of the stitch length monitor 104 is connected to the input IE 2; the hem projection length sensor 42 is connected to the input IE 3 via an inversion member 107; the hem projection length sensor 42 is connected directly to the input IE 4; and the hem projection length sensor 43 is connected to the input IE 5 via an inversion member 108.
The output A of the input device 106 is connected to an input E 1 of a control element 110, which may be formed by, e.g., a microprocessor. A measuring device 111, which has a counting device 112 that continuously adds up the pulses of the pulse generator 8, is connected to an input E 2 of the control element 110. A control panel 113 is connected to an input EZ as well as to an output AZ of the control element 110 via a buffer memory 114. An EPROM memory 115, in which a program for presetting the sequence of steps to be performed by the control element 110 is stored, is connected to an input EE as well as to an output AE of the control element 110. The steps are read from the EPROM memory 115 in a cadence predetermined by a timing generator 116 of the control element 110. A RAM memory 117 is connected to the input ER as well as to the output AR of the control element 110.
The control element 110 has further outputs A 1 through A 7, each of which is connected to a respective input OE 1 through OE 7 of an output device 118. The signals of the control element 110 are amplified by the output device 118.
The output device 118 is provided with outputs OA 1 through OA 7. The actuating drive 34 for displacing the cylinder 31 carrying the stop 36 is connected to the output OA 1; the drive mechanism 46 for the spindles 44 and 45 of the hem projection length sensors 42 and 43 is connected to the output OA 2; and the drive 53 of the cutting device 50 is connected to the output OA 3. One striker magnet each of an electromagnetically switchable directional control valve 119 through 121, hereinafter called E valve for short, which can be reset into its starting position by spring action, is connected to the outputs OA 4 through OA 6 of the output device 118. Of the E valves 119 through 121, all of which are connected to a compressed air source 122, the E valve 119 is connected to the cylinder 31 for the stop 36; the E valve 120 is connected to the cylinder 26 of the presser foot device 25; and the E valve 121 is connected to the cylinders 22 for switching off the needle bar. The control part 123 of a positioning motor 124 which drives the main shaft 6 via a V-belt drive 125 is connected to the output OA 7 of the output device 118.
An adjusting device 126 is formed by the elements 31 through 48 together with the control device 105.
The sewing machine operates as follows:
Prior to the beginning of a sewing process, the needle bars 21, the presser foot 30, the stop 36, and the movable blade 51 of the cutting device 50 are in the respective top reversal position. Before a fabric part Z is positioned by an operator, the operator sets the stitch formation frequency desired for the next sewing process on the control panel 113, and presets the edge width between the front edge 240 of the fabric Z and the beginning of the seam 200. These data are read into the input EZ of the control element 110 from the control panel 113 via the buffer memory 114 in the form of digitized signals.
The signal associated with the stitch formation frequency is sent from the output A7 of the control element 110 and is sent to the control part 123 of the positioning motor 124 via the output device 118. In contrast, the signal associated with the edge width causes the control element 110 to send one signal each from the outputs A1 and A2. The signal of the output Al is sent to the actuating drive 34 and presets for it the number as well as the direction of the drive steps to be performed. Based on its connection with the cylinder 31 via the spindle 33, the actuating drive 34 displaces the cylinder 31 in the direction of the guide rails 32 in relation to the stitch formation site during the performance of these drive steps. The distance between the stop 36 and the stitch formation site 60 is thus predetermined, as a result of which the width or dimension of a seamless front fabric edge 230, which extends from the front edge of the fabric 240 to the beginning of the seam 200, is determined.
The signal at the output A2 of the control element 110 causes drive steps to be predetermined for the drive mechanism 46 for driving the spindles 44 and 45, and the number and the direction of these drive steps are predetermined as a function of the distance of the stop 36 from the stitch formation site 60. It is thus achieved that the distance of each of the two sensors 42 and 43 from the cutting device 50 will always correspond to the distance of the stop 36 from the stitch formation site 60.
As soon as the adjustment process by the actuating drive 34 and the drive mechanism 46 is concluded, the control element 110 actuates the striker magnet of the E valve 119 by sending a continuous signal from its output A4, as a result of which this valve will be displaced to the right from its position shown in FIG. 3. This causes the piston rod 35 to extend from the cylinder 31. As a result, the stop 36 is lowered onto the base plate 2.
To position the cut part Z on the base plate 2, the cut part is placed with its front edge against the stop 36 and is pushed in the direction of the hem feed means 54 until it comes to lie against its the guide plate 57. In this position, the cut part Z covers the sensor 41, so that this sensor 41 will not receive any more light beams from the photodiode 38, and consequently it will not send any more signals to the input IE 1 of the input device 106.
After being introduced into the hem feed means 54, the hem B is folded in the middle as a consequence of its passage through the folding plates 55 and 56, so that its edges, which were in one plane before, will be opposite each other after the folding process. The hem B is fed by the hem feed means 54 to the cut part Z such that one of its hem halves will be arranged above the cut part Z and its other half will be located under this cut part Z.
After conclusion of the positioning process, the sewing process is started, e.g., by depressing a foot pedal, not shown, as a result of which a signal is sent to the control element 110 via a line, also not shown. The control element 110 now stops sending signals from its output A4, whereupon the E valve 119 returns into its starting position under spring action, thereby causing the cylinder 31 to lift the stop 36 off the base plate 2 by withdrawing the piston rod 35. A signal sent simultaneously from the output A5 of the control element 110 causes a continuous signal to be sent to the striker magnet of the E valve 120 for extending the piston rod 27 of the cylinder 26 to lower the presser foot 30 onto the fabric to be sewn. The positioning motor 124, which drives the main shaft 6 and, via this shaft, the needle bars 21, the stitch length mechanism drive shaft 71, which imparts its movement to the feed dog 58, as well as shuttle (or hook) drive shafts (not shown), is switched on by another signal sent from the output A7 of the control element 110. The shuttle drive shafts are driven in a ratio of 2:1 in relation to the other shafts.
As soon as the hem projection length sensor 42 is covered by the front edge of the fabric being sewn, the input device 106 receives a signal at its the input IE 3 because of the inversion member 107. After conversion and transmission to the input E1 of the control element 110, this signal causes the control element 110 to send a signal from the output A3. This signal is sent to the drive 53 of the cutting device 54, after which this performs a movement, by which the movable blade 51 is pivoted in the downward direction and cuts through the hem B. The fabric-side hem projection length 210 is now reduced to a length that corresponds to the distance between the hem projection length sensor 42 and the cutting device 50 and consequently to the width of the seamless front fabric edge 230, which is predetermined via the stop 36 at the beginning of sewing, so that the front hem projection length 210 can be pushed over its entire length into the associated part of the hem after conclusion of the sewing process. The movable blade 51 is subsequently pivoted back into its starting position by another signal being sent from the output A3 of the control element 110.
Simultaneously with the initiation of the cutting process, the control element 110 establishes at the input E2 the readiness for receiving the next count from the counting device 112. This count is stored in the RAM memory 117.
As soon as the fabric is fed to the extent that its front edge covers the hem projection length sensor 43, a signal is sent to the input IE 5 of the input device 106 because of the inversion member 108 succeeding the sensor 43. A signal subsequently sent to the control element 110 causes the control element 110 to receive a second count on the input E2, and, after the first count has been read from the RAM memory 117, to determine a hem projection length count associated with the distance between the two hem projection length sensors 42 and 43 and consequently with the length of the front and rear hem projection lengths 210, 220 by forming the difference of these counts. To determine this hem projection length count, only the difference between the two counts is needed, but their absolute value is not, so that it is not necessary to reset the counting device 112 to a predeterminable initial value before the first count is received. The hem projection length count is stored in the RAM memory 117.
When the sewing process has advanced so much that the rear edge of the fabric being sewn releases the sensor 41, the latter will receive light beams from the photodiode 38, and send a signal to the input IE 1 of the input device 106. This sends a signal to the input E1 of the control element 110, after which the control element reads at the input E2 the next count of the counting device 112, and polls the stitch length at the input E1. The stitch length is obtained by the photodetector 101 of the stitch length monitor 104 sending an electric signal, whose intensity corresponds to the intensity of the light beams received, to the input IE 2 of the input device 106, which latter will then send a digital signal associated with the signal intensity to the control element 110.
The distance between the sensor 41 and the stitch formation site 60, which will hereinafter be called fabric end length, is constant, and its value is stored in the RAM memory 117. After polling the fabric end length from the RAM memory 117, the number of stitch formation cycles that is needed to cover this distance is determined by the control element 110 by using the stitch length. The control element 110 also reads the hem projection length count from the RAM memory 117 and, depending on the stitch formation frequency, a correction value stored there, and computes the correction value by halving the hem projection length count to obtain the count associated with the rear hem projection length. The control element 110 then enters this correction value in the RAM memory 17. The control element 110 subsequently determines a residual seam count associated with the residual seam length by forming the difference of the fabric end count associated with the fabric end length and the halved hem projection length count, with which the correction value is taken into account.
Beginning from the count entered on release of the sensor 41, which will hereinafter be called the first value, the control element 110 receives the respective last count of the counting device 112 during each subsequent stitch formation cycle, and forms the difference from this and the first value. As soon as this difference reaches the residual seam count, the control element 110 stops receiving further counts at the input E2, and sends a signal to the output device 118 from the output A6. The output device 118 then sends a signal from the output OA 6 to the striker magnet of the E valve 121 for withdrawing the piston rods 23 into the cylinder 22 and consequently for switching off the needle bars 21 via the switching device 20. The time lag which develops between the sending of the signal from the output A6 of the control element 110 and the switching off of the needle bars 21 and during which a number of stitch formation cycles, whose number depends on the stitch formation frequency, are performed, is taken into account when the residual seam count is determined such that this residual seam count decreases with increasing stitch formation frequency due to the inclusion of the correction value. As a result, the signal for switching off the needle bars 21 is sent at a greater distance from the rear edge of the fabric being sewn if the stitch formation frequency increases.
After the needle bars 21 have been switched off, the feed of the fabric being sewn is continued, and the seamless rear fabric edge following the last stitch of the seam formed passes through the stitch formation site 60.
When the rear edge of the fabric releases the hem projection length sensor 43, the sensor becomes conductive by receiving the light beams arriving from the photodiode 40, as a result of which a signal is present at the input IE 5 of the input device 106. This signal causes signals to be sent to the outputs A3 and A7 of the control element 110. The drive 53 of the cutting device 50 is again activated for a cutting process by the signal at the output A3, so that the rear hem projection length will be cut through at a distance from the rear edge of the fabric corresponding to the width of the seamless rear fabric edge. As a result, the rear hem projection length can also be pushed over its entire length into the associated part of the hem.
The signal at the output A7 of the control element 110 causes a signal for stopping to be sent to the control part 123 of the positioning motor 124. The positioning motor 124 comes to a stop in a rotation position of the main shaft 6 in which the opening 9 in the pulse disk 7 is located in the path of light between the photodiode 10 and the photodetector 12 and which rotation position is associated with the top reversal position of the needle bars 21.
With a slight delay from the signals at the outputs A3 and A7, the control element 110 sends signals to the outputs A5 and A6. The signal at the output A5 causes the cylinder 26 to withdraw its the piston rod 27 and thus to lift off the presser foot 30 from the fabric being sewn, while the signal at the output A6 causes pressure to be released in the cylinder 22. The piston rods 23 of the cylinder 22 will then extend and switch on the needle bars 21 for the next sewing process via the switching device 20.
The fabric can then be removed.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | A sewing machine is provided with an adjusting device for hem projection length sensors that can be moved relative to a cutting device, wherein the first hem projection length sensor is provided for sending a signal that brings about a cutting process for the front hem projection length, and the second of the sensors is provided for sending a signal that brings about a cutting process for the rear hem projection length. The length of the respective hem projection length and the width of an associated seamless fabric edge shall be able to be set depending on each other with minimum operator effort by the adjusting device both at the beginning and the end of the fabric. The adjusting device has a stop that is movable in the direction of feed for the front edge of the fabric for presetting the width of a seamless front fabric edge. The distance from the stitch formation site can be used to preset the position of the hem projection length sensor, and which serves to dimension a seamless rear fabric edge adjoining the end of the seam. A residual seam length is determined from the difference between the fabric end length and the width of the seamless front edge of the fabric. A control is provided for stopping the needle bar in its top reversal position when this residual seam length is reached. A measuring device for measuring the feed distances of the fabric can be activated by a signal of a sensor which is arranged in front of the stitch formation site and indicates the fact that the actual fabric end length drops below a predeterminable fabric end length. | 3 |
PRIORITY
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/371,751, filed Aug. 9, 2010.
BACKGROUND
[0002] The present invention relates to systems, methods, and products for distributed media access, including, more particularly, network-based delivery of media.
[0003] Prior art streaming architectures and methods have been employed to deliver media via network. Many of these prior art devices have, however, proven cumbersome to use, bandwidth intensive, and unreliable in circumstances of low bandwidth. In particular, when transferring a media stream over a connection that cannot provide the necessary throughput, several undesirable effect arise. For example, a network buffer may overflow, resulting in packet loss, causing garbled video or audio playback; or a media player buffer may underflow resulting in playback stall.
SUMMARY
[0004] The present invention relates to distributed media access, including, more particularly, network-based delivery of media. Aspects of the invention include enhanced distributed content delivery via a network. Other aspects include web-based media delivery, such as, for example, media delivery via web browser. Other aspects include networked camera solutions integrated with enhanced media publishing for camera control and upload parameter modification according to detected network conditions.
[0005] In one general embodiment, content may be fragmented for storage and delivery from multiple distributed nodes. Fragmentation may be implemented in a variety of ways and carried out in various sizes and formats to provide optimally conditioned fragments for improved content delivery across a wide range of projected network conditions. Some embodiments may involve generating copies of content fragments in multi-coded formats for distribution and consumption worldwide across a wide range of network conditions. Distribution may include multi-threaded delivery from cloud file storage region points.
[0006] One general embodiment includes a system comprising one or more servers configured to deliver content over a network to a client on a client device in communication with the server(s). The content may include various media in one or more of several formats. The content may be generated from an application program, which may be executable program code running on the server or other computer in communication with the server. In some implementations, the application program may comprise an originating client on an originating client device, or may receive content from an originating client, either directly or indirectly. Alternatively, content may also be received from other nodes or retrieved from storage. One or more servers may be configured to capture the content (e.g., computer-generated output from the application program), process the captured output, and transmit the processed output to the client device. Alternatively, the server may store the processed output for later transmission to the client device. In specific embodiments, a first server may capture and process the content, and a second server may transmit the processed output to the client device. In some cases, the processed output may be transmitted after being stored by either the first or second server.
[0007] The server may be configured to process the captured output to achieve constant or relatively constant quality of variable bit rate output upon transmission to the client. The client may be configured to receive transmitted converted output and execute, decode, and/or render graphics, video, and/or audio on the client device. The server may be further configured to process the captured output in order to provide either compressed file size or lower overall average bit rate at low latency. The data may be partitioned into variable-size chunks.
[0008] Processing may include converting sequences of frame set time blocks in multi-threaded encoding sequences in accordance with multiple formats such as Windows Media Video (‘WMV’), Flash Video (‘FLV’), 3GPP, M3U (m3u8), Moving Picture Experts Group (‘MPEG’), and the like through the use of one or more encoders. An encoder may publish video codec data of converted output in parallel.
[0009] Processing may further include configuring multi-pass variable bit rate control of data segmentation, splicing of file packet size into intervals of frame set time blocks, and so on. The server may be configured to control encoding parameters to produce output of relatively constant quality. An encoder may set checkpoints in the second pass to adjust the control parameters and/or subsequent checkpoints. An encoder may define peak bit rate constraints to limit peak bit rate in accordance with client device screen architecture parameters. An encoder may store auxiliary information from earlier passes for use in later passes to increase the performance of the later passes (e.g., to decrease processing time); perform signature encryption of input data and intercept user input decryption to check consistency between passes; and transmit the intercepted user region-defined publishing point of the cloud file storage server over the network internet protocol.
[0010] One aspect of the invention includes a scalable architecture for delivery of real-time video packet data sent over a communication network. A control mechanism may be embedded in the architecture to provide for the management and administration of users who are to receive the real-time video packet data.
[0011] Aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of 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 module. Embodiments of the invention may be implemented as any viable computing device including logic and memory, or software modules including computer program instructions executed thereon, as will occur to one of ordinary skill in the art, including devices where logic is implemented as field-programmable gate arrays (‘FPGAs’), application-specific integrated circuits (‘ASICs’), and the like.
[0012] Aspects of the present invention are described below with reference to flowchart illustrations of methods, devices, and computer program products according to embodiments of the invention. Each block of the flowchart illustrations (or combinations of blocks in the flowchart illustrations) can be implemented by computer program instructions provided to a processor of a special purpose computer or other programmable data processing apparatus for execution to implement the functions specified in the flowchart blocks. These computer program instructions may also be stored in a computer readable medium, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the functions specified in the flowchart blocks.
[0013] Aspects of the present invention are described below with reference to flowchart illustrations of methods, devices, and computer program products according to embodiments of the invention. Each block of the flowchart illustrations (or combinations of blocks in the flowchart illustrations) can be implemented by computer program instructions provided to a processor of a special purpose computer or other programmable data processing apparatus for execution to implement the functions specified in the flowchart blocks. These computer program instructions may also be stored in a computer readable medium, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the functions specified in the flowchart blocks.
[0014] Other embodiments may include a controller for enhancing distributed content delivery. The controller may include circuits configured to facilitate enhancing distributed content delivery. The controller may include programmed logic circuit for enhancing distributed content delivery. The programmed logic circuit may be adapted to capture media content output and encode segmented media.
[0015] Other embodiments of the present invention include a design structure embodied in a machine readable storage medium for at least one of designing, manufacturing, and testing a design. The design structure may include the controller for enhanced media delivery, constituent modules or circuits thereof, or constituent modules or circuits of the apparatus. The design structure may include a netlist which describes the controller, apparatus, or constituent modules or circuits. The design structure may reside on the machine readable storage medium as a data format used for the exchange of layout data of integrated circuits.
[0016] Other embodiments of the present invention include computer program products embodied in one or more computer readable media having computer readable program code disposed thereon. These computer program products may include computer program code adapted to carry out the methods of the present invention on one or more data processing system (computer).
[0017] Other general embodiments include a system comprising one or more data processing systems. The data processing systems comprise a processor and a computer memory operatively coupled to the processor. The computer memory has disposed within it computer program instructions for execution on the processor to implement one or more of the method embodiments described above. Other embodiments include computer program products disposed on a computer readable medium comprising computer program instructions for carrying out one or more of the method embodiments described above by their execution on a computer processor.
[0018] The foregoing and other objects, features and advantages of the disclosure will be apparent from the following more particular descriptions of exemplary embodiments of the invention as illustrated in the accompanying drawings wherein like reference numbers generally represent like parts of exemplary embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The following figures are part of the present specification, included to demonstrate certain aspects of embodiments of the present disclosure and referenced in the detailed description herein.
[0020] FIG. 1A is a simplified flow diagram illustrating aspects of one embodiment according to the invention;
[0021] FIG. 1B is yet another simplified flow diagram illustrating aspects of one embodiment according to the invention;
[0022] FIG. 2 is a simplified illustration for enhanced distributed content delivery in accordance with one embodiment of the invention;
[0023] FIG. 3 is a simplified block diagram of an exemplary computer embodying aspects of the invention;
[0024] FIG. 4A is a simplified diagram illustrating an exemplary method for enhanced distributed media delivery according to the invention;
[0025] FIG. 4A is a simplified diagram illustrating another exemplary method for enhanced distributed content delivery according to the invention;
[0026] FIG. 4A is a simplified diagram illustrating an exemplary method for enhanced distributed content delivery according to the invention; and
[0027] FIG. 5 is a simplified diagram of graphical display in accordance with the present invention.
DETAILED DESCRIPTION
[0028] The principles of the invention are explained by describing in detail, specific example embodiments of devices, products, and methods for distributed media delivery, including, more particularly, network-based delivery of media. Those skilled in the art will understand, however, that the invention may be embodied as many other devices, products, and methods. For example, various aspects of the methods and devices may be applied to other content, advertising, or data. Many modifications and variations will be apparent to those of ordinary skill in the art. Embodiments were chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. The scope of the invention is not intended to be limited by the details of exemplary embodiments described herein. The scope of the invention should be determined through study of the appended claims.
[0029] Aspects of the present invention are 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, implement the functions/acts specified in the flowchart and/or block diagram block(s).
[0030] These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block(s).
[0031] The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices 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(s).
[0032] FIG. 1A is a data flow diagram illustrating a use case in accordance with embodiments of the invention. Referring to FIG. 1A , content 106 is output ( 104 ) from an application program 102 . The content 106 may include various media (e.g., songs, video, graphics, etc.) in one or more of several formats, such as, for example, formats according to the standards for Moving Picture Experts Group (‘MPEG’), Audio Video Interleave (‘AVI’), QuickTime (.mov), Windows Media Video (‘WMV’), DV, Flash Video (‘FLV’), Small Web Format (‘SWF’), Legacy RealMedia (.rm), and so on. The content may output the content of a media file as an output stream. The application program 102 may be executable program code running on a computer, such as, for example, a client device or server device. A server program 110 running on a server device receives the content 106 . The application program 102 may be running on the same device as the server 110 , or may be coupled to the server device directly or through a network. In some implementations, the application program may comprise an originating client on an originating client device, or may receive content from an originating client, either directly or indirectly. Alternatively, content 106 may also be received from other nodes or retrieved from storage (not shown). The server 110 captures ( 112 ) content 106 , processes ( 114 ) the captured content 106 , and transmits ( 118 ) the processed content 116 to a client 140 on a client device 150 . The client device 150 may be any device capable of consuming media, such as, for example, a computer, a smart phone, a digital media player, an automobile, or any other device having digital audio or video rendering capabilities.
[0033] Alternatively, the server 110 may store ( 120 ) the processed output 116 in storage 130 for later transmission to the client device 150 . In specific embodiments, a first server may capture and process the content, and a second server may transmit the processed output to the client device. In some cases, the processed output may be transmitted after being stored by either the first or second server.
[0034] FIG. 1B is a data flow diagram illustrating a use case in accordance with embodiments of the invention. Referring to FIG. 1B , server 160 transmits ( 162 ) processed content 116 to client 140 . Server 160 may be the same server as server 110 , or a separate server. Content 116 may be transmitted directly following processing at server 160 or following transmission from another server, such as, for example server 110 ; or after being retrieved from storage 130 . Client 140 consumes 164 content 116 by rendering content on client device 150 .
[0035] Transmitting the content according to embodiments of invention provides enhanced distributed content delivery, as discussed in further detail below. Processing is carried out to facilitate enhanced distributed content delivery, by providing processed content 116 which is more readily transmitted in the manner disclosed. Transmitting ( 162 ) of server 160 to client 140 allows delivery of high definition media across PC, android, television, and PlayStation3 platforms without downloading third party plug-ins (e.g., FLASH player) or other software. All software for receiving and rendering media on the client device is contained in the browser environment. Playlist strings allow continual stream and progressive delivery manner. Use of distributed storage decreases bandwidth consumption. Data is published in a cloud storage; users retrieve a playlist to redirect browser to specific cloud storage and retrieve a fresh copy of that segment point in the time frame playlist, so bandwidth is not affected and content quality is maximized.
[0036] In other embodiments, an embedded device platform in client-side video capture equipment processes the video and segments it from its originating source.
[0037] FIG. 2 illustrates a system for enhanced distributed content delivery in accordance with one embodiment of the invention. The system of FIG. 2 includes a source device 202 providing media content as output. The source device 202 is coupled (directly or through a network) to one or more media delivery network servers 204 running a processing module. The media delivery network servers 204 are coupled to regional database servers 206 a , 206 b , 206 c via network. The regional database servers 206 a , 206 b , 206 c provide playlists and serves HTTP files. Regional database servers 206 a , 206 b , 206 c are coupled to regional cloud storage 208 a , 208 b , 208 c via network.
[0038] The media delivery network servers 204 include a capture segmenter and various encoders for multi-threaded encoding. The regional database servers 206 a , 206 b , 206 c may also comprise front end functionality for administration and user functionality, a bit rate controller, a database module comprising a playlist signature generator, and a publisher module comprising a frame packet service API. The encoders encode MPEG-4 frames a210s .ts files encoded to multi-device formats and tagged by device format. The bitrate manager strings together encoded .ts files and tags by frame sequence. The publisher generates a playlist from frames and publishes to cloud storage; the publisher also tags the playlist by region of cloud storage and segment.
[0039] A client device 210 is connected via networks to an appropriate regional database server 206 a , 206 b , 206 c . Client device may be a smart phone, touchscreen computer, laptop computer, desktop computer, digital media player, automobile, or the like.
[0040] Networks may include, alone or in combination, one or more local area networks (‘LANs’), wide area networks (‘WANs’), wired or cellular telephone networks, intranets, or the Internet. Embodiments of the present invention include computer implemented methods operating on any of source device 202 , media delivery network servers 204 , regional database servers 206 a , 206 b , 206 c , regional cloud storage 208 a , 208 b , 208 c , or computer client device 210 , alone or in combination. Embodiments of the present disclosure may include any or all of the devices depicted in FIG. 2 .
[0041] The devices disclosed in FIG. 2 are provided for illustration and not for limitation. Embodiments of the invention could be implemented as any viable computing device including logic and memory, or software modules including computer program instructions executed thereon, as will occur to one of ordinary skill in the art, including devices where logic is implemented as field-programmable gate arrays (‘FPGAs’), application-specific integrated circuits (‘ASICs’), and the like.
[0042] Embodiments of the presently disclosed invention are implemented to some extent as software modules installed and running on one or more data processing systems (‘computers’), such as servers, workstations, tablet computers, PCs, personal digital assistants (‘PDAs’), smart phones, digital media players, and so on. Each of computer source device 202 , media delivery network servers 204 , regional database servers 206 a , 206 b , 206 c , regional cloud storage 208 a , 208 b , 208 c , or computer client device 210 is typically implemented as a computer.
[0043] FIG. 3 sets forth a block diagram of an exemplary computer used in embodiments of the present disclosure. Computer 302 includes at least one computer processor 354 as well as a computer memory, including both volatile random access memory (‘RAM’) 404 and some form or forms of non-volatile computer memory 350 such as a hard disk drive, an optical disk drive, or an electrically erasable programmable read-only memory space (also known as ‘EEPROM’ or ‘Flash’ memory). The computer memory is connected through a system bus 340 to the processor 354 and to other system components. Thus, the software modules are program instructions stored in computer memory.
[0044] An operating system 310 is stored in computer memory. Operating system 310 may be any appropriate operating system such as Windows XP, Windows Vista, Windows 7, Windows Server, Mac OS X, UNIX, LINUX, or AIX. A network stack 312 is also stored in memory. The network stack 312 is a software implementation of cooperating computer networking protocols to facilitate network communications.
[0045] Computer 302 also includes one or more input/output interface adapters 356 . Input/output interface adapters 356 may implement user-oriented input/output through software drivers and computer hardware for controlling output to output devices 372 such as computer display screens, as well as user input from input devices 370 , such as keyboards and mice.
[0046] Computer 302 also includes a communications adapter 352 for implementing data communications with other devices 360 . Communications adapter 352 implements the hardware level of data communications through which one computer sends data communications to another computer through a network.
[0047] Also stored in computer memory is an enhanced distributed content delivery module 308 . The enhanced distributed content delivery module 308 may include device-specific computer program instructions for implementing methods of the present invention. For example, enhanced distributed content delivery module 308 may be implemented, in part, as a web browser application running on a client device operated by a user.
[0048] Enhanced distributed content delivery module 308 may also be implemented, in part, as server applications. On each of source device 202 , media delivery network servers 204 , regional database servers 206 a , 206 b , 206 c , and regional cloud storage 208 a , 208 b , 208 c , enhanced distributed content delivery module 308 has different functionality.
[0049] The enhanced distributed content delivery module on regional database servers 206 a , 206 b , 206 c operates to transmit content as described above with reference to FIG. 2 (e.g., etc.). The module 308 may be embedded or installed on media delivery network servers 204 .
[0050] The enhanced distributed content delivery module on media delivery network servers 204 operates to process content as described above with reference to FIG. 2 (e.g., etc.). The module 308 may be embedded or installed on media delivery network servers 204 . The module manages and implements control requests and notifies class drivers on a client device to any data transfer of video segmented frames; and transmits data into a network server container using a standard mpeg-2 transport stream file format. Data ingest of the bitrate data file are multi-threaded encoded and published to the cloud.
[0051] In other implementations, the module may be installed or embedded on a recording device, such as a camera. The module may include a set of application modules that manages the recording or capturing device. A capturing application stack operates in conjunction with a corresponding host stack on another system to which the device is connected. The system is designed to manage multiple controllers, implement standard control requests and notify the class drivers of any data transfers initiated by the Host. It provides the necessary abstraction to the class drivers, and interfaces with the controller hardware driver to provide data transfer services over IP capable of a programmable, multiple level response to threshold events received by the capturing application stack embedded on the network camera, input source of satellite feed, third party device enable, or any other typical input.
[0052] An application containing the capturing stack embedded on the camera may contain a Segmenter trigger module designed to segment object container video frames according to a sementation strategy, and a strategy model which is programmed and/or configured to adapt the sementation strategy depending on the network conditions. The module may segment video streams into variable second chunks which may be published using a standard MPEG-2 transport stream file format. To maximize the efficiency of the system from affecting network bandwidth, capture functions are configured to transmit frames and/or a “video stream” to a network server via standard digital I/O connections on the system (which may have video publishing triggering capabilities). A standard web browser (such as web browsers that support standard HTTP protocols and are supported by Microsoft Windows operating systems) may be used for all functions. For browser-based access software, camera specific ActiveX controls/Java Applets may be automatically loaded on the end-user device system.
[0053] The module may manage multiple controllers, implement standard control requests and notify the class drivers of any data transfers initiated by the Host. The module may also provide the necessary abstraction to the class drivers, and interfaces with the controller hardware driver to provide data transfer services over IP. The API makes facilitates implementation of all of the necessary initialization and callback functions. The Progressive Camera Compression system includes a device stack and controller driver (when available) or a driver development kit. Device side class drivers may support specific cam device types so that the host can recognize and enumerate these devices when they are attached. Available class drivers may include Mass Storage, CDC Abstract Control Model (Serial Emulation) and Ethernet Emulation for Windows connectivity.
[0054] For live events, the module responds to changes in network conditions by adjusting the bitrate and the media encoding sequence to optimize the viewing and audio experience of the user.
[0055] Processing may include fragmenting media content for storage and delivery from multiple distributed nodes. Fragmentation may be implemented in a variety of ways and carried out in various sizes and formats to provide optimally conditioned fragments for improved content delivery across a wide range of projected network conditions. Some embodiments may involve generating copies of content fragments in multi-codec formats for distribution and consumption worldwide across a wide range of network conditions. Distribution may include multi-threaded delivery from cloud file storage region points.
[0056] For further explanation, FIG. 4A sets forth a block diagram illustrating a method for enhanced distributed media delivery in accordance with one embodiment of the invention. Referring to FIG. 4A , the method begins by capturing media content output (block 402 ). After capture, the content is segmented (block 404 ) and encoded (block 406 ). Encoding may comprise multi-thread encoding. Next, the system assigns a playlist signature to the segments (block 408 ) and tags the segments according to frame (block 410 ). The segments are then published to the cloud (block 412 ).
[0057] Once the data is published, a user may select media by clicking on a link in a web browser. In response, the web browser downloads a playlist from a network server which redirects the browser to a data packet of playlist files in cloud storage, where it is viewed from cache memory.
[0058] Some implementations include variations of progressive Hypertext Transfer Protocol (‘HTTP’), where users would request a playlist and retrieve a dynamically generated cache playlist for use in viewing live or on-demand media on any web-enabled device. Transcoding playlist techniques are used, similar to U.S. patent application Ser. No. 12/125,407 to Lee. However, techniques of the present embodiment include segmenting files to encode and publish to cloud file storage. Additionally, playlists are system compiled and encrypted to upload contents to the cloud. Once a user clicks on an HTTP link in a browser, the playlist obtained from the network server redirects to the data packet playlist files from the cloud and views the cache copy. Thus, the platform formats to device player requirements for delivery via HTTP, so no additional downloads, plug-ins, or apps are required.
[0059] The HTTP links are directed at frames uploaded to the cloud which play in HD from an embedded player code. The frames may be less than a minute in duration. The playlist requests instruct the cloud file storage to load the playlist in order: playlistset1, then playlistset2, playlistset3 and so on. The system programs the list to operate on retrieving published files from the cloud and playing them in sequence order: playlistset1 retrieves segment pulled from http://cloudfilecontainer1, playlistset2 retrieves segment pulled from http://cloudfilecontainer2; and so on. Cloud distribution allows multiple users to access the playlist at different times and pickup cache playlist copies—minimizing network bandwidth weight on the network server and on the stream.
[0060] Encoding of segment frames may involve encoding to four formats and publishing to the cloud. For live events, continuous uploading of a data file can quickly be done if data packets are small and uploaded one at a time.
[0061] The server may be configured to process the captured output to achieve constant or relatively constant quality of variable bit rate output upon transmission to the client. The client may be configured to receive transmitted converted output and execute, decode, and/or render graphics, video, and/or audio on the client device. The server may be further configured to process the captured output in order to provide either compressed file size or lower overall average bit rate at low latency. The data may be partitioned into variable-size chunks.
[0062] FIG. 4B sets forth a block diagram illustrating a method for enhanced distributed media delivery in accordance with one embodiment of the invention. Referring to FIG. 4B , a user request to view a playlist link (block 422 ). A request command is issued. Request is sent to the server, where the bitrate controller analyzes the device header (block 424 ). The post playlist command publishes the playlist to the user (block 426 ). The Post command redirects the user to published playlist in cloud storage, retrieves frame sequence defined in the device header (block 428 ). The playlist string request command calls sequence frame from cloud storage container and posts live video (block 430 ).
[0063] Processing may include converting sequences of frame set time blocks in multi-threaded encoding sequences in accordance with multiple formats such as Windows Media Video (‘WMV’), Flash Video (‘FLV’), 3GPP, M3U (m3u8), Moving Picture Experts Group (‘MPEG’), and the like through the use of one or more encoders. An encoder may publish video codec data of converted output in parallel.
[0064] Processing may further include configuring multi-pass variable bit rate control of data segmentation, splicing of file packet size into intervals of frame set time blocks, and so on. The server may be configured to control encoding parameters to produce output of relatively constant quality. An encoder may set checkpoints in the second pass to adjust the control parameters and/or subsequent checkpoints. An encoder may define peak bit rate constraints to limit peak bit rate in accordance with client device screen architecture parameters. An encoder may store auxiliary information from earlier passes for use in later passes to increase the performance of the later passes (e.g., to decrease processing time); perform signature encryption of input data and intercept user input decryption to check consistency between passes; and transmit the intercepted user region-defined publishing point of the cloud file storage server over the network internet protocol.
[0065] FIG. 5 is a diagram illustrating a graphical display in accordance with one embodiment of the invention.
[0066] Embodiments of the present invention include design structures. Such embodiments may be contained on one or more machine readable media as a text file or a graphical representation of hardware embodiments of the invention. Typically, planning design structures are provided as input to design processes used in semiconductor design, manufacture, and/or test, to generate manufacturing design structures, with the exact processes used depending on the type of integrated circuit (‘IC’) being designed, such as an application specific IC (‘ASIC’), a standard component, and so on. A first design structure may be input from an IP provider, core developer, or any other source. A first design structure may include an embodiment of the invention in the form of schematics or a hardware-description language (‘HDL’), e.g., Verilog, VHDL, C, etc. Design processes may be used to translate an embodiment of the invention into a netlist, e.g., a list of wires, transistors, logic gates, control circuits, I/O, models, and so on. These processes may employ automation tools and applications, and may include inputs from a library which may house a set of commonly used elements, circuits, and devices, including models, layouts, and symbolic representations. The netlist describes the connections to other elements and circuits in an IC design, and may also be disposed on a machine readable medium. A netlist may be composed iteratively depending on design specifications and parameters for the circuit.
[0067] The design process may translate a planning design structure into a manufacturing design structure that resides on a storage medium in a data format used for the exchange of layout data of integrated circuits (for example, data stored in a GDSII (GDS2), GL1, OASIS, or any other suitable manufacturing design structure format). The manufacturing design structure may comprise information such as, for example, test data files, design content files, manufacturing data, layout parameters, wires, levels of metal, vias, shapes, or any other data required by a semiconductor manufacturer to produce a hardware embodiment of the invention. A producer may then employ the manufacturing design structure in tape-out and manufacture.
[0068] The discussion above has focused primarily on embodiments of the invention for use with published segmented media files retrieved according to a modified progressive HTTP. Other embodiments may be used with other file types and data transfer methods. It should be understood that the inventive concepts disclosed herein are capable of many modifications. To the extent such modifications fall within the scope of the appended claims and their equivalents, they are intended to be covered by this patent. | A method is disclosed for delivering enhanced distributed media. The method entails accepting a request, analyzing a device header, publishing a playlist to a user, and redirecting the user to a published playlist in cloud storage. The method further involves retrieving the frame sequence defined in the device header, calling frames in order according to the frame sequence, and then, posting video defined by frames. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of the filing of U.S. Provisional Patent Application Ser. No. 60,168,479, entitled “Apparatus Using Oscillating Rotating Piston,” filed on Dec. 1, 1999, and the specification thereof is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to piston operated devices, and, more particularly, to motors, expanders, compressors, and hydraulics having rotating cylinders.
2. Background Art
The world is running on internal combustion engines. For over a century, internal combustion gasoline and diesel engines, turbines, and Stirling engines have been used. More recently the Wankel engine was developed.
The response time of turbines and Stirling engines is too slow for automobile use. Wankel engines have fallen out of favor. Gasoline and diesel motors have been the mainstays of the auto industry in spite of low efficiency. Considering the combustion temperatures in these motors, the theoretical efficiency (Carnot efficiency) should be above 70%. Typically the efficiency of today's automobile motors is 25%. One of the chief reasons for the low efficiency is the high-energy losses due to sliding friction of the pistons against cylinder walls. This loss is turned into heat and carried away by the cooling water around the engine block.
Piston engines have been functioning since the early days of steam powered devices. Standard internal combustion engines are everywhere. Variations of the internal combustion engine are the Wankel motor and rotary piston engine such as that described in U.S. Pat. Nos. 3,741,694. 5,813,372 describes a rotary piston engine in which internal friction is reduced since the pistons do not touch the cylinder walls. Only piston rings touch the walls. The cylinders and pistons rotate around an axis and rely on a sliding valve arrangement to open ports for intake and exhaust. The difficulty with this device is that the large sliding surfaces of the head past the valve ports supply a large amount of friction.
U.S. Pat. No. 5,803,041 describes a rotary engine in which linear piston motion is translated into rotary motion of the cylinder.
U.S. Pat. No. 5,138,994 describes a rotary piston engine in which a rectangular piston rotates in an annular cavity. As the piston rotates continuously in one direction, a gate that blocks the annular cavity opens once during each revolution of the piston to allow the piston to pass. The piston is connected to a central shaft by a disk that penetrates the inner cylindrical wall of the cavity. The problem with this device is that large sliding friction forces occur all the way around the rotary piston as it rubs against cylinder walls. Additional friction occurs where the disk penetrates the cylindrical wall.
U.S. Pat. No. 4,938,668 shows a rotating piston design in which two sets of rotating pistons oscillate together and apart forming cavities that change in volume as the two sets of pistons rotate around a common shaft. A cam system provides the thrust that drives the shaft. The pistons slide against an end plate in which are located intake and exhaust ports. This device would also have large sliding friction as the rotating pistons rub against the outer cylinder and against the end plates where the ports are located.
U.S. Pat. No. 4,002,033 is a rotary displacer that has a rotary-abutment sealing rotor that rotates against the main rotary piston. However, there is a slight space between the sealing rotor and the rotary piston, since the surface speeds are different. They both rotate at the same angular velocity, but since their diameters are different, the abutting surface velocities are different. The rotary piston does not touch the walls of the cylinder to eliminate sliding friction. This allows for excessive blow-by. To reduce the blow-by, grooves are formed in the piston walls to create turbulence in the gas flow. Blow-by is still a problem with this design.
U.S. Pat. No. 4,099,448 shows, rotating vanes that have rotating gears about the axes that keep the vanes synchronous. Sliding friction is prominent in this design, since the outer tips of the vanes have seals that slide on the cylinder walls.
U.S. Pat. No. 3,282,513 describes an engine that has rotating vanes that have sliding seals at the end of the vanes, which slide on cylinder walls. Lubricating oil must be supplied to the seals from the central rotating shafts. This device has some features in common with our single cylinder engine, but our single-cylinder engine has the seals mounted in the wall of the cylinder rather than in the rotating piston, and lubricating oil can be supplied from outside the cylinder rather than through the shaft and piston.
U.S. Pat. No. 2,359,819 is a pump that has sliding seals at cylinder walls. Similarly, U.S. Pat. Nos. 5,228,414, 3,315,648, 3,181,513, 2,989,040, 2,786,455, 1,010,583, and 526,127 describe designs that have rotating members that have seals that slide on cylinder walls.
Since oil supplies are being depleted and the atmosphere is being polluted with greenhouse gases, it is long past time for today's gasoline engines to be replaced by a more efficient power plant. In accordance with the present invention, which is called “MECH”, (acronym for motor, expander, compressor, or hydraulics) a new fluid displacement machine is provided that, with appropriate modifications, can function as an internal combustion engine, an expander (analogous to a turbine), a compressor, a hydraulic motor, or a pump. MECH incorporates rolling friction rather than sliding friction.
Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
SUMMARY OF THE INVENTION
To achieve the foregoing and other objects, and in accordance with the purposes of the present invention, as embodied and broadly described herein, the present invention is a motor, expander, compressor, or hydraulic device having in one embodiment an oscillating rotating piston comprising a partial-cylindrical piston having an axis of rotation and end surfaces and defining an oscillating compression volume and expansion volume. An axial sealing member separates the compression volume and the expansion volume and radial seal members seal the end surfaces of the piston. Valves operate to close the compression volume and open the expansion volume at each oscillation of the piston. Means are provided for reversing the rotation of the piston at the end of each cycle of the piston. In advanced embodiments, one or more pistons may be provided that contact other pistons along axial surfaces to form axial seal surfaces with rolling contacts.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
FIG. 1 is a radial cross-sectional view of a four-cycle engine according to one embodiment of the present invention.
FIG. 2 is an end view of one embodiment of the invention, showing a crank for converting oscillating motion to continuous rotary motion.
FIG. 3 is a radial cross-sectional view of a two-cycle engine according to another embodiment of the present invention.
FIG. 4 is a radial cross-sectional view of an expander according to one embodiment of the present invention.
FIG. 5 is an enlarged view of and more particularly depicts an exhaust valve arrangement for the expander shown in FIG. 4 .
FIG. 6 is a radial cross-sectional view of a compressor according to another embodiment of the present invention.
FIG. 7 is a radial cross-sectional view of a single rotary piston for use in various applications of the present invention.
FIG. 8 is radial cross-sectional view of a crank design for a four-piston configuration of the present invention.
FIG. 9 is a radial cross-section view of a four-piston configuration of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As used herein, the term “MECH” means a motor, expander, compressor, or hydraulics, including two-cycle and four-cycle gasoline and diesel engines. The present invention provides internal friction losses that are much less than those of standard engines. Thus, operating efficiencies and fuel economy are significantly better.
For the same volume of engine, the inventive MECH has four times the displacement of an ordinary gasoline motor, which translates to four times the power. But since MECH has less friction loss, it is projected that a MECH engine would have five times the power of the same size gasoline motor. Or conversely, a MECH engine would weigh about one-fifth the weight of a gasoline engine for the same power.
A MECH engine can be used as the power plant of a car or truck, or it can be used as the power source in a hybrid automobile. MECH engines can also be manufactured for lawn mowers, motorcycles, electric power generators. Their lightweight would make them attractive for chain saws and other handheld power equipment. Large MECH diesel or gasoline engines can used in electric power plants. Home or business self-generation units can be constructed using small MECH engines.
It is known that rolling friction is much less than sliding friction. Pistons sliding in cylinders have high friction losses. In the present invention, rolling friction is involved when two rotating pistons roll together, rather than slide along their longitudinal axes. Most people associate the word “piston” with a cylindrical object that slides axially in a cylinder. In the present description, a “rotating piston” is defined to be a partial cylinder that oscillates in a rotating manner about an axis. It does not translate axially. The rotating piston actually rotates within the cylinder in contrast to a “rotary piston” (described in some prior art) in which the piston and cylinder rotate about some external axis. “Cylinder” in this specification and claims is used in the general sense of a “piston chamber”, and may include chambers having other than a strictly cylindrical shape.
FIG. 1 shows the concept of a MECH four-cycle internal combustion engine. In engine block 1 , rotating pistons 2 and 3 rotate in an oscillating manner about shafts 6 and 7 in cylinders 4 and 5 and roll together at contact point 15 (actually a “contact line”). This rolling contact point forms an axial rolling seal that prevents gases from passing between the lower chambers 26 , 27 and upper chambers 24 , 25 . This rolling seal has much less friction than a sliding seal. Note that the pressure in upper chamber 24 is about the same as that in upper chamber 25 , and the pressure in lower chamber 26 is about the same as the pressure in lower chamber 27 , so that there would be little tendency for gas to flow through gap 22 . It is seen therefore, that the shafts 6 , 7 are coaxial with the axes of the cylinders, and the pistons pivot eccentrically about an axis of rotation defined by, and essentially coaxial with, the shafts.
In this specification and in the claims, “eccentric” refers to a piston having its axis of rotation—or more specifically to this application, its pivotal axis—displaced from its center of gravity so that it is capable of imparting reciprocating motion. Ordinarily in the invention, a piston's pivotal axis is parallel to, but offset from, the piston's longitudinal axis running through its center of gravity. Thus, as a piston pivots “eccentrically,” the bulk of its mass is always offset from its pivotal axis, although the piston's center of gravity reciprocates along an arc concentric to the pivotal axis.
The rotating pistons shown in the FIG. 1 are hemi-cylindrical. That is, the angle drawn from one face to the other is 180 degrees. This angle can be varied to suit the application, and while 180 degrees is preferable for some applications the hemi-cylindrical shape shown in the figures is by way of example rather than limitation. The wedges 8 and 9 can also be varied in angle for different applications. Gap 22 between the rotating pistons 2 , 3 and the cylinder walls should be large enough so that the rotating pistons do not rub the walls. The gap 22 should be large enough to prevent the quenching of combustion, which would lead to hydrocarbon emissions.
End plates (not shown in FIG. 1) cover the ends of the rotating pistons 2 , 3 and are secured to the engine block 1 . Sliding friction occurs between the ends of the rotating pistons and the end plates, but this friction is relatively small since the rotating pistons 2 , 3 can be very long compared to their diameter. For example, the cylinder diameter might be four inches, while the length might be two or three feet. Installing radial end seals 20 in grooves in the end plates can reduce this sliding friction further by eliminating the need to have the pistons tightly pressed against the end plates. These seals 20 are similar to piston rings in ordinary motors. End seals 20 are “U” shaped with the bottom ends abutted and the opposite ends pressed against the shafts 6 and 7 . Oil can be injected between the end seals. Springs (not shown) within the end plate grooves bias the seals 22 against the ends of the rotating pistons.
In operation, as rotating piston 3 rotates clockwise, piston 2 rotates counterclockwise, and the fuel-air mixtures in upper chambers 24 and 25 are compressed. When compression is complete, a spark plug (not shown) fires and ignites the fuel-air mixture. The explosive pressure reverses the direction of rotation of the rotating pistons 2 , 3 . The counter-rotating pistons compress the fuel-air mixtures in lower chambers 26 and 27 . Ignition in chambers 26 and 27 then again reverses the direction of the rotating pistons 2 , 3 . Valve rods 11 , actuated by cams (not shown) open upper valves 10 and allow exhaust gases to escape from upper chambers 24 and 25 through upper channels 12 and past upper valves 10 . (By “upper” and “lower” in this description, we mean the upper and lower parts of the drawing, not necessarily upper and lower parts of a physical machine). If a piston is very long, more than one intake and exhaust valve and spark plug may be advantageous; all embodiments of the invention functioning as an internal combustion engine may optionally feature more than one spark plug, more than one intake valve, and more than one exhaust valve per chamber.
During the next cycle, rods 14 open lower valves 13 to allow exhaust gases to escape from lower chambers 26 and 27 via lower channels 12 ′ while a new fuel-air mixture is drawn into upper chambers 24 and 25 through intake valves. These intake valves are located directly behind the exhaust valves 10 (further into the page) and are thus not shown. Similar intake valves are located behind lower valves 13 . The cycles repeat.
FIG. 2 shows end plate 50 and the mechanism that is located on the end plate. This end plate attaches to the end of the engine block 1 and abuts the ends of the rotating pistons 2 , 3 . Shafts 6 and 7 from FIG. 1 extend through the end plate 50 and are attached to gearwheel 60 and gearwheel 61 . These gearwheels have gear teeth on their circumferences that mesh to maintain gearwheels in 60 and 61 in proper mutual orientation. The purpose of this gear meshing is to prevent slippage of the rotating pistons 2 and 3 as they roll together. The gears also transmit energy from gearwheel 60 to gearwheel 61 so that this energy can be transmitted to the crank rod 51 , which is pivotally attached to gearwheel 61 by shaft 52 . Crank rod 51 then drives flywheel 54 by pivoting shaft 53 . (The phantom lines of 53 and the end of the crank rod 51 mean that these parts are beneath the flywheel 54 from the viewer's perspective.) Crankshaft 55 is connected to flywheel 54 and carries power from the engine to the exterior. The crankshaft 55 exits through the engine housing (not shown) that is on the viewer's side of FIG. 2 .
The oil pump consists of a plunger 75 (a curved rod) and curved chamber 76 . Plunger 75 is attached to one of the gearwheels. As the gearwheel oscillates, plunger 75 plunges into chamber 76 and forces oil (which rests in the housing in which the gearwheels are located) to flow through the check valve 78 . The oil is piped to wherever it is needed. Check valve 77 allows oil to flow into chamber 76 .
The end plate on the opposite end of the engine block 1 may have a similar gear mechanism, but it is not required. That end plate provides bearings for shafts 6 and 7 and end seals 20 . The engine needs a starter, intake and exhaust manifold, ignition wiring, timing chain, valve cams, and other items common to gasoline or diesel motors. For clarity, these items are not added to the figures. Water flowing through channels in the engine block 1 can cool the engine. These channels are not shown. They can be added by those skilled in the art.
One of the important advantages of the MECH engine is that the cylinder walls and the rotating pistons can be very hot, since the rotating pistons do not touch the cylinder walls and no lubrication is required there. If the surfaces are very hot, less heat will be lost from the burning gases to the surfaces. This will provide greater fuel economy. In ordinary internal combustion engines, a large fraction of the fuel energy is lost to the cylinder walls and carried away by cooling water to the radiator. In MECH, the end plates will require cooling, since lubrication is applied there. Internal gaps in the walls can provide insulation between the hot cylinder walls and the end plates. Heat from the gases will be lost to the end plates, but if the cylinders are long compared to the diameter, this loss will be relatively small.
In FIG. 3, showing a two-cycle engine, fuel-air mixture is drawn through tubes 106 and 116 in engine block 100 , past reed valves 117 (or other type of check valve) into lower chambers 126 and 127 as rotating piston 102 rotates counterclockwise and rotating piston 103 rotates clockwise. Fuel-air mixtures in upper chambers 124 and 125 are compressed. At the completion of compression, spark plugs (not shown) fire, and the explosion forces the rotating pistons 102 , 103 to reverse directions. Reed valves 117 close and the gases in lower chambers 126 and 127 are compressed.
When the rotating pistons approach the end of a cycle, they contact the ends of shafts 111 at points 122 , which are cutouts in the face of the pistons to provide near-normal contact. This forces valves 110 to open allowing exhaust gases from upper chambers 124 and 125 to exit through tubes 115 . Reduction of pressure in upper chambers 124 and 125 allows compressed gases in lower chambers 126 and 127 to pass through interior channels 120 through reed valves (or other types of check valves) 121 into upper chambers 124 and 125 . By having valves 121 at one end of the cylinders defined in the engine block 100 and exhaust valves 110 at the other end, the gas flowing in through 121 will tend to purge the exhaust gases and fill the upper chambers 124 and 125 with fresh fuel-air mixtures. Thus, the channels 120 and valves 121 preferably are located in the wedge 108 near the periphery of the cylinder (behind the exhaust valve 110 in the drawing), but for the sake of clarity of illustration, it is shown in the narrower part of the wedge 108 as though the channels 120 and valves 121 were at the same end of the cylinder.
When the rotating pistons 102 , 103 again reverse direction, springs 112 cause valves 110 to close so that the trapped gases in upper chambers 124 and 125 will again be compressed. The cycles are repeated.
A two-cycle MECH engine will be similar to the four-cycle MECH engine in other respects. That is, it will have a mechanism similar to that of FIG. 2 on one end plate, and it will have end seals 20 as seen in FIG. 1, but which are not seen in FIG. 3 . Rolling contact point 15 provides a seal to prevent gas flow from high-pressure chambers to low-pressure chambers.
When a high-pressure gas (such as steam, air, refrigerant vapor, etc.) is available, an expander can extract energy from the expansion of the gas to a lower pressure. Turbines are typically regarded as the expanders in steam power plants. MECH units with the appropriate construction can also serve as expanders.
Industry has used rotary vane, geroter, gear motor, and screw expanders for various applications. These devices typically have high internal friction and excessive blow-by. This leads to low volumetric efficiency. MECH expanders would have low internal friction and much lower blow-by.
MECH expanders would be much less expensive to build than turbines and could be used for steam, compressed air, and low-boiling point fluids. A similar configuration can be used as a hydraulic motor. For applications such as driving irrigation pumps or other pump applications, the MECH expander can be coupled directly to a MECH pump without having to have a generator and electric motor to drive a pump. When an expander drives a generator, which drives a motor, which drives a pump, the inefficiencies of this series of the devices are multiplied together.
FIG. 4 shows a MECH expander. Steam, air, or other high-pressure gas enters the intake tubes 216 , passes through valve assemblies 220 , and flows into lower chambers 226 , 227 , when valves 214 are open, and drives rotating pistons 202 and 203 in opposite directions about shafts 206 , 207 . When pistons 202 and 203 approach the end of their stroke, valve shifters 222 strike valves 213 and force valves 214 to close and valves 213 to open. High-pressure gas then enters upper chambers 224 , 225 via intake tubes 116 and reverses the direction of rotation of the rotating pistons 202 , 203 . The valve assemblies 220 are located in wedges 209 that separate upper chambers 224 , 225 from lower chambers 226 , 227 . High-pressure gas tends to hold the valves 211 in one position until the rotating pistons 202 , 203 shift them to the other positions.
FIG. 5 shows an exhaust valve assembly 230 , which is located behind valve assembly 220 in FIG. 4 . When high-pressure gas is entering lower chamber 227 , gas is exhausting from upper chamber 225 through exhaust valve assembly 230 past valve 233 and into exhaust tube 236 . Valve shifters like 222 (FIG. 4) strike the exhaust valves 231 at the end of each stroke to alternately open and close valves 233 and 234 by rod 231 .
The MECH expander has an end assembly like that of FIG. 2 and has other similarities to the MECH internal combustion engine.
The MECH expander of FIG. 4 can also function as a hydraulic motor. For an expander engine such as this, there is the possibility that when the high pressure gas supply is shut off, the pistons or the valves might stop in such a position that the engine would not start when the pressure is turned on again. A starter may be required.
An alternative valve system for the expander would be a crankshaft-driven cam that opens spring-loaded valves. This method would allow the intake valve to close before the piston reached the end of its stroke to allow adiabatic expansion of the gas for better efficiency.
The people of China, India, and other developing nations increasingly seek the benefits of air conditioning. Factories cannot keep up with the demand. A major problem is that the power grids and power plants in those countries do not have the capacity to provide the necessary power for all the new air conditioners. Even in the U.S., power brownouts have occurred in California and New York on hot days. A more efficient air conditioner would alleviate these problems.
Refrigerant compressors are the main energy consumers in refrigeration equipment and air conditioners. Piston compressors have high internal friction. Scroll, rotary vane, and screw compressors have high friction and excessive blow-by. The inventive MECH compressors would solve these difficulties. Small, compact, MECH compressors can be built for refrigerators, while large units can be manufactured for large air conditioners.
FIG. 6 is a schematic of a MECH compressor. The rotating pistons are shown as quadrants of cylinders with the angle from face-to-face of about 90 degrees. The face-to-face angle could be 180 degrees as shown in the previous figures, or some other angle, but it is depicted in FIG. 6 at 90 degrees to demonstrate the flexibility of design parameters for MECH geometries.
In block 300 , rotating piston 302 alternately compresses gas in chambers 324 and 326 , while rotating piston 303 alternately compresses gas in chambers 325 and 327 . When a particular piston face is receding, gas is drawn into the corresponding chamber past reed valves 310 (or other type of check valve) through tubes 313 . When the gas is compressed, valves 310 close, and the gas is forced out past reed valves 311 and through tubes 312 .
The gear mechanism on the end plate is similar to that shown in FIG. 2, but the gear wheels 60 and 61 could be only half-wheels (that is, 180 degrees) if the rotating pistons 302 , 303 are only quadrants of a cylinder, and the stroke length of the crankshaft would be less. In this case, power is input to the crankshaft, and the crankshaft drives the rotating pistons to compress the gas.
This design also serves as a liquid pump. For liquids, gap 322 is not excessively small so that resistance to piston motion would not be large. The intake and exhaust tubes could be larger.
For a compressor or liquid pump, a MECH motor or expander can be used to drive a MECH compressor or pump directly. For example, if an expander is the driver, shafts 206 and 207 of FIG. 4 extend into the compressor and become shafts 306 and 307 of FIG. 6. A crank rod and crankshaft are not necessary.
FIG. 7 shows a single piston embodiment of a MECH useful for a motor, expander, or compressor. Rather than have two pistons that roll together, one rotating piston 403 in block 400 has seals 433 to prevent gases from flowing from one chamber 460 to the other 462 . These seals are similar to the piston rings in a car engine, but are straight. Seals 433 are free to slide in slots 434 and are forced by serpentine strip springs 435 to press radially inward against the rotating piston. Oil can be injected between the two seals for lubrication. The ends of these seals 433 are placed next to the ends of seals 444 that are in slots in the end plates (not shown). This design does not exploit the advantage of rolling friction, but does provide a compact engine of high power density.
A similar seal 430 in slot 431 in wedge 409 prevents blow-by past the shaft 407 . Serpentine spring 432 presses the seal against the shaft. Valves are not shown in this figure, since the design is applicable to the different configurations of MECH. This design can be adapted to multiple rotating pistons in a single block, but each rotating piston and its cylinder would be separated from the others.
Counterweights may be attached to the gear wheels 60 and 61 in FIG. 2 (and their counter parts in other embodiments) to reduce vibration of the engine due to the motion of the rotating pistons. Being made hollow can make the pistons lighter. If the motor is a four-cylinder design (constructed by duplicating the two-cylinder design and attaching them side-by-side) with the sets of pistons rotating 180 degrees out of phase, vibration would be cancelled, and the counterweights would be unnecessary. This can be accomplished by having all four rotating pistons drive a single flywheel as shown in FIG. 8 . In this case, the upper pistons are not exactly 180 degrees out of phase with the lower ones, but are close to 180 An alternative method would be to have two flywheels and crankshafts, and the two flywheels would have gear teeth on the circumference that would mesh with each other. This provides a very smooth running motor.
An alternative geometry to cancel vibration is shown in FIG. 9, which is a cross section through the rotating pistons and engine block. Four rotating pistons 501 , 502 , 503 , and 504 are mounted in engine block 500 . On the end plate of this design, all four gear wheels (not shown) would mesh to keep the rotating pistons appropriately aligned. Note that the center of mass of the upper pistons moves downward as the center of mass of the lower ones moves upward.
Left and right pistons roll together at contact point 515 . During part of the cycle, the upper and lower pistons roll together at contact points 516 . It is not really necessary that the pistons touch at point 516 for proper function of the engine, but since all four gear wheels must mesh, the pistons will touch there. The body 520 occupies the space between the pistons to prevent unused gas from occupying that space. This body is held in place by attachment to the end plates. It could contain channels for cooling water. These methods of reducing vibration apply to all versions of MECH.
The foregoing description of the invention has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto. | A motor, expander, compressor, or hydraulic device is formed with an oscillating rotating piston comprising a cylinder having an axis of rotation and end surfaces and defining an oscillating compression volume and an expansion volume. An axial sealing member separates the compression volume and the expansion volume, and seal members seal the end surfaces of the piston. Valves operate to close the compression volume and open the expansion volume at each oscillation of the piston. Means are provided for reversing the rotation of the cylinder at the end of a compression cycle of the piston. One or more pistons may be provided that contact other pistons along axial surfaces to form axial seal surfaces with rolling contacts that reduce friction energy losses. | 5 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates generally to commercial ware wash and laundry machines and, more particularly, to an improved sensor for dispensers used with these machines.
BACKGROUND OF THE INVENTION
[0002] Accessory dispensing systems for commercial washing machines, such as ware wash and laundry machines, are frequently provided as accessory items by commercial cleaning chemical supply companies to help promote their cleaning products. As such, these systems are installed onto washing machines that are already in place and in use. The washing machines are typically self-contained units but require manual addition of the required chemicals, like rinse agent or detergent, for every load. The accessory dispensing systems provide for automatic dispensing of these chemicals from bulk storage reservoirs for less “hands-on” operation. These washing machines typically have at least one electrical motor or electrically controlled solenoid valve that operate various functions, e.g., wash, rinse, dry cycles, of the machine. These electrically operated devices are controlled by the washing machine and, therefore, do not require outside control.
[0003] These accessory dispensing systems must directly or indirectly communicate with the washing machine in order to determine the appropriate time to transfer each particular required chemical to the washing machine. For example, the dispensing system must determine when a wash cycle is starting in order to trigger operation of the appropriate pump to transfer detergent to the machine. Similarly, the system must identify the beginning of a rinse cycle so that rinsing agent can be pumped into the washing machine at that time. The timing of the various cycles of these washing machines is typically indicated by the operation of specific motors or solenoid valves within the machine. Therefore, connecting the dispensing system to these specific motors and solenoid valves such that operation of these devices sends an electrical signal to the dispensing allows the system to determine the appropriate timing for transferring fluids.
[0004] Currently, these dispensing systems are connected to the electrical components of washing machines through a hard-wired connection to each electrical component. This requires substantial dismantling of the washing machines to access the motors and solenoid valve electrical connections. These installation requirements introduce several significant drawbacks to these systems. First, because the interiors of the machine's motors and solenoid valve wiring are exposed, the danger of electrocution is present. Second, in part due to the preceding danger, it is necessary to involve a skilled electrician for installation. In some facilities, the requirement of utilizing an electrician can be prohibitive in terms of the resulting time and expense. Furthermore, in some systems it is difficult to locate the proper electrical contacts.
[0005] The present invention is directed to overcoming one or more of the problems set forth above.
SUMMARY OF THE INVENTION
[0006] An aspect of the present invention is to provide a means for controlling an accessory dispenser controller for commercial washing machines that eliminates the need for a hard-wired connection between the controller and the washing machine.
[0007] Another aspect of the invention is to provide a means for controlling an accessory dispenser controller for a washing machine that may be installed without the assistance of an electrician.
[0008] Yet another aspect of the invention is to provide an improved and safer method of installing a dispenser for a commercial washing machine.
[0009] In accordance with the above aspects of the invention, there is provided a dispenser control system for a washing machine having at least one electrically operated device that includes a controller; at least one fluid transfer mechanism in communication with the controller and in fluid communication with the washing machine; a magnetic field sensor removably connected to an exterior housing of the electrically operated device, the connection being made by a non-invasive mechanical connector; and means for communicating a signal from the magnetic field sensor to the controller, the signal generated by the magnetic field sensor in response to detection by the sensor of a magnetic flux generated by the electrically operated device outside of the housing of the electrically operated device.
[0010] In accordance with another aspect of the invention, there is provided a surface-mounted sensor for use with an accessory controller for electrically operated equipment that includes a surface mount mechanical connector; a housing adaptable for connection with said surface mount mechanical connector; a circuit board within said housing, said circuit board defining a flux field sensor; and means for communicating a signal from said circuit board to said accessory controller.
[0011] These aspects are merely illustrative of the various aspects associated with the present invention and should not be deemed as limiting in any manner. These and other aspects, features and advantages of the present invention will become apparent from the following detailed description when taken in conjunction with the referenced drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Reference is now made to the drawings which illustrate the best known mode of carrying out the invention and wherein the same reference numerals indicate the same or similar parts throughout the several views.
[0013] FIG. 1 is a block diagram of a dispenser control system according to an embodiment of the present invention.
[0014] FIG. 2 is a perspective view of a dispenser control system according to another embodiment.
[0015] FIG. 3 is a plan view of a magnetic field sensor according to another embodiment for use in a dispenser control system.
[0016] FIG. 3A is a section view of the magnetic field sensor taken along line A-A of FIG. 3 .
[0017] FIG. 4 is a plan view of a printed circuit board suitable for use in a magnetic field sensor according to another embodiment.
[0018] FIG. 5 is a circuit diagram for the printed circuit board of FIG. 4 .
[0019] FIG. 6 is a block diagram of a dispenser control system incorporating a wirelessly operating magnetic field sensor.
DETAILED DESCRIPTION
[0020] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. For example, well-known methods, procedures, and components have not been described in detail so as not to obscure the present invention.
[0021] One embodiment of a magnetic field sensor 10 according to the present invention is illustrated in FIGS. 3 and 3 A. The sensor 10 includes a housing 12 , alternately referred to as a potting box. The housing 12 contains and protects the electronic components of the sensor 10 , as well as providing a ready means for mounting the sensor where needed. In a preferred embodiment, the housing 12 is molded from a plastic material, such as polypropylene. The housing 12 is of a generally rectangular box shape, although the particular shape of the housing 12 is not central to the nature of the invention. The housing 12 is provided with one open end to allow for insertion of the sensor's electronic components. Depending on the manner in which the electronic components of the sensor 10 are mounted within the sensor 12 , the performance of the housing may be enhanced by orienting the housing 12 in a specific manner relative to the device being monitored. For example, if the electronic components are mounted to one side of the housing 12 , it is preferred to mount that side of the housing 12 against the exterior of the monitored device. This mounting preference may be clearly shown by a suitable alignment indicator 14 provided on the exterior surface of the housing 12 . In the illustrated embodiment, the alignment indicator 14 takes the form of writing on the exterior surface of the housing 12 intended to indicate that the opposite side of the housing 12 should be mounted against the exterior of the monitored device and, in particular, against the housing of the device's electrical coil in the case of a solenoid valve.
[0022] In one embodiment, the electronic portion of the sensor 10 includes a printed circuit board 16 containing the circuitry comprising a Hall Effect sensor, an amplifier, and a filter. These elements are known to those in the art. A circuit diagram for the illustrated embodiment is shown in FIG. 5 . The components utilized in the printed circuit board 16 of the illustrated embodiment are as shown in the following table:
No. Quantity Component Description Manufacturer 1 3 C1, C2, C9 .01 uF 50 V X7R 2 3 C3, C5, C7 .1 uF 25 V X7R 3 2 C6, C10 10 uF 35 V 4 1 C8 .22 uF 16 V X7R 5 4 D1, D2, D3, D4 1N4148 6 1 D5 LED-Green Lumex 7 3 OUT, V+, V− Spring Socket Amp 8 1 Q1 2N3904 9 3 R1, R4, R12 10 K 1/10 W 5% 10 1 R10 470 K 1/10 W 5% 11 1 R16 2.2 K 1/10 W 5% 12 6 R2, R5, R7, 4.7 K 1/10 W 5% R8, R13, R15 13 2 R3, R9, R11 1 M 1/10 W 5% 14 2 R6, R14 100 K 1/10 W 5% 15 1 S1 SS495A2SP Honeywell 16 1 U1 LM324D 17 1 PWB Printed Wiring Panel
[0023] The printed circuit board 16 includes pin receptacles 18 to enable connection of the printed circuit board 16 to a cable assembly 20 . The cable assembly 20 , as shown in FIG. 6 , advantageously includes three wires 22 ; one for power to the sensor, one return wire, and one for transmission of signals from the sensor. The wires 22 are preferably housed within a wiring jacket 24 for protection. At the controller end of the cable assembly 20 , a quick connector 26 is provided with terminals for each wire in the assembly. While it is not essential to the present invention, the quick connector 26 does allow for simple plug-in installation to the dispenser controller.
[0024] During assembly of the sensor 10 , the printed circuit board 16 is inserted into the housing 12 . Wires 22 are inserted into the appropriate pin receptacle 18 on the printed circuit board 16 . The housing 12 is then filled completely with a potting compound 30 , such as a clear silicone, to further secure and protect the printed circuit board 16 and the connection between the PCB 16 and the cable assembly 20 .
[0025] FIGS. 1 and 2 depict a dispenser system according to one embodiment incorporating a magnetic field sensor as previously described. The dispenser system includes a controller 32 , at least one fluid pump, valve, or other fluid transfer mechanism 34 , and at least one sensor 10 . The pump is operative for drawing fluid, such as rinse agent or detergent, from a reservoir 36 , and transferring the fluid via a supply line 38 to a washing machine 40 , such as a commercial ware wash or laundry machine. The fluid may be supplied into a specific fluid inlet of the washing machine or directly into the machine's washing tank.
[0026] Dispensing systems as described herein are frequently provided as accessory items by commercial cleaning chemical supply companies to help promote their cleaning products. As such, these systems are installed onto washing machines that are already in place and in use. The washing machines are typically self-contained units but require manual addition of the required chemicals, like rinse agent or detergent, for proper cleaning. The accessory dispensing systems provide for automatic dispensing of these chemicals from bulk storage reservoirs for less “hands-on” operation. These washing machines typically have at least one electrical motor or electrically controlled solenoid valve that operate various functions, e.g., wash, rinse, dry cycles, of the machine. These electrically operated devices are controlled by the washing machine and, therefore, do not require outside control.
[0027] Accessory dispensing systems as described herein must directly or indirectly communicate with the washing machine in order to determine the appropriate time to transfer each particular required chemical to the washing machine. For example, the dispensing system must determine when a wash cycle is starting in order to trigger operation of the appropriate pump to transfer detergent to the machine. Similarly, the system must identify the beginning of a rinse cycle so that rinsing agent can be pumped into the washing machine at that time. The timing of the various cycles of these washing machines is typically indicated by the operation of specific motors or solenoid valves within the machine. Therefore, connecting the dispensing system to these specific motors and solenoid valves such that operation of these devices sends an electrical signal to the dispensing allows the system to determine the appropriate timing for transferring fluids.
[0028] Installation of the accessory dispensing systems described herein is accomplished by first mounting the dispenser controller 32 to a solid surface. Typically, the pump(s) 34 associated with the system are integrated with the controller 32 . A first fluid supply line 38 is installed between a pump 34 and a respective fluid reservoir 36 . A second supply line 38 is installed between each pump 34 and the washing machine 40 . Next, each sensor 10 is connected to the controller 32 by means of the cable assembly 20 . If a quick connector 26 is provided, the cable assembly 20 may simply plugged-in to a mating female connector on the controller 32 . One sensor 10 is used for each relevant electrically operated valve or motor 42 in the washing machine. A typical ware wash application will require two sensors. Laundry dispensers may require multiple sensors. Each sensor 10 is connected to the exterior housing of its associated electrically operated device. Advantageously, the sensor need not be hard-wired into the electrically operated device. Simply mounting the sensor 10 to the exterior housing of the device, in particular, adjacent the electrical coils of the solenoid or motor, suffices. In a preferred embodiment, the sensor 10 is strapped to the housing of the electrically operated device with a hook and loop fastener. However, many other surface mounting arrangements, for example releasable adhesives, are perfectly suitable.
[0029] All of the controllable machine components on these washing machines operate on electromagnetic principles and, therefore, produce flux fields. Practical considerations of the design of these devices dictate that some portion of the flux field will leave the designed flux path. This stray flux will exist in a field surrounding the particular component. It will only be present when power is supplied to the solenoid or motor. The magnetic field sensor described herein detects stray flux fields around these electrically operated devices. It then converts this stray flux into an electrical signal that can be used to trigger operation of the dispenser. In the preferred embodiment, the sensor uses a Hall Effect sensor to sense the flux density in the vicinity of the sensor. The Hall Effect sensor produces an analog output proportional to the magnitude and polarity of the flux field surrounding it. This signal is then amplified and filtered to remove noise before it is transmitted to the controller.
[0030] In another preferred embodiment, the sensor can be tuned to detect any specific flux fields. In one embodiment, the sensor is tuned to respond to fields surrounding alternating currents in the 50 Hz to 60 Hz range. The “tuning” of the sensor is a sensitivity adjustment. The flux density to which the sensor responds is adjusted. Generally speaking, the flux density decreases by the square of the distance from the source. Limiting the sensitivity allows sensors to be applied to closely positioned independent flux sources. This requires close magnetic coupling of the sensor to the flux source (putting the sensor in the right place on the coil). The ability to tune the sensor eliminates false signals due to spurious noise from transients in the subject machine. It also eliminates false triggers from permanent magnets that may be in the vicinity of the sensor. The sensitivity of the sensor can be advantageously limited so that the sensor does not respond to nearby electromechanical components. In another embodiment, the sensor incorporates a visual indicating LED that indicates when the sensor is activated by a flux field. This feature eases proper positioning of the sensor on the respective motor or solenoid during initial installation. When properly positioned, the sensor will reliably indicate the operation of the subject device and provide electrical isolation from it.
[0031] While a wired version of the sensor has been previously described, the sensor may also be utilized in conjunction with wireless transmission of triggering signals to the dispenser controller. For example, radio frequency (RF) or infrared (IR) signals may be utilized. These transmission systems are well known in general, but have not been utilized in this capacity. In such a system, as illustrated in FIG. 6 , the dispenser controller 44 is provided with a wireless signal receiver 46 . The connections between the controller 44 and the pump(s) 34 , reservoir 36 , and supply lines 38 remain the same. Rather than a wired cable assembly, the wireless magnetic field sensor 48 is provided with a wireless transmitter 50 . Because there is no electrical connection by which to supply the sensor 48 with power, the sensor 48 is also supplied with a power source 52 , such as a battery pack. The remainder of the sensor 48 is essentially the same as its wired counterpart. The sensor 48 and controller 44 operate in the same manner as the wired version.
[0032] Other objects, features and advantages of the present invention will be apparent to those skilled in the art. While preferred embodiments of the present invention have been illustrated and described, this has been by way of illustration and the invention should not be limited except as required by the scope of the appended claims and their equivalents. | A dispenser control system for a washing machine having at least one electrically operated device includes a controller; at least one fluid transfer mechanism in communication with said controller and in fluid communication with said washing machine; a magnetic field sensor removably connected to an exterior housing of said electrically operated device, said connection made by a surface mount mechanical connector; and means for communicating a signal from said magnetic field sensor to said controller, said signal generated by said magnetic field sensor in response to detection by said sensor of a magnetic flux generated by said electrically operated device outside of said housing of said electrically operated device. | 3 |
[0001] This application claims the benefit of U.S. Provisional Application No. 62/300,146, filed Feb. 26, 2016, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a hamper. More particularly, the invention relates to a hamper for receiving and drying wet clothes.
BACKGROUND OF THE INVENTION
[0003] A question faced by many athletes is what to do with post workout clothes that are thoroughly soaked through by perspiration. People that work outdoors in the hot sun or in rainy conditions face a similar problem. Swimmers are another example of people that often have wet clothes. Since daily laundry is typically not an option, the wet clothes pile up between laundry days. If the wet clothes are placed in a hamper with the normal laundry, the moisture, smell and bacteria may be transferred to the normal laundry. While a second, common hamper may be considered, such does not solve the problem since the wet clothes just sit in the hamper without getting dry, but instead remaining in a wet pile. By laundry day, the clothes remain wet and allow for bacteria, mold, or bad odor to develop. Some people instead choose to place the clothes in the bathroom, bedroom or laundry room on the floor or to hang, but it is an eyesore.
[0004] Accordingly, there is a need for a storage device for wet clothes that is aesthetically pleasing while allowing the clothes to dry out.
SUMMARY OF THE INVENTION
[0005] In at least one embodiment, the present invention provides a wet clothes drying hamper which allows the user to store soaked clothes in an aesthetically pleasing way, and have them dry for the next laundry day. No more wet piles of clothes on the floor or hanging in the bathroom, or wet, smelly clothes when doing laundry.
[0006] In at least one embodiment, the present invention provides a clothes hamper including a hamper body extending from a generally closed end to a generally open end with an interior chamber defined within the hamper body. A rack assembly defines one or more hanging elements and is sized and configured to fit within the interior chamber. An extension assembly is positioned within the interior chamber and is configured to facilitate movement of the rack assembly between a retracted position within the interior chamber and an extended position wherein at least a portion of the rack assembly is outside of the hamper body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate the presently preferred embodiments of the invention, and, together with the general description given above and the detailed description given below, serve to explain the features of the invention. In the drawings:
[0008] FIG. 1 is a perspective view of an exemplary wet clothes drying hamper in accordance with an embodiment of the invention.
[0009] FIG. 2 is a cross-sectional view along the line 2 - 2 in FIG. 1 with the extension and rack assemblies omitted.
[0010] FIG. 3 is a perspective view of the wet clothes drying hamper of FIG. 1 with the extension and rack assemblies in an extended position.
[0011] FIG. 4 is a perspective view of the wet clothes drying hamper of FIG. 1 with the draw open, the extension and rack assemblies in an extended position, and the basket body omitted.
[0012] FIG. 5 is a perspective view of the wet clothes drying hamper of FIG. 1 with the extension and rack assemblies in a retracted position with the cedar panels omitted.
[0013] FIG. 6 is a perspective view of an exemplary wet clothes drying hamper in accordance with another embodiment of the invention with the extension and rack assemblies in an extended position and the basket body and cedar panels shown transparently.
[0014] FIG. 7 is a perspective view of an exemplary wet clothes drying hamper in accordance with another embodiment of the invention with the lid removed.
[0015] FIG. 8 is a cross-sectional view along the line 8 - 8 in FIG. 7 showing the telescoping pole assembly in a retracted position.
[0016] FIG. 9 is a cross-sectional view similar to FIG. 8 showing the telescoping pole assembly in an extended position.
DETAILED DESCRIPTION OF THE INVENTION
[0017] In the drawings, like numerals indicate like elements throughout. Certain terminology is used herein for convenience only and is not to be taken as a limitation on the present invention. The following describes preferred embodiments of the present invention. However, it should be understood, based on this disclosure, that the invention is not limited by the preferred embodiments described herein.
[0018] Referring to FIGS. 1-5 , an exemplary wet clothes drying hamper 10 in accordance with embodiment of the invention will be described. The hamper 10 generally includes a basket 12 , a cover 20 , a rack assembly 30 and an extension assembly 40 . The basket 12 is preferably a normal size hamper body 14 extending between a closed end 11 and an open end 13 . The basket 12 is shown having a rectangular configuration but may have any desired configuration, eg, square, round, oval, whichever looks the best and holds the most clothes. Preferably it has aesthetically pleasing modern looking exterior. The cover 20 extends across and generally closes the open end 13 of the basket 12 . In the present embodiment, the cover 20 is attached to and moves with the rack assembly 30 , as illustrated in FIG. 3 , but may be removable independent of the rack assembly 30 . The cover 20 includes a pair of slots 21 . The slots 21 provide for air flow, but also define a handle which allows the cover 20 to be gripped and moved to the open position illustrated in FIG. 3 .
[0019] The basket body 14 preferably is made of high quality plastic or other desired materials and has passages 15 therethrough to allow for ventilation. In the present embodiment, a cedar strip or panel 16 extends over each passage 15 . Referring to FIG. 2 , the cedar panels 16 are spaced from the interior surface of the basket body 14 , for example, via standoffs, such that air may flow into and out of the basket 12 , as indicated by the arrows. The cedar panels 16 are configured to absorb moisture and odor and provide a pleasant smell. While cedar panels are described herein, the invention is not limited to such and may include other natural or synthetic moisture and/or odor absorbing materials. Additionally, the passages 15 are not limited to the size, configuration or number illustrated. For example, alternatively the basket body 14 may have a mesh configuration with a plurality of small passages. The panels 16 could then be placed in desired locations within the basket 12 , independent of the location of the passages.
[0020] At the closed end 11 of the basket 12 , an absorbent mat 28 is preferably provided to collect moisture which may drip from clothes supported on the rack assembly 30 . The mat 28 is preferably a thick, industrial absorbent mat made from, for example, cellulose or meltblown polypropylene. In the illustrated embodiment, the mat 28 is supported on a support surface 25 of a pull-out draw 24 . In the illustrated embodiment, the pull-out draw 24 includes a handle 26 , which may extend from the draw surface, may be a hole in the surface or any other desired structure which allows the draw 24 to be gripped and pulled from the basket body 14 to access the absorbent mat 28 . The draw 24 may include side walls 27 (see FIG. 4 ) which extend partially or fully along the sides of the support surface 25 to maintain the position of the mat 28 .
[0021] Referring to FIGS. 3 and 4 , the rack assembly 30 has a configuration which complements the interior configuration of the basket 12 . In the present embodiment, the rack assembly 30 includes four corner posts 31 which are supported on and extend from a portion of the extension assembly 40 , as will be described in more detail hereinafter. A plurality of shelves 32 a, 32 b, 32 c are supported by the posts 31 in spaced relation to one another. While three shelves are illustrated, the invention is not limited to such. For example, the hamper 10 ′ illustrated in FIG. 6 includes two shelves 32 a, 32 b. In other respects, the hamper 10 ′ is substantially the same as the hamper 10 of the present embodiment. Each of the shelves 32 a, 32 b, 32 c includes a plurality of hanging rods 34 extending between end rods 33 which connect to respective posts 31 . The configuration of the shelves 32 a, 32 b, 32 c allows a user to lay clothing across multiple hanging rods 34 or drape a piece of clothing over one or more of the hanging rods 34 . Portions of the rack assembly 30 , for example, the shelves 32 a, 32 b, 32 c, may be made from moisture absorbing materials, for example, cedar. The rack assembly 30 is not limited to the illustrated shelves and may have other configurations, including configurations which have other types of hanging elements, e.g. hooks, cords, planar surfaces with through holes and the like.
[0022] Referring to FIG. 4 , the exemplary extension assembly 40 will be described. In the present embodiment, the extension assembly 40 includes a scissor lift assembly 50 extending between bottom rails 42 a, 42 b and top rails 44 a, 44 b. The bottom rails 42 a, 42 b are secured on the bottom surface 11 of the basket 12 . The posts 31 of the rack assembly 30 are connected to respective ones of the top rails 44 a, 44 b. As such, the rack assembly 30 moves between the retracted position within the basket 12 , as illustrated in FIG. 5 , and the extended position extended from the basket 12 , as illustrated in FIGS. 3 and 4 , as the scissor lift assembly 50 is retracted or extended.
[0023] The illustrated scissor lift assembly 50 includes a pair of lower fixed pivot arms 52 a, 52 b, each with one end pivotally attached to a respective bottom rail 42 a, 42 b at a fixed pivot location 53 a, 53 b. A pair of lower sliding pivot arms 54 a, 54 b cross the fixed pivot arms 52 a, 52 b, with mid-pivots 56 connecting the respective arms 52 a, 54 a and 52 b, 54 b. One end of each lower sliding pivot arm 54 a, 54 b has a wheel 55 or the like that rides in a track 45 of the respective bottom rail 42 a, 42 b. The wheels 55 slide within the tracks as the scissor lift assembly 50 is extended or retracted. A plurality of intermediate pivot arms 58 are pivotally connected to the lower fixed and sliding pivot arms 52 a, 52 b, 54 a, 54 b at end-pivots 57 . The intermediate pivot arms 58 may be pivotally connected to one another at mid-pivots 56 , if desired for additionally stability. Stability bars 51 may also extend between some or all of the arms as desired.
[0024] The intermediate pivot arms 58 ultimately pivotally connect with upper fixed pivot arms 60 a, 60 b and upper sliding pivot arms 62 a, 62 b. The number of intermediate pivot arms 58 is selected based on the desired amount of extension. Each of the upper fixed pivot arms 60 a, 60 b has one end pivotally attached to a respective top rail 44 a, 44 b at a fixed pivot location 59 a, 59 b. One end of each upper sliding pivot arm 62 a, 62 b has a wheel 55 or the like that rides in a track 45 of the respective top rail 44 a, 44 b. The wheels 55 slide within the tracks as the scissor lift assembly 50 is extended or retracted. As illustrated in FIGS. 4 and 6 , the bottom and top rails 42 a, 42 b, 44 a, 44 b may have notches 46 or the like to accommodate the arms as they pivot relative to the rails. To assist with extension and retraction of the scissor lift assembly 50 , pneumatic struts 48 may extend between the bottom rails 42 a, 42 b and respective arms 52 a, 52 b.
[0025] In operation, a user grips the cover 20 via the slots 21 and extends the rack and extension assemblies 30 , 40 such that the rack assembly 30 is in the extended position illustrated in FIG. 3 . The wet clothes are then placed on the shelves 32 a, 32 b, 32 c and/or hung on the hanging rods 34 . Once the clothes have been positioned on the rack assembly 30 , the cover 20 is lowered such that the extension assembly 40 is retracted and the rack assembly 30 is lowered to the retracted position, as illustrated in FIG. 5 , such that the shelves 32 a, 32 b, 32 c, and thereby the wet clothes, are supported within the basket 12 in a non-piled configuration. The non-piled wet clothes more easily dry do to ventilation through the basket 12 along with absorption by the cedar panels 16 and the mat 28 .
[0026] Referring to FIGS. 7-9 , an exemplary wet clothes drying hamper 110 in accordance with another embodiment of the invention will be described. The hamper 110 includes a basket 112 and a cover 116 . The basket 112 is preferably a normal size hamper body 114 extending between a closed end 113 and an open end 115 . In the present embodiment, the basket 112 is shown having a round configuration but may have any desired configuration as in the previous embodiments. Preferably it has aesthetically pleasing modern looking exterior. The basket body 114 preferably is made of high quality plastic or other desired materials and has passages therethrough, for example, due to a mesh configuration, to allow for ventilation.
[0027] On the interior, the basket 112 preferably includes cedar strips or panels 130 , or the like, which absorb moisture and odor and provide a pleasant smell. The panels 130 may take up any desired surface area, but preferably have space therebetween or holes therethrough such that air can circulate through the basket 112 . In the illustrated embodiment, the cover 116 also has a cedar panel 118 on the interior surface thereof. At the closed end 113 of the basket 112 , an absorbent mat 132 is preferably provided to collect moisture which may drip from the clothes. The mat 132 is preferably a thick, industrial absorbent mat as in the previous embodiment.
[0028] A telescoping pole assembly 120 within the basket 112 defines the extension assembly and rack assembly of the present embodiment. The telescoping pole assembly 120 includes an outer pole 124 and an inner pole 126 . The inner pole 126 is secured relative to the closed end 113 of the basket 112 . The outer pole 124 includes a handle 122 which may be grasped to extend the outer pole 124 from the retracted position shown in FIG. 8 to the extended position shown in FIG. 9 . As an alternative, the outer pole 124 may be connected to the lid 116 such that the lid may be used to extend the outer pole 124 . A push button or the like may be provided between the outer and inner poles 124 , 126 to lock the outer pole 124 in the extended position if desired. A plurality of hanging rods 128 extend outwardly from the outer pole 124 and are configured to hang wet clothes thereon. The hanging rods 128 may be provided in any desired configuration.
[0029] In operation, a user removes the cover 116 and extends the outer pole 124 to the extended position illustrated in FIG. 9 . The wet clothes are then hung on the hanging rods 128 and thereafter the outer pole 124 is lowered to the retracted position such that the hanging rods 128 , and thereby the wet clothes, are supported within the basket 112 in a non-piled configuration. The cover 116 may be returned to the open end 115 of the basket 112 . The non-piled wet clothes more easily dry do to ventilation through the basket 112 along with absorption by the cedar panels 130 and the mat 132 .
[0030] These and other advantages of the present invention will be apparent to those skilled in the art from the foregoing specification. Accordingly, it will be recognized by those skilled in the art that changes or modifications may be made to the above-described embodiments without departing from the broad inventive concepts of the invention. It should therefore be understood that this invention is not limited to the particular embodiments described herein, but is intended to include all changes and modifications that are within the scope and spirit of the invention as defined in the claims. | A clothes hamper includes a hamper body extending from a generally closed end to a generally open end with an interior chamber defined within the hamper body. A rack assembly defines one or more hanging elements and is sized and configured to fit within the interior chamber. An extension assembly is positioned within the interior chamber and is configured to facilitate movement of the rack assembly between a retracted position within the interior chamber and an extended position wherein at least a portion of the rack assembly is outside of the hamper body. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to gas turbine engines and, more particularly, to oil scavenging systems.
[0003] 2. Description of the Prior Art
[0004] Proper scavenging of used oil in bearing assemblies is essential to prevent overheating and premature wear of gas turbine engine mechanical parts. The used oil is usually circulated to an oil treatment system to remove air and particles therefrom before being returned to the bearing assemblies.
[0005] Oil scavenging systems typically rely on a simple pressure imbalance to direct the used oil into collection tubes for transport to a main oil pump of the oil treatment system. More efficient systems have been devised, employing special pumps or spinning vanes to improve the used oil circulation. However, such special pumps and vanes increase the weight of the engine and thus the costs of operation.
[0006] Accordingly, there is a need for an efficient scavenge system for a bearing assembly that has a minimal weight.
SUMMARY OF THE INVENTION
[0007] It is therefore an aim of the present invention to provide an improved scavenge system for a bearing assembly of a gas turbine engine.
[0008] Therefore, in accordance with a general feature of the present invention, there is provided a scavenge system for a bearing assembly, the system comprising a scavenging passage extending axially through a rotating shaft supported by the bearing assembly, and at least one scoop provided on the rotating shaft, said at least one scoop impelling oil internally of said rotating shaft into said scavenging passage as said at least one scoop rotates with said rotating shaft.
[0009] In accordance with a further general aspect of the present invention, there is provided a scavenge system for a bearing assembly, the system comprising a scavenging passage extending axially through a rotating shaft supported by the bearing assembly, and means provided on the rotating shaft for drawing oil internally of said rotating shaft into said scavenging passage as said shaft rotates.
[0010] In accordance with a further general aspect of the present invention, there is provided a gas turbine engine comprising a compressor section, a combustor and a turbine section in serial flow communication with one another, a main rotating shaft supported by a bearing assembly, and a scavenge system for the bearing assembly, the scavenge system comprising a scavenging passage extending axially through said main rotating shaft, and at least one inlet hole defined in said main rotating shaft and in flow communication with said scavenging passage, said at least one inlet hole extending at an angle to a radius of the main rotating shaft to thereby cause oil about the rotating shaft to be drawn into said scavenging passage in said main shaft via said at least one inlet hole as said main shaft rotates.
[0011] Also in accordance with another general aspect of the present invention, there is provided a scavenge system for a bearing assembly supporting a rotating shaft in a gas turbine engine, the system comprising first fluid communication means between a lubricant cavity containing the bearing assembly and an annular inner surface closely surrounding an outer surface of the rotating shaft, second fluid communication means within the rotating shaft communicating with a stationary chamber, and third fluid communication means between the outer surface of the rotating shaft and the second fluid communication means, the third fluid communication means being defined such as to communicate with the first fluid communication means during at least a portion of a rotation of the shaft, and such that the rotation of the shaft causes used lubricant coming from the lubricant cavity to be moved from the first fluid communication means to the third fluid communication means so as to deliver the used lubricant to the stationary chamber through the second fluid communication means.
[0012] In accordance with a still further general aspect of the present invention, there is provided a method of evacuating scavenge air and oil from a bearing assembly supporting a main shaft of a gas turbine engine, the method comprising the steps of: a) feeding the scavenge air and oil from the bearing assembly to an interface with said main shaft, b) drawing the scavenge air and oil from said interface into said main shaft, and c) evacuating the oil axially through said main shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Reference will now be made to the accompanying drawings, showing by way of illustration a preferred embodiment of the invention and in which:
[0014] FIG. 1 is a schematic side view of a gas turbine engine, in partial cross-section, to which an embodiment of the present invention is applied;
[0015] FIG. 2 is a cross-sectional side view showing bearing assemblies supporting a rotating shaft of the gas turbine engine of FIG. 1 ; and
[0016] FIG. 3 is a cross-sectional view of a scavenge system taken along lines B-B of FIG. 2 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] FIG. 1 illustrates a gas turbine engine 10 of a type preferably provided for use in subsonic flight, generally comprising in serial flow communication a fan 12 through which ambient air is propelled, a multistage compressor 14 for pressurizing the air, a combustor 16 in which the compressed air is mixed with fuel and ignited for generating an annular stream of hot combustion gases, and a turbine section 18 for extracting energy from the combustion gases. A rotating shaft 20 extends within the engine 10 and transfers energy from the turbine section 18 to the compressor 14 and the fan 12 .
[0018] Referring to FIG. 2 , the rotating shaft 20 is supported by a plurality of annular bearing assemblies 22 , as well known in the art. Each annular bearing assembly 22 comprises a series of roller bearings 24 located in a bearing compartment 26 . The bearing compartment 26 is defined such that each bearing assembly 22 is located within an annular oil cavity 28 . The annular oil cavity 28 contains oil providing adequate lubrication to the bearing assembly 22 .
[0019] During use, used oil from the oil cavity 28 is circulated to an oil treatment system (not shown) in order to remove unwanted debris and air from the used oil. A scavenge system 40 is used to direct the mixture of air and oil from the oil cavity 28 to the oil treatment system. The scavenge system 40 is illustrated in FIGS. 2-3 and will be described in the following.
[0020] In the bearing compartment 26 , a series of axial tubes 50 extend along an axial direction of the rotating shaft 20 , and a series of radial tubes 48 extend along a radial direction relative to the rotating shaft 20 . Each axial tube 50 has one end connected to one end of a corresponding radial tube 48 . The opposed end of each axial tube 50 is in fluid communication with the oil cavity 28 . The opposed end of each radial tube 48 defines an opening 51 in an inner annular surface of the bearing assembly 22 which closely surrounds the rotating shaft 20 . The openings 51 are distributed along a circumference of the inner annular surface.
[0021] The combination of each axial tube 50 with the corresponding radial tube 48 forms a conduit going from the oil cavity 28 to an opening 51 at the interface between the bearing compartment 26 and the rotating shaft 20 .
[0022] An annular channel 42 is defined within the rotating shaft 20 and is concentric therewith. A plurality of holes 44 are defined around a circumference of an outer surface of the rotating shaft 20 . The holes 44 are in fluid communication with the annular channel 42 . The holes 44 are preferably perpendicular to the annular channel 42 and defined at a large angle with respect to a radius of the rotating shaft 20 . The holes 44 are machined so that the remaining shaft material between adjacent holes forms a curved scoop 46 . The holes 44 are located in the same diametrical plane as the openings 51 , such that each hole 44 can be aligned in turn with each opening 51 and be in fluid communication therewith during the rotation of the shaft 20 .
[0023] The scoops 46 preferably have a curved section, and are progressively thinner toward the outer surface of the shaft 20 . As such, they have a profile which is similar to an airfoil. The scoops 46 are curved in the direction of rotation of the shaft 20 as depicted by arrow 47 in FIG. 3 . A space between adjacent scoops 46 , which is curved and thinner toward the center of the shaft 20 , defines the shape of the holes 44 . The shape and angle of the holes 44 and scoops 46 minimizes the effects of the centrifugal forces acting to push the air and oil mixture away from the shaft 20 . Thus, a rotation of the holes 44 and scoops 46 brought by the rotation of the shaft 20 will “pick up” and draw the air and oil mixture coming from the openings 51 to bring it to the annular channel 42 through the holes 44 .
[0024] Because the angle of the holes 44 with respect to the radial direction of the shaft 20 is preferably large, the number of holes 44 and scoops 46 is preferably limited to three. As illustrated in FIG. 3 , a preferred embodiment of the scavenge system 40 includes three groups having each three radial tubes 48 and axial tubes 50 defined in proximity to one another such as to have a common opening 51 for each group. The holes 44 , scoops 46 and groups of tubes 48 , 50 , are all equally angularly spaced apart in order to provide a balanced scavenge system 40 .
[0025] Thus, the mixture of air and oil can be transported from the oil cavity 28 to the openings 51 at the interface between the bearing compartment 26 and the rotating shaft 20 , then from the openings 51 to the holes 44 . The mixture then travels along the annular channel 42 to an extremity thereof which extends such as to define an annular exit port at the end of the shaft 20 . This exit port provides fluid communication between the annular channel 42 and a stationary chamber 52 located at the downstream end of the shaft 20 , where the mixture is collected. Pipes 54 provide fluid communication between the chamber 52 and an oil treatment system. A sufficient pressure gradient ensures that the air and oil mixture will circulate adequately from the oil cavity 28 to the oil treatment system following arrow 56 . The following treatment of the air and oil mixture and subsequent return of the cleaned oil to the oil cavity 28 is well known in the art and as such will not be discussed herein.
[0026] In an alternate embodiment, it is contemplated to replace the chamber 52 located at the end of the shaft 20 by an annular stationary chamber located around the rotating shaft 20 and in fluid communication with the channel 42 through a series of radial holes. In this case, the centrifugal forces acting on the used oil propels it from the channel 42 to the annular chamber, where it can be led to the oil treatment system through appropriate piping.
[0027] The scavenge system 40 can also be used with other types of bearing assemblies supporting a rotating shaft, and as such should not be construed as being limited to aircraft engines.
[0028] The scavenge system 40 uses a channel 42 which is directly machine within the shaft, and scoops 46 are preferably formed by removing material from the rotating shaft 20 in order to machine the holes 44 . Thus, these components reduce the weight of the rotating shaft rather than increase the overall engine weight, as added components would. The scavenge system 40 therefore has the advantage of representing a minimal weight increase for the engine.
[0029] It is understood that the present invention applies to any gas turbine engines, and in fact to any rotating machinery in which oil is scavenged.
[0030] The embodiments of the invention described above are intended to be exemplary. Those skilled in the art will therefore appreciate that the forgoing description is illustrative only, and that various alternatives and modifications can be devised without departing from the spirit of the present invention. Accordingly, the present is intended to embrace all such alternatives, modifications and variances which fall within the scope, of the appended claims. | A bearing scavenge system comprises a scavenging passage extending axially through a rotating shaft supported by the bearing assembly. Oil and air are drawn from an oil cavity of the bearing assembly and evacuated through the rotating shaft as the shaft rotates. | 5 |
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
This invention relates to a method of refining pulp stock in which the pulp material to be ground is introduced into a grinding space located between a first rotatable grinding device carried by a shaft and being axially displaceable by a servo motor, and a second non-rotatable grinding device. The servo motor is actuated by pressurized fluid for adjusting and controlling the grinding space, producing a grinding pressure between the first and the second grinding devices, and for preventing axial displacement of the first rotatable grinding device relative to the second non-rotatable grinding device in response to fluctuating axial grinding forces. The second non-rotatable grinding device includes a plurality of concentrically arranged annular grinding members, at least one of which is axially adjustable by a setting device.
The invention also relates to a grinding apparatus which includes grinding discs in opposed relationship, and forming a grinding space therebetween. A rotatable grinding member is carried by an axially displaceable shaft, and the axial position of the shaft determines the size of the grinding space. The space is controlled and maintained by a servo motor, as exemplified in U.S. Pat. No. 2,964,250. The stationary grinding disc comprises two or more concentrically arranged, annular members for grinding disc elements, which are axially adjustable relative to each other to form the most efficient contour of the grinding space.
The grinding product, such as lignocellulosic material from wood chips or the like, is fed into an opening at the grinding space and forced through the grinding discs primarily in an outward radial or spiral direction by centrifugal forces in combination with the feeding effect of the grinding disc patterns used. During this forced passage by the grinding discs, the treated material generates a high grinding pressure which is transferred to the grinding members as axial forces that are absorbed and counteracted by a rotary side hydraulic main servo motor acting on the rotatable shaft with its grinding member and, on the stator side, by set screws of the adjustable annular grinding members and directly by the stator base of the non-adjustable part of the stationary grinding member.
HISTORY OF RELATED ART
Hydraulic and/or mechanical methods to adjust the axial position of one or more concentrically arranged annular holder members for non-rotating grinding disc elements have been used in different applications as exemplified by U.S. Pat. Nos. 3,684,200, 4,283,016 and 4,253,613.
With the use of increasingly larger refiners with connected power in excess of 60,000 HP, however, the generated axial grinding forces have reached levels far above 100 tons. This axial load is directed to, and is equal for, both the rotating and the non-rotating grinding members, and has necessitated the use of increasingly sophisticated mechanisms for the independent axial adjustment of the non-rotary annular grinding members.
The previously used threaded set screws or other threaded components for adjusting the axial positions of the different non-rotating grinding elements are, with these increasing axial loads, no longer acceptable due to the associated heavy frictional turning resistance and excessive wear.
In order to minimize the frictional forces and wear of the set screws, ball and roller set screws having different designs have been used. These devices are expensive, however, and require the frequent repair of their internal components that absorb the axial forces.
Hydraulically operated or assisted stator position control systems with separate and independent hydraulic systems as exemplified by U.S. Pat. No. 3,684,200, have also been used and in some cases have provided acceptable performance. But, compared to the system of this invention, the known systems are complicated and expensive.
The use of hydraulic booster cylinders for the stator set screws is described in U.S. Pat. No. 4,253,613. These hydraulic boosters, however, operate with a preset hydraulic pressure, and generate a constant set axial force, which unloads the threaded set screws but does not follow the variation in axial forces generated during the grinding process. The set screws will thus carry the difference in axial load between the actual grinding load and the preset hydraulic force, in the direction toward the rotating grinding elements, which in turn have to be set to a level well above the maximum grinding load in order to prevent unwanted and uncontrolled outward movement of the controlled non-rotating grinding element.
Furthermore, the position of the controlled non-rotary grinding member is adjusted during start-up procedures, and when the axial grinding forces are zero or slightly greater, the set screws will carry the full preset force of the hydraulic boosters. Thus, the system will not protect the stator set screws from the heavy peak loads, but will only lower the average performance loads. Reference is also made to U.S. Pat. Nos. 2,964,250 and 3,717,308 for relevant disclosures.
SUMMARY OF THE INVENTION
The present invention has been made in view of the above inadequacies of the prior art and has as a principal object to provide a method and apparatus for refining pulp stock permitting counterbalancing of all of the varying axial forces exerted on the controlled non-rotatable grinding member.
The method in accordance with the present invention comprises absorbing and counterbalancing fluctuating axial forces from a grinding process that are projected on setting devices, by using the pressure of a pressurized fluid of a rotating side servo motor to directly or indirectly provide a counter pressure on an axially adjustable non-rotatable grinding member in order to relieve the setting devices from the axial forces.
In accordance with an embodiment of the present invention, at least one annular, non-rotating grinding element is axially balanced and actuated by a set of hydraulic servo motors working in tandem, either directly or indirectly, with the main servo motor for the rotating shaft, and the axial movements of the annular grinding member are controlled and restricted by adjustable stop means.
The servo motors are arranged at spaced intervals about the circumference of the annular grinding member to be controlled, or they may be placed separately intermediate, or in combination with, an adjustable stop for the annular grinding member.
The stator servo motors may be reduced versions of the main rotating side servo motor; i.e., have the same ratios between front and rear piston areas which when added together, have a total area equal to the portion of the total refiner axial load, carried by the controlled annular grinding member.
The stator servo motors are hydraulically connected or governed, directly or indirectly, by the main shaft servo motor, and thus always are able to jointly generate a counterbalancing axial force that corresponds to the portion of total refiner axial load exerted on the controlled annular stator grinding member. By adjustment of the servo motor areas and/or supplied pressure, however, it is possible to generate a pro rata axial balancing force that is either lower or higher than the actual grinding forces exerted on the controlled annular stator grinding member, but which maximum force difference falls within a limit for safe operation of the adjustable stop.
The above-described principal arrangement is also applicable for grinding equipment using one-sided servomotors; i.e., pistons having only one side subjected to a hydraulic pressure medium. In such instances, the servomotors for the annular stator grinding members also are one-sided and set to operate in the opposite direction relative to the main shaft servomotor.
One-sided servo motors for counterbalancing the axial forces exerted on the annular non-rotating grinding member may also be used with two-sided main shaft servo motors if a hydraulic pressure converter is used to produce a pressure corresponding to the resultant forces of the two-sided servo motor.
Other types of adjustable pressure converters, namely mechanical, hydraulic, pneumatic, electric, electronic or computer-controlled pressure converters/regulators, may also be used to adjust the pressure levels from the shaft main servo motor, introduced to the stator side servo motors in order to conform more closely to the available plunger area and the change of axial fores absorbed by the controlled annular grinding member, which may occur with different types of grinding tools and/or refining processes.
A separate hydraulic pressure medium supply for the stator servo motors may also be used. In such instances, the pressure transferred to the stator servo motors is momentarily governed by the fluctuating pressure levels maintained in the shaft main servo motor, either directly or indirectly, through the use of the above-described pressure converters and/or regulators.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal view, partially in cross-section, of a grinding apparatus in accordance with the present invention having two-sided servo motors.
FIG. 2 is a longitudinal view, partially in cross-section, of a grinding apparatus in accordance with the present invention having a two-sided main servo motor which, via one type of a pressure converter, is connected to one-sided servo motors for an adjustable stator grinding member.
FIG. 3 illustrates an adjustable pressure converter of the type shown in FIG. 2, for use with one-sided stator servo motors.
FIG. 4 illustrates a hydraulic system for the control of two-sided stator servo motors by use of a separate hydraulic medium supply which pressure is controlled by hydraulic pressure maintained in the shaft main servo motor.
FIG. 5 illustrates a hydraulic system for the control of one-sided stator servo motors, by use of a separate hydraulic medium supply which pressure is controlled by the hydraulic pressure maintained in the shaft main servo motor.
FIG. 6 illustrates an embodiment of the present invention including one annular central stator plunger for the transfer of the axial counterbalancing forces projected on the controlled annular grinding member.
FIG. 7 illustrates an embodiment of a stator servo motor with combined position control by use of a threaded control wheel supported in a fixed axial position outside the servo motor plunger.
FIG. 8 illustrates a stator servo motor similar to that of FIG. 7 in which the threaded control wheel is supported only in the direction towards the rotating grinding member.
FIG. 9 illustrates an embodiment of a separate control for the axial position of the annular grinding member, with the threaded control wheel supported in a fixed axial position, and which arrangement is used in combination with separate servo motors as shown in FIG. 11, placed concentrically on and around the controlled annular grinding member or used in combination with a central servo motor as shown in FIGS. 6 and 17.
FIG. 10 illustrates an embodiment of the control of FIG. 9, in which the control wheel is only supported against movements toward the rotating grinding member.
FIG. 11 illustrates separate servo motors to be used in combination with position controls as illustrated in FIGS. 9, 10 and 17.
FIG. 12 illustrates an embodiment of a stator servo motor with combined position control by use of a threaded control wheel, supported in a fixed axial position between the stator and an outer servo motor.
FIG. 13 illustrates an embodiment of a stator servo motor with combined position control, by use of a threaded control wheel supported in a fixed axial position only in the direction towards the rotating grinding member and placed intermediate the stator and an outer servo motor.
FIGS. 14 and 15 illustrate an embodiment of the present invention in which the servo motors are placed on the inside of the stator in combination with position controls placed on the outside of the stator.
FIG. 16 illustrates the same embodiment as in FIGS. 14 and 15, and also including the use of annular concentrical plungers for the internal servo motors.
FIG. 17 illustrates the same embodiment as in FIG. 7, and also including an annular concentrical plunger for the external servo motor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be described in detail with reference to the drawings.
In the drawings, the present method and device are shown in combination with a grinding apparatus which includes a refiner for treating fibrous material such as wood chips, sawdust or wood shavings. It will be apparent to those skilled in the art, however, that the present invention can be applied to other fields of use as well.
FIG. 1 illustrates a grinding apparatus 10 having a rotatable shaft 14 supported in two bearing housings 16 and 18, all being mounted in a base frame 20. The bearing housings are arranged so that the rotatable shaft is axially displaceable. U.S. Pat. No. 3,212,721 describes further details in addition to those disclosed herein and illustrated in the drawings. The shaft 14 carries a rotor 22 provided with a grinding disc 24. Both the rotor 22 and the grinding disc 24 are rotatable together with the shaft 14. Located opposite to the rotatable grinding disc 24 are two non-rotatable grinding members 26,28 fastened to a circular stator 12. These non-rotatable grinding discs consist of one axially adjustable annular ring 26 and one outer non-adjustable grinding member 28 in the form of a ring or disc both supported in the stator 12. The outer annular disc 28 is rigidly fastened to the stator 12 in a fixed axial position, while the inner annular ring 26 is axially adjustable and fastened to the stator 12 by multiple threaded set screws 30. The axial positions of the set screws are adjusted and set by rotating the threaded and interconnected position control wheels 32.
The position control wheels 32 are mounted within an enclosure bracket 34 (FIGS. 1 and 7) which is rigidly secured to the stator 12, either directly or via a hydraulic cylinder permitting rotation of the threaded wheels 32 in a fixed axial position, thereby adjusting the axial position of the threaded screws 30 and the annular grinding member 26. There are preferably two and, more preferably, three or more set screws 30, each preferably equipped with interconnected positioning wheels 32 driven by a common adjusting drive 38.
The grinding discs 24,26,28 are enclosed by a casing 40 and stator 12 which form a housing. Material which is to be ground is supplied to the apparatus 10 through a central inlet channel 42 connected to the center of an inlet opening of the housing 40,12, and is fed into the space between the grinding discs 24,26,28. It is there ground by the generation of heavy axial forces on the grinding members, and the ground material is discharged from the housing 40 through a discharge opening 44.
To counteract the heavy axial forces exerted on the non-rotatable annular grinding member 26 and the set screws 30 with its threaded positioning wheel 32, a plunger 46 (FIGS. 1 and 7) enclosed in a cylinder 36 is placed between the stator 12 and the enclosure brackets 34 for the threaded positioning wheels 32.
The cylinder 36 with plunger 46 carrying the positioning wheels 32 with its set screws 30, is fastened in the stator 12 and thus, when hydraulically activated, absorbs the axial forces transferred to the annular grinding member 26 from the rotating side main servo motor.
The pressure in the cylinder housing 36 with its hydraulic pressure chambers 50 and 52 (FIGS. 7 or 8), is either directly or indirectly connected to, or governed by, the pressure in the main servo motor 48 with its pressure chambers 72,76 which controls the axial position of the rotating shaft 14 with the grinding member 24.
The main servo motor 48 is concentrically mounted around the shaft 14 and is rigidly secured to the bearing in casing 18 which controls the axial position of the shaft 14. The servo motor 48 comprises a casing or cylinder 56 which may be integral with the bearing casing 18, and a piston 58 which concentrically and loosely surrounds the shaft 14. The front end thereof is rigidly fastened to the shaft positioning control bearing in casing 18. The piston 58 has a central flange 60 which divides the cylinder 56 into two separated hydraulic pressure chambers 72 and 76. A hydraulic pressure medium is maintained within the pressure chambers by a pilot valve 66 to create sufficient axial forces to maintain the shaft 14 and the rotatable grinding member 24 in their desired positions.
The pilot valve 66 is described in detail, for example, in U.S. Pat. Nos. 2,971,704 and 4,073,442. It is rigidly secured to the casing 18, and is actuated by an arm 68 with a set screw 70 working against the end of the piston of the pilot valve. The arm is attached to the servo motor piston 58 and moves axially therewith.
The pilot valve 66 is actuated by the axial movement of the rotating shaft through the servo motor piston 58, and creates simultaneous changes of the hydraulic pressures in the opposing pressure chambers 72 and 76 of the servo motor 48, thereby counteracting all of the axial movement of the shaft caused by changes in the axial grinding load between the rotating and stationary grinding members and always maintaining the shaft in a predetermined position.
By utilizing the hydraulic balancing pressures of the pressure chambers 72 and 76 in the main shaft servo motor 48 in similar hydraulic devices placed separately or in combination with the set screws 30 for the non-rotating annular grinding member 26, it is possible to instantaneously hydraulically counterbalance all axial forces of varying magnitude transferred from the rotating grinding member 24 to the non-rotating annular grinding member 26.
The multiple stator servo motors 36 mounted either separately or in combination with the set screws 30 for the control of the annular grinding member 26, preferably have the same, or approximately the same, area proportions between opposing areas as the main hydraulic servo motor 48 for the rotating grinding member, but with their combined active areas reduced to correspond to the area proportion of the controlled annular grinding member 26 compared to the total non-rotating grinding area of the stator 26+28.
The main servo motor chamber 72 is connected to the chamber 50 by a line 74, and the chamber 76 of the rotary side servo motor is connected to chamber 52 of the stator side servo motor by a line 78.
With the present invention, the heavy axial loads on the set screws 30 for the annular grinding member 26 are controlled and always counteracted by the combined effect of the stator side and the rotary side servo motors and all grinding load variations will instantaneously be balanced. This eliminates the high axial loads that have previously been absorbed entirely by the threaded axial positioning control 32 and 30, which as a result minimizes the frictional forces and wear of the adjusting means for controlling the annular stator grinding member.
The transfer of pressure from the main rotary side servo motor to the stator side servo motor can either be direct as described above, or indirect by intermediate pressure control equipment of mechanical, hydraulic, pneumatic, electric or electronic function, or be computer-controlled. The pressures transferred will be governed by the pressure in the rotary side servo motor, or a separate source of hydraulic supply may be used where the pressure from the main servo motor 48 will act only as a governing signal component for the control of pressure supplied to the stator servo motors.
In FIGS. 2-17, all elements which are common to the embodiment illustrated in FIG. 1 have the same reference numerals. Elements which are altered may have the number 1 or higher before the reference numeral used in FIG. 1, and new added elements have new reference numerals.
FIG. 2 illustrates an embodiment of the present invention including a two-sided main servo motor 48 for position control of the rotary shaft as described above. The pressure is transformed to a resulting pressure by way of a hydraulic converter 80 which, when connected to one-sided servo motors with adjusted area for the control of the stator annular ring 26, will in the same way as described above, provide full counterbalancing of the axial loads on the set screws.
The pressure converter shown in FIG. 2 is an embodiment of a conventional hydraulic converter wherein the outgoing pressure is the resultant of the two ingoing and opposing pressures from the servo motor 48. The pressure converter 80 includes a cylinder 82 containing a piston 84 which is equipped with two end flanges or pistons, 86,88, which are hydraulically separated by a centrally located pressure tight seal 90. The areas of these two flanges may have the same ratio with respect to each other as the areas of the piston 60 in the rotary side position controlling servo motor 48.
The pressure chamber 92 of the converter is connected to the main servo motor chamber 72 by line 74 and the opposing chamber 94 is connected to the main servo motor chamber 76 by line 78. Thus, the resulting axial force on the piston 84 in the pressure converter 80 will always change in proportion to the axial force transmitted to the rotary shaft 14 with its grinding member 24 by the main servo motor 48.
The chamber next to the smaller flange 88 communicates to the atmosphere, while the chamber 98 next to the larger flange 86 is filled with a hydraulic medium and is pressure tightly connected to chamber 50 of the servo motor 36 (FIG. 7 or FIG. 8) controlling the annular stator ring 26 by line 100.
The resulting hydraulic pressure in chamber 98, line 100 and chamber 50 always produces a counteracting axial force on the set screws 30 corresponding to the axial forces projected thereon from the servo motor for the rotary grinding member 24. As described above, this results in minimized frictional forces on, and wear of, the adjusting mechanism for the controlled annular ring 26.
FIGS. 2 and 3 illustrate an embodiment of adjustable pressure converters which enables the adjustment of the total counteracting force transferred from the rotary side servo motor 48 to the balancing servo motors for the stator set screws 30.
By changing the type of grinding tools and/or the grinding distance between the rotary and stationary grinding members, the axial forces projected on the controlled annular grinding member may be changed to some extent. Although the changes are relatively small and well within the limits for safe and problem-free operation, with set screws 30 equipped with the hydraulic counterbalancing servo motors in accordance with the present invention (FIGS. 1 and 2), an adjustable pressure converter (FIG. 3) may be used to precisely adjust the forces transferred from the rotary main servo motor 48 to the stator set screws 30 to within a minimal deviation from the actual forces projected thereon.
The adjustable pressure converter 102 shown in FIG. 3 may comprise two independent hydraulic cylinders 104 and 106 that are interconnected by a link system 108,110,112 having an adjustable length for levers A and B. Adjustment is made by changing the position of the balance point 114 using a threaded control rod 116 having a rotatable handle 118.
The hydraulic cylinder 104 is of the same general type as shown in FIG. 2, and has the same area relationship as the main servo motor 48. The piston 120, however, is prolonged in length, and through a linkage 108 is connected to another hydraulic piston 122 within cylinder 106. The resulting hydraulic pressure in chamber 128 is connected to chamber 50 in the stator servo motors, as shown in FIGS. 3, 7 and 8.
The resulting force transferred to the stator servo motors from the rotary side main servo motor is thus easily modified by changing the position of the balance point 114. For a lower transferred force, the balance point is moved closer to the piston 120 and, for increased force, in the opposite direction.
FIG. 4 illustrates an embodiment of the present invention including a separate hydraulic pressure medium supply 130 for the control of the stator servo motors 36. The pressures are governed by the use of the pressure levels in the pressure chambers 76,72 of the main servo motor 48 as control signals for regulators 132 and 134. These regulators have a conventional design and the ratio of resulting pressures for the servo motors 36 can be adjusted to be equal to or higher or lower than, the signal pressures from the main servo motor 48 by varying the plunger areas or otherwise.
For controlling one-sided stator servo motors as shown in FIGS. 2, 3 and 5, using a separate hydraulic pressure medium supply, one of the above-described pressure regulators 132 may be combined with the principle of the pressure converter 80 of FIG. 2, and the piston 84 is prolonged to control the pressure reducing valve 136 (see FIGS. 4 and 5).
It will be apparent to those skilled in the art that the above-described pressure converters or controls can be replaced by controls of any type, which permit the use of the principle of this invention; i.e., that the fluctuating hydraulic pressures in the main servo motor, controlling the axial forces projected on the rotating grinding member, can be utilized directly or indirectly, or act as a signal medium for controlling the pressurized medium supplied to the stator servo motors for instantaneously counteracting the likewise fluctuating axial forces projected on the adjustable non-rotating annular grinding members.
The above-described stator servo motors 36 can be replaced by a central stator servo motor as shown in FIG. 6, wherein a pressure medium of adjusted levels governed by the pressures in the shaft main servo motor 48, is introduced to the rear area of the non-rotating, axially adjustable grinding member 26, or to a connected annular ring plunger 25 having the same or adjusted area. The central servo motor is axially controlled by the set screws 30 as shown in FIGS. 9 and 10, and may receive a pressurized medium, transformed to the required level by the use of any of the above-described pressure converters and/or regulators, either directly or indirectly connected to the shaft main servo motor 48.
With the use of threaded control wheels that are supported only in the direction towards the rotating grinding member, it is necessary, in order to create and secure a stable position of the control wheel without outward axial vibrations, to adjust either the area proportions of the stator servo motor or motors or the pressure supplied to the outer servo motor chamber or chambers, to achieve a counterbalancing axial force that exceeds the axial forces between the rotating grinding members by a few percent.
It will also be apparent as shown in FIGS. 12 and 13, that the above-described threaded stator position control wheels 32 can be placed between the stator 12 and an outer-placed servo motor 36, or as is shown in FIGS. 14, 15 and 16, that the servo motors can be placed on the inside of the stator and controlled by outside position controls, or as shown in FIG. 17, an annular concentrical servo motor plunger can be placed either inside or outside in the stator while being controlled in the same manner.
The foregoing description of the preferred embodiment of the invention has been presented to illustrate the principles of the invention and not to limit the invention to the particular embodiment illustrated. It is intended that the scope of the invention be defined by all of the embodiments encompassed within the following claims, and their equivalents. | This invention relates to a method of refining pulp stock in which the pulp material to be ground is introduced into a grinding space located between a first rotatable grinding device carried by a shaft and being axially displaceable by a servo motor, and a second non-rotatable grinding device. The servo motor is actuated by pressurized fluid for adjusting and controlling the grinding space, producing a grinding pressure between the first and the second grinding devices and for preventing axial displacement of the first rotatable grinding device relative to the second non-rotatable grinding device in response to fluctuating axial grinding forces. The second non-rotatable grinding device comprises a plurality of concentrically arranged annular grinding members, at least one of which is axially adjustable by a setting device. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application 61/352,219, filed on Jun. 7, 2010, which is incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates generally to application development in an integrated development environment (IDE). In particular, described embodiments are directed to automatic discovery of implicit dependencies by the IDE.
[0004] 2. Description of Related Art
[0005] Modern software development is typically carried out using an integrated development environment (IDE). An IDE generally provides a source code editor, a compiler, a debugger and build tools. Build tools, which collectively can be referred to as a build system, perform compiling, linking, copying and similar activities in order to produce an application or other output from inputs such as source code.
[0006] In an IDE such as Xcode, available from Apple Inc. of Cupertino, Calif., a “target” specifies a product to build and contains the instructions for building the product from a set of files in a project. A target defines a single product; it organizes the inputs into the build system—the source files and instructions for processing those source files—required to build that product.
[0007] Generally, a single project may contain a number of targets, and each target builds a single product. The particular files required by the target to build its product may themselves be products of other targets. In that event, one target is said to depend on the other target.
[0008] If a first target depends upon a second target, then the second target must be built before the first target. To ensure this, developers explicitly specify target dependencies in the IDE. Once the dependencies are specified, they are enforced during build of the project by the IDE. Thus, if the first target depends upon the second, then the IDE will build the second target before attempting to build the first. If the second target cannot be built, for example because of an error, then the IDE will typically not attempt to build the first.
SUMMARY
[0009] The present invention enables the use of implicit workspace dependencies. Implicit dependences allow a user to add multiple independent software components to a workspace, which results in the automatic establishment of ad-hoc dependencies.
[0010] An IDE system of the present invention includes a workspace module that provides a workspace to users of the IDE system. A workspace is a container for multiple projects that the user can use to group projects and other files that are related. In one embodiment, all the projects in the workspace share the same build directory.
[0011] By relating projects in a common workspace, each project can use the products of another project while building. If one project depends on the products of another in the same workspace, a dependency manager detects this, causing a build engine to automatically build the projects in the correct sequence.
[0012] Because each file in one project is visible to the other projects in the workspace, the user does not need to copy shared libraries into each project folder separately.
[0013] Each project retains its individual identity, so a project can be included in more than one workspace or removed from a workspace without affecting the project. The workspace module maintains pointers to the projects and other files that the workspace includes. The pointers to the source files, included libraries, build configurations, and other data are stored in the project files.
[0014] A target and the product it creates can be related to another target. That is, a first target that requires the output of a second target in order to build depends upon the second. If both targets are in the same workspace, the dependency manager discovers the dependency, for example using a heuristic such as file name recognition, and the build engine then builds the products in the required order. Such a relationship is referred to as an implicit dependency. The user can also specify explicit target dependencies. For example, the user might build both a library and an application that links against that library in the same workspace. The dependency manager discovers this relationship and the build engine will automatically build the library first. However, if the user actually wants to link against a version of the library other than the one built in the workspace, the user can create an explicit dependency in the build settings, which overrides this implicit dependency. In one embodiment any or all implicit dependencies can be prevented through a preference setting or other control.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a block diagram of an integrated development environment system for creating implicit dependencies in accordance with an embodiment of the present invention.
[0016] FIG. 2 is a flowchart illustrating a method for creating implicit dependencies in accordance with an embodiment of the present invention.
[0017] FIG. 3 is a flowchart illustrating a method for creating implicit dependencies in accordance with an embodiment of the present invention.
[0018] FIG. 4 is a flowchart for building a build product using implicit dependencies in accordance with an embodiment of the present invention.
[0019] FIG. 5 illustrates a workspace with a single project in accordance with an embodiment of the present invention.
[0020] FIG. 6 illustrates a workspace with multiple projects in accordance with an embodiment of the present invention.
[0021] FIG. 7 is a screen shot illustrating an example view of an IDE in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] FIG. 1 illustrates a block diagram of an IDE system 100 in accordance with an embodiment of the present invention. IDE system 100 includes a workspace module 104 , a build engine 102 , dependency manager 106 and code database 108 . Many standard components of an IDE system not germane to this description are omitted from FIG. 1 for clarity, but are well known to those of skill in the art. An example of an IDE is the Xcode IDE available from Apple Inc. of Cupertino, Calif. FIG. 7 illustrates a screen shot of an IDE.
[0023] Workspace module 104 provides functionality associated with the workspace of an IDE. For example workspace module 104 provides text-editing functionality, the ability to add and remove source folders and files from a project, specify explicit dependencies and linkages for a target, and other input/output features conventionally available in an IDE.
[0024] Code database 108 provides computer-readable data storage media for source code, object code, and other files used either by modules of IDE system 100 or by the user. Although illustrated in FIG. 1 as a single file store, those of skill will understand that code database 108 may be implemented as one or several physical or logical devices, and may be a local device or accessed via a network. The particular type of computer-readable storage media constituting code database 108 may be any combination of conventional media types.
[0025] Dependency manager 106 is responsible for tracking explicit and implicit dependencies between build targets in the workspace. Build engine 102 executes building operations to create build products. The operation of dependency manager 106 and build engine 102 are described further below.
[0026] As the user creates the code and structure of his project, he explicitly specifies the libraries each target will link against, and may also explicitly identify some of the target dependencies. Referring now to FIG. 2 , the user specifies 202 the target blueprint and identifies 204 the libraries the target will link against. Dependency manager 106 checks each identified library to determine 206 whether the current workspace already has a target that produces the identified library as a product. If the linked library is already the result of an existing target, then dependency manager 106 creates 208 an implicit dependency upon the target that builds the library. In either event, a reference to the library is added 210 to a link table maintained by workspace module 104 , which has a mapping of all libraries required for projects in the workspace.
[0027] Referring to FIG. 3 , if the user adds 302 a source code folder to a project in the current workspace, dependency module 106 identifies 304 the target products identified in the folder and determines 306 whether a target product of the source folder is linked against any existing targets in the workspace. If so, dependency module 106 creates 308 an implicit dependency on the newly added source code.
[0028] In one embodiment, dependency module 106 tracks both explicit and implicit dependencies by maintaining the transitive closure of a directed acyclic graph, as will be understood by those of skill in the art. The graph may be stored in a matrix or other data structure.
[0029] Referring now to FIG. 4 , when the user instructs 402 IDE system 100 to build a target product, build engine 102 identifies 404 the target dependencies associated with the product being built, for example by consulting the dependencies matrix maintained by dependency module 106 . Build engine 102 then builds 406 the identified dependent targets and, assuming the targets are successfully built, then builds 408 the requested target product.
[0030] FIG. 5 illustrates a workspace 500 with a sample project, Foo.project. Foo.project has two targets, MyFooClient and MyFooServer. MyFooClient links to the framework MyFramework.framework, as does MyFooServer (which also links to Carbon.framework). When the user instructs IDE system 100 to build either target in the project, build engine 102 will link the MyFramework.framework library binary that is available, for example, in a shared library directory or a default location.
[0031] If the user then adds the MyFramework.framework source to the workspace, this results in the creation of an implicit dependency. This is illustrated by the example of FIG. 6 . Workspace 600 includes the Foo.project project described above with respect to FIG. 5 , as well as a second project, Bar.project. Bar.project includes two targets, MyBarClient, which links MyFramework.framework; and MyFrameworkPrime, which creates the product MyFramework.framework.
[0032] As described above, because Foo.project and Bar.project are both in the same workspace 600 , dependency module 106 maintains information about the linked libraries and build products of each target in both projects. In the illustrated case, both the MyFooClient and the MyFooServer targets of the Foo.project project require the MyFramekwork.framework framework, though the user has not specified an explicit dependency on the MyFrameworkPrime target that produces that framework. Dependency module 106 , however, identifies the product MyFramework.framework of target MyFrameworkPrime as linked against both targets of the Foo.project project and also of the MyBarClient target of the Bar.project project. Dependency module 106 therefore creates an implicit dependency by MyFooClient, MyFooServer and MyBarClient on MyFrameworkPrime. As a result, build engine 102 will ensure that MyFramework.framework is produced prior to the other products, and is then linked against them. This differs from the case illustrated by FIG. 5 , in which source code was not in the same workspace, and the library binary was simply linked. Here, the created implicit dependency causes the library to be compiled from the source present in the workspace rather than allowing build engine 102 to simply link against the shared library version.
[0033] In one embodiment, removing a source code folder from the workspace causes dependency manager 306 to remove any implicit dependencies that depend upon the target in the removed folder.
[0034] In one embodiment, implicit dependencies are created (and removed) automatically by dependency manager 306 as described above. In an alternative embodiment, IDE system 100 asks the user to confirm or reject the establishment of a dependency, either as the potential implicit dependencies are identified, or alternatively at build time.
[0035] The present invention has been described in particular detail with respect to a limited number of embodiments. Those of skill in the art will appreciate that the invention may additionally be practiced in other embodiments.
[0036] Within this written description, the particular naming of the components, capitalization of terms, the attributes, data structures, or any other programming or structural aspect is not mandatory or significant, and the mechanisms that implement the invention or its features may have different names, formats, or protocols. Further, the system may be implemented via a combination of hardware and software, as described, or entirely in hardware elements. Also, the particular division of functionality between the various system components described herein is merely exemplary, and not mandatory; functions performed by a single system component may instead be performed by multiple components, and functions performed by multiple components may instead be performed by a single component.
[0037] Some portions of the above description present the feature of the present invention in terms of algorithms and symbolic representations of operations on information. These algorithmic descriptions and representations are the means used by those skilled in the art to most effectively convey the substance of their work to others skilled in the art. These operations, while described functionally or logically, are understood to be implemented by computer programs. Furthermore, it has also proven convenient at times, to refer to these arrangements of operations as modules or code devices, without loss of generality.
[0038] It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the present discussion, it is appreciated that throughout the description, discussions utilizing terms such as “selecting” or “computing” or “determining” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system memories or registers or other such information storage, transmission or display devices.
[0039] Certain aspects of the present invention include process steps and instructions described herein in the form of an algorithm. It should be noted that the process steps and instructions of the present invention could be embodied in software, firmware or hardware, and when embodied in software, could be downloaded to reside on and be operated from different platforms used by real time network operating systems.
[0040] The present invention also relates to an apparatus for performing the operations herein. This apparatus may be specially constructed for the required purposes, or it may comprise a general-purpose computer selectively activated or reconfigured by a computer program stored in the computer. Such a computer program may be stored in a computer readable storage medium, such as, but is not limited to, any type of disk including floppy disks, optical disks, DVDs, CD-ROMs, magnetic-optical disks, read-only memories (ROMs), random access memories (RAMs), EPROMs, EEPROMs, magnetic or optical cards, application specific integrated circuits (ASICs), or any type of media suitable for storing electronic instructions, and each coupled to a computer system bus. Furthermore, the computers referred to in the specification may include a single processor or may be architectures employing multiple processor designs for increased computing capability.
[0041] The algorithms and displays presented herein are not inherently related to any particular computer or other apparatus. Various general-purpose systems may also be used with programs in accordance with the teachings herein, or it may prove convenient to construct more specialized apparatus to perform the required method steps. The required structure for a variety of these systems will appear from the description above. In addition, the present invention is not described with reference to any particular programming language. It is appreciated that a variety of programming languages may be used to implement the teachings of the present invention as described herein, and any references to specific languages are provided for disclosure of enablement and best mode of the present invention.
[0042] Finally, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and may not have been selected to delineate or circumscribe the inventive subject matter. Accordingly, the disclosure of the present invention is intended to be illustrative, but not limiting, of the scope of the invention. | Implicit dependences allow a user to add multiple independent software components to a workspace, which results in the automatic establishment of ad-hoc dependencies. If one project depends on the products of another in the same workspace, a dependency manager detects this, causing a build engine to automatically build the projects in the correct sequence. Each project retains its individual identity, so a project can be included in more than one workspace or removed from a workspace without affecting the project. The workspace module maintains pointers to the projects and other files that the workspace includes. A target and the product it creates can be related to another target. If both targets are in the same workspace, the dependency manager discovers the dependency and the build engine builds the products in the required order. Such a relationship is referred to as an implicit dependency. | 6 |
This application is a divisional of application Ser. No. 09/129,067, filed Aug. 4, 1998 now U.S. Pat. No. 6,446,237. The application is incorporated herein by reference.
CROSS-REFERENCE TO RELATE APPLICATIONS
This application is related to the following co-pending and commonly-assigned patent applications, all of which are filed on the same date herewith, and all of which are incorporated herein by reference in their entirety:
“Distributed Storage System Using Front-End And Back-End Locking,” by Jai Menon, Divyesh Jadav, Kal Voruganti, U.S. Pat. No. 6,272,662, issued Aug. 7, 2001; “System for Updating Data in a Multi-Adaptor Environment,” by Jai Menon, Divyesh Jadav, Deepak Kenchammana-Hosekote, U.S. Pat. No. 6,332,197, issued Dec. 18, 2001; “System For Changing The Parity Structure Of A Raid Array,” by Jai Menon, Divyesh Jadav, Deepak Kenchammana-Hosekote, U.S. Pat. No. 6,279,138, issued Aug. 21, 2001; “Updating Data and Parity With and Without Read Caches,” by Jai Menon, U.S. Pat. No. 6,446,220, issued Sep. 3, 2002; and “Updating and Reading Data and Parity Blocks in a Shared Disk System with Request Forwarding,” by Jai Menon and Divyesh Jadav, U.S. Pat. No. 6,128,762.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system for updating data, reading data, and handling storage device and adaptor failures in a shared disk system.
2. Description of the Related Art
In Redundant Arrays of Independent Disks (RAID) systems, data files and related parity are striped across multiple disk drives. In storage subsystems which manage numerous hard disk drives as a single direct access storage device (DASD), the RAID logic is implemented in the controller of the subsystem. RAID storage methodologies have also been implemented in software for execution on a single host computer. This allows the single host computer, such as a personal computer, to implement RAID storage techniques on local hard disk drive space. Such software RAID methodologies are described in “Algorithms for Software and Low Cost Hardware RAIDS,” by Jai Menon, Jeff Riegel, and Jim Wyllie, document no. 1063-6390 (IEEE 1995), which is incorporated herein by reference in its entirety.
One problem with the single storage subsystem is the risk of failure. Techniques have been developed to improve failback and recovery in case of failures in the hardware controller. One such failback technique is the Fast Write Technique which provides two separate controllers on different power boundaries that control the flow of data from host systems to DASDs. If one controller fails, the other controller can continue writing data to the DASD. Typically a non-volatile storage unit (NVS) is included with each separate controller, such that each NVS connected to a controller backs up the data the other controller is writing to DASD. Such failback systems employing the two-controller failsafe structure are described in U.S. Pat. Nos. 5,636,359, 5,437,022, 5,640,530, and 4,916,605, all of which are assigned to International Business Machines, Corporation (IBM), the assignee of the subject application, and all of which are incorporated herein by reference in their entirety.
RAID systems can also be implemented in a parallel computing architecture in which there is no central controller. Instead, a plurality of independent controllers that control local hard disk storage devices are separate nodes that function together in parallel to implement RAID storage methodologies across the combined storage space managed by each node. The nodes are connected via a network. Parity calculations can be made at each node, and not centrally. Such parallel RAID architecture is described in “The TickerTAIP Parallel RAID Architecture,” by Pei Cao, Swee Boon Lim, Shivakumar Venkatarman, and John Wilkes, published in ACM Transactions on Computer Systems, Vol. 12, No. 3, pgs. 236-269 (August, 1994), which is incorporated herein by reference in its entirety.
One challenge in shared disk systems implementing a parallel, shared disk RAID architecture is to provide a system for insuring that data is properly updated to disks in the system, that a write or update request invalidates stale data so such stale data is not returned, and that a read request returns the most current data.
SUMMARY OF THE INVENTION
To overcome the limitations in the prior art described above, preferred embodiments of the present invention disclose a system for updating data at a data block. A first processing unit receives update data. The data block to update is located in a first storage device and a second storage device stores parity data for the data block. A parity group comprises a data block and corresponding parity data for the data block. The first processing unit obtains the data at the data block and calculates partial parity data from the data at the data block and the update data. The first processing unit stores the partial parity data in a storage area and writes the update data to the data block in the first storage device. The first processing unit further updates parity data for parity groups for which partial parity data is maintained by obtaining control of access to the parity group to update from a second processing unit if the first processing unit does not control access to the parity group. When the first processing unit controls access to the parity group, the first processing unit calculates new parity data from the partial parity data and the parity data in the second storage device, and writes the new parity data to the second storage device.
Further embodiments concern processing a request to read data. A first processing unit receives a request to read a data block in a storage device from a requestor. The first processing unit returns the data from a first cache after determining that the requested data is in the first cache. The first processing unit requests permission from a second processing unit to transfer the data in a second cache to the first cache after determining that the data is in the second cache. The first processing unit transfers the data from the second cache to the first cache and returns the data to the requestor after receiving permission from the second processing unit. After receiving a message from the second processing unit denying permission, the first processing unit reads the data block in the first storage device and returns the read data to the requester.
Preferred embodiments of message exchanging insure that the first processing unit does not provide data in a read cache that is stale in view of data updates performed by the second processing unit. Moreover, with the preferred embodiments, access to data blocks is controlled. Controlling access helps insure that parity updates are properly handled, data in memory locations is invalidated so that stale or outdated data is not returned to a later read request, stale data is not destaged to a storage device, and a read request returns the latest version of the data block.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings in which like reference numbers represent corresponding parts throughout:
FIG. 1 illustrates a preferred hardware and software environment in which preferred embodiments of the present invention are implemented;
FIG. 2 illustrates a preferred hardware and software architecture of an adaptor in accordance with preferred embodiments of the present invention;
FIGS. 3 a, b illustrates embodiments of how data and parity blocks are arranged on storage devices;
FIG. 4 illustrates a flowchart showing logic to update a data block in accordance with preferred embodiments of the present invention;
FIG. 5 illustrates a flowchart showing logic to update parity in accordance with preferred embodiments of the present invention;
FIG. 6 illustrates a flowchart showing logic to update a data block in the event of a disk failure;
FIG. 7 illustrates a flowchart showing logic to rebuild a failed drive and handle update requests;
FIG. 8 illustrates a memory area of the adaptor, including data structures in accordance with preferred embodiments of the present invention;
FIG. 9 illustrates a flowchart showing logic to handle a read request in accordance with preferred embodiments of the present invention;
FIG. 10 illustrates a flowchart showing logic to update a data block using data structures in accordance with preferred embodiments of the present invention; and
FIGS. 11 a, b illustrate flowcharts showing permission exchange logic to grant permission to an adaptor to add data to its read cache in accordance with preferred embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, reference is made to the accompanying drawings which form a part hereof, and which is shown, by way of illustration, several embodiments of the present invention. It is understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.
Hardware and Software Environment
FIG. 1 illustrates a shared device environment comprised of nodes 4 a, b, c . Each node includes a computer 6 a, b, c , i.e., central processing unit, and an adaptor card 8 a, b, c . A plurality of storage devices 10 a, b, c interface via a network 12 to the adaptor cards 8 a, b, c and attached computers 6 a, b, c . The computer 6 a, b, c may be a personal computer, workstation, mainframe, etc. The adaptor cards 8 a, b, c interface with their respective computers 6 a, b, c via a PC bus, such as the PCI bus, and include one or more disk interface ports, such as SCSI or Serial Storage Architecture (SSA) ports. The adaptor cards 8 a, b, c include logic to execute the RAID algorithms. The storage devices 10 a, b, c may be any suitable non-volatile storage device known in the art, including hard disk drives, magnetic tape, optical disks, non-volatile RAM, holographic units, etc. The nodes 4 a, b, c and storage devices 10 a, b, c interface via the network 12 , which is preferably a high speed interconnect, such as SCSI, SSA, SNA, SAN, FDDI, etc. Additionally, the network 12 may be a SCSI or SSA bus. In further embodiments more nodes than shown may be included in the shared device system 2 . Each node may include multiple adaptors, multiple processors and/or local (non-shared) storage devices.
FIG. 1 further illustrates an additional network 13 providing an additional communication line among the computers 6 a, b, c . This additional network 13 may be comprised of any suitable network known in the art, e.g., ETHERNET, LAN, etc.
In preferred embodiments, the computers 6 a, b, c run parallel processing software, such as the ORACLE PARALLEL SERVER™, the MICROSOFT® Wolfpack Clustering System or any other clustering software. ORACLE PARALLEL SERVER is a trademark of Oracle Corporation; MICROSOFT is a registered trademark of Microsoft Corporation. This parallel processing software allows the computers 6 a, b, c to share storage devices 10 a, b, c such that any node 4 a, b, c may access any block in any of the storage devices 10 a, b, c . This parallel architecture allows data to be distributed across different storage devices 10 a, b, c throughout the shared device system 2 . The parallel processing software, implemented in the computers 6 a, b, c , may perform logical locking to insure that only one write request is made to a block in any of the storage devices 10 a, b, c , at any given time and to insure that an application does not attempt to read a block being modified by another application. To perform logical locking under control of the parallel processing software, the computers 6 a, b, c would exchange messages, data, and information via the additional network 13 . The adaptors 8 a, b, c perform physical locking.
FIG. 2 illustrates a preferred embodiment of the adaptors 8 a, b, c . Each adaptor 8 a, b, c includes a processor 14 a, b, c , a non-volatile RAM 16 a, b, c for storing control information, a read cache 18 a, b, c , and a write cache 20 a, b, c . The read 18 a, b, c and write 20 a, b, c caches may be comprised of volatile memory, such as RAM, or a non-volatile memory unit, e.g., non-volatile RAM. In certain embodiments, the read cache 18 a, b, c and write cache 20 a, b, c may be areas within the same memory device or located within separate memory devices. In further embodiments, there may be no read 18 a, b, c and/or nvrite 20 a, b, c caches. In preferred embodiments, the write caches 20 a, b, c contain dirty blocks, which is data intended for a block in the storage device 10 a, b, c that is more recent than the block actually maintained in the storage device 10 a, b, c . Once the data is written from the write cache 20 a, b, c to the storage device 10 a, b, c , the copy of the data in the cache is “clean.” Because the write cache 20 a, b, c only maintains “dirty” blocks, the clean copy in the cache after the update is considered to be in the read cache 18 a, b, c , not the write cache 10 a, b, c anymore. The components of the adaptors 8 a, b, c may be implemented as PC cards such the PC ServeRAID SCSI adaptor from IBM. Alternatively, components and functionality of the adaptors 8 a, b, c could be implemented in the computers 6 a, b, c.
In certain embodiments, the read cache 18 a, b, c may be implemented in a volatile memory device, e.g., DRAM, RAM, etc., and the write cache 20 a, b, c may be attached to a battery 22 which makes the write cache 20 a, b, c a non-volatile memory device. In such case, an update to a block is initially written in both the RAM (read cache) and the battery 22 backed up write cache 20 a, b, c . Once the dirty data is destaged to the storage device 10 a, b, c , the copy from the write cache 20 a, b, c is marked as invalid for later removal, leaving only the clean copy in the RAM, i.e., read cache. In alternative embodiments, the dirty data may be sent to all other adaptors in the system to invalidate any stale data in their caches. In embodiments with only a single memory device for the read 18 a, b, c and write 20 a, b, c caches, the data is considered to be in the write cache 20 a, b, c prior to destaging and in the read cache 18 a, b, c after destaging even though the data remains in the same memory device.
In preferred embodiments, the adaptors 8 a, b, c must satisfy all of the following correctness conditions:
(1) a request to write a data block from adaptor 8 a simultaneous with a request to write another data block from adaptor 8 b , where the two data blocks have the same parity block, causes a correct parity update in the sequence which the updates were made;
(2) a write request through one adaptor 8 a for a block in the read 18 b or write 20 b cache at another adaptor 8 b causes the invalidation of data in cache 18 b or 20 b so that stale data is not returned to a subsequent read request or later destaged to the storage device 10 b from old data in caches 18 b , 20 b ; and
(3) a read request through one adaptor 8 a for a block cached at adaptor 8 b in read 18 b or write 20 b cache, returns the latest version of the data block from adaptor 8 b.
Those skilled in the art will recognize that alternative conditions to the three mentioned above may also be satisfied.
Parity in a RAID Environment
FIG. 3 a illustrates a 4 +P RAID disk array in which a parity block P i protects four data blocks D i in four storage devices. Each vertical column represents a storage device. A parity group is a row in the illustration of FIG. 3 a that consists of four data blocks D i , one in each storage device, and a parity block P i maintaining parity information for the four data blocks D i . A parity value P i is the exclusive OR of the data blocks D i in the same parity group of a given i. If a disk fails, then the data can be recreated by processing the parity block (P i ) and the remaining data blocks D i for the parity group. FIG. 3 a further shows the rotation of parity in that parity blocks P 5 through P 8 are on a different disk, storage device 4 , than the previous parity blocks which are on storage device 5 .
In preferred embodiments, a parity block can be updated with the following exclusive OR operation, where the new parity (P i ′)=(old data (D i ) XOR new data (D i ′) XOR old parity (P i ).
In certain embodiments, data may be stored in “stripe units” on the storage devices. FIG. 3 b illustrates a “stripe unit” of data. A stripe unit consists of multiple consecutive blocks of data on a storage device. The “stripe unit” shown in FIG. 3 b has two consecutive blocks of data, blocks 1 and 2 . A “stripe” consists of multiple stripe units. The “stripe” shown in FIG. 3 b has five stripe units. In the exemplar of FIG. 3 b , a stripe unit includes blocks from two parity groups throughout each storage device. In alternative embodiments a “stripe unit” and “stripe” could be defined in alternative manners, e.g., including more than two blocks of data, depending on the number of storage devices and parity groups.
In alternative embodiments, other parity schemes may be utilized, such as mirrored RAID, bit-interleaved parity, block-interleaved distributed-parity or P+Q redundancy, etc. These various RAID schemes are discussed in “RAID: High-Performance, Reliable Secondary Storage,” by Peter M. Chen, Edward K. Lee, Garth A. Gibson, Randy H. Katz, and David A. Patterson, published in ACM Computing Surveys, Vol. 26, No. 2, pgs. 145-185 (June, 1994), which publication is incorporated herein by reference in its entirety.
Updating Data Blocks In the Same Parity Groups
FIGS. 4 and 5 illustrate logic implemented in the adaptors 8 a, b, c , to update parity P i when simultaneously updating different data blocks D i in the same parity group. The logic of FIGS. 4 and 5 utilizes the NVRAM 16 to store partial parity data that keeps track of changes that must be made to the parity groups as a result of updating data. With respect to FIG. 4, control begins at block 30 which represents an adaptor, e.g., updating adaptor 8 a , receiving a request to update a block of data from D to D′ on a disk, e.g., block B in disk i. Disk i may be one of the storage devices 10 a, b, c or a storage subunit within one of the storage devices 10 a, b, c . Control transfers to block 32 which represents the updating adaptor 8 a reading the old data D from block B in disk i via the network 12 . Control then transfers to block 34 which represents the updating adaptor 8 a calculating partial parity for the data update from the update D′ and old data D. In preferred embodiments, partial parity is calculated as D xor D′. However, in alternative embodiments, alternative means known in the art for calculating parity may be used.
After calculating the partial parity, control transfers to block 36 which represents the updating adaptor 10 a storing the partial parity in the NVRAM 16 a . The updating adaptor 10 a would further store information indicating the parity group number to which the partial parity applies. Control then transfers to block 38 which represents the updating adaptor 8 a writing the updated data D′ to block B on disk i. At block 40 , the updating adaptor 8 a returns DONE to the system.
In preferred embodiments, the updating adaptor 8 a does not immediately update the parity P′ after updating the data. The adaptor 8 a would perform a parity flushing algorithm to update the parity at a later time, such as when the NVRAM 16 a includes a predetermined threshold of partial parities. FIG. 5 illustrates logic implemented in the adaptors 8 a, b, c to update parity P′ based on partial parity data maintained in the NVRAM 16 a . Control begins at block 50 which represents an adaptor, e.g., adaptor 8 a , initiating an operation to flush parity from the NVRAM 16 a . Control transfers to block 52 which represents the adaptor 8 a determining from the partial parity data in the NVRAM 16 a the parity group numbers for those parity groups that need to be updated, i.e., inconsistent parity groups. Methods for identifying inconsistent parity groups are known in the art and described in U.S. Pat. No. 5,574,882, entitled “System and Method for Identifying Inconsistent Parity in an Array of Storage,” assigned to IBM, which patent is incorporated herein by reference in its entirety.
Control then transfers to block 54 which is a decision block representing the flushing adaptor 8 a determining whether it has ownership of the locks of all the inconsistent parity groups. Only adaptors 8 a, b, c having the lock for a parity group or data block, or other stored unit, can access such unit. The lock system arbitrates access to stored units to insure that data consistency is maintained for read and write operations. If the flushing adaptor 8 a has ownership of locks for all the inconsistent parity groups in its NVRAM 16 , then control transfers to block 56 ; otherwise, control transfers to block 58 . Block 58 represents the adaptor 8 a sending a message including a list of the inconsistent parity groups for which partial parity data is maintained, for which adaptor 8 a does not have lock ownership, to the other adaptor, e.g., 8 b . The adaptor 8 a may send a message as a single message or as multiple messages. In a two adaptor 8 a, b system, the flushing adaptor 8 a would request ownership from the second adaptor 8 b as there is only one other possible owner of the lock. However, in the N adaptor case, the flushing adaptor 8 a , would have to send a message to all other N- 1 adaptors in the system to obtain lock ownership.
Control transfers to block 60 which represents the flushing adaptor 8 a waiting for a response from the other adaptor(s) granting ownership of the lock for the parity group. After receiving ownership at block 60 or if the adaptor 8 a already had ownership at block 54 , control transfers to block 56 which represents the flushing adaptor 8 a going to the inconsistent parity group in the NVRAM, i.e., first partial parity entry. Control then transfers to block 62 which represents the adaptor 8 a reading old parity P from block B in disk j. Control transfers to block 64 which represents the adaptor 8 a applying the partial parity (D xor D′) to the old parity P read at block 62 and calculating the new parity P′. Control transfers to block 66 which represents the adaptor 8 a writing the new parity P′ back to block B on disk j to replace the old parity P.
Control then transfers to block 68 which is a decision block representing the flushing adaptor 8 a determining whether there are any additional inconsistent parity groups not yet updated maintained in the NVRAM 16 a . If so, control transfers to block 70 to proceed to the next inconsistent parity group and partial parity data in the NVRAM 16 a , and update the parity for that inconsistent parity group by proceeding to blocks 62 et seq. Otherwise, if there are no further inconsistent parity groups, control transfers to block 72 which represents the completion of the parity flushing operation.
In further embodiments, if an adaptor receives an update of data from D to D′ and subsequently receives another update from D′ to D″, before the adaptor updates the parity, the adaptor can store a combined partial parity of the two updates (D′ xor D″) instead of separately storing two partial parities D xor D′ and D′ xor D″. In this way, the updating adaptor 8 a can save space in its NVRAM 16 a by combining partial parities. If, in alternative embodiments, the adaptor 8 a stores two or more partial parities in NVRAM 16 a , e.g., D xor D′ and D′ xor D″, then the adaptor 8 a can apply all partial parities to the parity block before writing the new parity to the parity block. For instance, the adaptor can calculate D xor D′ xor D″ xor P. In this way, the adaptor 8 a can optimize writes to the parity block in the disk j. However, in optimizing writes to the disk, the adaptor does not optimize partial parity storage space in the NVRAM 16 because it does not combine partial parities into a single partial parity entry.
Handling Disk Failure
If a disk fails, the adaptors must do parity flushing using partial parity data in their NVRAMs 16 a, b, c . To rebuild the data, input/output requests to the shared data would be halted, and an adaptor would rebuild the lost data to a spare disk using a RAID algorithm known in the art. FIG. 6 illustrates preferred logic to update data and parity blocks in the event one of the storage devices 10 a, b, c has failed. Read and write activity may be stopped until the parity flushing and rebuild are complete. Alternatively, read and write activity may continue during parity flushing and rebuild operations.
Control begins at block 80 which represents an adaptor, e.g., updating adaptor 8 a , receiving an update to block B on disk i from D to D′. As before, parity data P is maintained in disk j at block B. Control transfers to block 82 which represents the updating adaptor 8 a determining if a failure bit set in the system 2 indicates that a disk failed. When a disk fails, which may be a storage device 10 a, b, c or a component of a storage device 10 a, b c , a failure bit somewhere in the system 2 may be set to indicate such failure. If the adaptor 8 a determines that the failure bit indicates that a disk failed, then control transfers to block 84 ; otherwise, control transfers to block 83 which represents the adaptor 8 a executing a an algorithm for the non-failure case, such as the algorithms described with respect to FIGS. 4 and 5. Block 84 is a decision block representing the updating adaptor 8 a determining whether adaptor 8 a has ownership of the lock for the parity group including block B. If so, control transfers to block 86 ; otherwise, control transfers to block 88 . If the updating adaptor 8 a does not have lock ownership, block 86 represents the updating adaptor 8 a sending a message to the other adaptor(s) requesting lock ownership. Control transfers to block 90 which represents the updating adaptor 8 a waiting for a response from the other adaptor(s) granting ownership. After receiving the grant of lock ownership, control transfers to block 91 which represents the updating adaptor 8 a locking the parity groups to prevent other adaptors from performing I/O operations on data blocks within the locked parity groups. If the updating adaptor had ownership at block 84 or after locking the parity groups at block 91 , control transfers to block 88 which is a decision block representing the updating adaptor determining whether disks i and j are operational. If so, control transfers to block 92 ; otherwise control transfers to block 94 .
If the disks i and j are operational, then at block 92 , the updating adaptor 8 a sends a message to the other adaptors(s) to flush their parity from the inconsistent parity groups in their NVRAMs 16 a, b, c . Control transfers to block 96 which represents the updating adaptor 8 a waiting for confirmation that the other adaptor(s) have flushed parity. After receiving such confirmation, control transfers to block 98 which represents the updating adaptor 8 a flushing the inconsistent parity groups from the NVRAM 16 a . The adaptor 8 a may use the flushing logic described with respect to FIG. 5 . Control transfers to block 100 which represents the updating adaptor 8 a reading the old data D from disk i and old parity P from disk j. The adaptor 8 a then computes the new parity P′ at block 102 from (P XOR D XOR D′). Control transfers to block 104 to write the new parity P′ to disk j and the new data D′ to disk i. Control then transfers to block 106 to return DONE to the system when the new data is updated to disk i. Control transfers to block 107 to unlock the parity groups after both the new data D′ and new parity P′ are updated at disks i and j. Thus, DONE can be returned to the system before the parity group is unlocked.
If one of disks i and j have failed, then at block 94 , the adaptor 8 a determines whether disk i failed. If so, control transfers to block 108 ; otherwise, control transfers to block 110 . Blocks 108 , 112 , and 114 represent the updating adaptor 8 a insuring that the other adaptor(s) flush their inconsistent parity before flushing parity from NVRAM 16 a . Control transfers to block 116 which represents the updating adaptor 8 a reading old parity P and all data at block B in the other disks in the parity group, except for the data in block B of the failed disk i. The updating adaptor 8 a then calculates old data D in the failed disk i from all the data read from block B in the other disks in the parity group and the old parity (P) in disk j. Control then transfers to block 118 which represents the updating adaptor 8 a calculating the new parity P′ from XORing the rebuilt old data D, new data D′, and old parity P. Control then transfers to block 120 which represents the updating adaptor 8 a starting the process of writing the new data D′ to a spare disk, if a spare disk is available, and the new parity P′ to disk j. Control then transfers to block 106 to return DONE when the writing of the new data D′ is complete and to block 107 to unlock the parity group when the writing of the new parity P′ to disk j is complete.
If, at block 94 , the updating adaptor 8 a determined that disk j failed, i.e., disk i did not fail, then at block 110 , the updating adaptor 8 a calculates the new parity P′ from the new data D′ and the data at block B in all disks in the parity group, including the old data D in disk i. As discussed, in preferred embodiments, parity is calculated by XORing the values. Control then transfers to block 122 which represents the updating adaptor 8 a beginning the process of writing the new data D to block B in disk i and new parity P′ to a spare disk. Control then transfers to block 106 et seq.
The logic of FIG. 6 to update a data block can be used in handling read requests to the data block B to which the data must be updated before flushing and rebuilding of the failed disk are complete. If disk i is not failed, then the requested data can be read from block B at disk i. If disk i failed, then the receiving adaptor would perform the logic of blocks 108 through 116 to calculate the data D on the failed disk i, and return the requested data D to the requestor.
Handling Adaptor Failure
If an adaptor fails, e.g., adaptor 8 a , the NVRAM 16 a of the failed adaptor can be moved to a new adaptor because the NVRAM contains information concerning lock ownership and partial parties. If the NVRAM of the failed adaptor 8 a cannot be removed or has failed, then parity must be entirely rebuilt. In such case, all the partial parities in NVRAMs would be discarded, and all the adaptors would go into a mode where update requests are handled by updating data to the data disks. In this mode, the adaptors may suspend generating partial parity data. One of the surviving adaptors would execute a rebuild algorithm to rebuild parity from all the data. The surviving adaptor would have to obtain lock ownership before rebuilding the parity data. After the rebuild, adaptors can return to saving partial parity information in NVRAM. The adaptors may return to calculating and saving partial parity data on a parity group by parity group basis.
As soon as a drive, i.e., storage device, fails, a degraded mode is entered if there are no spare disks or a rebuild mode is entered if there are spare disks onto which to rebuild the data in the failed disk. FIG. 7 illustrates logic implemented in the adaptors 8 a, b, c that is executed when a drive fails. After a drive fails, the adaptors begin transmitting information on inconsistent parity groups to the other adaptor(s). In this way, each adaptor has a view of the inconsistent parity groups so that in the event that one of the adaptors fails, the information on such inconsistent parity groups maintained by the failed adaptor will not be lost. The surviving adaptor(s) would know which groups are inconsistent and, thus, be able to rebuild the data without the failed adaptor.
Logic begins at block 130 which represents a part or whole of a storage device 10 a, b, c failing. Control transfers to block 132 which represents an adaptor 8 a, b, c transmitting information on inconsistent parity groups in the NVRAM 16 a, b, c to the other adaptors. In this way, the adaptors exchange information on the inconsistent parity groups maintained in their NVRAMs 16 a, b, c . Control transfers to block 134 which represents an adaptor 8 a, b, c flushing the first inconsistent parity group from NVRAM 16 a, b, c in the manner described with respect to blocks 62 - 66 in FIG. 5 . Control then transfers to a parallel mode to simultaneously process tasks beginning at blocks 138 and 146 in a multi-tasking manner.
Block 138 represents an adaptor 8 a, b, c sending a message to the other adaptors indicating the parity group just flushed or made consistent. This allows the adaptors to have a current view of inconsistent parity groups across all other adaptor(s). Control transfers to block 140 which represents the adaptor 8 a, b, c rebuilding the data or parity data in the just flushed parity group to a spare disk. Control then transfers to block 142 which represents the adaptor 8 a, b, c determining whether there are further inconsistent parity groups in the NVRAM 16 a, b, c . If so, control transfers to block 144 which represents the adaptor 8 a, b, c flushing the next inconsistent parity group from the NVRAM 16 a, b, c and proceeding back to blocks 138 et seq. If there are no further inconsistent parity groups, control transfers to block 145 to end the flushing task.
Block 146 represents the adaptors waiting to receive an update to a data block. After receiving such update, control transfers to block 148 which represents the updating adaptor sending a message to the other adaptor(s) indicating the update and the blocks to update. The updating adaptor may also transmit the updated data. Control transfers to block 150 which represents the adaptor updating both data and parity. Control then transfers to block 152 which represents the updating adaptor sending a message to the other adaptor(s) indicating the completion of the update. In this way, if an adaptor fails, the surviving adaptor(s) know which parity groups are inconsistent and the parity group where failure occurred.
In another embodiment, the adaptors 8 a, b, c may maintain a list of flushed parity groups that recently became consistent. To maintain such a list, additional messages must be generated to inform other adaptors when a parity group is updated and made consistent. Maintaining such a list reduces the workload in case an adaptor fails because the surviving adaptor(s) have a view of parity groups recently flushed and made consistent. This additional embodiment including the list of consistent groups involves a modification of the logic of FIGS. 4 and 5 for updating and flushing parity. The modification involves adding a step prior to block 32 in FIG. 4 to have the updating adaptor send a message to the other adaptor(s) with the parity group being updated and the list of recently flushed parity groups. The updating adaptor would then wait for a response from the other adaptor(s) acknowledging receipt of the message. When parity flushing, the algorithm of FIG. 5 would be modified to add a parity group to the list of recently flushed parity groups after completion of parity flushing of the inconsistent parity group in the NVRAM between blocks 66 and 68 .
Update Requests With Read Caches
If the adaptors 8 a, b, c include read caches 18 , then the algorithms should satisfy two correctness conditions: (1) when an update occurs to different blocks having the same parity block, parity is likewise updated and (2) an update request through one adaptor, e.g., adaptor 8 a , which is cached at another adaptor, e.g., adaptor 8 b , causes the invalidation of the caches in the other adaptor 8 b so that the adaptor 8 b does not return or destage stale data.
In the embodiments utilizing read caches 18 a, b, c , the adaptors 8 a, b, c maintain a data structure indicating data cached at other remote adaptors. Preferred embodiments are described with respect to a two adaptor 8 a, b system. However, the logic could be extended to an N adaptor case. FIG. 8 illustrates a RAM 154 a, b, c within each adaptor 8 a, b, c storing three data structures. The first data structure 155 is a list of data blocks waiting to be added to the read cache 18 a, b, c . Until the adaptor 8 a, b, c adds the data blocks to the read cache 18 a, b, c they are maintained in the adaptors RAM 154 a, b, c . Data structure 156 a, b, c is a list of blocks recently updated by the adaptor 8 a, b, c and data structure 158 a, b, c is a list of blocks in the other adapter's read cache 18 a, b, c , i.e., a directory of the other adaptor's read cache. Each adaptor 8 a, b, c also maintains a list of inconsistency groups in its NVRAM 16 a, b, c.
FIG. 9 illustrates logic implemented in the adaptors 8 a, b to handle a read request using the data structures 155 , 156 , 158 . Control begins at block 160 which represents an adaptor, e.g., receiving adaptor 8 a , receiving a read request for block B from disk i. Control transfers to block 162 which represents the receiving adaptor 8 a determining whether the block is in its read cache 18 a . If so, control transfers to block 164 to return the data from the read cache 18 a to the user, and complete the program. Otherwise, if the data is not in the read cache 18 a , control transfers to block 166 which represents the receiving adaptor 8 a determining whether the requested block B is in the data structure 155 a indicating blocks to add to the read cache 18 a . If the data is in the data structure 155 a , then a copy of the data is maintained in a wait buffer portion of the RAM 154 . Data is held in this wait buffer area until the other adaptor grants permission to add the data to the read cache 18 a . If so, control transfers to block 168 ; otherwise, control transfers to block 170 . Block 168 represents the adaptor 8 a determining whether the remote adaptor 8 b has provided permission to add the block to the read cache 18 a . Permission may be granted according to the permission exchange algorithm described with respect to FIGS. 11 a, b.
If permission was granted, control transfers to block 172 , which represents the receiving adaptor 8 a adding the data in the wait buffer to the read cache 18 a and returning the data just added to the read cache 18 a to the user. If permission has not yet been granted, control transfers to block 174 which represents the adaptor 8 a waiting for a response to the permission request from the remote adaptor 8 b . Once the response is provided, control transfers to block 176 , which represents the receiving adaptor 8 a determining if permission was granted. If so, control transfers to block 172 to return the data to the user for those blocks where permission was granted. For those blocks where permission was denied or where the requested block was not in the data structure 155 a , control transfers to block 170 which represents the receiving adaptor 8 a reading the block B from disk i. Control then transfers to block 180 which represents the adaptor 8 a determining whether the read block is listed in the data structure 155 a indicating blocks to add to the read cache 18 a . If so, control transfers to block 182 ; otherwise, control transfers to block 184 .
Block 182 represents the receiving adaptor 8 a adding the data read from disk i to the wait buffer in the RAM 154 a . Control then transfers to block 186 which represents the adaptor 8 a returning the block to the user. If the block is not in the data structure 155 a indicating blocks to add, then at block 184 , the adaptor 8 a appends information on the blocks to the data structure 155 a indicating blocks to add, and then proceeds to blocks 182 et seq. to return the data to the user.
In this way, a read request is processed in either two ways. If the data is in the read cache 18 a , read the data from the cache 18 a and send it to the user. If the data is in the disk i, then read from disk, send to the user, and then add to the list of blocks 155 a to add to the cache 18 a . However, the requested data cannot go into the read cache until the remote adaptor 8 b provides permission pursuant to the permission exchange algorithm discussed in FIGS. 11 a, b or other permission exchange algorithms known in the art. The permission exchange algorithm of FIGS. 11 a, b insures that an adaptor with data in the wait buffer will not add that data to its read cache if the granting adaptor has recently updated to that data block on disk i.
FIG. 10 illustrates logic implemented in the adaptors 8 a, b to handle an update request of a block B in disk i, wherein disk j maintains parity data, using the data structures 155 , 156 , 158 . Control begins at block 190 with an adaptor, e.g., updating adaptor 8 a , receiving a request to update block B in disk i. Control transfers to block 192 which represents the updating adaptor 8 a determining whether the old version D of the data to update is in the read cache 18 a . If so, control transfers to block 194 to read the old data from disk i. If the data is in the read cache 18 a at block 192 or if the data D is read from the disk i at block 194 , then control transfers to block 196 , which represents the updating adaptor 8 a determining whether the data structure 158 a indicating the blocks in the remote adaptor's 8 b read cache 18 b includes the block to update. If so, control transfers to block 198 ; otherwise, control transfers to block 200 . Thus, with the data structure 158 a, b, c , an adaptor 8 a, b, c can determine the contents of the read cache 18 a, b, c of another adaptor without messaging the adaptor.
If the remote adaptor 8 b includes the block to update in its read cache 18 b , then at block 198 , the updating adaptor 8 a sends a message to the remote adaptor 8 b to invalidate the data block B to update from the remote read cache 18 b . Otherwise, at block 200 , the updating adaptor 8 a adds block B to the data structure 158 a indicating the block as recently updated. From block 198 or 200 , control transfers to block 202 which represents the updating adaptor 8 a calculating partial parity, e.g., D xor D′, and invalidating the old data D from its read cache 18 a if the old data D is in the read cache 18 a . Control then transfers to block 206 which represents the updating adaptor 8 a saving the partial parity and parity group number for the partial parity data in the NVRAM 16 a . Control then transfers to block 208 which represents the updating adaptor 8 a writing the new data D′ to block B in disk i.
From block 208 , control transfers to block 210 which represents the updating adaptor 8 a determining whether a message was sent to the remote adaptor 8 b at block 198 . If so, control transfers to block 212 ; otherwise, control transfers to block 214 . At block 212 , the updating adaptor 8 a waits for a response from the remote adaptor 8 b to its message to invalidate the data sent at block 198 . Upon receiving the response, control transfers to block 216 which represents the updating adaptor 8 a updating the data structure 158 indicating the remote adaptor's 8 b read cache 18 b to indicate that the data block B was removed. From blocks 210 or 216 , control transfers to block 214 to return DONE to the user.
FIGS. 11 a and b are flowcharts illustrating logic implemented in adaptors 8 a, b , respectively, when a requesting adaptor, e.g., adaptor 8 a , requests permission from a remote adaptor 8 b to add a block of data to its read cache 18 a . The logic of FIG. 11 a describes operations performed by the requesting adaptor 8 a seeking permission to add data blocks to read cache 18 a . The logic of FIG. 11 b describes operations performed by the remote adaptor 8 b to determine whether to grant permission to the requesting adaptor 8 a . The purpose of the permission requesting algorithm is to insure that the requesting adaptor 8 a does not add stale data to its read cache 18 a . With respect to FIG. 11 a , control begins at block 220 which represents the requesting adaptor 8 a selecting a block to remove from the read cache 18 a for each block the adaptor 8 a intends to add to the read cache 18 a . Control transfers to block 222 which represents the adaptor 8 a removing the selected blocks from the read cache 18 a . Control then transfers to block 224 which represents the requesting adaptor 8 a sending a message to the other adaptor 8 b with a list of blocks the requesting adaptor 8 a intends to add to the read cache 18 a and the list of blocks removed.
Control transfers to block 226 which represents the requesting adaptor 8 a waiting for a response from the granting adaptor 8 b . Control transfers to block 228 which represent the requesting adaptor 8 a adding those blocks to which permission was granted to the read cache 18 a . Those blocks where permission was denied are not added. Control transfers to block 230 which represents the adaptor 8 a setting the data structure 155 a indicating blocks to add to the read cache 18 a to NULL.
With reference to FIG. 11 b , control begins at block 232 which represents the granting adaptor 8 b receiving the list of blocks the requesting adaptor 8 a seeks to add to the read cache 18 a . Control transfers to block 234 which represents the granting adaptor 8 b processing the data structure 156 b indicating the list of recently updated blocks to determine whether any blocks the requesting adaptor 8 a intends to add were recently updated. At block 234 , the granting adaptor 8 b determines whether the requesting adaptor 8 a intends to add data to its read cache 18 a that is outdated in view of data the granting adaptor 8 b recently updated. Control transfers to block 236 which represents the granting adaptor 8 b sending a message to the requesting adaptor 8 a denying permission to add those blocks included in the data structure 156 b indicating blocks the granting adaptor 8 b recently updated and permitting the requesting adaptor 8 a to add those blocks not in the data structure 156 b of recently updated blocks. Control transfers to block 240 which represents the granting adaptor 8 b setting the data structure 156 b indicating recently updated blocks to NULL.
Conclusion
This concludes the description of the preferred embodiments of the invention. The following describes some alternative embodiments for accomplishing the present invention.
In preferred embodiments, adaptors 8 a, b, c interface the nodes 4 a, b, c to allow sharing of storage resources. The adaptors 8 a, b, c were described as having specific components, such as a processor 14 a, b, c , NVRAM 16 a, b, c , read cache 18 a, b, c , write cache 20 a, b, c , and NVS unit 22 a, b, c . In alternative embodiments, some or all the components of the adaptors 8 a, b, c may be located elsewhere in the node 4 a, b, c or share resources with the computer 6 a, b, c . In yet further embodiments, there may be a central computing resource or node that monitors or controls intercommunication between the nodes 4 a, b, c.
The write cache 20 a, b, c and read cache 18 a, b, c may be memory locations within a single memory device or memory locations within a separate memory device, comprised of any suitable memory device known in the art, including volatile and non-volatile memory devices.
The logic of FIGS. 4-7 and 9 - 11 is for illustrative purposes. Additional or alternative steps may be performed in addition to those illustrated in the logic. Further, the order of the steps in the preferred logic may also vary.
Updated parity P′ was calculated by taking the exclusive OR (XOR) of the old data D, new data D′, and old parity P. However, those skilled in the art will appreciate that alternative methods known in the art for determining parity may be used in addition to the exclusive or operation (XOR) described herein.
The preferred embodiments may be implemented as a method, apparatus or article of manufacture using standard programming and/or engineering techniques to produce software, firmware, hardware, or any combination thereof. The term “article of manufacture” (or alternatively, “computer program product”) as used herein is intended to encompass one or more computer programs and data files accessible from one or more computer-readable devices, carriers, or media, such as a magnetic storage media, “floppy disk,” CD-ROM, a file server providing access to the programs via a network transmission line, holographic unit, etc. Of course, those skilled in the art will recognize many modifications may be made to this configuration without departing from the scope of the present invention.
In summary, preferred embodiments in accordance with the present invention provide a system for updating data at a data block. A first processing unit receives update data. The data block to update is located in a first storage device and a second storage device stores parity data for the data block. A parity group comprises a data block and corresponding parity data for the data block. The first processing unit obtains the data at the data block and calculates partial parity data from the data at the data block and the update data. The first processing unit stores the partial parity data in a storage area and writes the update data to the data block in the first storage device. The first processing unit further updates parity data for parity groups for which partial parity data is maintained by obtaining control of access to the parity group to update from a second processing unit if the first processing unit does not control access to the parity group. When the first processing unit controls access to the parity group, the first processing unit calculates new parity data from the partial parity data and the parity data in the second storage device, and writes the new parity data to the second storage device.
The foregoing description of the preferred embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto. The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. | A shared device environment having multiple nodes ( 4 a -4 c ), each node containing a computer ( 6 a -6 c ), an adaptor ( 8 a -8 c ) and multiple storage devices ( 10 a -10 c ). Adaptors ( 8 a -8 c ) facilitate read access to storage devices ( 10 a -10 c ) such that the data records accessed are the latest version data records. Adaptors ( 8 a -8 c ) are operative to provide the latest version of data blocks requested by computers ( 6 a -6 c ) by first searching the read cache of each adaptor for data blocks requested by computers ( 6 a -6 c ). If the requested data blocks are not found in the read cache of any adaptors, then data structures ( 155, 156 and 158 ) within the adaptors are searched for any data blocks waiting to be added to the read cache of any adaptors. If no data blocks are found, then the read access is conducted directly from the storage device itself. | 6 |
BACKGROUND OF THE INVENTION
This is a continuation application of Ser. No. 705,712, filed Feb. 26, 1985, now U.S. Pat. No. 4,597,991 which, in turn, is a divisional application of Ser. No. 437,431, filed Oct. 27, 1982, now U.S. Pat. No. 4,518,039, which, in turn, is a continuation-in-part of Ser. No. 294,813, filed Aug. 20, 1981, now abandoned.
The present invention relates to an improved method for producing heat curable particles. The improved particulate material of this invention has utility, including but not limited to, use as a proppant in hydraulic fracturing, use as a fluid loss agent in hydraulic fracturing and as a screening material in gravel packing. The invention also relates to a method for producing improved particulate material for use in the production of shell molds and shell cores in the foundry industry.
In the completion and operation of oil wells, gas wells, water wells, and similar boreholes, it frequently is desirable to alter the producing characteristic of the formation by treating the well. Many such treatments involve the use of particulate material. For example, in hydraulic fracturing, particles (propping agents) are used to maintain the fracture in a propped condition. Smaller size particles (70 to 140 mesh) are used to control fluid loss during fracturing. Also in sand control techniques, particulate matter is placed in the well to prevent the influx or encroachment of formation sand or particles.
Although particulate material is used in the treatment of formations for a variety of reasons, there is one problem common among such treatments, the problem of particle stability. This problem can best be appreciated when considered in connection with specific treating techniques.
In hydraulic fracturing, propping agent particles under high closure stress tend to fragment and distintegrate. At closure stresses above about 5,000 p.s.i., silica sand, the most common proppant, is not normally employed due to its propensity to disintegrate. The resulting fines from this disintegration migrate and plug the interstitial flow passages in the propped interval. These migratory fines drastically reduce the permeability of the propped fracture.
Other propping agents have been used to increase well productivity. Organic materials, such as the shells of walnuts, coconuts and pecans have been used with some success. These organic materials are deformed rather than crushed when the fracture closes under the overburden load. Aluminum propping agents are another type which deform rather than disintegrate under loading. While propping agents such as these avoid the problem of creating fines, they suffer the infirmity of allowing the propped fracture width to close as the proppant is squeezed flatter and flatter with time. In addition, as these particles are squeezed flatter and flatter, the spaces between the particles grow smaller. This combination of decreased fracture width and decreased space between the particles results in reduced flow capacity.
An improved proppant over the materials mentioned above is spherical pellets of high strength glass. These high strength glass proppants are vitreous, rigid, and have a high compressive strength which allows them to withstand overburden pressures of moderate magnitude. In addition, their uniform spherical shape aids in placing the particles and provides maximum flow through the fracture. While these beads have high strength when employed in monolayers, they are less satisfactory in multilayer packs. In brine at 250° F., the high strength glass beads have a tendency to disintegrate at stress levels between 5000 and 6000 p.s.i. with a resultant permeability which is no better, if not worse, than sand under comparable conditions.
Resin coated particles have been used in efforts to improve the stability of proppants at high closure stresses. Sand or other substrates have been coated with an infusible resin such as an epoxy or phenolic resin. These materials are superior to sand at intermediate stress levels. However, at high termperature and high stress levels, the resin coated particles still show a decrease in permeability to about the same degree as silica sand.
In gravel pack completions, particularly sized aggregate is placed in the well adjacent to the formation to form a filter bed through which produced fluids must flow. In one type of gravel packed completion, e.g. a linerless gravel pack, the aggregate material is injected through the well casing perforations to provide a filter outside the casing for each perforation. This type of completion frequently fails because of the inability of the aggregate to bridge across the perforation, resulting in aggregate and formation sand entering the well bore.
Another type of gravel packed completion frequently used for sand control purposes is the liner gravel pack. This type of completion employs a well liner or screen packed in aggregate. Because, of settling or migration of the aggregate it is frequently difficult to maintain the gravel in surrounding relation to the liner. Also, failure of the liner caused by corrosion or collapse results in the loss of the filter bed surrounding the liner, at least in the vicinity of the liner failure.
Obviously, a desirable characteristic of well completions involving the use of particulate material is one of particle stability. Efforts to provide such stability, particularly in gravel packed completions, include the use of organic resins or resinous materials.
U.S. Pat. No. 3,857,444 to Copeland discloses a method for forming a permeably consolidated gravel pack in a well bore. The slurry containing a particulate material coated with an uncured epoxy resin and a curing agent in a solvent is slurried in liquid hydrocarbon and introduced into place in the formation. The well is shut in until the resin coated particulate mass cures to form a permeable consolidated sand or gravel pack.
U.S. Pat. No. 3,929,191 to Graham et al discloses a method for producing coated particles for use in treating subterranean formations. The particles in this method are coated with a resin dissolved in a solvent which is then evaporated. This patent also discloses that the coating may be produced by mixing the particles with a melted resin and subsequently cooling the mixture, forming a coating of resin on the particles.
The Graham patent also discloses that the addition of coupling agents to the system improves the bonding of the resin to the particles. This improved bonding strength between the resin and particles increases the strength of the mass formed when the resin coated particles are fused and cured into a porous mass. This increased strength is important due to the high stresses the material may be subjected to in use, such as when used as a proppant in hydraulic fracturing.
SUMMARY OF THE INVENTION
The present invention provides an improved method for producing heat curable resin coated particles comprised of high strength centers, a coupling agent chemically bound to the centers and a heat curable resin coated over the centers. The final product is a composite material consisting of high strength centers encapsulated with a coating of a heat curable solid resin. The material is free flowing and requires no special handling or storage conditions. The particles when cured have even greater compressive and tensile strength than those known in the prior art. The material produced by the invention is thus more useful than the materials of the prior art when used in high stress environments. For example, the method of the present invention may be used in hydraulic fracturing in situations where the material of the prior art would fail under the high closure stress of the formation. The method also yields superior gravel packs to that obtainable with the prior art. In addition, the improved bonding of the resin to the centers yields a cured material with increased tensile strength. This allows shell molds and cores in the foundry industry to be made from material with a higher particle to resin ratio than heretofore possible.
These improved curable resin coated particles are produced by first coating the centers with a coupling agent. The treated centers are then heated to drive off any solvent employed with the coupling agent and to react the coupling agent with the centers. This heating also serves to raise the temperature of the centers above the melting point of the resin. The solid resin, into which a coupling agent was incorporated during its manufacture, is then added in either flake or powdered form to the heated centers. The centers and resin are mixed until the resin forms an even coating on the surface of the centers. The mixture is then quenched with water which serves to harden the coating on the centers and to prevent further reaction of the resin.
Improved results have also been obtained using a coupling agent only in the resin. It is also possible to obtain beneficial results by using only the pretreatment of the centers. However, coating the center with a coupling agent as described above and incorporating a coupling agent in the resin has produced the best results and accordingly is the preferred method.
DESCRIPTION OF THE INVENTION
Particle Substrate
The present invention can be carried out with any suitable high strength substrate as the particle centers. Choice of the particle substrate is governed by the properties required of the cured mass.
For example, in the oil and gas industry extremely high strength proppants are needed to hold open formation fractures created by hydraulic fracturing. In such an application, the present invention may use spherical glass beads as the center. Such beads are available commercially in a variety of mesh sizes. For example, Union Carbide Corporation supplies vitreous, rigid, inert, substantially spherical pellets under the trade name UCAR Props. Such beads, while of extremely high compressive strength when employed in monolayers are less satisfactory when placed in multilayer packs. These beads, when resin coated by the process of this invention and then cured in place, yield a permeable mass of higher compressive strength than either the beads alone or of resin coated beads of the prior art. Beads from about 6 to about 200 mesh are generally used. In extreme environments where stresses are very high sintered bauxite, aluminum oxide and ceramics such as zirconium oxide and other mineral particles may be coated. Particles from 6 to 200 mesh are generally used. (All reference to mesh size in the claims and specification are to the U.S. Standard Sieve Series.)
In less severe conditions conventional frac sand is the preferred particle substrate of the invention. An advantage of the present invention is that due to the increased strength obtained by the coating process, it allows the lower cost frac sand to be used under more severe conditions than possible with the materials of the prior art. Silica sand of about 6 to about 200 mesh (U.S. Standard Sieve) is generally used.
In other applications such as shell and core mold manufacture in the foundry industry, the siliceous materials common to that industry may be employed.
Resin
The resins suitable for use in forming the coating include true thermosetting phenolic resins of the resole type and phenolic novolac resins which may be rendered heat reactive through the addition of catalysts. The resins must form a solid nontacky coating at ambient temperatures. This is required so that the coated particles remain free flowing and so that they do not agglomerate under normal storage conditions. Resins with softening points of 185°-240° F. (Ball and Ring Method) are acceptable.
Regardless of which type of resin is employed a coupling agent as subsequently described is preferably incorporated into the resin during its manufacture. The coupling agent, which has a functional group reactive in the phenol-formaldehyde system of the resin is added in an amount ranging from about 0.1 to 10 percent by weight of the resin. The preferred range is from about 0.1 to 3.0 percent by weight of the resin. The coupling agent is incorporated into the resin under the normal reaction conditions used for the formation of phenol-formaldehyde resins. The coupling agent is added to the resin reactants prior to the beginning of the phenol-formaldehyde reaction. This incorporation of the coupling agent in the resin is partly responsible for the increased resin-center bond strength provided by the invention.
The preferred resin to be used with the method of the present invention is a phenolic novolac resin. When such a resin is used it is necessary to add to the mixture a cross-linking agent to effect the subsequent curing of the resin. Hexamethylenetetramine is the preferred material for this function as it serves as both a catalyst and a source of formaldehyde.
It is also advantageous to add an organic acid salt such as calcium stearate to the resin-center mixture to act as a lubricant. Such an addition imparts a degree of water repellancy to the finished product and aids in preventing sintering of the product during storage. The organic acid salt may be added to the resin or more conveniently may be simply added as a powder at the time the resin is added to the heated centers.
Problems associated with sintering of the product during storage can be further minimized by increasing the "stickpoint" of the resin. Raising of the stickpoint avoids problems of sintering and lumping of the resin coated particle when stored at high temperatures (100°-120° F.).
Stickpoint is measured by applying the resin coated particles to a square metal rod heated at one end. The rod has a uniform temperature gradation from its heated end to its unheated end. After one minute the particles are dusted from the rod. The temperature of the point along the rod at which the particles adhere to the rod is measured and is the stickpoint.
To increase the stickpoint a small amount of dry hexamethylenetetramine is added to the flake novolac resin before it is discharged to the muller. The blending of the hexamethylenetetramine with the resin during the initial phase of the hot coating process allows for some polymerization of the resin to occur before cooling. This polymerization results in an increase in the resin stickpoint.
The amount of hexamethylenetetramine added in this manner is dependent upon the final stickpoint desired. Generally about 1 to about 10% dry hexamethylenetetramine based on the weight of the flake resin is added. For example, the addition of 2.8% hexamethylenetetramine to the resin in the manner just described elevated the stickpoint of the finished product from 210° F. to 238° F. This increase in stickpoint is sufficient to remedy the storage problems of sintering and lumping.
Another problem encountered in the use of the product of the instant invention is the creation of dust during handling operations in the field. The resin coating on the particles is brittle, and abrasive action between the particles during high velocity transport generates fine particles of free resin. This dust is objectionable to observe and its elimination is desirable.
The incorporation of a small amount of polyvinyl acetal resin into the resin coating has been found to increase the resin strength and thereby reduce its brittleness. This results in the virtual elimination of the dusting problem.
The preferred polyvinyl acetal for this application is polyvinyl butyral although other resins such as polyvinyl formals may be used.
Specifically a polyvinyl butyral, BUTVAR B-76, manufactured by Monsanto Co. has proven to be effective in strengthening the resin coating and eliminating the dust problem.
Coupling Agent
The coupling agent to be employed is chosen based on the resin to be used. For phenolic resins, the preferred coupling agents are organo-functional silanes such as aminoalkylsilanes. Gamma-aminopropyltriethoxysilane has given excellent results when used with phenolic resins. Preferably the coupling agent is both incorporated into the resin structure and reacted with the center surface prior to the resin coating step. This unique dual treatment with the coupling agent results in a higher resin-center bond strength and a concomitant increase in the strength of the cured mass. The same coupling agent may be used in both the resin and the center treatment, or two different coupling agents may be employed. It is also possible to obtain some improvement in the strength of the cured mass by only pretreating the center surfaces.
Coating Process Parameters
The centers to be coated are weighed and then transferred to a heated rotating drum. During the transfer, the centers are sprayed with a solution containing the coupling agent. A solution is used to insure adequate wetting of the center surface with the coupling agent. The preferred solvent is water.
A sufficient quantity of water must be used to insure adequate dispersion of the coupling agent over the surface of the centers. It is also important not to use too much water as excessive time and heat are then needed to drive off the water during the evaporation step. The amount needed is of course dependent upon the size of the centers. For example, for 20/40 mesh sand, it has been found that 0.1 to 3 gallon per 1000 lb. of sand gives adequate coverage.
The concentration of coupling agent in the water depends on the surface area of the centers, the amount of water to be used and the nature of the coupling agent. The concentration is generally between 0.1% and 10.0% by volume. The preferred range is generally between 0.5% and 3.0%.
After the coupling agent sprayed centers have entered the heater drum, the mixture is agitated without heat for a period of time ranging from 5 seconds to 1 minute to insure proper dispersion of the coupling agent over the surface of the centers.
The heater is then fired and the centers are heated by a hot air blast to approximately 250°-350° F. During this heating period the water is evaporated and the coupling agent reacts with the surface of the centers. In addition, the hot air blast can be utilized to remove fines from the centers which can lower the permeability of the cured particle mass.
The heated centers are then discharged into a mixer. The flake resin into which a coupling agent has been incorporated is then added. The ratio of resin to the centers varies with the strength required and the size of the centers. Typically the resin coating constitutes between about 1 and about 8 percent by weight of the particles. Dry hexamethylenetetramine may also be added at this time to elevate the stickpoint as previously described.
A lubricant such as calcium stearate is added to the centers with the resin. The amount of lubricant is generally in the range of 0.1 to 10 percent based on the weight of the resin. The preferred amount is in the range of about 0.5 to 5.0 percent. Also a polyvinyl acetal may be added at this time to improve the resin strength and eliminate the creation of dust during handling.
The mixture of heated centers and resin is then agitated for a period of about 30 seconds to 5 minutes. There must be sufficient agitation time to insure complete coverage of the centers.
An aqueous solution of hexamthylenetetramine is then added to the resin-center mixture. This solution serves as a vehicle for the addition of the hexamethylenetetramine and as a quench. The amount of hexamethylenetetramine is generally between about 10 and 20 percent based on the weight of the resin. The preferred range is between about 13 and about 17 percent. The amount of water should be sufficient to cool the mixture sufficiently to prevent reaction of the hexamethylenetetramine and to harden the resin. The amount of water needed ranges generally from about 1 to 5 gallons per 1000 lbs. of particles. In such a case the quench is still necessary to prevent further reaction of the resin and to begin the hardening process.
After the quench solution is added, the agitation of the mixture is continued and the coated particles are further cooled by blowing air through them.
The hardened particles are then discharged to conveyors which carry the coated particles to screening and bagging operations.
Typical Coating Cycle
One thousand pounds of 20/40 frac sand is weighed in a weigh hopper. As the sand is discharged from the weigh hopper to a heater drum it is sprayed with six quarts of a water solution containing 0.89 percent by volume of silane A-1100 (an aminoalkylsilane purchased from Union Carbide Corporation). The sprayed sand is then rotated in the heater drum for 15 seconds prior to ignition of the heater in order to insure a thorough wetting of the sand by the silane water solution.
The heater fire is ignited and the sand is heated to approximately 270° F. by the hot air blast in approximately three minutes. During this period the water is evaporated and the coupling agent reacts with the sand surface. In addition, the force of the hot air blast carries away any fines form the sand.
The heated sand is then discharged into a muller where 35 pounds of the novolac resin which contains 0.5% gamma-aminopropyl-triethoxysilane along with one-half pound of calcium stearate powder is added. This mixture is mulled for 60 seconds during which time the resin melts and forms an even coating on the particles of sand. At the conclusion of the mull cycle an aqueous solution of hexamethylenetetramine is added to the mixture as a quench. The amount of hexamethylenetetramine is equal to 15% of the resin by weight. The quench water cools the resin coating to harden it and also prevents reaction of the novolac with the hexamethylenetetramine. After addition of the quench water solution, agitation is continued for approximately another minute as cool air is blown through the mixture to further cool the coated particles.
The coated sand is then discharged to a screw conveyor where it is then transported to screening equipment and shakers and ultimately bagged. The product thus produced is free flowing and may be handled with ordinary particle handling machinery typical to the oil, gas and foundry industries.
Comparative Strength Data
Table 1 shows comparative tensile strengths for cured specimens of coated sand. In each case sand (American Foundry Society #95) was coated with 3% (based on the weight of the sand) of a novolac resin. The coated sand was then cured and the hot and cold tensile strengths measured. Sample A was prepared with a standard commercial novolac (Reichold 24-713) commonly used for coating foundry sand. Sample B was prepared according to the preferred method of the invention.
TABLE 1______________________________________ Sample A Sample B (no coupling agent; (coupling agent Reichold 24-713 in resin and on resin) substrate)______________________________________Hot Tensile 283 psi 390 psiStrength (450° F.) (Average of 3 tests) (Average of 6 tests)Cold Tensile 628 psi 978 psiStrength (75° F.) (Average of 6 tests) (Average of 12 tests)______________________________________
MICROSCOPIC OBSERVATIONS OF COATED PARTICLES
Particles produced by the method of the present invention were subjected to microscopic examination in both the cured (in brine) and uncured state. Examination of uncured particles prepared without a coupling agent in either the resin or on the substrate reveals an uneven, non-uniform coating. Examination of the same particles after curing in brine show that the resin coating has pulled away from the center. Such "peel back" of the resin from the center leads to failure of the cured mass when used downhole in the oil and gas industry.
Another group of particles was coated using a coupling agent in the resin, but with no pretreatment of the centers with coupling agent. Microscopic examination of these particles shows that the coating is more uniform than the coated particle without any coupling agent. However, the coating is still uneven and the uneveness is more pronounced after curing in brine. This uneveness results in lower strength in the cured mass.
A third group of particles was coated by the preferred method of the present invention. The coupling agent was incorporated in the resin and used to pretreat the centers. Examination of the uncured particles shows a uniform, even coating. This is a desirable property as it allows closer and more uniform packing of the particles with resulting higher strength. Examination of the cured particles reveal that they maintain the smooth uniform coatings after curing in brine, completely and evenly encapsulating the center.
The strength of cured multi-layer packs made from the three preparations of resin coated particles just discussed was measured. In the first, prepared without any coupling agent, very little consolidation was obtained in a multi-layer pack. In the second, prepared with coupling agent in the resin only, a consolidated core having low to medium strength was obtained. Finally, using coated particles prepared by the method of the invention, consolidated cores of high strength were produced.
Formation Treatment
The free-flowing, heat curable particles as produced by the above method may be used as proppants or fluid loss agents in hydraulic fracturing, as aggregate in gravel packs, and in other subterranean formation treatments requiring particulate material.
In carrying out a hydraulic fracturing operation, a fracture is first generated by injecting a viscous fluid into the formation at a sufficient rate and pressure to cause the formation to fail in tension. Injection of the fluid is continued until a fracture of the desired geometry is obtained. A carrier fluid having the proppant suspended therein is then pumped into the fracture. The temperature of the carrier fluid during pumping operations will be low so as to prevent premature curing of the resin. The carrier fluid bleeds off into formation and deposits the propping agent in the fracture. This process is controlled by fluid loss agents which are small aggrregate particles that temporarily slow the fluid loss to the formation.
After the proppant is placed, the well is shut in with pressure maintained on the formation. As the pressure within the fracture approaches the normal formation pressure, the fracture walls close in on the proppant and apply an overburden stress thereto. At the same time, ambient formation temperature heats the resin. Initially, the resin fuses and unites at contact areas between contiguous particles or with the formation walls. As the temperature increases the polymerization reaction proceeds until the resin is cured into an insoluble and infusable cross-linked state. The pendular regions between adjacent particles bond the packed particles into a permeable network having considerable compressive strength.
In carrying out linerless gravel pack completions the particles, suspended in a carrier fluid, are injected into the well and forced through the well casing perforations. During the particle placement, the carrier fluid bleeds off into the formation and deposits the free-flowing heat curable particles in the cavity previously formed. Following placement of the particles, the well is shut in permitting the temperature to equalize in the well. Increase in the temperature in the packed interval softens or melts the resin coating and then cures the resin into an infusible cross-linked state. The permeable network resulting from this treatment provides a self-sustaining, consolidated interval which prevents the aggregate from flowing through the perforations and entering the well bore.
A more detailed description of the standard industry practices for the use of such heat curable particles in hydraulic fracturing and gravel pack completion is disclosed in U.S. Pat. No. 3,929,191 which is hereby incorporated by reference.
Further modifications and alternate embodiments of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be considered as illustrative only and for the purpose of teaching those skilled in the art the manner of carrying out the invention. Various modifications may be made in the method. It is intended that all such modifications, alterations, and variations which fall within the spirit and scope of the appended claims be embraced thereby. | An improved particulate material for use in treating subterranean formations as a proppant and/or as a fluid loss agent in hydraulic fracturing and as a screening material in gravel packing comprised of heat curable particles capable of forming a cohesive mass, said particles comprised of a high strength center, a coupling agent chemically bound to the center with a heat curable resin coated over the center. | 4 |
BACKGROUND OF INVENTION
1. Field to Which Invention Relates
The invention relates to a tool, more particularly a tool for bending pipes, rods, bands or girders, comprising a pressing part adapted to slide with the use of a thrust rod, and one or more counter pressing parts adapted to be fixed on the tongs. For the sake of simplicity, the novel tool is in the following specification referred to as a tongs.
2. The Prior Art
Tongs of this type all comprise toothed thrust rods, something which leads to a series of disadvantages. In the case of such prior art tongs the thrust rod can only be advanced in steps, the length of the steps corresponding to the pitch of the individual teeth. Furthermore they have the disadvantage that on moving out the thrust rod also a number of the laterally projecting teeth project from the tongs housing and if the thrust rod is rapidly withdrawn into the housing again this may injure the user. Furthermore there is the disadvantage that these teeth of the thrust rod and the corresponding teeth of the acting mechanism are subject to wear in the case of long periods of use on their front edges so that reliable operation of such tongs is not always ensured or the tongs may only operate for a relatively short time.
SUMMARY OF INVENTION
One aim of the present invention is that of providing a tongs of the initially specified type which does not have the disadvantage of prior art tongs.
This aim is achieved in the case of tongs of the initially mentioned type by a thrust rod with a smooth surface, on which a sprag and an advancing lever are fitted, whose openings through which the thrust rod extends have opposite clamping edges, a first spring, which urges the advancing lever with its one end against an inner end section of the tongs lever located in the rest position and accordingly urges with an upper edge zone and the lower edge zone of its opening against the thrust rod with a tilting action, a second spring between the advancing lever and the sprag, which is journalled for pivoting movement with respect to the housing and the second spring so urges the sprag into its locking position making tilting engagement with its upper edge part and the lower edge part of its opening on the thrust rod that an acutation of the tongs lever the advancing lever is advanced with a tilting action to a great extent, the sprag is sufficiently released and the thrust rod is advanced and a release means which unjams the advancing lever and the sprag.
The advantage obtained with the invention is to be regarded as residing more particularly in that the use of a thrust rod with a smooth surface is made possible. This leads to the further advantages that such a tongs can be used without the danger of injury to the user, since the thrust rod does not have any projecting parts and the thrust rod is not worn even in the case of pronlonged periods of use and accordingly always operates satisfactorily. There is the further advantage that the thrust rod is continuously, i.e., not in steps adjustable. This stepless displacement of the thrust rod makes possible extremely precise bending, as for example of tubes or pipes with an accuracy to fractions of one degree of angle using such a tongs.
On each actuation of the tongs lever the advancing lever is tilted towards the thrust rod to a greater extent than in its rest position and is then moved clear again. As a result the thrust rod is entrained. Simultaneously however the second spring, which is arranged between the advancing lever and the sprag in a compressed condition, is relaxed so that the sprag releases the thrust rod during this stroke for displacement. If the tongs lever is released the advancing lever moves back into its normal position while the sprag reliably prevents any sliding back of the thrust rod, since under the increasing pressure of the second spring it is swung into its locking position. If the tongs is used to bend an article, which on releasing the tongs lever exert the pressure of the thrust rod and which tends to force the thrust rod into the housing, this pressure serves to force the sprag, jamming by tilting against the thrust rod, is forced to an even greater degree into its locking position jammed up against the thrust rod, so that a sliding back of the thrust rod is impossible.
If the thrust rod is to be withdrawn back into the tongs housing after bending a tube for example, by means of the releasing device via a linkage a pressure is exerted both on the sprag and also on the advancing lever and this pressure swings the two out of their jammed position so that the thrust rod is released. Since the latter has a smooth surface and is only locked by the jamming clamping edges of the openings in the advancing lever and the sprag, a minimum clearance of the clamping edges of these two levers from the surface of the thrust rod is sufficient to release the latter. The advancing lever and the sprag do therefore not to be swung for more than a minimum angle for withdrawing the thrust rod in the case of the device, the angle being substantially smaller than the necessary movement of the locking means in the case of prior art racks, since in this case for release movements are required whose displacement must be in accordance with the height of the teeth used for the rack etc.
The thrust rod and the openings in the advancing lever and in the sprag can have a rectangular cross-section. Preferably the thrust rod and the openings of the advancing lever and the sprag have a round constant cross-section. This development of the invention involves the advantage that the thrust rod and the openings in the advancing lever and the sprag are particularly simple and cheap to produce.
In accordance with a further development of the invention the advancing lever has at an end zone, remote from the tongs lever, a projection, which in the rest position of the tongs urges the sprag, which at one end is pivotally mounted in the housing, towards its locking position. This further development involves the advantage that the releasing means can be constructed in a particularly simple manner. In this case it only has to act on the sprag itself and swing it out of its clamping position. In this case simultaneously via the projection on the advancing lever, which is displaced on swinging the sprag, the advancing lever is moved out of its locking position, so that the thrust rod can be rejected into the tongs housing.
The openings in the advancing lever and the sprag can be inclined in opposite directions with respect to the thrust rod and the engagement position for the projection on the advancing lever can be arranged between the thrust rod and the pivot point of the sprag on the latter.
Advantageously the advancing lever and the sprag are so constructed that the openings have such upper and opposite lower edges that an optimum clamping or jamming action is obtained.
In accordance with a further development of the invention the advancing lever has a roller adapted to rotate and arranged perpendicularly with respect to the longitudinal direction of the advancing lever and in every position this roller is urged into engagement with an operating surface arranged on the inner section of the tongs lever. This operating surface is preferably so inclined that the roller and accordingly the preloaded advancing lever experience a force directed against the thrust rod. This further development of the invention offers the advantage that the advancing lever is always correctly adjusted perpendicularly with respect to the thrust rod and is pressed by the first spring into its correct position, in which a lower and an upper edge part of its opening jam up against the thrust rod.
In accordance with a further development of the invention the inclined operating surface of the inner section of the tongs lever can be so shaped that on acting on the tongs lever the operating surface exerts on the roller of the advancing lever a force which remains the same in all angles of tightening. This further development has the advantage that the direction of force, with which the advancing lever is swung into its tilted jamming position, remains the same. This form of construction makes it possible to use a relatively weak first spring between the housing and the advancing body, since owing to the constant torque of the advancing lever exerted on the thrust rod no oversize dimensions of this first spring are called for.
The releasing means can comprise a rod, which on being displaced against the spring force comes into engagement with the sprag and swings the latter out of its tilted jamming position. In accordance with an advantageous development of the invention the releasing device has at the lower end of the tongs handle a release knob, which is connected with the sliding rod and is urged by a compression spring downwardly. In the case of this embodiment of the invention a smart blow from below against the release knob is all that is required to release the thrust rod. By means of the smart blow from below on the release knob the thrust rod is jerked in the direction opposite to the direction of thrust.
Preferably a retracting spring is connected with the housing and with the thrust rod and this spring returns the thrust rod into the tongs housing when the release knob is struck.
In accordance with a further development of the invention the thrust rod has a pin which can be seen through a slot in the housing. On one or both sides of the slot scales can be marked. A second pin opposite to the first pin is guided in a further groove in the housing which cannot be seen from the outside. This prevents twisting of the thrust rod. This further development of the invention makes possible a precise reading of the displacement of the thrust rod and accordingly of the bending carried out, for example of the tube placed between the pressing part and the counter-pressing part. The bending already carried out of a body between the pressing part and the counter-pressing parts depends not only from the degree of displacement of the thrust rod out of the tongs housing but also on the diameter of the tube to be bent. On one side of the slot it is therefore possible to provide a simple scale which corresponds to a bending of the tube of for example 90° . The individual markings of this scale would then indicate the diameter of the tube to be bent.
If for example a tube with a diameter of 17 mm is to be bent, the thrust rod must be advanced out of the tongs housing until the pin connected with the thrust rod and visible through the slot lies on this 90° scale adjacent to the mark which corresponds to the diameter of 17 mm.
At this point attention should be drawn to a special advantage of the tongs in accordance with the invention over known tongs with toothed thrust rods. In the case of known thrust rods after pressing the tongs lever as far as it will go to tooth engagement the tongs lever must be released completely again. This is not necessary with the tongs in accordance with the invention, and it is sufficient only to release the tongs to a slight extent and then to move it back towards the handle again. This offers the advantage that for displacement of the thrust rod by small distances the hand only has to be opened slightly so that substantially more force and "feel" are available than if the fingers of the hand had to be spread out completely again. This advantage is particularly noticible if the thrust rod has been displaced after several complete pressing actions and release of the tongs lever practically into its desired position. If for example the index pin is just short of the marking which indicates that the tube to be bent with a diameter of 17 mm has been bent through 90° , the last slight displacement is carried out by releasing the tongs lever only to a slight extent and then tightening it again, something which can be carried out with much more feel and a higher degree of accuracy.
On the other side of the slot, through which the index pin can be seen on the thrust rod, another scale can be provided corresponding for example to a bending angle of 60°, in the case of which the scale can again indicate the various diameters of the tube to be bent in millimeters.
In accordance with another further development of the invention the front end of the thrust rod has several parts with different diameters for fitting different pressing bodies or tools.
This further development has the advantage that both pressing bodies already commercially available can be used and also other pressing bodies which in accordance with load to be expected have differently dimensioned holes for receiving the front end of the thrust rod.
Naturally it is also possible to mark scales on both sides of the viewing slot in the housing, which correspond to a bending of a tube through 90°. These scales, which again can indicate diameters of the tubes to be bent can correspond to pressing bodies with different degrees of curvature.
In the case of the tongs in accordance with the invention it is also possible to provide a different scales which can be detachable and which have a slot corresponding to the viewing slot. These detachable scales can be so constructed that they can be inserted in a removable manner through the viewing slot into the housing of the tongs. The various scales can then be in accordance with pressing bodies and counter-pressing bodies with different degrees of curvature of different angles of bending and the marks on the scales themselves can indicate respectively the diameter of the tubes to be bent, for example in millimeters.
The use of the tongs in accordance with the invention is certainly not restricted to the bending of articles. The invention also comprises the use of the tongs for punching or notching materials such as sheet metal, bands etc., for lifting articles as for example tightening chains, ropes, wires etc. or rivetting sheet metal, bands, etc., for drawing off, for example, bearings, keyed-on or pressed on hubs, for pressing together various parts as for example sheets to be glued together or to be soldered or welded, or the like. It can also be used for straightening articles and for carrying out all operations possible in accordance with the application in the home, in the workshop or in the factory. For this purpose it is only necessary to fit on suitably shaped pressing parts and counter-pressing parts or tools on the tongs housing. It is also important that the tongs can be used for cutting tubes.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in what follows with reference to an embodiment in conjunction with the accompanying drawing.
FIG. 1 shows a plan view of a tongs with a pressing part and a counter-pressing part, between which a tube is bent.
FIG. 2 shows a longitudinal section through a tongs.
FIG. 3a and 3b show a side view and, respectively, a plan view of a locking lever.
FIGS. 4a and 4b show a side view and a plan view of an advancing lever.
FIG. 5 shows a plan view of the upper end of the thrust rod.
FIG. 6 is a perspective view of an alternative configuration of the thrust rod, sprag, and advancing lever.
DESCRIPTION OF PREFERRED EMBODIMENT
In FIG. 1 a tongs is shown, whose housing 10 is partly constructed as a handle 12. On the right-hand side of the housing 10 there is a projecting tongs lever 14.
At the upper end a tooth-less advancing rod extends partly from the housing 10. The advancing rod 30 has at its front end a projecting pin 32 and on this pin a pressing segment 34 is plug-mounted.
On a holding plate 36 two counter-pressing parts 38 are attached. The holding plate 36 is for its part attached by means of two pins 40, which are plugged into receiving holes 42 of the housing 10, on the latter in a removable manner. Between the pressing segment 34 and the counter-pressing parts 38 there is a partly bent article 44 to be seen.
On the flat side of the tongs handle 12 there is a slot 80, along whose two sides respective scales 82 and 83, respectively are provided. In the slot an indexing pin 84 will be seen which is connected with the thrust rod 30. The position of this indexing pin 84 in relation to the two scales indicates how far the thrust rod has been advanced out of the housing 10. These scales can be so calibrated that they indicate the bending of the article 44 in accordance with the diameter of this article.
On the bottom side of the tongs handle 12 a release knob 70 projects downwardly. By means of a blow on this release knob the tongs is unlocked or released, that is to say the thrust rod 30 is released and is retracted by a return spring, later to be described, into the tongs housing 10. As a result the pressing segment 34 is drawn clear of the bent articles so that the article 44 can be removed from the tongs.
FIG. 2 shows a longitudinal section through the tongs of FIG. 1. Since the tongs of FIG. 1 consists or comprises two housing shells, the FIG. 2 simultaneously provides the view of the inner side of the lower housing shell.
This housing shell has two large receiving holes 42 and two smaller receiving holes 43, in which the holding pins 40 of plates 36 can be received, which carry the counter-pressing parts 38. In these receiving holes 42 and 43 small springs 41 will be seen, which arrest the pins in these receiving holes.
In the upwardly projecting walls of the handle shell small holes 16 will be seen, which are constructed so as to be complementary to corresponding pins, which are provided on the other handle shell. These holes 16 and the complementary pins serve for fitting together the two housing shells, which are held together by four screws 18.
At the position generally coinciding with the center axis of the housing a round thrust rod 30 will be seen, which is guided by the housing both in the upper part of the housing and also in the center part of the housing. On this thrust rod 30 a locking lever or sprag 50 and an advancing lever 60 are placed. The locking lever 60 has a cranked, lateral projection 51, which has a lower rest lying on a shoulder 53 in the handle shell. This locking lever or sprag 50 furthermore has a cylindrical hole 55, which has clamping edges which are inclined to the right with respect to the direction of the thrust rod 30. In the position shown both an upper left-hand part and also a lower right-hand edge part of the hole 55 engages the thrust rod 30. These edge parts form clamping edges 56 and 57 respectively. As can be seen best from FIGS. 3a and 3b, the sprag 50 has an upwardly projecting plug 58 with a generally horizontal surface.
Above the sprag 50 there is an advancing lever 60 through which the thrust rod 30 passes. This advancing lever 60 has generally in its middle part a cylindrical hole 65, which has an inclined center axis giving rise to clamping edges which are inclined to the left with respect to the direction of the thrust rod 30. In the position shown the advancing lever 60 makes engagement both with an upper right-hand edge part of the hole and also with a lower left-hand edge part of the hole against the thrust rod 30. These engaging edge parts form clamping edges 66 and 67. At its lower left-hand end the advancing lever 60 has a downwardly projecting projection 62, which makes engagement with the generally horizontal surface of the lug 58 of the sprag 50.
While the thrust rod 30 has been described as having a round configuration, and the sprag 50 and advancing lever 60 as having round holes therein, it is also contemplated by the instant invention that, as illustrated in FIG. 6, the thrust rod 30 and the openings of the sprag 50 and advancing lever 60 may have a rectangular cross-section.
The advancing lever has at its right-hand end part a roller 68, which is fixed between two fork prongs 69 to allow rotation, as will be seen best in FIGS. 4a and 4b. This roller 68 makes engagement with one end of the tongs lever 14, which is pivoted on a pin 15, see FIG. 2. A first compression spring 20 extends between the advancing lever 60 and the wall of the handle shell and surrounds the thrust rod 30. This compression spring 20 urges the roller 68 against the lever 14, which is represented in its fully displaced end position. The point of engagement of the roller 68 with the lever 14 accordingly simultaneously forms a fulcrum point for the advancing lever 60, which is urged downwards by the compression spring 20 and has its lower projection 62 lying on the lug 58 of the sprag 50. The dimensions are so made that in this position the two clamping edges 66 and 67 of the advancing lever lie against the thrust rod 30. Between the advancing lever 60 and the sprag 50 there is a compression spring 21 on the thrust rod 30. This spring 21 tilts the sprag 50 or clamping lever into its clamping position, in which its clamping edges 56 and 57 jam up against the thrust rod 30. Further points of engagement are required niether for the sprag 50 nor for the advancing lever 60.
The tongs lever 14 has at its inner end an operating surface 24, which is inclined to the left downwardly in relation to the roller 68. Owing to this inclination of the operating surface 24 the roller 68 and accordingly the whole advancing lever 60 are displaced under the force of the first spring 20 to the left.
In the handle part of the housing there is furthermore a slot 80 to be seen, adjacent to which a scale 82 is indicated.
Adjacent to this scale 82 an index pin 84 will be seen, which is connected in a fixed manner with the thrust rod 30. On the lower screw 18 in the tongs handle there is a return spring 22, whose lower end is attached to a holding pin 23 of the thrust rod 30.
At the lower ends of the tongs housing it is furthermore possible to seen the release knob 70, which on its upper side has a larger diameter than the opening in the housing handle, through which the release knob projects. This release knob is urged downwardly by a compression spring 25, which furthermore engages the inner surface 26 of the housing handle. The release knob 70 is connected in a moving manner with a release rod 28 by means of a pin 29. The release rod 28 is also arranged to be displaced in the housing 10.
The tongs described operates in the following manner. On acting on the tongs lever 14 to move it towards the handle 20 the operating surface 24 at the inner end of the tongs lever 14 is raised. As a result this operating surface 24 exerts via the roller 68 a torque on the advancing lever 60, which tilts the lever 60 with a still greater force against the thrust rod 30. Simultaneously, since the clamping edges 66 and 67 can only penetrate to an extremely small amount into the surface of the thrust rod 30, the advancing lever 60 is raised against the spring 20 with its pressing force. Simultaneously the lower projection 62 of the advancing lever 60 is moved clear of the surface of the lug 58. Simultaneously the spring 21 is relaxed so that the sprag 50 can swing to the left and can release the thrust rod 30. During the whole stroke of the thrust rod 30 the sprag 50 remains in this release position.
If the tongs lever 14 is released, it swings back into its spread out position in the case of which the operating surface 25 moves downwards in relation to the roller 68. As a result the pressure on the roller 68 is reduced so that the spring 20 can swing out the advancing lever 60 out of its tilted position and can move it downwardly. Simultaneously the pressure of the spring 21 is increased again so that the sprag 50 is forced immediately into its clamping position. Since the swinging of the sprag 50 out of its tilted position is extremely small -- the clamping edges 56, 57 lie always against the thrust rod 30 -- a sliding back movement of the thrust rod 30 is out of the question. As soon as the clamping lever or sprag 50 is in its locking position, it is forced by any force which may act on the thrust rod 30 in a still more forceful manner into this tilted or jamming clamping position so that the thrust rod 30 cannot slide back.
This operation described of pressing the tongs lever 14 as far as it will go and releasing it again can be carried out repeatedly until the article, for example a tube, to be bent has been bent through the desired angle.
When this has been carried out the thrust rod 30 must be released so that it can be moved back into the housing 10.
This is carried out by a simple blow from below against the release knob 70. As a result the release rod 28 is displaced back upwards through the housing handle so that its upper end comes to lie from below against the right-hand side of the sprag 50 and swings the latter to the left out of its locking or clamping position. Since the thrust rod 30 has a smooth surface, only a small swinging of the sprag 50 is required in order to release the thrust rod 30.
In the case of this swinging movement of the sprag 50 simultaneously by means of its cam or lug 58 and the lower projection of the advancing lever 60 the latter is swung to the right. As a result the advancing lever is unjammed and releases the thrust rod 30. By means of pressure or a blow on the release knob the two levers are therefore swung out of their jamming positions into the release positions so that the return spring 22 immediately retracts the thrust rod 30.
At the upper end of the thrust rod 30 portions 90 and 92 can be seen having different diameters which serve for fitting different pressing parts as are indicated in FIG. 1 for example. In order to make the drawing more readily intelligible in FIG. 2 no pressing parts and counter-pressing parts are shown.
The pressing parts 34 are provided with a stepped hole 93, into which the parts 90 and 92 of different diameter can be fitted. The portions 90 and 92 have semi-circular grooves 94 and 95, into which pins 96 and 97, which pass through the pressing parts 34 in such a manner that their axes form a tangent with respect to the hole 93, can fit into the grooves. In order to be able to mount the pressing parts 34 on the thrust rod 30 the portions 90 and 92 are provided with surfaces 98 and 99 in such a manner that the pins 96 and 97 can slide past the latter and by rotation of the turning the pressing parts 34 through an angle of 90° the pins can come to lie in the grooves 94 and 95. Owing to this measure the pressing parts 34 are prevented from falling of the thrust rod 30. Turning of the surfaces 98 and 99 in relation to the tongs housing is prevented by the index pins 84 guided in the grooves 80.
It is pointed out once again the operating surface 24 of the tongs lever 14 is so curved that in all positions of the tongs lever it exerts a force on the roller 68 which always have the same angle with respect to the thrust rod. | The specification describes a tool more especially for bending tubes and rods in which the rod or tube is acted upon by a pressing part mounted on a thrust rod. The thrust rod is arranged to be moved along its axis by means of a lever operated advancing lever which makes frictional engagement at edges engaging the thrust rod on opposite sides of the latter. Between repeated reciprocating movements of the advancing lever the thrust rod is retained by a sprag having a hole through which the thrust rod passes. This hole has diametrally opposite clamping edges for engaging the thrust rod. The thrust rod is adapted to be released by a blow against a release knob which indirectly acts on the sprag bringing it out of engagement with the thrust rod. | 1 |
BACKGROUND OF THE INVENTION
In following the teachings of the prior art, e.g., Spurrell in U.S. Pat. No. 3,770,578 or Goyette in U.S. Pat. No. 2,981,175 according to which hot or cold air is applied to individual longitudinal sections of a calender roll from a hot air plenum or a cold air plenum in response to variations from the normal thickness of a paper web passing through the calendar, it is now recognized from actual practice that the temperature of the air in the walls of the hot or cold air plenums and associated air supply systems approaches room temperature during periods of little demand for air. Hence, when a caliper correction is required, the nozzles responsible for delivering air at a control temperature discharge air for at least a measurable time period at an improper temperature until the hot or cold air supply system reaches equilibrium with the temperature of air passing through it. Such a mode of operation prevents quick correction of the web thickness and thus achievement of the quality potential of the web product that is possible.
In past practice, control of the caliper by changing the diameter of the calendar roll was affected by impinging hot or cold air on one circumference of the roll and varying by velocity of air impingement to achieve the effect desired. Frequently, however, the roll diameter at each side of the circumference being corrected was unduly disturbed. The remedy was to impinge either cool or hot air, as the case required, on the roll at the sides of the circumference being corrected. The velocity of the air was varied according to the judgment of the operator. According to this earlier practice, air was not applied to the roll except during circumference correction.
Objects of the invention are to provide an apparatus that will enable more precise control in the processing of webs especially webs of paper to desired thicknesses or caliper; to provide apparatuses more responsive to caliper-sensing mechanism; to provide a continuous flow of air at a standard temperature to maintain a uniform circumference along the calender roll and eliminate the need for compensating or correcting air application to the roll at both sides of a target circumference being corrected; and to adopt a method which will require merely changing one variable, i.e., temperature of the air issuing from the nozzles to effect proper circumference correction of the roll along its length for uniform web thickness.
SUMMARY OF THE INVENTION
The present invention is based on the discovery that hot and cold air supplied to a web thickness controlling mechanism associated with a plural-roll calender, is preferably stored in and delivered by plenums, ducts and the like in which the hot and cold air is normally moving continuously through respective supply systems to separate mixing chambers, one for each nozzle of a manifold of nozzles aligned lengthwise of, but aimed at, a calender roll. The apparatus is arranged for discharging a normal mixture of hot and cold air corresponding to an average or target thickness to which the web is being formed. The apparatus is responsive to deviations of the target thickness by causing mixtures of mostly hot air or mostly cold air, as the occasion may demand, to pass through the nozzles and impinge on a target portion of the roll needing change of circumference.
Each nozzle is connected directly to, and supplied by, a mixing chamber connected to a hot air plenum and a cold air plenum through proportioning apparatus, such as a proportioning valve. In order that the proportioning of hot and cold air to any mixing chamber may be accomplished by a relatively simple device, the plenums are preferably maintained at respective uniform temperatures and a common pressure. By this arrangement, all nozzles of a manifold are continuously discharging air at substantially uniform flow rates with the temperature of the air issuing from each individual nozzle being varied in temperature as a caliper sensing device indicates a variation in the thickness of a corresponding portion of the web from its intended norm.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective diagrammatic view of an air supply system for controlling the circumferential size of a calender roll at a multiplicity of circumferences spaced uniformly along its length for the purpose of controlling web thickness.
FIG. 2 is a fragmentary perspective view with portions broken away of an air-dispensing manifold or assembly shown in FIG. 1 which includes hot and cold headers, a plurality of air nozzles, and a corresponding plurality of mixing chambers and valve mechanisms associated therewith.
FIG. 3 is a transverse cross sectional view of the assembly shown in FIG. 2 illustrating an arrangement thereof for mixing and proportioning hot and cold air.
FIG. 4 is a fragmentary view in cross section taken along line IV--IV of FIG. 3.
FIG. 5 is a fragmentary perspective view in section of a valve construction as employed in the apparatus of FIGS. 1 to 4.
FIG. 6 is a transverse cross section of a modified air distribution assembly.
FIG. 7 is a transverse cross section of another modified air distributing assembly.
FIG. 8 is a diagram of an entire system operating in connection with a calender roll to control web thickness incorporating the fluid supply system illustrated by FIG. 1; and various other thickness sensor, transducer computer and controller components.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates schematically elements of the fluid supplying system functioning as a sub-assembly of the overall automatic web thickness control system illustrated in FIG. 8. FIG. 1 illustrates that a web 5 passes through calender rolls 6,7 and through a web-thickness sensing device 8. In accordance with the embodiment as illustrated as FIGS. 1, 2 and 3, a fluid (usually air) dispensing device 10 is arranged lengthwise of the calender roll 6 with nozzles 11 thereof projecting in a substantially radial direction in respect to the axis of the roll 6. The nozzles 11 are uniformly spaced along the length of the roll 6 to enable any fluid issuing therefrom to effect by temperature changes of the diameter of the corresponding portions of the cylindrical surface of the roll 6 revolving within the ejection pattern of each nozzle. The dispenser 10 comprises a plurality of mixing chambers 14, each of which has as its outlet, one of the nozzles 11. The chambers 14 are separated one from the other by vertical walls 15 extending between the outer vertical wall 16 and an inner vertical wall 17.
For the particular valve mechanism shown, the chamber 14 is separated along its top portion from a hot intermediate or secondary chamber 17 by a horizontal wall or orifice plate 18, and along its bottom portion from a cold intermediate or secondary chamber 21 by a horizontal wall or orifice plate 22.
The dispenser 10 further comprises a hot header 25 extending the full length of the dispenser and communicating with the various hot air secondary chambers 17 through a plurality of apertures 26, one from each secondary chamber 17. A cold air header 28 separated from the hot air header by a wall 29 has a plurality of apertures 31, of which each opens into one of the cold air secondary chambers 21.
The object of releasing hot and cold air into the mixing chamber 14 is to control the flow from the secondary chambers to the mixing chamber in such a manner that a constant volume is supplied thereto regardless of the ratio of hot air to the cold air discharged thereinto from the secondary chambers. In principle then, such operation requires that the quantity of cold air entering the mixing chamber be reduced in accordance with an increase in the quantity of hot air entering from the chamber 17 to obtain an increase in the temperature of the air discharged from the nozzle. When cooler air is desired from the nozzle 11, the flow of cooler air from the mixing chamber 21 is increased in correspondence with reduction of hot air from the secondary chamber 17.
Adjustment of the temperature of the air discharged from the nozzle 11 is effected in accordance with one embodiment by valve mechanism of the type shown most plainly in FIGS. 3 and 5 wherein the walls 18 and 22 are coaxially apertured to receive an assembly 32 comprising a longitudinally reciprocable valve shaft 33 and a pair of cylindrical closed end valve elements 34,35 supported within apertures therefor in the walls 18,22, respectively. The valve elements 34,35 are typified by element 34 in FIG. 5 wherein the element comprises a cylindrical sidewall 39 extending from its closed end 36 to define saw teeth 37 tapering away from the closed end. Elements 34,35 are positioned along the rod 33 so that at neutral position portions of the notches 38 between the saw teeth on both elements are exposed within the chambers 17 and 21 so that equal amounts of hot and cold air may flow from chambers 17 and 21, respectively, into the mixing chamber 14. As the valve assembly is moved in one direction or the other, the notches of one element 34,35 or the other, is exposed within the respective adjacent secondary chamber 17 or 21 and correspondingly less of the notches of the other valve element are exposed in its respective adjacent secondary chamber. Even though the assembly is moved to a complete shutoff from one of the secondary chambers, the quantity of air passing through the mixing chamber 14 and outwardly through the nozzle 11 is maintained at substantially constant volume.
As part of the apparatus for automatically individually changing the positions of each valve assembly, the rod 33 terminates in a small fluid operated spring return cylinder piston unit 41. In the practice of the invention being now described, the units 41 are provided with return springs capable of yielding resiliently to pressures in the range of 5 to 30 pounds applied to the units. As it is desired that the units 41 respond to varying signal pressures in an extremely responsive manner, units 41 are preferred in a design which is frictionless as possible. Air cylinders, such as Part No. 421-980-008 manufactured by the Bellofram Corp. of Burlington, Massachusetts providing a stroke length of approximately 1 inch had been found satisfactory for the required valve travel.
As an example of a system for supplying air to the hot and cold air headers 25,28, FIG. 1 depicts a blower 44 which supplies air under pressure to branch lines 45 and 46 leading into hot air and cold air sub-systems, respectively. In supplying hot air to the header 25, air is supplied by line 45 to a heater 48 and thence through line 49 to the hot air header 25. To maintain the header and the air therein at a constant temperature through quiescent periods, the hot air system may include a recirculation line 51 connected with one end of the hot air header and with the inlet portion of line 45 to the heater 48 through which air flow is effected by a recirculation blower 52. In a similar manner, air passes through line 46 to a cooler 55 and thence through line 56 to the cold air header 28. To maintain a uniform temperature in the cold air header, cold air may be recirculated through the cooler and the header by means of a recirculation line 57 and a recirculating blower 58 in this line.
As shown, the various nozzles 11 are aimed in a radial direction against the periphery of the calender roll 6 which, in cooperation with calender roll 7, advances the web 5 in the downward direction indicated by the arrows as the web leaves the calender rolls it passes through a scanning device 8 which by electronic means, such as manufactured by the Measurex Corp. of Cupertino, California, continuously scans the entire width of the web in a back and forth pattern to collect web-thickness information transmitted into a computer 60 of known design. The computer in turn issues electrical signals to an electropneumatic transducer 61. Pneumatic signals therefrom are received by a mechanical multiplexer 62 in synchronism with the scanning device 8. The multiplexer 62 provides a plurality of control points 63 which individually connect with corresponding pneumatically operated selector valves typified by valve 64 which transmits a modulated pressure signal through the pressure regulator 65 to the air cylinder unit 41 for proper adjustment of the valve assembly 32 with respect to valve orifice plates 18 and 22. Line 66 bypasses the pressure regulator for the purpose of permitting escape of air from the cylinder 41 through the four-way selector valve 64 during settings of the valve mechanism requiring reduction of pressure in the unit 41. Air lines 67 and 68 are merely of lines leading to other apparatus similar to that connected with line 69 for serving each nozzle and valve assembly.
FIG. 6 illustrates a modified air dispenser 70 comprising walls defining hot and cold air chambers 71 and 72, and a manifold 73 having a nozzle 74. The manifold defines a valve chamber at 76 within which a partly cylindrical valve element 77 is rotatable in opposite angular directions about its fulcrum shaft 78 to increase or decrease the air passing from the hot branch 81 of the manifold into the nozzle 74 while correspondingly decreasing or increasing, respectively, the air passing from the cold branch 82 of the manifold to the nozzle. Automatic operation in proportioning the air passing from the passageways 81,82 is effected through a lever 83 connected by linkage 84 to the reciprocatable push rod 85 of an air cylinder 80 which may be similar to air cylinders 41 of the previously described embodiment. Automatic control of the hot and cold air mixture entering the nozzle 74 may be effected by the apparatus of FIG. 8 as hereinbefore described with respect to dispenser 10.
FIG. 7 schematically sets forth another modified air dispenser 90 comprising walls defining a hot header 86 and a cold header 87 and an individual mixing chamber 88 for each nozzle 99. The mixing chambers are separated from the hot and cold headers by a wall 89 having an aperture 91 through which hot air passes into chamber 88 from the hot header, and an aperture 92 through which cold air passes from the cold header into the mixing chamber. Passage of air from headers 86,87 is regulated by an orifice plate 95 having openings 96,97 therethrough which preferably have equal diameters and diameters that are equal to those of the apertures 91,92. As shown, the openings 96,97 are spaced apart by a distance which is less than the spacing of apertures 91,92 by a difference approximately equal to the diameter of an opening 96 or 97. Consequently, as the orifice plate is moved to vary the passage of air from chambers 86,87, the orifice plate 95 moves to progressively close one opening 91 or 92 while progressively opening the other aperture 92 or 91, respectively. The mixture of hot and cold air thereby received into the mixing chamber 88 passes from the dispenser 90 through its nozzle 99. | Disclosed is an apparatus for controlling the caliper of a web, such as a continuous paper sheet issuing from a nip of a plural-roll device, such as a calender. One or more rolls of the device is subjected to a multiplicity of air jets issuing substantially at constant flow rates but at temperatures which may vary as desired from nozzles spaced lengthwise of the roll. | 3 |
FIELD OF THE INVENTION
The present invention relates to a scaler having a selectably variable modulus, and more particularly to a prescaler in a phase-locked loop of a synchronous digital clock supply.
BACKGROUND OF THE INVENTION
In telecommunication systems, digital clock supplies are commonly used to generate local clock signals which are synchronized to incoming signals on transmission lines. A well-known technique employs a high-speed scaler driven by an internal free running local clock, whose modulus is varied in accordance with external control signals, to provide phase correction of the output clock signals of the scaler, thereby maintaining synchronization. The frequency of the internal free running clock pulses, is nominally a multiple of the clock pulses. Typically, when the scaler's division is changed, a phase correction of ±0.5 internal clock cycle occurs.
In a typical prior art system having flip-flops, the internal clock pulses are inverted under control of the external control signals, to provide this phase correction. This has the effect of momentarily interrupting the internal clock pulses applied to the flip-flops, by shifting their phase by 180°. The result is that the scaler effectively responds to rising then falling edges of the internal clock pulses with each inversion, even though the output of the internal clock remains uninterrupted. In one such application, a divide-by-2 scaler, comprising a plurality of flip-flops, provides one output pulse for every two input clock pulses. As its modulus is changed from 2 to 1.5 or 2.5, it provides ±90 degree phase correction of the output clock signals. In high speed clock applications, where the internal clock runs at a frequency of typically 20 MHz or higher, interrupting the internal clock signal applied to the flip-flops tends to generate signal jitter on the output clock, due to settling times of the associated gates controlling the interruptions. Because of this jitter, the operation of the flip-flops can malfunction.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a variable modulus scaler, utilizing flip-flops that are continuously and synchronously clocked (without gated interruptions) so as to avoid any jitter caused by gated clock signals, thereby providing improved robustness.
The present invention also provides a scaler in which alternate sets of flip-flops are continuously clocked by alternate clock edges, so that the clock speed can be effectively halved relative to scalers where all flip-flops are clocked by the same clock edges.
The present invention additionally provides a scaler whose modulus is selectably variable by ±0.5 clock cycle.
According to the most general aspect of the present invention, a scaler having a selectively variable modulus, for receiving input clock pulses and generating a train of output pulses, comprises: first and second sets of flip-flops responsive only to rising and falling edges respectively, of the input clock pulses; and a plurality of gates interconnected with the flip-flops to control the scaler's state. In the scaler, the scaler transits along one of two loops, each loop generating output pulses having identical repetition rates and being shifted in phase relative to each other by an integral number of half cycles of the input clock pulses; and the scaler's state transits in response to a control signal, from one of the two loops to the other, so as to generate at least one output pulse at an alternative repetition rate, which differs from the identical repetition rates by an integral number of half cycles of the input clock pulses.
When the control signal is a set of first and second control signals and each of the sets of flip-flops has two flip-flops, the scaler's state is continuously changed in response to the input clock pulses, as it transits along one of the two loops without changing the state of one flip-flop of each set. The alternative repetition rate, in response to the first and second control signals respectively, includes first and second repetition rates. The first and second repetition rates are lower and higher, respectively, than the identical repetition rates.
Preferably, the pattern according to the identical repetition rates is "1-0-1-1" and according to the first and second repetition rates are "1-0-1" and "1-0-1-1-1", respectively. The scaler's frequency division is 2 corresponding to the identical repetition rates and is 1.5 and 2.5 corresponding to the first and second repetition rates, respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the present invention will now be described by way of example only with reference to the accompanying drawings in which:
FIG. 1 is a block diagram of a phase correction circuit which utilizes a scaler according the present invention;
FIG. 2 is a block diagram of the scaler according to the present invention;
FIG. 3 is a state transition diagram of the scaler shown in FIG. 2; and
FIGS. 4-9 are timing charts of the scaler shown in FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the phase correction circuit comprises a signal sampler 11 which receives an incoming a bit rate of 2.5 Mbps and samples it to signal SI having a bit rate of 2.5 Mbps and samples it to provide an outgoing signal SO. A free running clock generator 17 provides internal clock pulses CK at a frequency of 20 MHz to a scaler 21, which functions as a finite state machine, having a selectably variable frequency division: 2 or 2±0.5. The scaler 21, initialized by a reset pulse R, counts the internal clock pulses CK and normally functions as a divide-by-2 frequency divider to provide output clock pulses OP at a frequency of 10 Mhz to a divide-by-4 frequency divider 24 which in turn supplies sampling clock pulses SC to the signal sampler 11 and a phase comparator 29. The frequency of the sampling clock pulses SC is 2.5 MHz (2.5 Mbps), the same as that of the incoming signal SI.
For accurate sampling, the phase of the incoming signal pulses SI, relative to that of the sampling clock pulses SC, must be precisely maintained. Due to asynchronization, a slow drift in the relative phase of the two signals can occur. This is detected by the phase comparator 29, which in turn generates either a control signal X or Y, that is then applied to the scaler 21 to initiate phase correction. To effect correction, the frequency division of the scaler 21 is momentarily changed from 2 to 1.5 or 2.5 in response to the control signal X or Y, respectively. This variation of ±0.5, which corresponds to a 0.5 internal clock cycle or 180° phase shift, changes the phase of the output clock pulses OP by ±0.25 cycle or ±90°. Following the divide-by-4 frequency divider 24, the minimum correction for the sampling clock pulses SC is ±0.0625 cycle or ±22.5°.
As shown in FIG. 1, in response to the incoming signal SI, a clock regenerating circuit 27 produces regenerated clock pulses RC having a frequency of 2.5 MHz. The phase comparator 29 then compares the phase of the regenerated clock pulses RC with that of the sampling clock pulses SC, to determine whether the phase of the latter should be corrected. When the phase of the sampling clock pulses SC lags or leads that of the regenerated clock pulses RC by more than a predetermined difference or threshold, the phase comparator 29 generates either the control signal X or Y, respectively. This threshold phase difference is small enough to avoid sample timing errors occurring in the signal sampler 11. When the control signal X or Y is applied to the scaler 21, it alters the frequency division of the output pulse OP. Accordingly, whenever the phase difference between the clock pulses SC and RC exceeds the threshold, the phase of the output clock pulses OP is corrected immediately by momentarily altering the frequency division of the scaler 21 and hence the phase of the sampling clock pulses SC.
FIG. 2 shows in detail the scaler 21, which includes four D-type flip-flops (hereinafter referred to as FFs) 31, 32, 33 and 34 (having logic states A, B, C and D), gating logic circuits and an output decoder, which coact to function as a finite state machine. One gating logic circuit consists of five NAND gates 41, 42, 43, 44 and 45, whose output is connected to the D input of the FF 31. Another gating logic circuit consists of four NAND gates 51, 52, 53 and 54, whose output is connected to the D input of the FF 32. Yet, another gating logic circuit consists of three NAND gates 61, 62 and 63, whose output is connected to the D input of the FF 34. The inverting output of the FF 34 is directly connected to the D input of the FF 33.
The output decoder, comprising a NAND gate 64, an AND gate 65 and the NAND gate 62, functions to decode the scaler's state Q as determined by the FFs 31--34, so as to provide digital output clock pulses OP. Both non-inverting and inverting outputs of the FFs 31-34 are connected to the gating logic circuits and the output decoder as shown in FIG. 2.
When the control signal X from the phase comparator 29, is applied to the NAND gate 44 and to both the NAND gates 51 and 61 through an inverter 71, the scaler's division is changed from 2 to 1.5. When the control signal Y from the phase comparator 29, is applied to the NAND gate 53 and to the NAND gate 41 through an inverter 72, the scaler's division is changed from 2 to 2.5.
During such operating conditions of the scaler 21, the signal logic applied to each D input of the FFs 31-34 is as follows:
__________________________________________________________________________(a) FF 31: B · C · D · .sup.-- Y + .sup.-- A · B · D + A · B · .sup.-- D + .sup.-- B · C · D · X(b) FF 32: A · B · C · .sup.-- X + A · .sup.-- C · D + .sup.-- A · .sup.-- B · D · Y(c) FF 33: -- D(d) FF 34: .sup.-- A · .sup.-- B · D · Y + B · C · .sup.-- D · .sup.-- X + .sup.-- A · .sup.-- B · C · .sup.-- D__________________________________________________________________________
The output logic of the output decoder which generates the output clock pulses is:
OP=A.B+A.B+A.C+A.C+D
The FFs 31-34 are clocked by the internal clock pulses CK, provided by the clock generator 17. The internal clock pulses CK are inverted by an inverter 73 and applied to the inverting clock inputs CK of two FFs 31 and 33. Furthermore, the output pulses of the inverter 73 are re-inverted by another inverter 74 and its output is applied to both inverting clock inputs CK of two FFs 32 and 34. Thus, one pair of FFs 31 and 33 always responds to the rising edges while the other pair of FFs 32 and 34 always responds to the falling edges of the internal clock pulses CK, respectively. With this arrangement the combined state of the FFs 31-34 can be continuously altered twice each clock cycle, with no interruption of the applied clock pulses through control gating. As a result, the FFs 31-34 are synchronously clocked by both rising and falling edges of the internal clock pulses CK at an effective clock rate of 40 MHz, so that some of the states A, B, C and D of the FFs 31, 32, 33 and 34 can be altered on each edge of the internal clock pulses CK to determine the scaler's state Q. The FF outputs are converted by the output decoder to provide the output clock pulses OP which are either high "1" or low "0". The reset pulse R is applied through an inverter 75 to all reset inputs R of the FFs 31-34.
Each of the control signals X, Y has two states: "1" when active and "0" when inactive. One or other control signal X or Y is active whenever the phase difference between the sampling clock pulses SC and the regenerated clock pulses RC is greater than a preselected threshold. The control signals X and Y are forced when:
A.B.C.D+A.B.C.D+A.B.C.D=1.
Depending upon the state of the control signals X and Y, there are three applicable patterns of logic transition of the output clock pulses OP: (i) "1-0-1-1" when X=Y=0; (ii) "1-0-1" when X=1, Y=0; and (iii) "1-0-1-1-1" when X=0, Y=1.
Table 1 shows the potential logic state transitions of the FFs 31-34 from each current state A, B, C and D to each next state, in response to both rising and falling edges (left and right columns) of the internal clock pulses CK and the various states of the control signals X and Y. As shown in this table, alternative state transitions only occur when the current states are:
"0001", "0011", "1110" and "1111" .
§ indicates applicable logic states of the scaler 21. It can be seen that although only some of the 16 possible logic states occur during normal operation, the circuit will always recover should an abnormal state be reached. Table II shows the logic state relationship between the FFs, the scaler, and the output clock pulses OP.
As shown in the state transition diagram of FIG. 3, the scaler's state Q transits along one of two regular loops unless either control signal X or Y changes its logic state from "0" to "1". Normally, both control signals X and Y cannot be active "X=Y=1" simultaneously. The first regular loop "a" transits are "-Q0a-Q1a-Q2a-Q3a-Q0a- -" and the second regular loop "b" transits are "-Q0b-Q1b-Q2b-Q3b-Q0b- -" as indicated by the suffix numbers. When either the control signal X or Y goes high "1", the scaler's state Q transits from one regular loop to the other through one of "intermediate states": Q0ab, Q4ab, Q0ba or Q4ba. The scaler's state Q never transits from Q0a or Q1a (Q0b or Q1b) to any intermediate state during the first (second) regular loop, regardless of whether or not X or Y is "1" or "0".
FIG. 4 shows the scaler's state Q transits following the first regular loop, after the reset pulse R has been applied, when neither control signal is active X=Y=0. Under these conditions, the states A and B of FFs 31 and 32 remain "0", and only the states C and D of FFs 33 and 34 change in response to the rising and falling edges respectively, of the internal clock pulses CK. This results in two transitions of the state Q during one clock cycle. The state Q transits "-Q0a-Q1a-Q2a-Q3a-Q0a-Q1a-Q2a-Q3a- -" resulting in the output clock pulse OP stream "-1-0-1-1-1-0-1-1- -". This decoded pattern "1-0-1-1" of the output clock pulses OP is repeated every two clock cycles. Consequently, the scaler 21 provides one output pulse OP for every two clock pulses CK to continuously function as a divide-by-2 frequency divider.
FIGS. 5 shows the scaler's state Q as it transits from the first regular loop "a" to the second loop "b" when the control signal X=1 is applied. When the phase of the sampling clock SC lags that of the regenerated clock RG by more than the preselected threshold, the control signal X goes to "1". The output of the NAND gate 44 goes to "0" at Q2a and the NAND gate 45 changes its output from "0" to "1". The state A of the FF 31 then transits from "0" to "1" in response to the rising edge of the next internal clock pulse CK and the scaler's state Q transits from Q2a to Q2ab as shown in FIG. 3. Thereafter, the NAND gate 52 changes its output from "1" to "0" and the output of the NAND gate 54 transits from "0" to "1". The state B of the FF 32 changes from "0" to "1" in response to the falling edge of the next internal clock pulse CK and simultaneously the state D of the FF 34 changes its state and the scaler 21 transits to Q1b.
Normally only the one intermediate state Q0ab is required to correct the phase shift so that the control signal X again becomes inactive. After the state Q1b is reached, neither of the FFs 31 or 32 continues to change its state (both output remains a "1"), until another phase correction is required. Thereafter, responding to either rising or falling edges of the internal clock pulses CK, the FFs 33 or 34 change their state C or D respectively, and, as shown in FIG. 5, the state Q transits "-Q1b-Q2b-Q3b-Q0b-Q1b-Q2b-Q3b- -" along the second regular loop "b".
Thus, as a result of a single application of the control signal X, the transition states Q, from the first regular loop "a" to the second loop "b", are "-Q0a-Q1a-Q2a-Q3a-Q0a-Q1a-Q2a-Q0ab-Q1b-Q2b-Q3b- -", and the state stream of the output clock pulses OP is "-1-0-1-1-1-0-1-1-0-1-1- -". During this transition the Q3a state is skipped so that one "1" is deleted in the state pattern of the output clock pulses OP. After one pattern of "1-0-1", the "1-0-1-1" is restored. Since the scaler 21 provides one output pulse during 1.5 clock cycles, it momentarily functions as a divide-by-1.5 frequency divider whenever generating the pattern of "1-0-1". However, it reverts to a divide-by-2 frequency divider when the pattern "1-0-1-1" is restored.
FIGS. 6 shows the scaler's state Q as it transits from the first regular loop "a" to the second regular loop "b" when the control signal "Y" is applied. When the phase of the sampling clock SC leads that of the regenerated clock RC by more than the preselected threshold, the control signal Y goes "1". The output of the NAND gate 53 goes "0" at Q3a and the NAND gate 54 changes its output from "0" to "1". The state B of the FF 32 then transits from "0" to "1" in response to the falling edge of the next internal clock pulse CK and the scaler's state Q transits from Q3a to Q4ab as shown in FIG. 3. Thereafter, the NAND gate 42 changes its output from "1" to "0" and the output of the NAND gate 45 transits from "0" to "1". The state A of the FF 31 changes from "0" to "1" in response to the rising edge of the next internal clock pulse CK and the scaler 21 transits to Q0b.
Normally only the one intermediate state Q4ab is required to correct the phase shift so that the control signal Y again becomes inactive. After the state Q0b is reached, neither of the FFs 31 or 32 continues to change its state (both output remains a "1"), until another phase correction is required. Thereafter, responding to each rising or falling edge of the internal clock pulses CK, the FFs 33 or 34 change their state, and, as shown in FIG. 6, the state Q transits "-Q1b-Q2b-Q3b-Q0b-Q1b-Q2b-Q3b- -" along the second regular loop "b".
Thus, as a result of a single application of the control signal Y, the transition states Q from the first regular loop "a" to the second loop "b" are "-Q0a-Q1a-Q2a-Q3a-Q4ab-Q0b-Q1b-Q2b-Q3b- -", and the state stream of the output clock pulses OP is "-1-0-1-1-1-1-0-1-1- -". During this transition, the Q4ab state is inserted so that a "1" is added to the state stream of the output clock pulses OP. In this stream, after one pattern of "1-0-1-1-1", the "1-0-1-1" is restored. Since the scaler 21 provides one output pulse during 2.5 clock cycles, it momentarily functions as a divide-by-2.5 frequency divider during the pattern of "1-0-1-1-1". However, it again reverts to a divide-by-2 frequency divider when the pattern of "1-0-1-1" is restored.
FIGS. 7 shows the scaler's state Q as it transits from the second regular loop "b" to the first regular loop "a" when the control signal X is applied in a manner similar to that described with reference to FIG. 5.
When because of an application of the control signal X, the state Q transits from loop "b" to loop "a" and continues the latter, the state stream of Q is "-Q0b-Q1b-Q2b-Q0ba-Q1a-Q2a-Q3a- - ", and the state stream of the output clock pulses OP is "-1-0-1-1-0-1-1- -". Thus the transition pattern is the same as that described with reference to FIG. 5, with the scaler 21 functioning in a similar manner.
FIGS. 8 shows the scaler's state Q as it transits from the second regular loop "b" to the first regular loop "a'when the control signal Y is applied in a manner similar to that described with reference to FIG. 6.
When because of an application of the control signal Y, the state Q transits from loop "b" to "a" and continues the latter, the state stream of Q is "-Q0b-Q1b-Q2b-Q3b-Q4ba-Q0a-Q1a-Q2a-Q3a- -", and the state stream of the output clock pulses OP is "-1-0-1-1-1-1-0-1-1- -". Thus the transition pattern is the same as that described with reference to FIG. 6, with the scaler 21 functioning in a similar manner.
FIG. 9 shows the scaler's state Q for continuous transits between the two regular loops and the resultant frequency division when the control signal X or Y is applied. The scaler's state Q does not show the suffix indicating which loop intermediate state it is in.
If either control signal X or Y stays high "1", the scaler's state Q continues to transit through the intermediate state from one regular loop to the other. When such loop transitions occur, one "1" state is continuously deleted or added, with the resultant change in the frequency division from 2 to 1.5 or 2.5, respectively.
Summing up, the control signals X or Y become active whenever a phase correction is necessary. Accordingly, the magnitude of the phase correction is not critical, and the scaler performs frequency division variations of ±0.5 without the phase correction circuit malfunctioning. While each FF can transit only once during each clock cycle, the scaler can transit twice per clock cycle since it responds to both rising and falling edges of the clock pulses, so that the internal clock frequency is halved. If all FFs responded to the same clock edges, the clock frequency would have to be doubled, with the result that higher speed circuitry would be required.
Although the frequency division in the described embodiment is variable from 2, to 2.5 or 1.5, other frequency divisions can be readily obtained by modifying the gating and/or number of FFs.
TABLE 1__________________________________________________________________________NEXT STATEX = 0 X = 1 X = 0 X = 1Y = 0 Y = 0 Y = 1 Y = 1STATEABCD ABCD ABCD ABCD ABCD ABCD ABCD ABCDABCD ↑EDGE ↓EDGE ↑EDGE ↓EDGE ↑EDGE ↓EDGE ↑EDGE ↓EDGE__________________________________________________________________________0000§0010§ 0000 0010§ 0000 0010§ 0000 0010 00000001§0001 0000§ 0001 0000§ 0001 0101§ 0001 01010010§0010 0011§ 0010 0011§ 0010 0011§ 0010 00110011§0001§ 0010 1001§ 0010 0001§ 0111 1001 01110100 0110 0000 0110 0000 0110 0000 0110 00000101§1101§ 0000§ 1101§ 0000§ 1101§ 0000§ 1101 00000110 0110 0011 0110 0010 0110 0011 0110 00100111 1101 0010 1101 0010 1101 0010 1101 00101000 0010 1000 0010 1000 0010 1000 0010 10001001§0001 1100§ 0001 1100§ 0001 1100§ 0001 11001010§0010§ 1010 0010§ 1010 0010§ 1010 0010 10101011 0001 1010 1001 1010 0001 1010 1001 10101100§1110§ 1000 1110§ 1000 1110§ 1000 1110 10001101§0101 1100§ 0101 1100§ 0101 1100§ 0101 11001110§1110 1111§ 1110 1010§ 1110 1111§ 1110 10101111§1101§ 1110 1101§ 1010 0101§ 1110 0101 1010__________________________________________________________________________
TABLE 2______________________________________ OUTPUT CLOCKFFs 31 - 34 SCALER 21 PULSE______________________________________A B C D Q OP0 0 0 0 Q0 10 0 0 1 Q3 10 0 1 0 Q1 00 0 1 1 Q2 10 1 0 0 N/A --0 1 0 1 Q4 10 1 1 0 N/A --0 1 1 1 N/A --1 0 0 0 N/A --1 0 0 1 Q0 11 0 1 0 Q0 11 0 1 1 N/A --1 1 0 0 Q1 01 1 0 1 Q0 11 1 1 0 Q2 11 1 1 1 Q3 1______________________________________ | A scaler comprising a plurality of flip-flops, varies its frequency division to correct phase by 0.5 clock cycle. Each flip-flop is continuously and synchronously responsive to either a rising or a falling edge of the clock pulses. Normally, the scaler's state transits along one of two loops, which generate output pulses having identical repetition rates. When a control signal is applied, the scaler's state transits from one loop to the other, generating at least one output at an alternative repetition rate. The alternative repetition rate is either lower or higher than the identical repetition rate by an integral number of half cycles of the input clock pulses. Where there are two control signals, a lower or higher alternative repetition rate can be selected. Since the flip-flops are responsive to either edge of the clock pulses without clock gating interruptions, there is no jitter and the scaler's robustness is improved. Also the clock frequency can be effectively halved. | 7 |
FIELD OF THE INVENTION
[0001] This invention relates to semi-batch type copolymerization processes. More specifically, the processes of the present invention are directed to the production of compositionally uniform copolymers, including the production of such copolymers from dissimilar monomers, e.g., from monomers with significantly different reactivity ratios.
BACKGROUND OF THE INVENTION
[0002] Typical copolymerizations are performed in the batch mode, where all monomers are charged at one time with or without solvent into a single reaction vessel and then a free radical or other polymerization initiator is added at the desired temperature to cause polymerization. However, using this batch procedure results in a polymer composition that is not uniform and/or a desired target and the molecular weight desired is not achieved. A semi-batch polymerization process is a modified batch process that seeks to address some of the deficiencies of a standard batch process for polymerization of monomers of different reactivities. In a semi-batch polymerization process, the reaction vessel is initially loaded with only a portion of the monomers and catalyst. Typically, the monomer(s) with lower reactivity will be present at a higher molar ratio during the initial charging of the vessel. As the reaction proceeds and monomers are consumed in the production of the copolymer, more monomers and optionally catalyst are fed to the reactor, at a ratio determined by both the relative reactivities of the monomers and the desired copolymer composition. This is generally referred to an “open loop” process and in the past has not been commercially successful because of its non-precise methodology utilized. In light of this facet, open loop semi-batch methodology, has not been used in processes to produce copolymers of high compositional uniformity in the chemical industry for use in photoresist applications The spectral characteristics of monomers and any polymers produced from these monomers are often quite similar, making it difficult to determine how much of any given monomer has been converted to polymer, thus the industry has resorted to the utilization of very automatic and sophisticated devices to carry out the desired end result. Under these circumstances, the economical costs are high and not feasible for some businesses. Therefore, there is a need in the industry for an inexpensive method to prepare these copolymers to achieve a target composition and a desired molecular weight. In U.S. Pat. No. 6,828,393 B1, there is disclosed a process wherein the desired end polymer is carried out in a two step process. In this manner, a test polymerization is conducted wherein two or more monomers are fed into a reactor vessel and then the reactor analyzed to determine the residual monomer content. Then the slower reacting monomer is fed to a second reactor and then the faster reactive monomer is fed to the reactor based upon the results from the first reactor study. This process still requires the use of two reactor vessels and the inaccurate analysis of the residual monomer in the first reactor vessel to determine the feed rates for the second reactor polymerization. This process is cumbersome and inaccurate in its methodology. Other attempts to carry out such open loop processes are disclosed in U.S. Pat. No. 5,504,166; both of these patents are incorporated herein by reference in toto.
SUMMARY OF THE INVENTION
[0003] It has been found that the above disadvantages of the prior art can be over come by the present invention set forth herein. It has been found that an open loop process can be successfully carried out when the monomer conversion is predetermined by batch kinetics and analyzed by HPLC and GC and the proper open loop monomer feed sequence can then be applied to produce polymers of the desired compositional uniformity, without the utilization of such automatic and sophisticated devices/equipment.
[0004] In one aspect of this invention, there is provided a polymerization process for reacting monomers in a reaction vessel comprising:
a. charging a first vessel with a pre-charge of at least two monomers at a target composition, and a first solvent, and mixing the materials to form a uniform first solution; b. charging a second vessel with a polymerization initiator and a second solvent, and mixing the materials to form a uniform second solution; and c. feeding said first solution and said second solution into a third, reaction vessel at predetermined rates wherein said monomers in solution are polymerized over a sufficient period of time and at a sufficient temperature to maintain a target composition and achieve a desired molecular weight.
DETAILED DESCRIPTION
[0008] Applicants have developed a semi-batch polymerization process that employs the controlled feed of monomers and initiator to a single reactor after using batch reaction kinetics data to establish the proper feed rates to achieve a desired molecular weight as well as a desired and uniform copolymer This process is especially useful for polymerizing monomers of widely varying polymerization reactivities (relative reactivity ratios greater than 2 or less than 0.5), but it can also be used for monomers of similar reactivities (relative reactivity ratios of between about 0.5 and 2).
[0009] One consequence of the ability to keep the liquid phase composition of the monomers constant is that copolymers made by the process of this invention have more uniformity in composition from chain-to-chain.
[0010] The impact of greater uniformity on the performance of the copolymers depends on both the nature of the copolymers and the application in which they are being used. It has been demonstrated, for example, that certain photoresist copolymers made by the process of this invention display improved line-edge roughness compared to copolymers made from the same monomers under standard batch process conditions.
[0011] The safety of certain polymerization processes can also be improved using the process of this invention, without sacrificing productivity. In a batch reactor, and particularly when one of the reactants is extremely reactive (e.g., acrylic acid), it is critically important from a process safety perspective that the polymerization exotherm be controlled. Typically, to achieve desireable reaction rates, high concentrations are used. A controlled feed reaction helps control the polymerization exotherm. To account for such exotherms, low concentration of monomer are commonly used limiting the reactor yield. Conversely, from an economic perspective it is highly desirable that the reactor be utilized to its maximum potential in each batch
[0012] The process of this invention combines the use of an initial batch copolymerization to obtain sufficient monomer conversion data with appropriate feed capability of maintaining the desired monomer concentrations throughout the course of a semi-batch copolymerization process by controlling the feed rates of each monomer as necessary and controlling the initiator feed rate.
[0013] The target liquid phase composition for the polymerization is determined before hand for a given target copolymer composition through the use of the classical polymer equation and is dependent upon the relative reactivities of each of the polymerizing monomers. The wider the disparity in reactivity ratios of the monomers, the more the target liquid phase composition will vary from the target copolymer composition. The monomer reactivity ratios can be obtained from kinetic studies of pair-wise copolymerizations or from non-linear parameter estimation techniques. Both of these techniques are well-known to those skilled in the art.
[0014] Analysis of reactivities of monomers suggest two approaches to attaining greater uniformity in the copolymerization of monomers that have different reactivities 1) to stop the reaction prior to complete conversion that will give the desired composition and 2) to start a standard polymerization process that gives the desired composition and to maintain the feed composition of the reaction by feeding the faster reacting monomer or monomers to the reaction and the reactions proceeds. For consideration of yield and commercial viability, only the second approach can has been used here.
[0015] The reactivities of each given set of monomers are determined by performing a series of conventional batch polymerizations at different monomer concentrations. Analysis of these polymerizations for the conversion of monomers through out the polymerization reaction can be used to determine the feed rate and concentration of monomers to be used in a controlled feed batch polymerization. A controlled feed batch polymerization can then be designed where the faster monomer or set of monomers can added at such a rate and concentration that maintains a constant monomer feed concentration at the desired composition. The process can be designed to feed the monomers as individual solutions of each monomer or as a mixture of monomers in solution. In the case of feeds using individual solution of each monomer, feed rates can be adjusted to compensate for the reactivity of each monomer.
[0016] The process of this invention can be used to make a variety of copolymers. The molecular weight of copolymers can be effectively controlled through the addition of a chain transfer agent (e.g., THF), the manipulation of the reaction temperature, or the rate of addition of free radical initiator. All of these methods for molecular weight control are well-known in the batch polymerization art. In one embodiment of this invention, a combination of initiator concentration and chain transfer agent concentration is used to regulate polymer molecular weight.
[0017] While one embodiment of this invention involves the polymerization of dissolved ASM with acrylate-type monomers, one skilled in the art would readily recognize the utility of the method to the free radical co-polymerization of other types of monomers, including styrenics and olefinics. Various type monomers can be used in the inventive step of the present invention, and are exemplified, without limitation, below.
[0018] Styrenics include, without limitation, a substituted styrene monomer of formula I,
[0000]
[0019] wherein R is either —C(O)R 5 or —R 5 ; in this formula I, the following are the definitions:
i) R 1 and R 2 are the same or different and independently selected from the group consisting of:
hydrogen; fluorine, chlorine or bromine; alkyl or fluoroalkyl group having the formula C n H x F y where n is an integer from 1 to 4, x and y are integers from 0 to 2n+1, and the sum of x and y is 2n+1; and phenyl or tolyl;
ii) R 3 is selected from the group consisting of:
hydrogen; and methyl, ethyl, n-propyl, iso-propyl, n-butyl, i-butyl or t-butyl;
iii) R 4 is selected from the group consisting of methyl, ethyl, n-propyl, i-propyl, n-butyl,
i-butyl, t-butyl, t-amyl, benzyl, cyclohexyl, 9-anthracenyl, 2-hydroxyethyl, cinnamyl, adamantly, methyl or ethyl adamantly, isobornyl, 2-ethoxyethyl, n-heptyl, n-hexyl, 2-hydroxypropyl, 2-ethylbutyl, 2-methoxypropyl, 2-(2-methoxyethoxyl), 2-naphthyl, 2-phenylethyl, phenyl, and the like.
iv) R 5 is C 1 -C 5 alkyl, either straight or branch chain.
[0033] Other monomers include, without limitation, an acrylate monomer having the formula II,
[0000]
[0034] wherein the definition of R3 and R4 are the same as set forth above.
[0035] In conjunction with Formula II (an acrylate monomer) set forth herein, some preferred acrylate monomers are (1) MAA-methyl adamantyl acrylate, (2) MAMA-methyl adamantyl methacrylate, (3) EAA-ethyl adamantyl acrylate, (4) EAMA-ethyl adamantyl methacrylate, (5) ETCDA-ethyl tricyclodecanyl acrylate, (6) ETCDMA-ethyl tricyclodecanyl methacrylate, (7) PAMA-propyl adamantyl methacrylate, (8) MBAMA-methoxybutyl adamantyl methacrylate, (9) MBAA-methoxybutyl adamantyl acrylate, (10) isobornylacrylate, (11) isobornylmethacrylate, (12). cyclohexylacrylate, and (13) cyclohexylmethacrylate. Other preferred acrylate monomers which can be used are (14) 2-methyl-2-adamantyl methacrylate; (15) 2-ethyl-2-adamantyl methacrylate; (16) 3-hydroxy-1-adamantyl methacrylate; (17) 3-hydroxy-1-adamantyl acrylate; (18) 2-methyl-2-adamantyl acrylate; (19) 2-ethyl-2-adamantyl acrylate; (20) 2-hydroxy-1,1,2-trimethylpropyl acrylate; (21) 5-oxo-4-oxatricyclo-non-2-yl acrylate; (22) 2-hydroxy-1,1,2-trimethylpropyl 2-methacrylate; (23) 2-methyl-1-adamantyl methacrylate; (24) 2-ethyl-1-adamantyl methacrylate; (25) 5-oxotetrahydrofuran-3-yl acrylate; (26) 3-hydroxy-1-adamantyl methylacrylate; (27) 5-oxotetrahydrofuran-3-yl 2-methylacrylate;(28) 5-oxo-4-oxatricyclo-non-2-yl 2 methylacrylate; (28) 2-Propenoic acid, 2-hydroxy-1,1,2-trimethylpropyl ester (PinMAc); (29) 2-Methyl-2-propenoic acid, 2-hydroxy-1,1,2-trimethylpropyl ester (PinMAc); (30) 2-hydroxy-2,2-bis(trifluoromethyl)ethyl methacrylate, or 2-methyl-2-propenoic acid, 2-hydroxy-2,2-bis(trifluoromethyl)ethyl ester (FOHMAc); (31) 2-hydroxy-2,2-bis(trifluoromethyl)ethyl acrylate, or 2-propenoic acid, 2-hydroxy-2,2-bis(trifluoromethyl)ethyl ester (FOHAc).
[0036] Additional acrylates and other monomers that may be used in the present invention with the substituted styrene to form various copolymers include the following materials:
[0037] Monodecyl maleate; 2-hydroxy ethyl methacrylate; isodecyl methacrylate; hydroxy propyl methacrylate; isobutyl methacrylate; lauryl methacrylate; hydroxy propyl acrylate; methyl acrylate; t-butylaminoethyl methacrylate; isocyanatoethyl methacrylate; tributyltin methacrylate; sulfoethyl methacrylate; butyl vinyl ether blocked methacrylic acid; t-butyl methacrylate; 2-phenoxy ethyl methacrylate; acetoacetoxyethyl methacrylate; 2-phenoxy ethyl acrylate; 2-ethoxy ethoxy ethyl acrylate; beta-carboxyethyl acrylate; maleic anhydride; isobornyl methacrylate; isobornyl acrylate; methyl methacrylate; ethyl acrylate; 2-ethyl hexyl methacrylate; 2-ethyl hexyl acrylate; glycidyl methacrylate; N-butyl acrylate; benzyl methacrylate; acrolein; 2-diethylaminoethyl methacrylate; allyl methacrylate; vinyl oxazoline ester of meso methacrylate; itaconic acid; acrylic acid; N-butyl methacrylate; ethyl methacrylate; hydroxy ethyl acrylate; acrylamide oil; acrylonitrile; methacrylic acid; and stearyl methacrylate.
[0038] Further acrylates that can be used in the present invention include the following:
2-Methyl-2-adamantyl methacrylate (MAMA) 2-Methyl-2-adamantyl acrylate (MAA) 2-Ethyl-2-adamantyl methacrylate (EAMA) 2-Ethyl-2-adamantyl acrylate (EAA) 2-Ethyl-2-norbornyl methacrylate 3-Hydroxy-1-adamantyl acrylate (HAA) 3-Hydroxy-1-adamantyl methacrylate (HAMA) α-γ-Butyrolactone methacrylate (α-GBLMA) α-γ-Butyrolactone acrylate (α-GBLA) Norbornene lactone methacrylate (NBLMA) Norbornene lactone acrylate (NBLA) Norbornene methacrylate (NOMA) Norbornene acrylate (NOA) Isobornyl methacrylate (IBMA) Isobornyl acrylate (IBA) Ethylcyclopentylmethacrylate (ECPMA) Ethylcyclopentylacrylate (ECPA) Ethylcyclohexylmethacrylate (ECHMA) Ethylcyclohexylacrylate (ECHA) 2-(Cyanomethyl)-2-adamantylmethacrylate (CNMM) 2-Adamantyloxymethylmethacrylate (AOMM) 2-[(2-Methyl-adamantyl)oxy]carbonylmethylmethacrylate (MACMMA)
[0061] Other monomers include one or more ethylenically unsaturated copolymerizable monomers (EUCM) selected from the group consisting of styrene, 4-methylstyrene, styrene alkoxide wherein the alkyl portion is C 1 -C 5 straight or branch chain, maleic anhydride, dialkyl maleate, dialkyl fumarate and vinyl chloride, wherein alkyl is having 1 to 4 carbon atoms, comprising the following steps.
[0062] Co-polymers having polyhydroxystyrene (PHS) and one or more of the above acrylate monomers are some of the materials that are made by the novel processes of the present invention.
[0063] In another embodiment, the reaction mixture may not only use the basic carboxylic acid solvent, but also use an additional co-solvent. The co-solvent is selected from the group consisting of tetrahydrofuran, methyl ethyl ketone, acetone, and 1,4-dioxane.
[0064] The carboxylic alcohol solvent is an alcohol having 1 to 4 carbon atoms and is selected from the group consisting of methanol, ethanol, isopropanol, tert-butanol, and combinations thereof The amount of solvent (and/or second solvent) used is not critical and can be any amount which accomplishes the desired end result.
[0065] The free radical initiator may be any initiator that achieves the desired end result. The initiator may be selected from the group consisting of 2,2′-azobis(2,4-dimethylpentanenitrile), 2,2′-azobis(2-methylpropanenitrile), 2,2′-azobis(2-methylbutanenitrile), 1,1′-azobis(cyclohexanecarbonitrile), t-butyl peroxy-2-ethylhexanoate, t-butyl peroxypivalate, t-amyl peroxypivalate, diisononanoyl peroxide, decanoyl peroxide, succinic acid peroxide, di(n-propyl)peroxydicarbonate, di(sec-butyl)peroxydicarbonate, di(2-ethylhexyl)peroxydicarbonate, t-butylperoxyneodecanoate, 2,5-dimethyl-2,5-di(2-ethylhexanoylperoxy)hexane, t-amylperoxyneodecanoate, dimethyl 2,2′-azobisisobutyrate and combinations thereof.
[0066] As a preferred embodiment, the initiator is selected from the group consisting of 2,2′-azobis(2,4-.dimethylpentanenitrile), 2,2′-azobis(2-metbylpropanenitrile), 2,2′-azobis(2-methylbutanenitrile), 1,1′-azobis(cyclohexanecarbonitrile), t-butyl peroxy-2-ethylhexanoate, t-butyl peroxypivalate, t-amyl peroxypivalate, and combinations thereof.
[0067] The amount of initiator is any amount that accomplishes the desired end result. However, as a preferred embodiment, said initiator is present to about three mole percent based upon the total moles of all of said monomers I, II, and said copolymerizable monomers.
[0068] The polymerization conditions are any temperature and pressure that will produce the desired end result. In general, the temperatures are from about 30° C. to about 100° C., preferably from about 40° C. to about 100° C., and most preferably from about 45° C. to about 90° C. The pressure may be atmospheric, sub-atmospheric or super-atmospheric. The polymerization time is not critical, but generally will take place over a period of at least one minute in order to produce a polymer of corresponding composition.
[0069] In one embodiment of this invention, the in-situ measurements are made by Raman spectroscopy. Equivalently, any in-line device that provides a measure of the molar composition of the liquid phase (FTIR, NIR, densitometry, GC, etc.) could be utilized.
EXAMPLES
[0070] Unless otherwise noted, all compositions are given as mole %.
Example 1
[0071] A 50 L round bottom glass reactor, fitted with an external heating mantle, an overhead stirrer, a chilled water reflux condenser and a nitrogen inlet and outlet was charged with 1,507.9 g of electronic grade methanol. The methanol was heated to reflux (65 deg. C.) at normal atmospheric pressure conditions with a low N2 sweep of approximately 1 L/min to remove all oxygen from the reactor. To a separate glass charge vessel, 834.5 g (3.36 moles) of 2,2′-azobis-2,4-dimethylvaleronitrile) (Vazo-52) was dissolved into 3557.4 g of electronic grade methanol and held at 25 deg. C. To a second glass charge vessel 6,048.0 g (37.33 moles) of 4-acetoxystyrene (ASM), 6,024 g (24.27 moles) of 2-ethyl-2-adamantylmethacrylate (EAMA) and 8,395 g of electronic grade methanol was mixed and held at 25 deg. C. Both charge vessels were outfitted with Teflon tubing and feed pumps leading to the 50 L reactor. After the main reactor charge of methanol had reached 65 deg. C., both charge vessels began feeding the monomer mix and initiator mix into the 50 L reactor. The feed rate of each vessel was separately set to completely feed their contents in 3.0 hours. One hour after both charge vessels had delivered their contents to the reactor, (four hours since the feeds were started) 208.62 g (0.84 moles) of Vazo-52 initiator dissolved in 500 g electronic grade methanol was added to the reactor in one charge. One hour later, (5 hours after feeds were started) 104.31 g (0.42 moles) of VAZO-52 as added to the reactor in one charge. One hour later, (6 hours after feeds were started) 52.15 g (0.21 moles) of Vazo-52 was added to the reactor. At each hour after start of the addition of monomers and initiator, a sample was taken and analyzed for unreacted monomers by capillary gas chromatography (GC). At seven hours, 775 g. of tetrahydrofuran (THF) was added to the reactor. At nine hours, an additional 482 g THF was added to the reactor. The THF was added to make the polymer more soluble and assist the mixing. The polymerization reaction was continued for a total of 10.5 hours. At the end of this period, the final polymer mixture sample showed conversion of ASM to be 95% and of EAMA to be 90% by weight conversion of the monomers to polymer. The polymer contents were allowed to cool to 55 deg. C. when an additional 6,230 g electronic grade methanol was added with mixing. The mixer was stopped and the contents let to settle, separating the bulk of the polymer layer to the bottom of the reactor. The upper methanol with residual monomers, initiator fragments and low molecular weight oligomers were removed with a dip tube and suction. An additional 1,660 g of THF and 12,850 g of methanol were added to the reactor. The reactor was heated again to 65 C and mixed for 60 minutes. The contents were allowed to settle and cool. The upper methanol layer (11,364 g) was again removed from the reactor and replaced with fresh methanol (12,750 g) and THF (1550 g). The reactor contents were again heated and stirred for 60 minutes, then allowed to settle and cool to 40 deg. C. This process was repeated a total of 6 times to achieve a greater than 99.9% replacement of the original methanol by dilution calculation. A final polymer sample was taken for analysis of residual monomers by capillary (GC). Residual ASM measured 324 ppm and residual EAMA measured 1900 ppm. The transesterification reactor of p-acetoxy groups to p-hydroxy groups was performed after adding an additional 9,034 g of methanol and 135 g of 25% sodium methoxide in methanol to the reactor and heating to reflux (65 deg. C.). The reaction mixture was continued to reflux with concomitant removal of methanol/methyl acetate as distillate and fresh methanol added to compensate for the distillate. The reaction mixture was allowed to react until the reaction mixture became clear in about 4 hours at which time the reaction mixture was allowed to react for an additional 7 hours to complete the reaction. A 13 C NMR of the reaction mixture indicated a >98% conversion of p-acetoxy to p-hydroxy groups. A 1 H NMR analysis indicated that the 2-ethyl-2-adamantly groups remained intact and no poly(methacrylic acid) was detected. A 13 C NMR for composition indicated a copolymer of 60 mole % 4-hydroxystyrene and 40 mole % EAMA.
Example 2
[0072] A 3 L—four neck round bottom glass reactor, fitted with an external heating mantle, an overhead stirrer, a chilled water reflux condenser and a nitrogen inlet and outlet was charged with 166.3 g of methyl ethyl ketone, 47.8 g (0.118 moles) of methyl 4-cyano-4-(dodecylsulfanylthiocarbonyl)sulfanyl pentanoate, 2.0 g of sodium carbonate, and 2.6 g ( 0.011 moles) of dimethyl-2,2′-azobisisobutyrate. This mixture was heated to 67 deg. C. at normal atmospheric pressure conditions with a low N2 sweep of approximately 1 L/min to remove all oxygen from the reactor. To a separate glass charge vessel (vessel 1), 2-methyl-2-adamantylmethacrylate (MAMA) 362.0 g (1.548 moles) and held at 25 deg. C. To a second glass charge vessel (vessel 2), 248.0 g (1.457 moles) of α-γ-butyrolactone methacrylate (α-GBLMA), 172.7 g (0.731 moles) of 3-hydroxy-1-adamntylmethacrylate (HADMA), and 500 g of methyl ethyl ketone was mixed and held at 25 deg. C. Both charge vessels were outfitted with Teflon tubing and feed pumps leading to the 3 L reactor. After the reactor reached 67 deg. C., both charge vessels began feeding the monomer mixtures into reactor. The feed rate of vessel 1 was set to completely feed the entire contents in 3.0 hours and the feed rate of vessel 2 was set to completely feed the entire contents in 4.0 hours. At each hour after start of the addition of monomers and initiator, a sample was taken and analyzed for unreacted monomers by high performance liquid chromatography (HPLC). The polymerization reaction was continued for a total of 10 hours. At the end of this period the reaction was cooled to room temperature. The polymer mixture sample showed conversion of MAMA to be 81%, of O-GBLMA to be 91.5%, and HADMA to be 91.8% by weight conversion of the monomers to polymer. To this mixture, an additional 1.3 g of dimethyl-2,2′-azobisisobutyrate was added and then the mixture was heated to 67 deg. C. The mixture was maintained at 67 deg. C. for and additional 2.5 hours. The polymer contents were allowed to cool to room temperature and the solution was diluted with 720 g of methyl ethyl ketone. A final polymer sample was taken for analysis of residual monomers by high performance liquid chromatography (HPLC). The polymer mixture sample showed conversion of MAMA to be 90.7%, of alpha-GBLMA to be 97.4%, and HADMA to be 97.9% by weight conversion of the monomers to polymer. Analysis of the polymer by gel permeation chromatography gave a weight average molecular weight of 9,400 with a polydispersity of 1.18. The polymer was isolated by precipitation into 4500 g of stirred hexanes. The solid was filtered and washed with hexanes and then was dried under vacuum (15 torr) at 40 deg. C. for 72 hours. A total of 159.6 g of a fine yellow solid was obtained.
[0073] A 3 L—four neck round bottom glass reactor, fitted with an external heating mantle, an overhead stirrer, a chilled water reflux condenser and a nitrogen inlet and outlet was charged with the above isolated solid, 160.0 g of methyl ethyl ketone, 0.58 g of dimethyl-2,2′-azobisisobutyrate, and 18.6 g of triethylamine hypophosphorous acid salt. The reactor was heated to 67 deg. C. for a total of 10 hours with an addition of 0.34 g of dimethyl-2,2′-azobisisobutyrate at one hour intervals. The mixture was cooled to room temperature and polymer was isolated by precipitation into 6280 g of hexanes. The solid was filtered and washed with hexanes and then was dried under vacuum (15 torr) at 40 deg. C. for 72 hours. A total of 176.0 g of a fine white solid was obtained.
Example 3
[0074] A 50-L 4-neck round bottom flask equipped with an overhead stirrer, heating mantle, thermo-well, thermocouple, N 2 sweep, chilled water condenser, and an addition inlet was charged with electronic grade methanol (1560.00 g). To a separate 5-L 1-neck round bottom flask was charged 2,2′-azobis-2,4-dimethylvaleronitrile (Vazo-52) (748.92 g, 3.02 moles) and electronic grade methanol (3192.8 g). To a separate 22-L 1-neck round bottom flask was charged ASM (7500.00 g, 42.29 moles), 2-ethyl-2-adamantylmethacrylate (EAMA) (3351.00 g, 13.50 moles), and electronic grade methanol (7540.00 g). The two smaller flasks were equipped with rubber stoppers to house the Teflon tubing leading to the 50-L reactor through feed pumps. The 50-L reactor was heated to 66° C. The smaller vessels were fed to the 50-L reactor at a rate so that the feed would be completed in 3 hours. The heat was turned off after 10.0 hours from the start of the feed. At this time a sample of the polymer was analyzed for conversion of monomer to polymer, ASM 97.4% and EAMA 97.9%. Methanol was charged (7220.00 g) and the reaction was stirred. The reactor was heated to 59° C. and stirred for 30 minutes. The stirring was stopped to allow the bulk polymer to settle out, the bottom layer. The top methanol layer (13,880.00 g), which contains residual monomers, initiator fragments and low molecular weight oligomers, was removed by with a dip tube and suction. Methanol (10,901.00) was slowly charged while stirring and heating (61.5° C). The mixture was stirred for 60 minutes. The contents were allowed to cool and settle. The top methanol layer (12,202.00 g) was removed by suction and methanol (12,322.00 g) was charged slowly while heating (65° C.) and stirring. The mixture was stirred for 60 minutes. The top layer (12,823.00 g) was removed and methanol (3320.00 g) was added. A sample of the polymer was analyzed for wt % residual monomers by GC, ASM <0.35% and EAMA 0.15%. The transesterification reaction of p-acetoxy groups to p-hydroxy groups was performed with the addition of methanol (4326.00 g) and 25 wt % sodium methoxide (121.40 g) in methanol and heating to 65° C. The reaction was allowed to reflux and the solution changed from opaque to clear after 1 hour. The heat was turned off after 7 hrs, methanol (1056.00 g) was charged to decrease the viscosity of the solution. The distillate, methanol and methyl acetate, was removed.
Example 4
[0075] A 50-L 4-neck round bottom flask equipped with an overhead stirrer, heating mantle, thermo-well, thermocouple, N 2 sweep, chilled water condenser, and an addition inlet was charged with electronic grade methanol (1507.90 g). To a separate 5-L 1-neck round bottom flask was charged 2,2′-azobis-2,4-dimethylvaleronitrile (Vazo-52) (834.56 g, 3.36 moles) and electronic grade methanol (3557.40 g). To a separate 22-L 1-neck round bottom flask was charged ASM (6048.00 g, 37.33 moles), 2-ethyl-2-adamantylmethacrylate (EAMA) (6032.60 g, 24.30 moles), and electronic grade methanol (8395.00 g). The two smaller flasks were equipped with rubber stoppers to house the Teflon tubing leading to the 50-L reactor through feed pumps. The 50 L reactor was heated to 66° C. The smaller vessels were fed to the 50-L reactor at a rate so that the feed would be completed in 3 hours. Four hours after the feed had begun, Vazo-52 (208.62 g, 0.84 moles) and methanol (500.00 g) were added. Five hours after the feed had begun, more Vazo-52 (104.31 g, 0.42 moles) and methanol (300.00 g) were added. Six hours after the start of the feed, a final charge of Vazo-52 (52.15 g, 0.21 moles) and methanol (300.00 g) were added to the reactor. Seven hours after the start of the feed tetrahydrofuran (THF) (775.00 g) was added to increase solubility. Nine hours after the start of the feed, an additional amount of THF (482.00 g) was added. The heat was turned off at 10.5 hours. At this time a sample of the polymer was analyzed for conversion of monomer to polymer, ASM 94.5% and EAMA 89.5%. Methanol was charged (6230.00 g) and the reaction was stirred. The stirring was stopped to allow the bulk polymer to settle out, the bottom layer. The top methanol layer, which contains residual monomers, initiator fragments and low molecular weight oligomers, was removed by with a dip tube and suction. An additional portion of THF (2422 g) and methanol (10,365.00) were then charged to the reactor and the solution was then heated 66° C. for 60 minutes. The contents were allowed to cool and settle. The top methanol layer was removed by suction and methanol (12,842.00 g) and THF (1358.00 g) were charged to the reactor. The reaction was allowed to settle overnight (15.5 hrs). The top layer was removed and THF (1550 g) and methanol (1 2735 g) were added. The solution was stirred at 62° C. for 1.5 hrs then the stirring was stopped. The reaction sat overnight (17 hrs) and the top layer was removed (14,136 g). A sample of the polymer was analyzed for wt % residual monomers by GC, ASM <0.03% and EAMA 0.30%. The transesterification reaction of p-acetoxy groups to p-hydroxy groups was performed with the addition of methanol (9034 g) and 25 wt % sodium methoxide (135 g) in methanol and heating to 65° C. The reaction was allowed to reflux and the solution changed from opaque to clear after 2 hrs. The heat was turned off after 3.5 hrs and the distillate, methanol and methyl acetate, (2623 g) was removed. An additional amount of THF (1 kg) was added to decrease cloudiness of the solution. The solution was then filtered with a Meissner CSTMO. 1-552 Ultra dyne, 0.1 um, ⅜″ filter to remove Fe from Vazo 52. An additional amount of THF (1.4 kg) was added to decrease cloudiness of the solution.
Example 5
[0076] A 3 L four neck round bottom glass reactor, fitted with an external heating mantle, temperature controller, thermowell, an overhead stirrer, a chilled water reflux condenser and a nitrogen inlet and outlet was charged with 647.4 g of Methyl Ethyl Ketone (MEK). In a separate container 15.63 g (dimethyl 2,2′-azobis(2-methylpropionate) (V-601) was dissolved into 40 g of MEK. The reactor contents was heated to 67° C. at normal atmospheric pressure conditions with a low N 2 sweep of approximately 1 L/min to remove all oxygen from the reactor. Once reactor contents reached reflux the V-601/MEK solution was added to the reactor. To a separate glass feed vessel, 192.8 g (6.8227 moles) of 2-methyl-2-adamantyl methacrylate (MAMA) was charged and held at 25° C. To a second separate glass feed vessel, 140.3 g (0.8245 moles) of α-γ-butyrolactone methacrylate (α-GBLMA), 97.5 g (0.4126 moles) of 3-hydroxy-1-adamantyl 2-methylacrylate (HAdMA) and 281.1 g of MEK was charged and held at 25° C. The charge vessels were outfitted with Teflon tubing and feed pump leading to the 3 L reactor. After the main reactor charge of MEK had reached reflux, the charge vessels began feeding the monomer mix and solvent mix into the 3 L reactor. The feed rate of the vessels was set to completely feed the contents in 3.0 hours for the MAMA and 4.0 hours for the α-GBLMA, HAdMA and MEK. Two hours after both charge vessels started delivering their contents to the reactor, 2.4 g (0.01 moles) of V-601 initiator dissolved in 3.7 g MEK was added to the reactor in one charge. The polymerization process continued for 4 additional hours. The polymerization reaction was continued for a total of 6 hours after monomers and solvent feeds were started. The reaction was allowed to cool to room temperature overnight. After the start of the addition of monomers and solvent, a sample was taken and analyzed for unreacted monomers by high performance liquid chromatography (HPLC) at 1, 2, 3, 4, 5 and 6 hours.
Example 6
[0077] A 1 L four neck round bottom glass reactor, fitted with an external heating mantle, temperature controller, thermowell, an overhead stirrer, a chilled water reflux condenser and a nitrogen inlet and outlet was charged with 0.4271 g (1.80 moles) of Triethylamine (TEA), 10.5138 g (1.86 moles) of methyl 4-cyano-4-(dodecylsulfanythiocarbonl)sulfany pentanoate (CTA 2.2), 1.4126 g (0.12 moles) of 2,2′-Azobisisobutyronitrile (AIBN) and 109.17 g of Methyl Ethyl Ketone (MEK). The reactor contents was heated to 67 deg. C. at normal atmospheric pressure conditions with a low N 2 sweep of approximately 1 L/min to remove all oxygen from the reactor. To a separate glass feed vessel, 57.83 g (0.2097 moles) of 1,4:5,8-dimetano-2-ethyl-decahydronaphtalene-2-yl-methacrylate (MDDx), 14.23 g (0.0838 moles) of 1-ethylcyclopentyl-2-methacrylate (MCp2), 49.52 g (0.2096 moles) of 3-hydroxy-1-adamantyl 2-methylacrylate (MAdOH), 75.19 g (0.3354 moles) of 7-oxa-norbornane-5,3-carbolactone-2-yl-methacrylate (MONL) and 345.3 g of MEK was charged, stirred until monomers dissolved in solution and held at 25° C. The charge vessel was outfitted with Teflon tubing and feed pump leading to the 1 L reactor. After the main reactor charge of TEA, CTA 2.2, AIBN, and MEK had reached 67 deg. C., the charge vessel began feeding the monomer mix and solvent mix into the 1 L reactor. The feed rate of the vessel was set to completely feed the contents in 2.0 hours for the MDDx, MCp2, MAdOH, MONL, and MEK. The polymerization process continued for 4 additional hours. Six hours after the charge vessel started delivering their contents to the reactor 7.02 g (0.04 moles) of AIBN initiator dissolved in 3.31 g of 2-mercaptoethanol was added to the reactor in one charge. The reaction cooled to room temperature two hours after the addition of AIBN and 2-mercaptoethanol to the reaction.
Example 7
[0078] A 5 L four neck round bottom glass reactor, fitted with an external heating mantle, temperature controller, thermowell, an overhead stirrer, a chilled water reflux condenser and a nitrogen inlet and outlet was charged with 301.40 g (1.72 moles) of 4-acetoxystyrene (ASM), 240.78 g (1.88 moles) of t-butylacrylate (tBA), 17.94 g (0.08 moles) of t-butylperoxypivalate (tBPP) and 648 g of electronic grade methanol. The reactor contents was heated to reflux (65° C.) at normal atmospheric pressure conditions with a low N 2 sweep of approximately 1 L/min to remove all oxygen from the reactor. To a separate glass feed vessel, 532.6 g (3.17 moles) of ASM and 362 g of electronic grade methanol was charged and held at 25 deg. C. To a second glass charge vessel 114.8 g (0.90 moles) tBA and 286 g of electronic grade methanol was mixed and held at 25 deg. C. Both charge vessels were outfitted with Teflon tubing and feed pumps leading to the 5 L reactor. After the main reactor charge of ASM, tBA, and methanol had reached 65 deg. C., both charge vessels began feeding the monomer mix and solvent mix into the 5 L reactor. The feed rate of each vessel was separately set to completely feed their contents in 6.0 hours for the ASM/methanol mixture and 4.0 hours for the tBA/Methanol mixture. Two hours after both charge vessels started delivering their contents to the reactor, 9.04 g (0.04 moles) of tBPP initiator dissolved in 10 g electronic grade methanol was added to the reactor in one charge. Two hours later, (4 hours after feeds were started) 6.02 g (0.03 moles) of tBPP and 10 g electronic grade methanol was added to the reactor in one charge. The tBA/methanol mixture charging was completed at 4 hours and the ASM/methanol mixture charging was completed at 6 hours after the charging was started. Six hours after feeds were started; 3.0 g (0.01 moles) of tBPP was added to the reactor. After the start of the addition of monomers and solvent, a sample was taken and analyzed for unreacted monomers by capillary gas chromatography (GC) at 1, 2, 3, and 5 hours. The polymerization reaction was continued for a total of 10 hours after monomers/methanol feed were started. The reaction was allowed to cool to room temperature overnight. A final sample was then taken and analyzed for unreacted monomers by GC. A charged of 1006 g of n-heptane was added to polymer mixture and stirred for ˜15 minutes. Stirring was stopped and solvent layers were allowed to separate. The upper n-heptane layer (512 g) was removed and replaced with fresh n-heptane (746 g). The reactor contents were again stirred for ˜15 minutes. Stirring was then stopped and solvent layers were allowed to separate. The upper n-heptane layer (846 g) was again removed and replaced with fresh n-heptane (615 g). The reactor contents were again stirred for ˜15 minutes. Stirring was then stopped to allow solvent layers to separate. The upper n-heptane layer (822 g) was removed for the final time. This process was repeated a total of 3 times to remove residual monomers remaining in polymer solution. The transesterification reactor of p-acetoxy groups to p-hydroxy groups was performed after adding an additional 510 g of methanol and 16.2 g of 25% sodium methoxide in methanol to the reactor and heating to reflux (65 deg. C.). The reaction mixture was continued to reflux with concomitant removal of methanol/methyl acetate as distillate and fresh methanol added to compensate for the distillate. The reaction mixture was allowed to react until the reaction mixture became clear in about 2 hours at which time the reaction mixture was allowed to react for an additional 5 hours to complete the reaction. A 13 C NMR of the reaction mixture indicated a >98% conversion of acetoxy to hydroxy groups. A 1 H NMR analysis indicated that the t-butyl acrylate groups remained intact. A 13 C NMR for composition indicated a copolymer of 66 mole % 4-hydroxystyrene and 34 mole % t-butylacrylate.
Example 8
[0079] A 5 L four neck round bottom glass reactor, fitted with an external heating mantle, temperature controller, thermowell, an overhead stirrer, a chilled water reflux condenser and a nitrogen inlet and outlet was charged with 301.38 g (1.80 moles) of 4-acetoxystyrene (ASM), 239.04 g (1.86 moles) of t-butylacrylate (tBA), 26.91 g (0.12 moles) of t-butylperoxypivalate (tBPP) and 646.81 g of electronic grade methanol. The reactor contents was heated to reflux (65° C.) at normal atmospheric pressure conditions with a low N 2 sweep of approximately 1 L/min to remove all oxygen from the reactor. To a separate glass feed vessel, 532.5 g (3.17 moles) of ASM and 637.1 g of electronic grade methanol was charged and held at 25 deg. C. To a second glass charge vessel 115.1 g (0.90 moles) tBA and 137.3 g of electronic grade methanol was mixed and held at 25 deg. C. Both charge vessels were outfitted with Teflon tubing and feed pumps leading to the 5 L reactor. After the main reactor charge of ASM, tBA, and methanol had reached 65 deg. C., both charge vessels began feeding the monomer mix and solvent mix into the 5 L reactor. The feed rate of each vessel was separately set to completely feed their contents in 6.0 hours for the ASM/methanol mixture and 4.0 hours for the tBA/Methanol mixture. Two hours after both charge vessels started delivering their contents to the reactor, 13.46 g (0.06 moles) of tBPP initiator dissolved in 10 g electronic grade methanol was added to the reactor in one charge. Two hours later, (4 hours after feeds were started) 8.99 g (0.04 moles) of tBPP and 10 g electronic grade methanol was added to the reactor in one charge. The tBA/methanol mixture charging was completed at 4 hours and the ASM/methanol mixture charging was completed at 6 hours after charging was started. Six hours after feeds were started; 4.49 g (0.02 moles) of tBPP was added to the reactor. After the start of the addition of monomers and solvent, a sample was taken and analyzed for unreacted monomers by capillary gas chromatography (GC) at 1, 2, 3, 4, and 5 hours. The polymerization reaction was continued for a total of 10 hours after monomers/methanol feed were started. A final sample was taken and analyzed for unreacted monomers by GC at 10 hours and the reaction was cooled to room temperature overnight. A charged of 771 g of n-heptane was added to polymer mixture and stirred for ˜15 minutes. Stirring was stopped and solvent layers were allowed to separate. The upper n-heptane layer (680 g) was removed and replaced with fresh n-heptane (821 g). The reactor contents were again stirred for ˜15 minutes. Stirring was then stopped and solvent layers were allowed to separate. The upper n-heptane layer (860 g) was again removed and replaced with fresh n-heptane (800 g). The reactor contents were again stirred for ˜15 minutes. Stirring was then stopped to allow solvent layers to separate. The upper n-heptane layer (894 g) was removed for the final time. This process was repeated a total of 3 times to remove residual monomers remaining in polymer solution. The transesterification reactor of p-acetoxy groups to p-hydroxy groups was performed after adding an additional 410 g of methanol and 16.2 g of 25% sodium methoxide in methanol to the reactor and heating to reflux (65 deg. C.). The reaction mixture was continued to reflux with concomitant removal of methanol/methyl acetate as distillate and fresh methanol added to compensate for the distillate. The reaction mixture was allowed to react until the reaction mixture became clear in about 2 hours at which time the reaction mixture was allowed to react for an additional 5 hours to complete the reaction. A 13 C NMR of the reaction mixture indicated a >98% conversion of acetoxy to hydroxy groups. A 1 H NMR analysis indicated that the t-butyl acrylate groups remained intact. A 13 C NMR for composition indicated a copolymer of 65 mole % 4-hydroxystyrene and 35 mole % t-butylacrylate. | This invention relates to semi-batch type copolymerization processes. More specifically, the processes of the present invention are directed to the production of compositionally uniform copolymers, including the production of such copolymers from dissimilar monomers, e.g., from monomers with significantly different reactivity ratios. | 2 |
FIELD OF THE INVENTION
[0001] The field of the invention is printable compositions (e.g., inks) for electronic type applications, such as for printing electrodes onto solvent sensitive substrates. More specifically, the printable compositions of the present disclosure contain one or more solvents, including at least one non-interactive solvent, a binding resin and optionally conductive particles and/or other fillers.
BACKGROUND OF THE INVENTION
[0002] Broadly speaking, printable inks for electronic applications are known. International patent publication WO12006076610, (PCT/US2006/001298), to Kowalski, et al. is directed to processes for controlling ink migration during the formation of printable electronic features. A need exists for improved printable inks for electronic applications, particularly for printing delicate and sensitive electronic features onto delicate substrates. For example, thin film transistor (“TFT”) substrates can be particularly susceptible to unwanted solvent interference or modification of the substrate, where the applied ink (for the purpose of forming an electronic component) has one or more solvents able to cause harm to the sensitive TFT substrate.
SUMMARY OF THE INVENTION
[0003] The present invention is directed to inks for electronic type applications. The inks comprise a non-interactive solvent, a binder, optionally one or more particulate fillers that may be conductive, semi-conductive or non-conductive, optionally a co-solvent and optionally other additives.
DETAILED DESCRIPTION
[0004] Non-Interactive Solvent Component
[0005] The conductive inks of the present disclosure comprise a non-interactive solvent. Non-interactive solvent is intended to mean a solvent that does not unduly harm the substrate upon which the ink is applied. Such harm can be detected by: i. placing a modest current (such as 100 milliamps and 100 volts) across a small (such as, 10 cm by 10 cm area by 1 millimeter in depth) sample of the substrate and measuring the resistivity as the substrate surface is doused with the solvent and then the solvent is slowly (e.g., for a period greater than at least ten minutes) and completely volatilized off of the substrate; ii. if the resistivity changes by less than 10% when doused with the solvent, then for purposes of the present disclosure, the solvent is non-interactive with respect to that particular substrate; iii. if the resistivity changes by more than 10% when doused with the solvent but then goes back to less than 10% after the solvent is slowly (e.g., over a period of time greater than ten minutes) and completely volatilized off of the substrate, then the solvent is non-interactive for purposes of the present disclosure; and iv. if the resistivity changes by more than 10% after being doused with the solvent and the resistivity change remains above 10% after the solvent is slowly and completely volatilized off of the substrate, then the solvent is not non-interactive with regard to that particular substrate.
[0006] The non-interactive solvents of the present disclosure are alkanes, whether linear, branched or cyclic. In one embodiment the non-interactive solvent is a halogen substituted or an unsubstituted alkane having a flash point above 25° C. In one embodiment, the non-interactive solvents of the present disclosure have nine or more carbon atoms. In one embodiment the non-interactive solvent comprises (or is derived from) one or more of the following:
1. decalin; 2. bicyclohexyl, 3. decane, 4. undecane, dodecane aromatic hydrocarbons such as toluene, xylene, mesitylene, anisole, chlorobenzene, dichlorobenzene, trichlorobenzene, trifluoromethyl benzene, dichlorobenzotrifluoride, and trifluoromethyl chlorobenzene; derivatives thereof such as chlorine substitution products and fluorine substitution products; naphthalene derivatives such as tetralin and decalin; and 5. cyclic ether compounds such as tetrahydrofuran, tetrahydropyran, and oxetane.
The above listed solvents can be suitably used alone or as a mixed solvent containing two or more of the above solvents.
[0012] Co-Solvents
[0013] In addition to the non-interactive solvents, a co-solvent can also be (optionally) used in an amount in a range between and optionally including any two of the following weight percentages, based upon the total weight of the non-interactive solvent and co-solvent: 0, 1, 2, 3, 4, 5, 7, 10, 15, 20, 25, 30, 35, 40 and 50 weigh percent. Examples of co-solvents include:
i. alcohols, such as, methanol, ethanol, isopropyl alcohol, and isobutyl alcohol; ii. esters, such as methyl acetate, ethyl acetate, propyl acetate, isopropyl acetate, and butyl acetate; iii. ethers, such as ethyl ether and dioxane; ketones such as acetone, methyl ethyl ketone, and methyl butyl ethyl ketone; iv. glycol ethers, such as propylene glycol monomethyl ether, propylene glycol monomethyl ether acetate, ethylene glycol monoethyl ether, ethylene glycol monoethyl ether acetate, ethylene glycol monobutyl ether, ethylene glycol monomethyl ether, diethylene glycol monomethyl ether, and diethylene glycol monomethyl ether acetate; and v. alicyclic hydrocarbons, such as cyclohexane, methylcyclohexanone, and vi. cyclohexanol; and aliphatic hydrocarbons such as n-hexane and heptane.
[0020] In one embodiment, the solvent is a mixture of non-interactive solvent and co-solvent, where one solvent has a low boiling point (e.g., 100° C. or lower) and at least one solvent has a relatively higher boiling point (e.g., 150° C. or higher). The lower boiling solvent is generally useful in improving initial fluidity and thin film uniformity. Subsequent to initial thin film formation, the lower boiling solvent can then be volatilized away to increase the viscosity of the coating and induce increased adhesivity to the substrate. The amount of the lower boiling solvent can be adjusted according to the ingredients of the ink, the printing speed, the printing environment, and/or the like. However in some embodiments of the present invention, the amount of this (low boiling) solvent is appropriately adjusted to be in the range of 10% to 90% of the total amount of the solvents of the ink composition. In some embodiments, preferred examples of the quick-drying solvent include hydrocarbon solvents such as cyclohexane; halogenated hydrocarbon solvents such as methylene chloride, tetrachloroethylene, chloroform, carbon tetrachloride, dichloroethane, and trichloroethane; and cyclic ethers such as tetrahydrofuran, oxetane, and tetrahydropyran. In addition, other examples include alcohols such as methanol, ethanol, and propanol; esters such as methyl acetate, ethyl acetate, and isopropyl acetate; ketones such as acetone and methyl ethyl ketone; and aliphatic hydrocarbons such as n-hexane. These co-solvents may be used alone or as a mixed solvent of two or more low boiling solvents. Broadly speaking, the amount of optional co-solvent is appropriately adjusted to be in the range of 0% to 50% of the total amount of the solvents of the ink.
[0021] Resin Component
[0022] The choice of resin component relates to the resin solubility in the (ink) solvent(s), where the higher the solubility, the better, while also providing limited or no interaction with the materials in the various layers or substrates that the inks of the current invention will be used to coat. In one embodiment, the resin component is a polymer or copolymer of polyethylene, polypropylene, halogenated polyethylene, halogenated polypropylene, halogenated polyolefin and any combination thereof, provided at least 50, 60, 70, 80, 85, 90, 92, 94, 96, 98, 99 or 100 weight percent of the polymer is polyethylene, polypropylene, halogenated polyethylene or halogenated polypropylene (or other halogenated polyolefin) or any combination thereof.
[0023] In one embodiment, the resin component comprises a poly alpha-olefin, where the monomer from which the polymer is partially or wholly derived is an alkene where the carbon-carbon double bond starts at the α-carbon atom, i.e. the double bond is between the #1 and #2 carbons in the monomer. Alpha-olefins such as 1-hexene or 1-decene may be used as co-monomers to provide an alkyl branched polymer for use as a resin component of the present disclosure. The pendant alkyl groups can shape themselves in numerous conformations, causing difficulty for the polymer to align itself side-by-side in an orderly way. This results in lower contact surface area between the molecules and decreases the intermolecular interactions between molecules, which in turn tends to inhibit crystallization or solidification; the decreased crystallization and/or solidification tends to impart a level (in some embodiments, a relatively small but perceptible level) of oily liquid characteristic to the resin component even at low temperatures, depending upon the selection and amount of alpha olefin copolymer.
[0024] Polyethylene copolymerized with a small amount of alpha-olefins (such as 1-hexene, 1-octene, or longer) will generally be more flexible than simple straight chain high density polyethylene, which has no branching. Depending upon the particular embodiment chosen, the methyl branch groups on a polypropylene polymer can be useful in accordance with the present invention.
[0025] In one embodiment, the resin component comprises a haloalkane (also known as halogenoalkanes or alky halides, which is an alkane having one or more halogen moieties), or a copolymer where at least one of the repeat units is a haloalkane. The haloalkane can be a primary, secondary or tertiarly haloalkane (or any combination thereof). The halogen moiety can comprise chlorine, bromine, fluorine or iodine. In one embodiment, the halogen is chlorine. The halogen moiety will tend to raise the temperature resistance of the resin, with regard to boiling point, melting point, flammability and the like, which may or may not be useful, depending upon the particular embodiment chosen or desired. Haloalkanes tend to be more polar than non-halogenated alkanes and tend to be more miscible (broadly speaking) with many common polymeric materials, and can be useful depending upon the particular embodiment chosen. The amount of haloalkane in the resin component can be in a range between and optionally including any two of the following weight percentages: 0, 2, 5, 10, 12, 15, 20, 25, 30, 35, 40, 50, 60, 70, 80, 90, 95, 98, and 100 weight percent. In one embodiment, the resin component comprises a cellulose, such as ethyl cellulose, or a derivative thereof. Examples of such resins include ethyl cellulose commonly referred to in the industry as N50 and T10. Other possible resins include acrylates and methacrylates, such as, poly methyl acrylate, poly methyl methacrylate, poly hydroxyl ethyl methacrylate or any combination or derivation thereof.
[0026] Other resin compositions are possible in accordance with the present invention, provided the resin composition can be dissolved into the ink and provided the resin composition does not harm or otherwise interfere with the materials the ink is used to coat.
[0027] Filler Component
[0028] The filler component comprises one or more materials which can be conductive, semi-conductive or non-conductive, depending upon the particular embodiment chosen. Useful conductive particles include metal particles, such as silver, gold, platinum or palladium. Alternatively or in addition, the conductive filler can comprise a conductive organic material, such as, polyacetylene, polypyrrole, polyaniline, their copolymers and PEDOT/PSS. PEDOT/PSS is intended to mean poly(3,4-ethylenedioxythiophene)/polystyrene sulfonate. PEDOT/PSS is a polymer mixture of two ionomers. One component is sodium polystyrene sulfonate which is a sulfonated polystyrene having part of the sulfonyl groups deprotonated to carry a negative charge. The other component poly(3,4-ethylenedioxythiophene) or PEDOT is a conjugated polymer and carries positive charges and is based on polythiophene. Together the charged the charged macromolecules form a macromolecular salt. Other conductive fillers useful in accordance with the present disclosure include carbon, graphite, graphene, silver nano wires, silver coated base metals and the like. Other materials, such as indium tin oxide (ITO) and antimony tin oxide (ATO) and composite materials such as ITO coated mica could also be of use in the current invention, depending upon the particular embodiment selected.
[0029] Depending upon the particular embodiment chosen, other useful fillers can be any ceramic, including nitrides, oxides, borides, carbides and the like, e.g., aluminum nitride, boron nitride, titanium dioxide, barium titanate, talc, industrial diamond, and alumina.
[0030] Other possible filler materials include an oxide, selenide, telluride, sulfide and arsenide filler materials, such as zinc oxide, cadmium selenide, zinc telluride, cadmium sulfide and indium arsenide would also be useful in the current invention.
[0031] The particle size of the filler components can range from several microns down to a few nanometers, depending upon the fabrication methods employed to synthesize or modify the filler particles and the desired end application. For some applications, where the materials of the current invention are deposited onto a very thin layer of sensitive material, the particle size of the filler particles can be crucial. Over-sized particles have the tendency to cause damage to the underlying layer, and the creation of short circuits are a possibility. In one embodiment, the particle has an average size in one dimension in a range between and optionally including any two of the following (in microns): 0.005, 0.010, 0, 0.015, 0.02, 0.03. 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.10, 0.20, 0,30, 0.40, 0.50, 0.60, 0.70, 0.80, 0.90, 1.0, 2.0. 5.0, 10, 20, 25, 30, 40, 50, 60, 70, 80, 90, 100 microns.
EXAMPLES
Example 1
[0032] A solution polymer was made by adding 27.75 grams of polyethylene powder (m w ˜35000) to 222.25 grams of bicyclohexyl solvent. The resulting mixture was then heated to a temperature of 60 degrees Celsius until the resin had fully dissolved. The resulting solution was then cooled to room temperature prior to use.
Example 2
[0033] A 27.00 gram amount of the solution polymer described in Example 1 was mixed with 108.00 grams of silver powder (surface area 0.6-1.0 m 2 /g). The resulting mixture was then triple roll milled to yield a smooth homogenous ink. The resulting ink had a solids content of 82.7 wt. % at 150 degrees Celsius and a viscosity of 73 Pa-s at 10 rpm.
Example 3
[0034] A 214.75 gram amount of the solution polymer described in Example 1 was mixed with 2.5 grams of bicyclohexyl solvent, 16.38 grams of pelletised carbon black powder (surface area ˜254 m 2 /g) and 16.38 grams of graphite (particle size 8-15 microns). The resulting mixture was then triple roll milled to yield a smooth homogenous ink. The resulting ink had a solids content of 22.7 wt. % at 150 degrees Celsius and a viscosity of 71 Pa-s at 10 rpm.
Example 4
[0035] A solution polymer was made by adding 20.00 grams of a chlorinated polyolefin resin powder (chlorine content 18-23 wt. %) to 80.00 grams of bicyclohexyl solvent. The resulting mixture was then heated to a temperature of 60 degrees Celsius until the resin had fully dissolved. The resulting solution was then cooled to room temperature prior to use. In the production of the various inks described below, this composition was remade numerous times.
Example 5
[0036] A 98.60 gram amount of the solution polymer described in Example 4 was mixed with 13.46 grams of pelletized carbon black powder (surface area ˜254 m 2 /g) and 13.46 grams of graphite powder (particle size 8-15 microns). The resulting mixture was then triple roll milled to yield a smooth, homogenous ink. The resulting ink had a solids content of 36.4 wt. % at 150 degrees Celsius and a viscosity of 193 Pa-s at 10 rpm.
Example 6
[0037] An 85.85 gram amount of the solution polymer described in Example 4 was mixed with 7.68 grams of pelletized carbon black powder (surface area ˜254 m 2 /g) and 20.47 grams of graphite (particle size 8-15 microns). The resulting mixture was then triple roll milled to yield a smooth, homogenous ink with a viscosity of 124 Pa-s at 10 rpm. Sufficient bicyclohexyl solvent was then added to reduce the solids and viscosity to an acceptable range. The resulting ink had a solids content of 38.0 wt. % at 150 degrees Celsius and a viscosity of 111 Pa-s at 10 rpm.
Example 7
[0038] A 95.25 gram amount of the solution polymer described in Example 4 was mixed with 3.75 grams of bicyclohexyl solvent and 26.0 grams of graphite powder (particle size 8-15 microns). The resulting mixture was then triple roll milled to yield a smooth, homogenous ink. The resulting ink had a solids content of 36.5 wt. % at 150 degrees Celsius and a viscosity of 26.9 Pa-s at 10 rpm.
Example 8
[0039] A 95.25 gram amount of the solution polymer described in Example 4 was mixed with 26.0 grams of pelletized carbon black powder (surface area ˜254 m 2 /g). The resulting mixture was then triple roll milled to yield a smooth, homogenous ink with a viscosity of 569 Pa-s at 10 rpm, Sufficient bicyclohexyl solvent was then added to reduce the solids and viscosity to an acceptable range. The resulting ink had a solids content of 32.2 wt. % at 150 degrees Celsius and a viscosity of 140 Pa-s at 10 rpm.
Example 9
[0040] A 107.31 gram amount of the solution polymer described in Example 4 was mixed with 25.59 grams of pelletized carbon black powder (surface area ˜254 m 2 /g) and 9.60 grams of graphite (particle size 8-15 microns). The resulting mixture was then triple roll milled to yield a smooth, homogeneous ink with a viscosity of 658 Pa·s at 10 rpm. Sufficient bicyclohexyl solvent was then added to reduce the solids and viscosity to an acceptable range. The resulting ink had a solids content of 33.0 wt. % at 150 degrees Celsius and a viscosity of 157 Pa-s at 10 rpm.
Example 10
[0041] A 59.4 gram amount of the solution polymer described in Example 4 was mixed with 4.05 grams of pelletized carbon black powder (surface area ˜254 m 2 /g), 4.05 grams of graphite (particle size 8-15 microns) and 78.00 grams of silver powder (surface area 0.6-1.0 m 2 /g). The resulting mixture was then triple roll milled to yield a smooth, homogeneous ink with a viscosity of 245 Pa-s at 10 rpm. Sufficient bicyclohexyl solvent was then added to reduce the solids and viscosity to an acceptable range. The resulting ink had a solids content of 61.3 wt. % at 150 degrees Celsius and a viscosity of 109 Pa-s at 10rpm.
Example 11
[0042] A 102.12 gram amount of the solution polymer described in Example 4 was mixed with 29.37 grams of pelletized carbon black powder (surface area ˜254 m 2 /g) and 11.01 grams of graphite (particle size 8-15 microns), The resulting mixture was then triple roll milled to yield a smooth, homogeneous ink with a viscosity of 766 Pa-s at 10 rpm. Sufficient bicyclohexyl solvent was then added to reduce the solids and viscosity to an acceptable range. The resulting ink had a solids content of 34.1 wt. % at 150 degrees Celsius and a viscosity of 116 Pa-s at 10 rpm.
Example 12
[0043] A 112.50 gram amount of the solution polymer described in Example 4 was mixed with 21.81 grams of pelletized carbon black powder (surface area ˜254 m 2 /g) and 8.19 grams of graphite (particle size 8-15 microns). The resulting mixture was then triple roll milled to yield a smooth, homogeneous ink with a viscosity of 241 Pa-s at 10 rpm. Sufficient bicyclohexyl solvent was then added to reduce the solids and viscosity to an acceptable range. The resulting ink had a solids content of 32.4 wt. % at 150 degrees Celsius and a viscosity of 103 Pa·s at 10 rpm. | A printable ink for electronic applications is disclosed. The ink contains at least one non-interactive solvent, a binder, optionally one or more particulate fillers that may be conductive, semi-conductive or non-conductive, optionally a co-solvent and optionally other additives. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of Provisional U.S. Application No. 61/560,879 filed 2011-11-17 and is a continuation-in-part of Non-provisional U.S. application Ser. No. 12/952,354 filed 2010-11-23, which claims benefit of Provisional U.S. Application No. 61/361,625 filed 2010-07-06, the complete disclosures of which, in their entirety are herein incorporated by reference.
GOVERNMENT INTEREST
[0002] The inventions herein may be made, used, sold, imported and/or licensed by or for the United States Government without payment of royalties thereon.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to electrolytes having a very wide electrochemical stability window, and can therefore support Li ion chemistries occurring near or above 5.0 V in electrochemical cells. More particularly, this invention relates to compounds that can be incorporated into electrolytes as co-solvents, additives, or solutes, so that the electrolytes can support the reversible Li ion intercalation/de-intercalation chemistry at potentials above 4.5 V. Still more particularly, this invention relates to compounds that can be incorporated into the electrolyte, which, upon the initial charging of the cathode, decompose sacrificially to form a passivation film on the cathode. This passivation film prevents sustaining decomposition of electrolyte components but does not hinder the reversible Li ion intercalation/de-intercalation chemistry at potentials above 4.5 V.
[0005] The invention of such an electrolyte will enable the use of high voltage cathode materials, affording new rechargeable battery chemistries with higher energy density as well as delivering energy of higher quality in the form of direct electricity current at higher voltages, which are unavailable otherwise from the state-of-the-art electrolytes. The state-of-the-art electrolytes, comprising mainly organic carbonate esters, decompose at potentials below 4.5 V on high voltage cathode surfaces and cause sustaining capacity fading accompanied with increasing cell impedances.
[0006] The high voltage cathodes include, but are not limited to, transition metal-oxides with spinel lattice structures or metal phosphates with olivine lattice structures, or metal fluorides with conversion reaction natures.
[0007] More particularly, the compounds of the present invention go beyond the battery application and could benefit any electrochemical devices that pursue higher operating potentials. The presence of the compounds in the electrolyte can stabilize the highly oxidizing surface of the positive electrode and hence enable new chemistry that is otherwise impossible with the current state-of-the-art electrolyte technology. Such electrochemical devices include, but are not limited to, rechargeable batteries, double layer capacitors, pseudo-capacitors, electrolytic cells, and fuel cells.
[0008] Still more particularly, the batteries or the electrochemical devices comprise, but are not limited to, (1) an anode such as lithium or other alkaline metals, alloys of lithium or other alkaline metals, intercalation hosts such as layered structured materials of graphitic, carbonaceous, oxides or other chemical natures, non-intercalating hosts of high surface area or high pseudo-capacitance; (2) a cathode such as an intercalation host based on metal oxides, phosphates, fluorides or other chemical natures, or non-intercalating hosts of high surface area or high pseudo-capacitance; and (3) an electrolyte of the present invention. These electrolytes comprise (a) one or more electrolyte solutes with various cations and anions, (b) a solvent or a mixture of solvents based on organic carbonates or other compounds, and (c) one or more additives. Any of (a), (b) and (c) may be selected from the claimed structures of the present invention.
[0009] 2. Description of the Prior Art
[0010] Li ion chemistry is established upon reversible intercalation/de-intercalation of Li ion into/from host compounds. The voltage of such an electrochemical device is determined by the chemical natures of the anode and cathode, where Li ion is accommodated or released at low potentials in the former, and at high potentials in the latter. Apparently, the reversibility of the cell chemistry and the resultant energy density are limited by the stability of the electrolyte to withstand the reductive and oxidative potentials of these electrodes. In today's market, a majority of Li ion batteries use organic carbonate as electrolyte solvents, which decompose oxidatively above 4.5 V vs. Li, and set an upper limit to the candidate cathode chemistry. In spite of the fact that 5 V Li ion chemistry has already been made available from such cathodes like olivine structured LiCoPO 4 (˜5.1 V) and spinel structured LiNi 0.5 Mn 1.5 O 4 (˜4.7 V), their advantages such as high energy density and quality cannot be realized due to the lack of an electrolyte that is able to withstand high voltage operation.
[0011] Early attempts have been made to identify an electrolyte system that can resist oxidation beyond 5.0 V, and unsymmetrical sulfones were shown to be such a system on spinel LiMn 2 O 4 surface (K. Xu, et al., J. Electrochem. Soc., 1998, Vol. 145, L70 ; J. Electrochem. Soc., 2002, Vol. 149, A920). However, intrinsic shortcomings of sulfone as a major electrolyte component, including its failure to form a protective layer on graphitic anode, slow Li ion kinetics, and poor electrode active material utilization caused by high viscosity, prevented wide application.
[0012] Additional improvements were also made on mitigating the oxidizing nature on the cathode surfaces through surface coating approaches, and various metal oxides or phosphates were shown to be effective in elongating the service life of the carbonate-based electrolytes (J. Liu, et al., Chem. Mater, 2009, Vol. 21, 1695). But these coating approaches have their own intrinsic shortcomings as well. They not only add additional cost to the manufacturing of the cathode materials, but also induce further interphasial resistance to the Li ion migration at electrolyte/cathode junction. Moreover, overall coverage of cathode particle surface with those inert coatings will inevitably decrease the energy density of the device.
[0013] It is therefore of significant interest to the battery industry to find a technology that can effectively enable the 5.0 V class cathode to be applied in Li ion batteries, without the aforementioned shortcomings.
[0014] To be more specific, it is therefore of significant interest to the battery industry to find a technology that can effectively enable the 5.0 V class cathode to be applied in Li ion batteries, while there is no major negative impacts on the original electrolyte and cathode materials. Such negative impacts have been exhibited in the prior art, and include but are not limited to, the failure of electrolyte to form desired interphasial chemistry on graphitic anode, the slowed Li ion kinetics and difficult electrode wetting due to high electrolyte viscosity, the increased electrolyte/cathode interphasial impedance, additional processing cost of material manufacturing, and sacrificed cathode energy density.
[0015] It is therefore still of significant interest to the battery industry to identify such electrolytes that can stably support reversible Li ion chemistry, without those shortcomings exhibited by the prior art.
[0016] It is therefore still of significant interest to the battery industry to identify such compounds that, once incorporated as an electrolyte component, can assist in forming a protective layer on the surface of the 5.0 V class cathodes.
[0017] It is therefore still of significant interest to the battery industry to identify such compounds that could serve the aforementioned purposes, either as electrolyte solvent, co-solvent, solute, or both molecular and ionic additives.
[0018] This invention will provide such a technology of the electrolytes with all those desired advantages.
SUMMARY OF THE INVENTION
[0019] Therefore, it is highly desirable to develop electrochemical cells that can reversibly store and release electricity at voltages above 4.5 V.
[0020] More specifically, it is highly desirable to develop electrochemical cells that can reversibly store and release electricity at voltages in the neighborhood of or above 5.0 V.
[0021] Still more specifically, it is highly desirable to develop the aforementioned electrochemical cells, which include, but are not limited to, rechargeable batteries that are based on Li ion chemistry, or electrochemical double-layer capacitors that comprise high surface area electrodes.
[0022] Still more specifically, it is highly desirable to develop the aforementioned electrochemical cells based on Li ion chemistry, which comprise 5.0 V class cathode materials such as, but are not limited to, spinel metal oxide LiNi 0.5 Mn 1.5 O 4 or olivine phosphate LiCoPO 4 or LiNiPO 4 .
[0023] Still more specifically, it is highly desirable to develop the aforementioned electrochemical cells based on electrochemical double layer capacitance, which comprise high surface area materials as electrodes, such as, but are not limited to, activated carbon, aligned or random carbon nanotubes, various aerogels and other materials having high surface area regardless of their chemical natures.
[0024] Further more specifically, it is highly desirable to formulate electrolyte compositions that would enable the aforementioned electrochemical cells.
[0025] Further more specifically, it is highly desirable to identify and develop compounds that, once incorporated into electrolytes either as solvent, co-solvent, solute or molecular and ionic additives, would assist in stabilizing the electrolyte against oxidative decompositions, without negatively impacting the properties and performances of the electrochemical cells as in the prior art.
[0026] It is therefore the primary object of the present invention to identify and develop such compounds.
[0027] It is another object of the present invention to develop the electrolyte compositions utilizing the said compounds either as solvent, co-solvent, solute, or molecular and ionic additives. Electrolytes so formulated will have an extra wide electrochemical stability window, and are capable of supporting electrochemical processes occurring at high potentials without degrading.
[0028] It is still another object of the present invention to assemble electrochemical cells utilizing the said electrolyte solutions. The said electrochemical cells include, but are not limited to, rechargeable batteries or electrochemical double-layer capacitors that have been described above. The cells thus developed should deliver superior performances as compared with the state-of-the-art technologies in terms of the energy density and energy quality.
[0029] These and additional objects of the invention are accomplished by adopting one or more compounds either as solvent, co-solvent, solute, or molecular and ionic additives in the non-aqueous electrolytes. More particularly, these objects are accomplished by adopting one or more compounds in the non-aqueous electrolytes, which are soluble in the non-aqueous, organic electrolyte solvents to certain concentrations. Still more particularly, these compounds, upon dissolution in the non-aqueous electrolytes, will form desirable interphasial chemistry on cathode surfaces.
[0030] Still more particularly, these compounds, upon dissolution in the non-aqueous electrolytes, will either form desirable interphasial chemistry on anode surfaces, or will not negatively impact the other electrolyte components to form desirable interphasial chemistry on anode surfaces.
[0031] With the electrolyte solutions comprising these compounds either as solvent, co-solvent, solute, or molecular and ionic additives in the non-aqueous electrolytes, all the said objects can be achieved.
DEFINITIONS
[0032] Before describing the present invention in detail, it may be helpful to define the terminologies used in this invention to understand the scope of this invention. It is to be understood that the definitions herein are for the purpose of describing particular embodiments only, and are not intended to be limiting.
[0033] “Organic” refers to a structure that contains hydrocarbon moieties.
[0034] “Inorganic” refers to a structure that contains no hydrocarbon moieties.
[0035] “Halogen” refers to fluorine, chlorine, bromine and iodine.
[0036] “Alkyl” refers to a hydrocarbon structure, with or without unsaturations, or their perhalogenated or partially halogenated derivatives.
[0037] “Solvent” refers to molecular components of the electrolyte.
[0038] “Solute” or “salt” refers to ionic components of the electrolyte, which will dissociate into cationic and anionic species upon dissolution in the solvents or mixture of co-solvents.
[0039] “Co-solvents” refers to molecular components of the electrolyte whose concentrations are at least 10% by weight.
[0040] Furthermore, “additives” are the molecular components of the electrolyte, whose concentrations are lower than 10% by weight.
[0041] “Molecular” refers to compounds that cannot be dissociated into any ionic species in non-aqueous electrolyte solvents.
[0042] “Ionic” refers to compounds that can be dissociated into a cation species that bears positive charge and an anion species that bears equal but negative charge in non-aqueous electrolyte solvents.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] A more complete appreciation of the invention will be readily obtained by reference to the following Detailed Description of the Preferred Embodiments and the accompanying drawings. The representations in each of the following figures and examples are intended to demonstrate the spirit of the present invention by way of illustration. They are by no means intended to limit the full extent of the invention; but rather, the present invention may be employed according to the full scope and spirit of the invention as defined in the appended claims.
[0044] FIGS. 1A and 1B show the comparison of voltage profiles between baseline, state of the art electrolyte ( FIG. 1A ) and 1% additive of Tris(1,1,1,3,3,3-hexafluoro-iso-propyl)phosphate (HFiP) in base electrolyte on LiNi 0.5 Mn 1.5 O 4 surface ( FIG. 1B ). FIG. 1A shows the standard electrolyte fading in capacity from the first cycle (furthest right curve) to the 80 th cycle (furthest left curve). For graphic clarity, only cycles between the initial and the 80 th were shown with an increment of 10 cycles. In FIG. 1B , the presence of 1% HFiP in the electrolyte suppresses the loss in capacity during cycling so that the 80 th cycle nearly overlaps with the first cycle.
[0045] FIG. 2 is a graphical representation of the capacity of cells using a 1% HFiP additive. This is a different way of looking at FIGS. 1A and 1B , where the materials and conditions are the same. In FIG. 2 , the results for the standard electrolyte is shown in the lower curve and clearly slopes downward with increasing large losses in capacity as cycle number increases. The HFiP-containing electrolyte shows no capacity fade (upper curve) and has a low linear rate of capacity loss over the duration of the test.
[0046] FIG. 3 shows the results when a 1% HFiP-containing electrolyte is used in a “full” lithium ion cell. Full cells refer to those having a cathode and an intercalation anode such as graphite. In this figure, the system used is the standard LiNi 0.5 Mn 1.5 O 4 cathode and a graphite anode and the electrolytes are standard and standard +1% HFiP. The lower curve shows the performance of the standard electrolyte, which initially has higher capacity than the HFiP-containing electrolyte but rapidly fades. The HFiP-containing electrolyte again shows a much more controlled rate of capacity loss which is steady and always less than that of the state of the art electrolyte cell.
[0047] FIG. 4 shows the performance of a LiNi 0.33 Mn 0.33 Co 0.33 O 2 cathode half cell (vs Li metal) using a state of the art electrolyte (lower curve) and the electrolyte +0.3% HFiP (upper curve). The voltage cutoff was 4.5V, lower than the 4.95V cutoff of the LiNi 0.33 Mn 0.33 Co 0.33 O 2 cathode material. Capacity utilization of the cathode was much greater in the cell with HFiP in the electrolyte and its resistance to fade and failure was markedly better than the cell using the standard electrolyte.
[0048] FIG. 5 shows the performance of 0.3% HFiP in a half cell (vs Li metal) configuration. against a LiNi 0.5 Mn 1.5 O 4 cathode with a cutoff voltage of 4.5V.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0049] As a primary aspect of the invention, the compounds of the present invention are constructed on the basis of the molecular or ionic compounds whose skeleton structures were shown in structures 1 through 8 in Table 1, below, where R 1 , R 2 , R 3 , R 4 , R 5 and R 6 designate a substituent, which can be identical or different from each other. These are hydrogen, hydroxyl, or halogen which includes at least one F atom. The hydroxyl is hydroxide salts with metal ions of various valences, examples of which include, but are not limited to, Li + , Na + , ½Mg 2+ , ⅓Al 3+ . R 1 -R 6 are normal or branched alkyls with a carbon number from 1 through 30, with or without unsaturation. These are halogenated normal or branched alkyls with a carbon number from 1 through 30, with or without unsaturation which can be partially halogenated or perhalogenated, normal or branched alkyls with a carbon number from 1 through 30, with or without unsaturation; which can be partially halogenated or perhalogenated normal or branched alkyls with carbon number from 1 through 30, where the halogen substituents can be identical or different selected from F, Cl, Br or I, or mixture of all halogens.
[0000]
TABLE 1
Structure of Compounds in the Present Invention
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
[0050] Examples of R 1 , R 2 , R 3 , R 4 , R 5 and R 6 include, but are not limited to, trifluoro-methyl, trichloromethyl, 1,1,1-trifluoroethyl, perfluoroethyl, perfluoro-iso-propyl, 1,1,1,3,3,3,-hexafluoropropyl, perfluoro-tert-butyl, and perfluorododecayl. As a way to illustrate, Table 2 lists selected compounds included in the compound families as described in Table 1.
[0000]
TABLE 2
Example of Compounds covered in Table 1
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
[0051] Preferentially, but not intended to be limiting, the compounds can be dissolved in a typical non-aqueous electrolyte solvent or mixture of solvents.
[0052] Preferentially but not intended to be limiting, the compounds can serve in the electrolyte either as major solvents, or co-solvents at concentrations above 10% by weight, or as salts at concentrations as high as 3.0 m, or as additives at concentrations below 10% by weight.
[0053] The above-mentioned typical non-aqueous electrolyte solvents comprise, but are not limited to, organic carbonate esters such as ethylene carbonate (EC), propylene carbonate (PC), dimethylcarbonate (DMC), ethylmethylcarbonate (EMC), diethylcarbonate (DEC), 1-(trifluoromethyl)ethylene carbonate (CF 3 -EC); or organic acid esters such as alkyl carboxylates or lactones; and inorganic acid esters such as alkyl sulfonates, alkyl sulfurates, alkyl phosphonates or alkyl nitrates; or dialkyl ethers that are either symmetrical or unsymmetrical, or alkyl nitriles.
[0054] The above-mentioned typical non-aqueous electrolytes also comprise electrolyte solutes that are based on a cation and an anion. The cation selections include but are not limited to, alkali metal salts such as lithium (Li), sodium (Na), potassium (K) or alkali earth metal salts such as beryllium (Be), magnesium (Mg), calcium Ca), or tetraalkylammonium or phosphate (R 4 N, R 4 P); whereas the anion selections include but are not limited to hexafluorophosphonium (PF 6 ), hexafluoroarsenate (AsF 6 ), tetrafluoroborate (BF 4 ), perfluoroalkylfluorophosphate (PF x R F(6-x) ), perfluoroalkylfluoroborate (BF x R F(4-x) ), bis(trifluoromethanesulfonyl)imide ((CF 3 SO 2 ) 2 N), bis(perfluoroethanesulfonyl)imide ((CF 3 CF 2 SO 2 ) 2 N), bis(oxalato)borate ((C 2 O 4 ) 2 B), (difluorooxalato)borate (C 2 O 4 FB).
[0055] Either the cation or the anion, or both the cation and the anion can be derived from the structures disclosed in Tables 1 and 2. The salts are selected by combining these cations and anions. Other derivatives with different compound structures may be used in this invention within the ordinary skill of the art.
[0056] More preferentially but not intended to be limiting, the compounds of this invention comprise at least one fluorine atom in the structure.
[0057] With the purpose of illustrating only and no intention to be limiting, compounds of this invention can be selected from the following list: tris(1,1,1,3,3,3-hexafluoro-iso-propyl)phosphate (compound 11 in Table 2), tris(perfluoroethyl)phosphate, tris(perfluoro-iso-propyl)phosphate (compound 12 in Table 2), bis(1,1,1-trifluoroethyl)fluorophosphate (compound 10 in Table 2), tris(1,1,1-trifluoroethyl)phosphite (compound 9 in Table 2); hexakis(1,1,1-trifluoroethoxy)phosphazene (compound 14 in Table 2), and tris(1,1,1-trifluoroethoxy)trifluorophosphazene (compound 15 in Table 2), hexakis(perfluoro-t-butyl)phosphazene and tris(perfluoro-t-butyl)phosphate.
[0058] In yet further aspects of the invention, electrochemical devices that are filled with the electrolyte solution formulated in this invention are fabricated. These devices include, but are not limited to, (1) lithium batteries with lithium metal cells as anode, and various transition metal oxides, phosphates and fluorides as cathode; (2) Li ion batteries with carbonaceous such as graphitic, carbon nanotube, graphene as anode, or non-carbonaceous such as titania or other Li + intercalating hosts as anode, and various transition metal oxides, phosphates and fluorides as cathode; (3) electrochemical double-layer capacitors with both carbonaceous and non-carbonaceous electrodes of high surface area or high pseudo-capacitance; and (4) dual intercalation cells in which both cation and anion intercalate simultaneously into lattices of anode and cathode materials of either carbonaceous or non-carbonaceous natures, respectively.
[0059] The above cells are assembled according to the procedures that can be readily performed by one with ordinary skill in the art. These electrochemical devices containing the electrolyte solutions as disclosed in the present invention can enable high voltage rechargeable chemistries that would be otherwise impossible with the state-of-the-art electrolyte technologies.
[0060] Having described the invention, the following examples are given to illustrate specific applications of the invention including the best mode now known to perform the invention. They are intended to provide those of ordinary skill in the art with a complete disclosure and description of how to make and use the solvents and additives of this invention. These specific examples are not intended to limit the scope of the invention described in this application.
EXAMPLES
Example 1
Synthesis of Tris(1,1,1,3,3,3-hexafluoro-iso-propyl)phosphate (compound II in Table 2)
[0061] To a flask containing 500 mL of diethyl ether, 175 g of 1,1,1,3,3,3-hexafluoro-isopropanol is added and stirred until a complete solution is made. To the stirred solution of diethyl ether and 1,1,1,3,3,3-hexafluoropropanol, 8.28 g of solid lithium hydride is added through a solid-addition funnel and allowed to react at room temperature. After 1 hour, the reaction mixture is chilled to the range of 0-5° C. by immersion in a water/ice bath. Once chilled, 53.21 g of phosphorus oxychloride is carefully added. The reaction is considered complete once no more insoluble lithium chloride is formed during reflux of the reaction mixture. The final product, tris(1,1,1,3,3,3-hexafluoroisopropyl)phosphate, is recovered by distillation after filtering off the precipitation.
Example 2
Synthesis of Tris(perfluoro-iso-propyl)phosphate (compound 12 in Table 2)
[0062] The synthesis of precursor tris(iso-propyl)phosphate was conducted in a similar manner as described in Example 1. The intermediate phosphate was then subjected to either elemental fluorination or electrochemical fluorination to achieve the perfluorinated product. The final product, tris(perfluoro-iso-propyl)phosphate, is recovered by distillation after purification.
Example 3
Synthesis of Tris(1,1,1-trifluoroethyl)phosphate
[0063] The synthesis of 1,1,1-trifluoroethoxide lithium was similar to the procedure as described in Example 1. 53.21 g of phosphorus oxychloride is carefully added to a flask containing 500 mL of diethyl ether. The reaction is considered complete after refluxing. The final product, tris(1,1,1-trifluoroethyl)phosphate, is recovered by distillation after filtering off the precipitation.
Example 4
Synthesis of Hexakis(1,1,1-trifluoroethoxy)phosphazene (compound 14 in Table 2)
[0064] To a flask containing 500 mL of diethyl ether, 69.1 g of 1,1,1-trifluoroethanol is added and stirred until a complete solution is made. Then 5.48 g lithium hydride was gradually added through a solid addition funnel. After 1 hour, the reaction mixture is chilled to the range of 0-5° C. by immersion in a water/ice bath. Once chilled, 40 g of phosphonitrillic chloride trimer was carefully added with vehement stirring. The purification process was similar to what described in Example 1. After repeated distillation, the final product is a colorless liquid with boiling point of 100° C. at 0.1 torr.
Example 5
Formulation of Electrolyte Solutions
[0065] This example summarizes a general procedure for the preparation of electrolyte solutions comprising the solvents, solutes and additives of this invention, whose structures have been listed in Table 1. Both the concentration of the lithium salts, the co-solvent ratios, and the relative ratios between the additives to solvents can be varied according to needs.
[0066] The salts selected include, but are not limited to, LiPF 6 , LiAsF 6 , LiBF 4 , LiP(C n F 2n+1 ) x F 6-x (0≦n≦10, 0≦x≦6), LiB(C n F 2n+1 ) x F 4-x (0≦n≦10, 0≦x≦4), LiIm, LiBeti, LiBOB, and LiBF 2 C 2 O 4 , triethylmethylammonium (Et 3 MeNPF 6 ), any one or more of the compounds whose structures are listed in Table 1, and mixtures thereof.
[0067] The solvents selected include, but are not limited to, EC, PC, DMC, DEC, EMC, FEC (fluoro ethylene carbonate), CF 3 -EC, any one or more of the compounds whose structures are listed in Table 1, and mixtures thereof.
[0068] The additives selected include any one or more of the compounds whose structures are listed in Table 1 or Table 2, and mixtures thereof.
[0069] The resultant electrolyte solution should contain at least one of those compounds that are disclosed in the present invention.
[0070] In one instance, 1000 g base electrolyte solution of 1.0 m LiPF 6 /EC/EMC (30:70) was made in glovebox by mixing 300 g EC and 700 g EMC, followed by adding 151.9 g LiPF 6 . The aliquots of the base electrolyte solution was then taken to be mixed with various amounts of tris(1,1,1,3,3,3-hexafluoro-iso-propyl)phosphate as synthesized in Example 1. The concentration of tris(1,1,1,3,3,3-hexafluoroisopropyl)phosphate ranges from 0.1 ppm to 5%.
[0071] In a similar instance, 1000 g base electrolyte solution of 1.0 m LiPF 6 /FEC/EC/EMC (15:15:70) was made in glovebox by mixing 150 g FEC, 150 g EC and 700 g EMC followed by adding 151.9 g LiPF 6 , and aliquots of the base electrolyte solution was then taken to be mixed with various amount of tris(1,1,1,3,3,3-hexafluoroisopropyl)phosphate as synthesized in Example 1. The concentration of tris(1,1,1,3,3,3-hexafluoroisopropyl)phosphate ranges from 0.1 ppm to 5%.
[0072] In another similar instance, 1000 g base electrolyte solution of 1.0 m LiPF 6 /tris(1,1,1,3,3,3-hexafluoroisopropyl)phosphate/EC/EMC (15:15:70) was made in glovebox by mixing 150 g tris(1,1,1,3,3,3-hexafluoroisopropyl)phosphate as synthesized in Example 1, 150 g EC and 700 g EMC, followed by adding 151.9 g LiPF 6 .
[0073] In other similar instances, the electrolyte solutions with other compounds at varying concentrations were also made with tris(perfluoro-iso-propyl)phosphate (compound 12 in Table 2), or hexakis(1,1,1-trifluoroethoxy)phosphazene (compound 14 in Table 2), or tris(1,1,1-trifluoroethyl)phosphate.
[0074] With purpose of illustrating only and no intention to be limiting, Table 3 lists some typical electrolyte solutions prepared and tested. It should be noted that the compositions disclosed in Table 3 may or may not be the optimum compositions for the electrochemical devices in which they are intended to be used, and they are not intended to limit the scope of the present invention.
[0000]
TABLE 3
Electrolyte Solutions with Additives
Salt
Additive
Concentration
Solvent Ratio
Concentration
(m)
(by Weight)
(by Weight)
LiPF 6 (1.0)
EC/FEC/EMC
1% Compound 9
(15:15:70)
LiPF 6 (1.0)
EC/tris(1,1,1-trifluoro-
1% Compound 11
ethyl)phosphate/EMC
(20:10:70)
LiPF 6 (1.0)
EC/EMC (30:70)
1% Compound 14
LiPF 6 (1.0)
EC/EMC (30:70)
1% Compound 9
LiBF 4 (1.0)
EC/EMC (30:70)
1% Compound 11
LiBOB (1.0)
EC/γBL/EMC/MB
1% Compound 9
(15:15:30:30)
Et 3 MeNPF 6 (2.0)
EC/EMC (30:70)
1% Compound 16
Example 6
Fabrication of an Electrochemical Cell
[0075] This example summarizes the general procedure of the assembly of electrochemical cell. These electrochemical cells include Li ion cell, double layer capacitor, or dual intercalation cell. Typically, a piece of Celgard polypropylene separator was sandwiched between an anode and a cathode. The cell was then activated by soaking the separator with the electrolyte solutions as prepared in Example 5, and sealed with appropriate means. All the above procedures were conducted under dry atmospheres in either glovebox or dryroom.
[0076] The electrolyte co-solvents or additives of this invention will perform most effectively in electrolyte solutions that are widely adopted by the industry of Li ion batteries. The electrolytes comprise of one or more lithium salts dissolved in neat or mixture of organic or inorganic esters, ethers, nitriles, sulfones or anhydrate, where the lithium salts are based on various fluorinated or non-fluorinated anions, the examples of which include but are not limited to, hexafluorophosphate, bis(trifluoromethanesulfonyl)imide, bis(oxalato)borate, fluorooxalatoborate, and tetrafluoroborate. The organic or inorganic solvents include but are not limited to ethylene carbonate, dimethylcarbonate, ethylmethylcarbonate, propylene carbonate or ethylmethyl sulfone. A typical baseline electrolyte solution pertaining to the above description is 1.2 M lithium hexafluorophosphate dissolved in a mixture of ethylene carbonate and dimethylcarbonate by 30:70 volume ratio. The concentration of co-solvent or additive should be adjusted to its optimum value in the above electrolyte solution to yield the most effective performance. The amount of additive to be used is scaled with the surface area of the cathode material. A typical electrolyte formulation is 5 mM additive mixed in the baseline electrolyte. For high surface area cathode materials, up to 20 mM additives can be used.
[0077] The electrolyte co-solvents and additives are expected to perform more effectively on those cathode materials whose reversible lithiation/de-lithiation potentials occur above 4.2 V vs. Li. The cathode materials include but are not limited to spinel metal oxides or olivine metal phosphates with varying ratio of metals selected from transition groups of the periodic table, examples of which include, but are not limited to, LiMn 1.5 Ni 0.5 O 4 , LiCoPO 4 , LiNiPO 4 and doped derivatives thereof. See for example the spinel oxide cathodes disclosed in K. Amine, et al., J. Power Source., 1997, Vol. 68, 604-608, U.S. Pat. No. 7,718,319 and U.S. Published Application 20100183925 in the names of Arumugam Manthiram et al., the disclosures of which are hereby incorporated by reference.
[0078] The test cells are to be assembled in either cathode half cell configurations with lithium metal as anode, or Li ion full cell configurations with either graphitic carbon or other intercalation materials such lithiated titanate as an anode. For the best performance, these cathode materials should be coated on Al foil, and should be placed on Al-clad cells parts when assembled into a cell. However, stainless steel should not be used as current collector at the cathode side. As an example, a typical coin cell is constructed by using the following coin cell parts:
1. Case: SUS304 Ni-plated with aluminum cladding (cathode current collector); 2. Cap: SUS316L stainless steel (anode current collector); 3. Gasket: Polypropylene; 4. Spacer disc: SUS316L stainless steel 15.5 mm diam.×0.5 mm thick (in contact with anode); and 5. Wave spring: SUS316L stainless steel 15 mm diam.×1.4 mm high (in contact with anode).
[0084] Celgard 2400 polypropylene with no surfactant coating is generally used as a separator. Amount of electrolyte added is <50 μL, and use of electrolyte is kept to the absolute minimum necessary to wet the separator sheets and provide continuous contact between electrodes. Effort should be made to avoid any wetting of unnecessary cell parts. Finally, for the purpose of demonstration and in no manner to be limiting, using the electrodes, electrolytes and cell parts as described above, the best cell performance is expected if the cell is formed in a series of “forming cycles”, where the cells are gradually brought to certain low voltage stages before being exposed to 5.0 V. As an example, a typical protocol for the forming of the cathode half cell based on LiNi 0.5 Mn 1.5 O 4 spinel material from Argonne National Laboratory is as follows using constant current:
[0085] Forming step 1: 3.5V-4.2V, C/10 rate, two cycles;
[0086] Forming step 2: 3.5V-4.5V, C/10 rate, two cycles; and
[0087] Forming step 3: 3.5V-4.95V, C/5 rate, two cycles.
[0088] FIG. 5 demonstrates the effectiveness of one of the additives disclosed in this invention, HFiP, on different cathode materials, which include the high voltage (4.6 V) spinel LiNi 0.5 Mn 1.5 O 4 , its derivatives and low voltage (4.2 V) layer oxide compounds based on LiNi 0.80 Co 0.15 Al 0.05 O 2 and LiNi 1/3 Mn 1/3 Co 1/3 O 2 , respectively. In this test, the state of the art electrolyte (lower curve) shows a lower capacity utilization of the cathode material as compared to a similar cell that had 0.3% HFiP in the state of the art electrolyte. In all cases, electrolytes with 5 mM of HFiP showed higher capacity utilization, slower fading rate and higher stability.
[0089] With the invention having been described in general and in details and the reference to specific embodiments thereof, it will be apparent to one ordinarily skilled in the art that various changes, alterations, and modifications can be made without departing from the spirit and scope of the invention and its equivalents as defined by the appended claims. | This invention described the preparation of a series of compounds selected from the group comprising tris(1,1,1,3,3,3-hexafluoro-iso-propyl)phosphate, tris(perfluoroethyl)phosphate, tris(perfluoro-iso-propyl)phosphate, bis(1,1,1-trifluoroethyl)fluorophosphate, tris(1,1,1-trifluoroethyl)phosphate, hexakis(1,1,1-trifluoroethoxy)phosphazene, tris(1,1,1-trifluoroethoxy)trifluorophosphazene, hexakis(perfluoro-t-butyl)phosphazene and tris(perfluoro-t-butyl)phosphate. These compounds may be used as co-solvents, solutes or additives in non-aqueous electrolytes in various electrochemical devices. The inclusion of these compounds in electrolyte systems can enable rechargeable chemistries at high voltages that are otherwise impossible with state-of-the-art electrolyte technologies. These compounds are chosen because of their beneficial effect on the interphasial chemistries formed at high potentials, such as 5.0 V class cathodes for new Li ion chemistries. These compounds may be used in Li ion battery technology and in any electrochemical device that employs non-aqueous electrolytes for the benefit of high energy density resultant from high operating voltages. | 8 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of U.S. Provisional Application No. 60/85,658, filed Feb. 2, 2000. This earlier provisional application is hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] The work of this invention is support in part by the USDA-NRICGP grants 95-82770, 97-35504 and 98-0185 to Henry Daniell.
FIELD OF INVENTION
[0003] This application pertains to the field of genetic engineering of plant plastid genomes, particularly chloroplasts and to methods of transforming plants to confer or increase drought tolerance and engineered plants which are drought tolerant.
DESCRIPTION OF RELATED ART
[0004] Patents of Interest
[0005] Londesborough et. al., in U.S. Pat. No. 5,792,921 (1998), entitled “Increasing the trehalose content of organisms by transforming them with combinations of the structural genes for trehalose synthase,” and U.S. Pat. No. 6,130,368 (2000), entitled “Transgenic plants producing trehalose”, proposed a method for increasing trehalose content in various organisms through nuclear transformation.
[0006] Hoekema, in U.S. Pat. No. 5,925,804 (1999), entitled “Production of Trehalose in Plants,” proposes a method of engineering plants to produce trehalose. This patent suggests the transformation of plants by introducing to the plant nuclear genome any trehalose phosphate synthase gene driven by an appropriate promoter.
[0007] Strom, et al., in U.S. Pat. No. 6,133,038 entitled “Methods and compositions related to the production of trehalose” (2000), described the genes involved in the biosynthesis of trehalose, trehalose synthase and trehalose-6-phosphate. Methods for producing trehalose biosynthetic enzymes in a host cell through transformation of the cell's nucleus are also proposed. In addition, the patent also suggests nuclear transgenic host cells which contain recomvinant DNA constructs encoding for a trehalose synthase, trehalose phosphatase or both trehalose synthase and, trehalose phosphatase.
BACKGROUND OF THE INVENTION
[0008] Effects of Increased Trehalose Accumulation
[0009] Water stress due to drought, salinity or freezing is a major limiting factor in plant growth and development. Trehalose is a non-reducing disaccharide of glucose and its synthesis is mediated by the trehalose-6-phosphate (T6P) synthase and trehalose-6-phosphate phosphatase complex in Saccharomyces cerevisiae. In S. cerevisiae, this complex consists of at least three subunits performing either T6P synthase (TPS1), T6P phosphatase (TPS2) or regulatory activities (TPS3 or TSLI). Trehalose is found in diverse organisms including algae, bacteria, insects, yeast, fungi, animal and plants. Because of its accumulation under various stress conditions such as freezing, heat, salt or drought, there is general consensus that trehalose protects against damages imposed by these stresses. Trehalose is also known to accumulate in anhydrobiotic organisms that survive complete dehydration, the resurrection plant and some desiccation tolerant angiosperms. Trehalose, even when present in low concentrations, stabilizes proteins and membrane structures under stress because of the glass transition temperature, greater flexibility and chemical stability/inertness.
[0010] Prior Efforts to Engineer Plants for Trehalose Production
[0011] There have been several efforts to generate various stress resistant transgenic plants by introducing gene(s) responsible for trehalose biosynthesis, regulation or degradation. When trehalose accumulation was increased in transgenic tobacco plants by over-expression of the yeast TPS1, trehalose accumulation resulted in the loss of apical dominance, stunted growth, lancet-shaped leaves and some sterility. Altered phenotype was always correlated with drought tolerance, plants showing severe morphological alterations had the highest tolerance under stress conditions.
[0012] Advantages of Transforming Plants through the Chloroplast
[0013] In order to minimize the pleiotropic effects observed in the nuclear transgenic plants accumulating trehalose, this invention compartmentalizes trehalose accumulation within chloroplasts. Several toxic compounds expressed in transgenic plants have been compartmentalized in chloroplasts, even through no targeting sequence was provided indicating that this organelle could be used as a repository like the vacuole. Also, osmoprotectants are known to accumulate inside chloroplasts under stress conditions. Inhibition of trehalase activity is known to enhance trehalose accumulation in plants. Therefore, trehalose accumulation in chloroplast may be protected from trehalase activity in the cytosol, if trehalase was absent in the chloroplast.
[0014] In addition, chloroplast transformation has several other advantages over nuclear transformation. A common environmental concern about nuclear transgenic plants is the escape of foreign genes through pollen or seed dispersal, thereby creating super weeds or causing genetic pollution among other crops. The latter has resulted in several lawsuits and shrunk the European market for organic produce from Canada from 83 tons in 1994-1995 to 20 tons in 1997-1998. These are serious environmental concerns, especially when plants are genetically engineered for drought tolerance, because of the possibility of creating robust drought tolerant weeds and passing on undesired pleiotropic traits to related crops. Chloroplast transformation should also overcome some of the disadvantages of nuclear transformation that result in lower levels of foreign gene expression, such as gene suppression by positional effect or gene silencing.
[0015] Chloroplast genetic engineering has been successfully employed to address aforementioned concerns. For example, chloroplast transgenic plants expressed very high level of insect resistance, due to expression of 10,000 copies of foreign genes per cell, thereby overcoming the problem of insect resistance observed in nuclear transgenic plants. Similarly, chloroplast derived herbicide resistance overcomes out-cross problems of nuclear transgenic plants because of maternal inheritance of plastid genomes. This invention thus presents a solution to the pitfalls of nuclear expression of TPS1 in transgenic plants.
[0016] Non-Obvious Nature of the Invention.
[0017] Trehalose is a non-reducing disaccharide of glucose and is found in diverse organisms including algae, bacteria, insects, yeast, fungi, animal and plants. Because of its accumulation under various stress conditions such as freezing, heat, salt or drought, there is general consensus that trehalose protects against damages imposed by these stresses. Trehalose is also known to accumulate in anhydrobiotic organisms that survive complete dehydration, the resurrection plant and some desiccation tolerant angiosperms.
[0018] There have been several efforts to generate various stress resistant transgenic plants by introducing gene(s) responsible for trehalose biosynthesis, regulation or degradation. When trehalose accumulation was increased in nuclear transgenic tobacco plants by over-expression of the yeast TPS1, trehalose accumulation resulted in the loss of apical dominance, stunted growth, lancet shaped leaves and some sterility. Altered phenotype was always correlated with drought tolerance; plants showing severe morphological alterations had the highest tolerance under stress conditions. Prior to this invention, it was not obvious that accumulation of trehalose within plastids would minimize the pleiotropic effects observed in the nuclear transgenic plants accumulating trehalose or damage plastids. There were no prior reports of trehalose accumulation within plastids or localization of enzymes of trehalose biosynthetic pathway within plastids.
[0019] Osmoprotectants are known to accumulate inside chloroplasts under stress conditions but their mode of action is to provide osmotic protection by accumulation of such compounds (as sugars or amino acids) in large quantities. This invention demonstrates that the protection is offered by accumulation of small quantities of trehalose which was not adequate to provide protection from dehydration but rather stability of biological membranes. Inhibition of trehalase activity is known to enhance trehalose accumulation in the cytosol but there are no reports of the presence or absence of trehalase within plastids. Therefore, it was unanticipated that trehalose accumulation within plastids would be protected from trehalase activity. Prior to this invention, there were no reports of using plastid transformation as a strategy to confer drought tolerance to transgenic plants.
BRIEF SUMMARY OF THE INVENTION
[0020] This invention provides a method to transform plants through the plastids, particularly chloroplasts, to confer drought tolerance to plants. The vectors with which to accomplish the chloroplast transformation is provided. The transformed plants and their progeny are provided. The transformed plants and their progeny display drought resistance. More importantly, they display no negative pleiotropic effects such as sterility or stunted growth.
[0021] The present invention is applicable to all plastids of plants. These include chromoplasts which are present in the fruits, vegetables and flowers; amyloplasts which are present in tubers like the potato; proplastids in roots; leucoplasts and etioplasts, both of which are present in non-green parts of plants.
[0022] The present invention provides a method to increase water stress tolerance in dicotyledonous or a monocotyledonous plant, comprising introducing an expression cassette into the cells of a plant to yield transformed plant cells. Plant cells include cells of monocotyledenous plants such as cereals, including corn ( Zea mays ), wheat, oats, rice, barley, millet and cells of dicotyledenous plant such as soybeans and vegetables like peas. The expression cassette comprises a preselected DNA sequence encoding an enzyme which catalyzes the synthesis of an osmoprotectant, operably linked to a promoter functional in the chloroplast plant cell. The enzyme encoded by the DNA sequence is expressed in the transformed plant cells to increase the level of osmoprotection so as to render the transformed cells substantially tolerant or resistant to a reduction in water availability that inhibits the growth of untransformed cells of the plant.
[0023] As used herein, an “osmoprotectant” is an osmotically active molecule which, when that molecule is present in an effective amount in a cell or plant, confers water stress tolerance or resistance, or salt stress tolerance or resistance, to the cell or plant; when present in lower amounts in a cell or plant, an “osmoprotectant” confers membrane stability. Those skilled in the art will appreciate that an osmoprotectant confers resistance to water or salt stress when present in the cell in high amounts, and confers membrane stability in lower amounts. Osmoprotectants include sugars such as monosaccharides, disaccharides, oligosaccharides, polysaccharides, sugar alcohols, and sugar derivatives, as well as proline and glycine-betaine. A preferred embodiment of the invention is an osmoprotectant that is a sugar. Useful osmoprotectants include fructose, erythritol, sorbitol, dulcitol, glucoglycerol, sucrose, stachyose, raffinose, ononitol, mannitol, inositol, methyl-inositol, galactol, hepitol, ribitol, xylitol, arabitol, trehalose, and pinitol.
[0024] Genes which encode an enzyme that catalyzes the synthesis of an osmoprotectant include genes encoding mannitol dehydrogenase (Lee and Saier, J. Bacteriol., 153 (1982)) and trehalose-6-phosphate synthase (Kaasen et al., J. Bacteriol., 174, 889 (1992)). Through the subsequent action of native phosphatases in the cell or by the introduction and coexpression of a specific phosphatase into the nucleus, these introduced genes result in the accumulation of either mannitol or trehalose in the nucleus, respectively, both of which have been well documented as protective compounds able to mitigate the effects of stress. Mannitol accumulation in the nucleus of transgenic tobacco has been verified and preliminary results indicate that plants expressing high levels of this metabolite are able to tolerate an applied osmotic stress (Tarczynski et al., cited supra (1 992), (1993)).
[0025] Also provided is an isolated transformed plant cell and an isolated transformed plant comprising said transformed cells, which cell and plant are substantially tolerant of or resistant to a reduction in water availability. The cells of the transformed monocot plant comprise a recombinant DNA sequence comprising a preselected DNA sequence encoding an enzyme which catalyzes the synthesis of an osmoprotectant. The preselected DNA sequence is present in the cells of the transformed plant and the enzyme encoded by the preselected DNA sequence is expressed in those cells to yield an amount of osmoprotectant effective to confer tolerance or resistance to those cells to a reduction in water availability that inhibits the growth of the corresponding untransformed plant cells. A preferred embodiment of the invention includes a transformed plant that has an improved osmotic potential when the total water potential of the transformed plant approaches zero relative to the osmotic potential of a corresponding untransformed plant.
[0026] As used herein, a “preselected” DNA sequence is an exogenous or recombinant DNA sequence that encodes an enzyme which catalyzes the synthesis of an osmoprotectant, such as sugar. The enzyme preferably utilizes a substrate that is abundant in the plant cell. It is also preferred that the preselected DNA sequence encode an enzyme that is active without a co-factor, or with a readily available co-factor. For example, the mild gene of E. Coli encodes a mannitol-1-phosphate dehydrogenase (M1PD). The only co-factor necessary for the enzymatic activity of M1PD in plants is NADH and the substrate for M1PD in plants is fructose-6-phosphate. Both NADH and fructose-6-phosphate are plentiful in higher plant cells.
[0027] As used herein, “substantially increased” or “elevated” levels of an osmoprotectant in a transformed plant cell, plant tissue, plant part, or plant, are greater than the levels in an untransformed plant cell, plant part, plant tissue, or plant, i.e., one where the chloroplast genome has not been altered by the presence of a preselected DNA sequence. In the alternative, “substantially increased” or “elevated” levels of an osmoprotectant in a water-stressed transformed plant cell, plant tissue, plant part, or plant, are levels that are at least about 1.1 to 50 times, preferably at least about 2 to 30 times, and more preferably about 5-20 times, greater than the levels in a non-water-stressed transformed plant cell, plant tissue, plant part of plant.
[0028] As used herein, a plant cell, plant part, plant tissue or plant that is “substantially resistant or tolerant” to a reduction in water availability is a plant cell, plant part, plant tissue, or plant that grows under water-stress conditions, e.g., high salt, low temperatures, or decreased water availability, that normally inhibit the growth of the untransformed plant cell, plant tissue, plant part, or plant, as determined by methodologies known to the art. Methodologies to determine plant growth or response to stress include, but are not limited to, height measurements, weight measurements, leaf area, plant water relations, ability to flower, ability to generate progeny, and yield. For example, a stably transformed plant of the invention has a superior osmotic potential during a water deficit relative to the corresponding.
[0029] As used herein, an “exogenous” gene or “recombinant” DNA is a DNA sequence that has been isolated from a cell, purified, and amplified.
[0030] As used herein, the term “isolated” means either physically isolated from the cell or synthesized in vitro in the basis of the sequence of an isolated DNA segment.
[0031] As used herein, a “native” gene means a DNA sequence or segment that has not been manipulated in vitro, i.e., has not been isolated, purified, and amplified.
[0032] The invention also provides, preferably, a plastid vector that is capable of stably transforming and conferring drought resistance to tolerance to different plant species.
[0033] The invention provides a plastid vector comprising of a DNA construct. The DNA construct includes a 5′ part of the plastid DNA sequence inclusive of a spacer sequence; a promoter that is operative in the plastid; heterologous DNA sequences comprising at least one gene of interest encoding a molecule; a gene that confers resistance to a selectable marker; a transcription termination region functional in the target plant cells; and a 3′ part of the plastid DNA sequence inclusive of a spacer sequence. The molecule can be a peptide of interest. Preferably, the vector includes a ribosome binding site (rbs) and a 5′ untranslated region (5′UTR). A promoter functional in green or non-green plastids is used in conjunction with the 5′UTR.
[0034] Further, the invention provides a heterologous DNA sequence, which codes for an osmoprotectant, such as the Yeast T6P synthase gene (TSP1 gene), the E. coli otsA gene. The invention also provides the psbA 3′ region, which enhances the translation of foreign genes.
[0035] The invention provides a promoter is one that is operative in green and non-green plastids such as the 16SrRNA promoter, the psbA promoter, and the accD promoter.
[0036] The invention provides a gene that confers resistance, such as antibiotic resistance like the aadA gene or an antibiotic-free selectable marker such as BADH or the ch1B gene, as a selectable marker.
[0037] All known methods of transformation can be used to introduce the vectors of this invention into target plant plastids including bombardment, PEG Treatment, Agrobacterium, microinjection, etc.
[0038] The invention provides transformed crops, like solanaceous plants that are either monocotyledonous or dicotyledonous. Preferably, the plants are those having economic value which are edible for mammals, including humans.
[0039] Any plant can be transformed to an osmprotectant-expressing plant in accordance of the inyention which can carry a helogerous DNA sequence which encodes a desired trait. The transformed osmoprotectant-expressing plant need not comprise such a trait other than the DNA sequence which encodes the osmoprotentant.
[0040] The invention provides plants that have been transformed via the chloroplast which accumulate trehalose at an amount at least 17-fold higher than non-transformed plants which are drought resistant.
[0041] The invention provides plants that have been transformed via the chloroplast which has at least a seven-fold increase in TPS1 activity.
[0042] The invention provides plants that have been transformed via the chloroplast which, in the T 0 generation, display otherwise normal phenotype other than decreased growth and delayed flowing. The invention further provides that the T 1 /T 2 generations of the transformed plants display no pleiotropic effects.
[0043] The invention provides the transformed chloroplasts of the target plants which contain high levels of trehalose.
[0044] The invention provides for chloroplast transformant seedlings which are drought resistant which are resistant to medium containing 3% to 6% PEG.
[0045] The invention provides a method to confer drought resistance to plants via chloroplast transformation with a universal chloroplast vector which contains a drought-resistant or osmoprotectant gene and the accumulation of high levels of trehalose in the chloroplast.
[0046] The invention provides a method to transform a target plant for expression of the TPS1 gene leading to accumulations of trehalose in the chloroplast of the plant cells and eliminating adverse pleiotropic effects.
[0047] The invention provides proof of integration of the heterologous DNA sequence into the chloroplast genome by PCR.
[0048] The invention provides an environmental friendly method of engineering drought resistance to plants through chloroplast transformation.
[0049] Yeast trehalose phosphate synthase (TPS1) gene was introduced into the tobacco chloroplast or nuclear genomes to study resultant phenotypes. PCR and Southern blots confirmed stable integration of TPS1 into the chloroplast genomes of T 1 , T 2 and T 3 transgenic plants. Northern blot analysis of transgenic plants showed that the chloroplast transformant expressed 16,966-fold more TPS1 transcript than the best surviving nuclear transgenic plant. Although both the chloroplast and nuclear transgenic plants showed significant TPS1 enzyme activity, no significant trehalose accumulation was observed in T 0 /T 1 nuclear transgenic plants whereas chloroplast transgenic plants showed 15-25 fold higher accumulation of trehalose than the best surviving nuclear transgenic plants. Nuclear transgenic plants (T 0 ) that showed significant amounts of trehalose accumulation showed stunted phenotype, sterility and other pleiotropic effects whereas chloroplast transgenic plants (T 1 , T 2 , T 3 ) showed normal growth and no pleiotropic effects. Chloroplast transgenic plants also showed a high degree of drought tolerance as evidenced by growth in 6% polyethylene glycol whereas untransformed plants were bleached. After 7 hr drying, chloroplast transgenic seedlings (T 1 , T 3 ) successfully rehydrated while control plants died. There was no difference between control and transgenic plants in water loss during dehydration but dehydrated leaves from transgenic plants (not watered for 24 days) recovered upon rehydration while control leaves died. In order to prevent escape of drought tolerance trait to weeds and associated pleiotropic traits to related crops, it is desirable to genetically engineer crop plants for drought tolerance via the chloroplast genome instead of the nuclear genome.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] [0050]FIG. 1. PCR analysis of control and chloroplast transformants. A. Map of pCt-TPS1, chloroplast transformation vector and primer landing sites. P denotes plus strand and M denotes minus strand. Please note that tRNA genes contain introns. B. 1% agarose gel containing PCR products using total plant DNA as template. M: 1 kb ladder; 1. N. Nicotiana tabacum Burley, untransformed control; Lanes 1, 3, 5: pCt basic vector transformants. 2, 4, 6: pCt-TPS1 transformants. C. Map of the nuclear expression vector pHGTPS 1.
[0051] [0051]FIG. 2. Southern blot analysis of control, T 1 and T 3 chloroplast transgenic plants. A. Site of integration of foreign genes into the chloroplast genome and expected fragment sizes in Southern blots. P1 is the 0.81 kb BamH1-BglII fragment containing chloroplast DNA flanking sequences used for homologous recombination. P2 is the 1.5 kb Xba1 Fragment containing the TPS1 coding sequence. B. Southern blot of DNA digested with BglII and hybridized with probes P1 or P2. Lanes: C, untransformed control; 1, T 1 generation chloroplast transformant; 2, T 3 generation chloroplast transformant.
[0052] [0052]FIG. 3. Northern and western blot analyses of control, nuclear and chloroplast transgenic plants. A, D Western blots detected through chemiluminescence (100 μg total protein per lane). B, E Northern blots detected using 32 P TPS1 probe. C, F Ethidium bromide stained RNA gel before blotting (10 μg total RNA loaded per lane). Panel A, B, C: T 0 nuclear and T 1 chloroplast transgenic plants. Lanes: 1. N. t. xanthi control; 2˜5: To nuclear transgenic plants. 2, X-113; 3. X-119; 4. X-121; 5. X-224; 6: N.t. Burley control; 7: chloroplast transgenic plant (T 1 ). Panel D, E, F: T 1 nuclear and T 2 chloroplast transgenic plants. Lanes: 1. N. t xanthi control; 2, 3: T 1 nuclear transgenic plants 2, X-113; 3.X-119; 4: Nt. Burley control; 5: chloroplast transgenic plant (T 2 ).
[0053] [0053]FIG. 4. Nuclear and chloroplast transgenic plants to illustrate pleiotropic effects. 1. N. t xanthi control; 2˜5: T 0 nuclear transgenic plants 2, X-113; 3.X-121; 4. X-119; 5. X-224; 6, T 1 chloroplast transgenic plant; 7, N. t. Burley control.
[0054] [0054]FIG. 5. Germination of T 1 , T 2 and T 3 generation of chloroplast transformants and untransformed control on MS plate containing spectinomycin (500 μg/ml).
[0055] [0055]FIG. 6. Assay for drought tolerance on PEG. Four week old seedlings on MS medium containing 3% (A, B) or 6% (C, D) polyethylene glycol (MW 8,000). A, C: Control untransformed N.t. Burley. B, D: T. Chloroplast transgenic plants.
[0056] [0056]FIG. 7. Dehydration/rehydration assay. Three week old seedlings from control and chloroplast transgenic lines germinated on agarose in the absence or presence of spectinomycin (500 μg/ml) were air-dried at room temperature in 50% relative humidity. After 7 hrs drying, seedlings were rehydrated for 48 hrs by placing roots in MS medium. A, untransformed; B,C, T 1 and T 3 chloroplast transgenic lines.
[0057] [0057]FIG. 8. Water loss assay. Detached leaves from mature plants at similar developmental stages were dried at room temperature in 25% relative humidity. Leaf weight during drying was recorded and shown as percentage of initial fresh weight.
[0058] [0058]FIG. 9. Dehydration and rehydration of potted plants. Potted plants were not watered for 24 days and rehydrated for 24 hours. Arrows indicate fully dried leaves that either recovered or did not recover from dehydration. A, C: Control untransformed; B,D: chloroplast transgenic plants.
DETAILED DESCRIPTION OF THE INVENTION
[0059] This invention discloses a method of conferring drought tolerance to plants by transforming plants via the chloroplast with a vector that contains a DNA sequence encoding a gene of interest that protects against water stress. In the preferred embodiment of this invention, the vector used is the universal vector as described by Daniell in WO99/10513, which is incorporated herein by reference. Other vectors that are capable of chloroplast transformation such as pUC, pBR322, pBlueScript, pGem and others described in U.S. Pat. Nos. 5,693,507 and 5,932,479 may be used. In the preferred embodiment of this invention, the osmoprotection is the yeast trehalose-6-phosphate synthase (TSP1). Other genes which are capable of conferring drought resistance or osmoprotection may also be used.
[0060] Expression of Yeast TPS1 in E. coli:
[0061] It is known that the yeast trehalose-6-phosphate synthase gene can be expressed in nuclear transgenic plants. Because chloroplasts are prokaryotic in nature, it is desirable to test expression levels of the eukaryotic yeast TPS1 gene in E coli. Because of the high similarity in the transcription and translation systems between E. coli and chloroplasts, expression vectors are, routinely tested in E. coli before proceeding with chloroplast transformation of higher plants. Therefore, the TPS1 gene from yeast was cloned into the E. coli expression vector pQE 30 (see FIG. 1A for details of pQE-TPS1) and expressed in a suitable E. coli strain M15 (pREP4). SDS-PAGE as shown in FIG. 1B shows the presence of TPS1 protein in crude cell extracts, even with Coomassie Blue stain (lane 1), indicating high levels of expression. Western blot analysis using TPS1-antibody confirms the true identity of the expressed protein as shown in FIG. 1B, lane 41. These results confirm that the codon preference of TPS1 is compatible for expression in a prokaryotic compartment. Hyper-expression also facilitated purification as shown in FIG. 1, lanes 2.55 and preparation of polyclonal antibody for characterization of transgenic plants.
[0062] Chloroplast and Nuclear Expression Vectors.
[0063] Having confirmed suitability for prokaryotic expression, the yeast TPS1 gene was inserted into the universal chloroplast expression vector pCt-TPS1 as shown in FIG. 2B. This vector can be used to transform chloroplast genomes of several plant species because the flanking sequences are highly conserved among higher plants. This vector contains the 16 SrRNA promoter (Prm) driving the aadA (aminoglycoside 3″-adenylyl transferase) and TPS1 genes with the psbA 3′ region (the terminator from a gene coding for photosystem II reaction center component) from the tobacco chloroplast genome. It is known that the 16 SrRNA promoter is one of the strong chloroplast promoters and the psbA 3′ region stabilized transcripts to avoid hyper-expression of TPS-1 and associated Pleiotropic effects. The yeast ribosme binding site (RBS) was used instead of the genome chloroplast RBS (GGAGG). This construct integrates both genes into the spacer region between the chloroplast transfer RNA genes coding for alanine and isoleucine within the inverted repeat (IR) region of the chloroplast genome by homologous recombination. For nuclear expression, the yeast TPS1 gene was inserted into the binary vector pHGTPS1 (FIG. 2C), in which the TPS1 gene is driven by the CaMV 35S promoter and the hph gene is driven by the nopaline synthase promoter. The expression cassette is flanked by both the left and right T-DNA border sequences.
[0064] The binary vector pHGTPS1 was mobilized into the Agrobacterium tumafaciens strain LBA 4404 by electroporation. Transformed Agrobacterium strain was introduced into Nicotiana tabaccum var xanthi using the leaf disc transformation method. Ninety two independent TPS1 nuclear tranformants were obtained on hygromycin selection. Seventeen confirmed nuclear tranformants were analyzed by northern blots. Among tranformants showing various levels of transcripts, five tranformants with strong, moderate, weak, very weak and absence of transcripts were chosen for further characterization. For chloroplast transformation, green leaves of N. tabacum var. Burley were transformed with the chloroplast integration and expression vector by the biolistic process. Bombarded leaf segments were selected on spectinomycin/streptomycin selection medium. Integration of foreign gene into the chloroplast genome was determined by PCR screening of chloroplast tranformants, (FIG. 2A). Primers were designed to eliminate mutants, nuclear integration and to determine whether the integration of foreign genes had occurred in the chloroplast genome at the directed site by homologous recombination. Primers 5P/5M land within the aadA gene and should generate a 0.4 kbp fragment if the aadA gene was present in transgenic plants and eliminates the possibility of mutation that could otherwise confer streptomycin/spectinomycin resistance. FIG. 2A shows the presence of 0.4 kbp PCR product in plants transformed with the universal vector alone (pCt,) or the universal vector containing the TPS1 gene (pCt-TPS1), but not in control untransformed plants, confirming that these are transgenic plants and not mutants. The strategy to distinguish between nuclear and chloroplast transgenic plants was to land one primer (3P) on the native chloroplast genome adjacent to the point of integration and the second primer (3M) on the aadA gene. This primer set generated 1.6 kbp PCR product in chloroplast tranformants obtained with the universal vector (pCt) and the universal vector containing the TPS1 gene (pCt-TPS1). Because this product can not be obtained in nuclear transgenic plants, the possibility of nuclear integration can be eliminated. Another primer set was designed to test integration of the entire gene cassette. The presence of the expected size PCR products using 5P/5M confirms that the entire gene cassette has been integrated and that there has been no internal deletions or loop outs during integration via homologous recombination.
[0065] Determination of Chloroplast Integration, Homoplasmy and Copy Number:
[0066] Since there are no significant differences in the level of foreign gene expression among different chloroplast transgenic lines, one line was chosen to generate subsequent generations (T 1 T 2 T 3 ). Southern blot analysis was performed using total DNA isolated from transgenic and wild type tobacco leaves. Total DNA was digested with a suitable restriction enzyme. Presence of a BglII at the 3′ end of the flanking 16S rRNA gene and the trnA intron allowed excision of predicted size fragments in the chloroplast tranformants and untransformed plants. To confirm foreign gene integration and homoplasmy, individual blots were probed with the chloroplast DNA flanking sequence (probe P1, FIG. 2A). In the case of the TPS1 integrated plastid tranformants (T 1 T 2 ), the border sequence hybridized with 6.13 and 1.17 kbp fragments while it hybridized with a native 4.47 kbp fragment in the untransformed plants (FIG. 2B). The copy number ofthe integrated TPS1 gene was also determined by establishing homoplasmy in transgenic plants. Tobacco chloroplasts contain about 10,000 copies of chloroplast genomes per cell. If only a fraction of the genomes were transformed, the copy number should be less than 10,000. By confirming that the TPS1 integrated genome is the only one present in transgenic plants, one could establish that the TPS1 gene copy number could be as many as 10,000 per cell.
[0067] DNA gel blots were also probed with the TPS1 gene coding sequence (probe P2) to confirm integration into the chloroplast genomes. In chloroplast transgenic plants (T 1 T 3 ), the TPS1 gene coding sequence hybridized with 6.13 and 1.17 kbp fragments which also hybridized with the border sequence in plastid transgenic lines (FIG. 2B). This confirms that the tobacco tranformants indeed integrated the intact gene expression cassette into the chloroplast genome and that there has been no internal deletions or loop out during integration via homologous recombination.
[0068] Analysis of Transcript Level in Nuclear and Chloroplast Tranformants:
[0069] For comparison of introduced gene expression between chloroplast and nuclear tranformants, northern blot analysis of transgenic tobacco at similar developmental stages was performed in T 1 , T, and T 2 plants. As shown in FIG. 3, quantification of transcription level showed that the chloroplast transformant (T2) expressed 16,960-fold (FIG. 3E, lane 5) more TPS1 transcript than that of highly expressing nuclear (T 1 ) transformant (FIG. 3E, lanes 2, 3). Similar results were obtained when T 1 chloroplast (FIG. 3B, lane 7) and To nuclear transgenic plants (FIG. 38, lanes 2-5) were compared. This large difference in TPS1 expression between nuclear and chloroplast transgenic plants should be due to the presence of thousands of TPS1 gene copies in each cell of transgenic tobacco. FIG. 3 (C, F) show ethidium bromide stained RNA gels before blotting; this confirms that equal amount of RNA (10 μg) was loaded in all lanes. It is remarkable that the 16SrRNA promoter is driving both genes very efficiently, eliminating the need for inserting additional promoters for the gene of interest.
[0070] Western Blot Analysis of Nuclear and Chloroplast Tranformants:
[0071] Polyclonal antibodies raised against the TPS1 protein overexpressed and purified from E. coli (see experimental protocol) were used for immunoblotting (FIGS. 3A, D). A 60 kDa TPS1 polypeptide was detected in the T 0 nuclear (FIG. 3A, lanes 2,3,5.), T 1 nuclear (3D lanes 2,3) and T 1 plastid (FIG. 3A, lane 7) and T 2 plastid (FIG. 3D, lane 0.5) tranformants. However, no TPS1 was detected in the untransformed control (FIG. 3A, lanes 1,6; 3D 1,4)) and transgenic plants which showed no TPS1 transcript (FIG. 3A, lane 4). As anticipated, western blots showed only a five or ten fold increase in TPS1 protein in chloroplast over highly expressing nuclear transgenic plants. This is because of the fact that the chloroplast vector pCt-TPS1 was intentionally designed to lower translation by not inserting a chloroplast preferred ribosome binding site (GGAGG), so that transgenic plants are not killed by hyper-expression of TPS1. This level expression was adequate to compare trehalose accumulation in cytosolic and chloroplast compartments and observe resultant phenotypic/physiological changes. T 1 nuclear and T 2 chloroplast transgenic plants had higher levels of TPS1 protein; this may be due to homozygous TPS1 alleles or homoplasmy.
[0072] Quantification of Trehalose-6-Phosphate and trehalose in Tranformants:
[0073] Trehalose formation is a two step process, involving trehalose-6-phosphate synthase and trehalose 6-phosphate phosphatase. Trehalose-6-phosphate was not detected in all tested chloroplast and nuclear transformers even though the TPS2, trehalose-6-phosphate phosphatase that converts T6P to trehalose, was not introduced (Table 1). Conversion of T6P to trehalose should have been accomplished by endogenous tobacco trehalose phosphatase or by any non-specific endogenous phosphatase. Simultaneous expression of both enzymes in transgenic plants resulted only in marginal increase of trehalose accumulation in previous studies, confirming that it is adequate to express only TPS1. Leaf extracts from both nuclear and chloroplast transgenic plants catalyzed the synthesis of trehalose 6-phosphate from glucose-6-phosphate and UDP-glucose whereas untransformed tobacco had very low activity. To Chloroplast and nuclear transgenic plants showed a 7-10 fold higher TPS1 activity than untransformed control plants. The amount of trehalose present in untransformed control plants and To nuclear transgenic plants were similar whereas chloroplast transgenic plants accumulated a 17-25 fold mm trehalose than the best surviving nuclear transgenic plants (Table 1). T 1 nuclear transgenic plants accumulated less trehalose than control untransformed plants whereas T 1 chloroplast transgenic plants continued to accumulate high levels of trehalose (Table 1). Observation of comparable TPS1 activity in both nuclear and chloroplast transgenic plants but lack of trehalose accumulation in nuclear transgenic planes indicates that trehalose may be degraded in the cytosol by trehalase but not in the chloroplast compartment. This is consistent with previous studies on inhibition of trehalase activity that resulted in trehalose accumulation in the cytosol.
[0074] Drought Tolerance and Pleiotropic Effects:
[0075] Chloroplast and nuclear tranformants were examined for drought tolerance and pleiotropic effects. After six weeks of growth in vitro, rooted shoots were transferred to pots and grown in the greenhouse. TPS1 nuclear tranformants showed moderate to severe growth retardation, lancet-shaped leaves and infertility (FIG. 4). The chloroplast tranformants (T 0 ) showed decreased growth rate and delayed flowering but all subsequent generations (T 1 , T 2 ) showed similar growth rates and fertility as controls. The nuclear transgenic lines of stunted phenotype showed delayed flowering and produced fewer seeds compared to wild type or did not flower. This result is consistent with prior observations which demonstrated that E. coli otsA (TPS1) and S. cerevisiae TPS1 transgenic plants exhibited-stunted plant growth and other pleiotropic effects. The nuclear transgenic line showing severe growth retardation did not flower. T 1 nuclear transgenic plants that survived showed no growth retardation and trehalose accumulation. Therefore, these plants could not be used for appropriate comparison with chloroplast transgenic plants. When the seeds of chloroplast transgenic plant (crossed between transgenic female and untransformed male) and wild type seeds were germinated on MS medium containing spectinomycin, all chloroplast transgenic progeny were spectinomycin resistant while all wild type seedlings were sensitive to spectinomycin (FIG. 5).
[0076] Because TPS1 transgenic lines showed accumulation of trehalose, they were tested for drought tolerance. Seeds of chloroplast and nuclear transgenic plants were germinated on the MS medium containing polyethylene glycol. As shown in FIG. 6, chloroplast transformant seedlings showed resistance to medium containing 3% and 6% PEG whereas control and nuclear transgenic seedlings exhibited severe dehydration, necrosis and severe growth retardation, ultimately resulting in death. Three-week-old seedlings were chosen to study drought tolerance by dehydration and subsequent rehydration. When seedlings were dried for 7 hours at room temperature in 50% relative humidity, they were all affected by dehydration. However, when dehydrated seedlings were rehydrated for 48 hours in MS medium, all chloroplast transgenic lines recovered while all control seedlings were bleached (FIG. 7). Even the couple of control seedlings that partly survived (because of uneven drying of seedlings on filter papers) eventually died. These results suggest that the loss of water from TPS1 transgenic plants may not be decreased but the ability to recover from drought was dramatically enhanced. This is consistent with existing understanding that trehalose functions by protecting biological membranes rather than regulating water potential (Iwahashi et al., 1995).
[0077] Mature leaves from fully-grown plants were tested for their ability to regulate water loss under drought conditions. When detached leaves were air dried, control and chloroplast transgenic plants lost water to the same extent (FIG. 8). Control and chloroplast transgenic potted plants were not watered for 24 days. Again, both showed dehydration to the same extent (FIGS. 9A,B). However, upon rehydration, fully dehydrated leaves (indicated by arrows, FIGS. 9C,D) recovered in chloroplast transgenic plants but not in controls.
[0078] This invention is exemplified by the following non-limiting example:
EXAMPLE ONE
[0079] Plant, A. tumefaciens and E. coli culture: For transformation experiments, Nicotiana tabacum var. xanthi and Burley were grown in MS medium in the Magenta culture box (Sigma, USA). For drought tolerance assays of transgenic tobacco plants, the rooted young plants were transferred to pre-swollen Jiffy-7 peat pellets (Jiffy Products, Norway) inside the greenhouse. Plants used for enzyme assays were grown and kept in Magenta culture boxes. Seven or 8 leaf stage plants were used for enzyme assays. Two to three-week old young transgenic tobacco plants were used for stress analyses. (Agrobacterium tumefaciens strain LBA4404 was grown in the YEP medium at 29° C. In a shaking incubator. Other E. coli strains were cultured and maintained as described in Sambrook et al. Plasmid construction and antibody production: For hyper-expression of the TPS1 in E. Coli for antibody production, the yeast TPS1 gene was cloned into plasmid pQE30 (Qiagen) and subsequently transformed into E. coli strain M15 [pREP4]. The resulting E. coli transformant was grown at 37° C. to an A 600 of 0.5-0.8 and induced by 2 mM isopropyl-p-β-thiogalactopyranoside (IPTG) for 1-5 hours. The induced cells were harvested and lysed by sonication. SDS-PAGE analysis showed the presence of TPS1 protein in crude cell extracts, even with Coomassie Blue stain, indicating high levels of expression. Western blot analysis using TPS1 antibody confirmed the true identity of the expressed protein (data not shown). The recombinant protein was purified using Ni 2+ resin, using the procedures provided by the manufacturer. Affinity column purified recombinant protein was analyzed for purity by SDS-PAGE. Protein concentrations were determined using ‘the Bio-Rad (USA) protein assay kit with BSA as a standard. Polyclonal antibody was generated using the purified TPS1 protein by the Takara Shuzo Co. (Japan).
[0080] Vector construction for plant transformation: The yeast 1.537 kbp TPS1 gene was inserted into the Xbal site of pCt vector generating pCt-TPS1 (FIG. 2B). For the nuclear transformation, the yeast TPS1 gene was inserted into the pHGTPS1 vector in which the TPS1 gene is driven by the CaMV 35S promoter. The resulting vector confers hygromycin resistance because of the hygromycin phosphotransferase gene driven by the NOS promoter.
[0081] Chloroplast and nuclear transformation: For chloroplast transformation, particle bombardment was carried out using a helium driven particle gun, Biolistic PDH1000. Briefly, chloroplast vectors, pCt and pCt-TPS1 were delivered to tobacco leaves (Burley) using 0.6 μm gold microcarriers (Bio-Rad) at 1,100 psi with a target distance of 9 cm. For nuclear transformation, pHGTPS1 was mobilized into the Acrobacterium tumefaciens strain LBA4404 by electroporation using Gene Pulsar (Bio-Rad. USA). The resulting Agrobacterium strain was used in leaf disc transformation of wild type N. tabacum var. xanthi.
[0082] Chloroplast DNA isolation and PCR: Total DNA was extracted from leaves of wild type and transformed plants using CTAB extraction buffer described. PCR was carried out to confirm spectinomycin resistant chloroplast tranformants using Peltier Thermal Cycler PTC-200 (MJ Research, USA). Three primer sets, 2P(5′-GCGCCTGACCCTG AGATGTGGATCAT-3′)-2M(5′-TGACTGCCCAACCTGAGAGCGGACA-3′), 3P(AAAACCCGTCCTCAGTTCGGATTGC)-3M(CCGCGTTGTTTCATCA AGCCTTACG) and -5P(CTGTAGAAGTCACCATTGTTGTGC), 5M(GTCCAAGAT AAGCCTGTCTAGCTTC) were used for the PCR. PCR reactions were carried out as described elsewhere (Daniell et al., 1998; Guda et al., 2000).
[0083] RNA isolation and Northern Slot analysis: Total RNA was extracted from transgenic tobacco plants using Tri Reagent (MRC, USA) following manufacturer's instruction. For northern blots, RNA samples (10 μg of total RNA per lane) were electrophoresed on a 1.5% agarose-MOPS gel containing formaldehyde. Uniform loading and integrity of RNAs were confirmed by examining the intensity of ethidium bromide bound ribosomal RNA bands under UV light. RNAs on the gel were transferred onto Hybond-N membrane (Amersham, USA). The membrane was hybridized to radiolabeled TPS1 probe and washed at 65° C. in a solution of 0.2×SSC and 0.1% SDS for 20 min twice. The blot was exposed to an X-ray film at −70° C. overnight. Transcripts were quantified using the BiolD++ program with Vilber Lourmat Image Analyzer (Bioprofil, France).
[0084] Western Blot analysis: Tobacco total protein extracts were prepared by modified methods described by Ausubel et al. The total extracts were fractionated on a 10% one-dimensional SDS-PAGE, transferred to Biotrace PDVF nitrocellulose membrane (Gelman Sciences, USA), and immunostained using Renaissance Western Blot Chemiluminescence Reagent (NEN Life Science Products, USA) according to manufacturer's instructions. Each lane was loaded with 100 μg of total protein. The primary antibody used was anti-TPS1 at a 5000-fold dilution. The secondary antibody was anti-rabbit IgG HRP conjugate at a 2000-fold dilution (Promega, USA).
[0085] Drought tolerance and biochemical characterization: For analyses of drought tolerance, 2-3 week old transgenic tobacco plants were used. Seeds of chloroplast and nuclear tranformants were germinated on MS plates containing 3% or 6% PEG (MW 8,000). TPS1 enzyme assay was performed spectrophometrically by the method described by Londesbrough and Vuorio. For quantitative determination of T6P and trehalose, carbohydrates were extracted from aerial parts of transgenic or wild type tobacco plants by treatment in 85% ethanol at 60° C. for 1 hour. The amount of T6P and trehalose were measured by high-performance liquid chromatography (HPLC) on a Waters system equipped with a Waters High Performance Carbohydrate Column (4.6×250 mm) and a refractive index detector. The insoluble phase system was 75% acetanitrile-25% H 2 O with a flow rate of 1.0 ml/min.
REFERENCES
[0086] Thevelein, J. M. & Hohmann, S. Trehalose synthase: guard to the gate of glycolysis in yeast? Trends in Bioscience. 20, 3-10 (1955).
[0087] Singer, M. A. & Lindquist, S. Thermotolerance in Saccharomyces cerevisiae: the Yin and Yang of trehalose. Trends in Biotech. 16, 460-468 (1998).
[0088] Elbein, A. D. The metabolism of a_-trehalose. Adv Carbohyd Chem Biochem. 30,227-256 (1974).
[0089] Mackenzie, K. F., Singh, K. K. & Brwon, A. D. Water stress plating hypersensitivity of yeast: protective role of trehalose in Saccharomyces cerevisiae. J Gen Microbial. 134, 1661-1666 (1988).
[0090] DeVigilio, C., Hottinger, T., Dominguez, J., Boller, T. & Wiekman, A. The role of trehalose synthesis for the acquisition of thermotolerance in yeast 1. Genetic evidence that trehalose is a thermoprotectant. Eur J Biochem. 219, 179-186 (1994).
[0091] Sharma, S. C. A possible role of trehalose in osmotolerance & ethanol tolerance in Saccharomyces cerevisiae. Fems Microbiology Letters. 152, 11-15 (1997).
[0092] Crowe J. H., Hoekstra F. A. & Crowe L. M. Anhydrobiosys. Annu Rev Physiol. 54, 579-599 (1992).
[0093] Bianchi, G. Gamba, A. & Limiroli, R. The unusual sugar composition in leaves of the resurrection plant Myrothamnus flatbellifolia. Physiol Plantarum. 87, 223-226 (1993).
[0094] Drennan, P. M., Smith, M. T., Goldsworthy, D. & Van Staden, J. The occurrence of trehalose in the leaves of the desiccation-tolerant angiosperm Myrothamnus flabellifolius Welw. J. Plant Physiol. 142, 493-496 (1993).
[0095] Colaco, C. Sen. S. Thangavelu, M., Pinder, S. & Roser, B. Extraordinary stability of enzymes dried in trehalose: simplified molecular biology. Biol technology, 10, 1007-1011(1992).
[0096] Iwahashi, H., Obuchi, K., Fujii, S. & Komatsu, Y. The correlative evidence suggesting that trehalose stabilizes membrane-structure in the yeast Saccharomyces cerevisiae. Cell. Mol. Biol. 41, 763-769 (1995).
[0097] Holmstrom, K. O., Mantyla, M., Wekin, B., Mandal, A., Palva. E. T., Tunnela, O. E. & Londesborough, J. Drought tolerance in tobacco. Nature. 379, 683-684 (1996).
[0098] Goddijyn, O. J. M., Verwoerd, T. C., Voogd, E., Krutwagen, W. H. H., ce Graff, P. T. H. M., Poels, J., van Dun, K., Ponstein, A. S., Damm, B. & Pen, K. Inhibition of trehalase activity enhances trehalose accumulation in transgenic plants. Plant Physiol. 113, 181-190 (1997).
[0099] Romero, C., Belles, J. M., Vaya, J. L., Serrano, R. & Culianz-Macia, F. A. Expression of the yeast trehalose-6-phosphate synthase gene in transgenic tobacco plants: pleiotropic phenotypes include drought tolerance. Planta. 201, 293-297 (1997).
[0100] Serrano, R., Culianz-Macia, F. A. & Moreno, V. Genetic engineering of salt & drought tolerance with yeast regulatory genes. Scientia Horticulture 78:261-269.
[0101] During K. Hippe S. Kreuzaler F, Schell J (1990) Synthesis and self-assembly of a functional monocional antibody in transgenic Nicotiana tabacum. Plant Molecular Biology. 15,281-293 (1999).
[0102] Daniell, H. & Guda, C. Biopolymer production in microorganisms and plants. Chemistry and industry. 14, 555-560 (1997).
[0103] Nuccio, M. L., Rhodes, D., McNeil, S. D. & Hanson, A. D. Metabolic engineering of plants for osmotic stress resistance. Crrunt opinion in plant biology 2: 128-134 (1999).
[0104] Daniell, H. New tools for chloroplast genetic engineering. Nat. Biotechnol. 17, 855-856. (1999).
[0105] Daniell, H. GM crops: Public perception and scientific solutions. Trends in Plant Science. 4,467-469 (1999).
[0106] Daniell, H. Environmentally friendly approaches to genetic engineering. In vitro Cellular and Developmental Biology-Plant. 35, 361-368 (1999).
[0107] Daniell, H. Genetically modified food crops: current concerns and solutions for the next generation crops. Biotechnology and Genetic Engineering Reviews, 17, in press.
[0108] Hoyle, B. Canadian farmers seek compensation for genetic pollution. Nat. Biotechnol 17, 747-748 (1999).
[0109] Finnegan J. & McElroy, D. Transgene Inactivation: Plants fight back. Biotechnology. 12, 883-888 (1994).
[0110] Kota, M., Daniell, H., Vatma, S., Garcynski, F., Gould. F. & Morar, W. J. Overexpression of Bacillius thuringiensis Cry2A protein in chloroplasts confers resistance to plants against susceptible and Bt resistant insects. Proc Natl Acad Sci USA. 96, 1840-1845 (1999).
[0111] Daniell, H., Data, R., Varma, S., Gray, S. & Lee, S. -B. Containment of herbicide resistance through genetic engineering of the chloroplast genome. Nature Biotech. 16, 345-348. (1998).
[0112] Scott. S. E. & Wilkinson, M. J. Low probability of chloroplast movement from oilseed rape ( Brassica napus ) into wild Brassica napa. Nat. Biotechnol. 17: 390-392. (1999).
[0113] Brixey,. P. J. Guda, C. & Daniell, H. The chloroplast psbA promoter is more efficient in E. coli than the T7 promoter for hyper-expression of a foreign protein. Biotechnology letters. 19, 2395-399 (1997).
[0114] Guda, G., Lee, S -B., & Daniell, H. Stable expression of a biodegradable protein-based polymer in tobacco chloroplasts. Plant Cell Reports 18, (1999).
[0115] Daniell, H. Transformation and foreign gene expression in plants mediated by microprojectile bombardment. Meth. Mol. Biol. 62, 453-488 (1997).
[0116] Roser, B. & Colaco, C. A sweeter way to fresher food New Scientist. 138, 24-28 (1993).
[0117] Sambrook. J., Maniatis, T. & Fritsch, E. J. Molecular Cloning: A Laboratory Manual. Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y. (1989).
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[0119] Ausubel, F., Brent, R., Kingston, R. E., Moore, D. D., Sediman, J. G., Smith, J. A. & Struhl, K. Short protocols in molecular biology. Wiley and Sons, Inc. USA (1995).
[0120] Londesbrough, J. & Vuorio, O. Trehalose-6 phosphate synthase/phosphat-ase complex from baker's yeast: purification of a protelytically activated form. J. Gen. Microbiology. 137, 323-330 (1991).
[0121] [0121] Herbicide Resistance Crops, Agricultural, Environmental, Economic, Regulatory and Technical Aspects, Duke, S. O., edt., CRC Press, Inc. (1996).
[0122] [0122] Herbicide Resistance in Plants, Biology and Biochemistry, Powles, S. B., and Holtum, J. A. M., eds., CRC Press, Inc. (1994).
[0123] [0123] Peptides: Design, Synthesis, and Biological Activity, Basava, C. and Anantharamaiah, G. M., eds., Birkhauser Boston, 1994.
[0124] [0124] Protein Folding: Deciphering the Second Half of the Genetic Code, Gierasch, L. M., and King, J., eds., American Association For the Advancement of Science (1990).
1
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1
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DNA
Artificial Sequence
Description of Artificial Sequence Primer
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gcgcctgacc ctgagatgtg gatcat 26
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Artificial Sequence
Description of Artificial Sequence Primer
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tgactgccca acctgagagc ggaca 25
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Artificial Sequence
Description of Artificial Sequence Primer
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aaaacccgtc ctcagttcgg attgc 25
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25
DNA
Artificial Sequence
Description of Artificial Sequence Primer
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ccgcgttgtt tcatcaagcc ttacg 25
5
24
DNA
Artificial Sequence
Description of Artificial Sequence Primer
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ctgtagaagt caccattgtt gtgc 24
6
25
DNA
Artificial Sequence
Description of Artificial Sequence Primer
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gtccaagata agcctgtcta gcttc 25 | This invention provides a method of conferring osmoprotection to plants. Plant plastid genomes, particularly the chloroplast genome, is transformed to express an osmoprotectant. The transgenic plants and their progeny display drought resistance. More importantly, such transgenic plants display no negative pleiotropic effects such as sterility or stunted growth. | 2 |
FIELD OF THE INVENTION
The invention relates to a method and a device for process management in the production of pulp and/or paper, using at least one measuring device for registering spectral characteristic values at different wavelengths and at least one regulating or controlling device for the operating means used in the production of pulp and/or paper.
BACKGROUND OF THE INVENTION
EP 0 445 321 A1 discloses a method for the production of pulp in a continuous digester. In the process, a desired pulp quality is prescribed with the aid of a so-called quality measure (Q). Using a process model, the digestion temperature (T*) belonging to the prescribed value of the quality measure (Q*) is prescribed as a main controlled variable. In this arrangement, the process model may be adapted to accommodate changed operating conditions of the pulp digester. For this purpose, it is important that the supplying of wood chips is included as a process variable in the process model, by means of physical characteristic values.
WO 94/20671 A1 describes a method for regulating the production process of cellulose in which the mass density of the wood chips fed as raw material for the process is taken into account and is envisaged to be variable. Corresponding samples of the mass density of wood chips fed into the process are taken into account in a computing unit and are designed to be as a function of the computational results.
Finally, EP 0 590 433 A2 describes a control method for the production of pulp by means of pressure and temperature control, in which the production process is subdivided into two phases. The first phase of the digestion includes the heating up of the suspension of groundwood and digester liquid which is subjected to as high a pressure as possible. The pressure is lowered in the second phase of the digestion which occurs at the final digestion temperature.
In the earlier international Patent Application WO 95/08019 A, which is not a prior publication, a device is proposed for operating an installation specifically for the production of so-called de-inked pulp. The device contains at least one waste paper preparation means which has a dewatering machine or at least a paper machine connected downstream thereof. In this arrangement, a measuring device for registering spectral and/or physical characteristic values of the waste paper suspension, which is fed to the waste paper preparation means or passes through the latter, is already used. Furthermore, regulating or control devices for the operating means of the waste paper preparation means is used there and at least one state analyzer for the waste paper suspension is proposed. The state analyzer is implemented in the form of one or more parallel neural networks. Using the characteristic values of the measuring device, the state analyzer outputs controlled variables for process management to the regulating or controlling devices of the operating means for the waste paper preparation means.
When the above-described device is used, in particular, for the production of de-inked stock, using as large a proportion as possible of waste paper, a problem particularly taken into account is that the quality of the waste paper introduced into the installation fluctuates severely. For example, depending on the respective mixture of the waste paper, it is possible for widely varying proportions of different types of waste papers to be present, for example, colored, illustrated papers, grey newsprint, white papers, contaminated papers, old books, for example including telephone directories, cartons, packages, coated papers and further contaminations of all types. The device previously described in the earlier patent application solves the problems in a satisfactory manner specifically for the production of de-inked pulp.
Furthermore, U.S. Pat. No. 4,886,576 describes an installation for use in the production of paper. Separate units of primary and secondary refiners for beating digest chips are connected downstream of one or more digesters for the production of pulp from chips. In this case, UV absorption measurements are carried out on the digester liquid, or the so-called pulp. Control or regulation signals are derived from the measured values, on one hand for the temperature management of the digester, and on the other hand for the primary refiner stage. It is important in this case to carry out the UV absorption measurements on the digester liquid with a non-solid consistency, in particular on a pulp, since the UV spectrum thereof is influenced by the constituents dissolved out of the wood.
OBJECTS AND SUMMARY OF THE INVENTION
An object of the present invention is to apply the measurement principle of the sort used in the prior art to the production of pulp and/or paper so that it is suitable for feedforward control.
The object is achieved according to the present invention in that, using a measuring device, the spectral characteristic values of at least the starting materials in the production of pulp and/or paper are registered. The starting materials (i.e., either the raw material “wood” or the secondary raw material “waste paper”) continuously pass by the measuring device, which registers the starting materials' spectral characteristic values.
Within the scope of the invention, neural networks are used in a manner known in the art as state analyzers for evaluating the spectral characteristic values. In particular, it is advantageously possible therewith to derive from the age of the wood and/or from the proportion of respective wood species such controlled variables as are important for the lignin content of the wood. Signals derived in such a way can be used, for example, for controlling the digester, which is necessary for the production of pulp and/or paper.
The associated device for carrying out the method contains at least one measuring device for registering spectral characteristic values and at least one regulating or controlling device for the operating means used. The measuring device may be a spectrometer for registering intensity measured values at different wave-lengths. By suitable evaluation of the measured values, correction variables for the regulating or controlling device may be derived. There can be additional measuring devices in the production line, so that in the same way characteristic values of the intermediate and/or final products can be registered, from which signal variables can be fed back to the controlling or regulating device.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details and advantages of the invention emerge from the description of figures relating to exemplary embodiments, with reference to the drawing, wherein:
FIG. 1 schematically illustrates one example of a system for registering the suitability of chips for use as the starting raw material in the chemical digestion for the manufacture of pulp;
FIG. 2 a schematically further illustrates the evaluation device employed in FIG. 1;
FIG. 2 b schematically illustrates the backscatter intensities I i for preferred wavelengths λ i ;
FIG. 3 schematically illustrate a further example, in which chips are assessed for use in a so-called refiner;
FIG. 4 schematically illustrates a further example, in which waste paper is assessed;
FIG. 5 schematically illustrates an example in which so-called groundwood is assessed.
DETAILED DESCRIPTION OF THE INVENTION
In FIGS. 1, 3 and 4 there is a conveyor belt 1 for the transport of raw materials from a store to a further location for their further processing. With regard to the production of pulp according to FIG. 1, this material consists of chips 5 . With regard to the example for the production of paper according to FIG. 4, this material is waste paper 15 . In each example, the raw materials are fed via the conveyor belt 1 to specific preparation installations which are only indicated in FIGS. 1, 3 and 4 . Fitted above the conveyor belt 1 is a spectroscope or spectrometer 10 , with which a measuring area 11 on the conveyer belt 1 is registered. Upstream of the location of the analysis area 11 , the stream of raw material is made uniform in terms of height and is leveled, by means of a doctor 3 (in the case of chips 5 ) or by means of a pressure roller 13 (in the case of waste paper 7 ), in order that reproducible measured values can be registered.
As shown in FIG. 1, after measurement, the chips 5 pass from the conveyor belt 1 into a digester 14 as processing unit, which is allocated a digester model 15 for process control. The digester model 15 is driven by the signals of the spectrometer 10 with the interposition of an evaluation unit 20 , which is described in detail with reference to FIG. 2 a . From the digester 14 , the finished product pulp passes for further processing into relevant production installations, for example, a paper machine for the production of paper and/or board.
In FIG. 2 a , the evaluation unit of FIG. 1 is represented as a three-layer neural network which, by way of example, comprises input neurons EN 1 to EN 6 , further neurons ZN 1 to ZN 5 and an output neuron AN. Using the neural network 20 , the spectrum from the spectrometer 10 is evaluated. The backscatter intensities I i with i=1 . . . , n from preferred wavelengths λ i of the schematic representation according to FIG. 2 b . are used as inputs for the neural network 20 .
In addition to the wavelengths I i to I n , further relatively simple to measure raw material properties—such as the moisture and the density or bulk density—can advantageously be used as additional input variables for the neural network 20 .
Important raw material properties which are needed for the process control of the preparation process, such as in particular the proportion of various types of wood, and which include, for example, a-cellulose content, wood mixture ratio, starting lignin content for the digester model, correction for the H-factor (offset), time correction (offset) for the digestion time (at constant temperature), and temperature correction (offset) for the digestion temperature (at constant digestion time), can be obtained at the output AN of the neural network 20 . For example, in the case of using Eucalyptus on the one hand and Spruce on the other hand as raw materials, the Eucalyptus/Spruce mixture for the sulphate digestion can be determined. On the basis of the mixture ratio, the starting lignin concentration is calculated therefrom, which is an important variable for the control of the digestion process. The lignin concentration CL is given as:
CL total =x*CL Eucalyptus +(1 −x )* CL Spruce
In case of the same wood species, the method specified can also be used for determining the starting lignin content of the raw wood used. The value determined is a measure for the pulp digestion, that is, a statement as to whether the wood may be digested easily or with difficulty.
From the measured values it is, moreover, possible to estimate the cellulose content of the wood, in particular in the case of Eucalyptus Globulus. In addition, it is advantageous to determine a model correction for the digester model 15 according to FIG. 1, using the spectrum via the neural network. If, for example, the known H-factor model is used for the control of the sulphate pulp, the wood quality can be taken into account by means of an offset to the H-factor. Hence, the quality of the pulp produced can be made uniform.
In addition to the variables specified, using the evaluation scheme according to FIG. 2 a , it is also possible to make, for example, a time correction or an offset for the digestion time at a prescribed constant temperature or, alternatively, a temperature correction or a relevant offset for the digestion temperature at constant digestion time.
Both correction variables are advantageously usable for determining the digester model 15 according to FIG. 1 .
Specifically in FIG. 3, chips 5 are delivered from a conveyor belt 1 into a so-called refiner arrangement 30 . The latter comprises a funnel 31 , a subsequent screw 32 , driven via a motor 33 , the beating discs 34 and 34 ′, which are likewise driven by a motor 36 , and an associated exit duct 37 . The refiner 30 is assigned a control unit 35 .
Similar to the embodiment shown in FIG. 1, in FIG. 3 there is a first spectrometer 10 which, as an alternative to being arranged above the conveyor belt 1 , is directed directly onto the entry funnel 31 of the refiner 30 and thus covers the funnel 31 as the measuring area 11 . The neural network 20 connected downstream of the spectrometer 10 , taking into account the spectral lines I l to I n and further parameters, determines the specific beating work which, together with the desired degree of beating, form the input variables for the controller 35 .
In the arrangement according to FIG. 3, a further spectrometer 10 ′ is assigned to the exit duct 37 for the beaten product. A neural network 20 , similar to that shown in FIG. 2 a and not shown in detail here, is assigned to the spectrometer 10 ′. With this arrangement, the quality of the output product can be taken into account and fed back to the control unit 35 as an influencing variable.
Conventional refiners have a high power demand. By means of defibring, matched to the problem, in the refiner 30 according to FIG. 3, it is possible to determine in advance the required specific beating work, which depends strongly on the quality of the wood, and thus to minimize it. This helps save power and provide beaten fibers of uniform quality.
In FIG. 4, waste paper 15 is specifically supplied on the conveyor belt 1 , and is panned into a so-called pulper 40 with rotary agitator 41 or into a pulper drum (not shown) for waste paper preparation. Connected to the pulper 40 is a stock preparation means, not shown in detail, to which there runs an outlet channel 42 provided with a valve 43 .
Similar to the embodiment shown in FIG. 1, FIG. 4 shows a spectrometer 10 arranged above the conveyor belt 1 with a measuring area 11 on the waste paper 7 . The waste paper 7 is made uniform by means of the pressure roller 13 , and is now directly registered as raw material by the spectrometer. Corresponding to FIG. 3, connected downstream of the spectrometer 10 is a neural network 20 whose output signal is passed to a control unit 45 with which the preparation installation is controlled. By means of switching in a neural network, the changing quality of the waste paper introduced into the production process can be taken into account directly in the preparation of different waste papers. The latter is carried out essentially in accordance with the method which was previously described in detail in the earlier Patent Application cited above.
In FIG. 5, logs 9 pass as raw material into a groundwood installation 50 , which essentially comprises a trough 51 , filled with water, with a rotating grinding roll 55 and conveyor belts 57 and 58 equipped with doctors. Spray water from a line 61 is delivered onto the grinding roll 55 via at least one spray nozzle 62 with valve 63 .
The grinding roll 55 and the conveyor belts 57 and 58 are driven via separate motors 56 and 59 , which can be controlled by a control unit 65 using a grinder model with respect to their rates of rotation, which have a decisive influence on the ground product. Furthermore, the amount of the spray water can be varied via the valve 63 .
The trough 51 has an outlet channel 52 , whose overflow level can be adjustable. In the trough 51 , the water temperature T is measured with a sensor 53 . In the outlet channel 52 the consistency of the water/groundwood mixture being discharged is measured with a sensor 54 . These temperatures are passed into the device 65 . Furthermore, the throughput of spray water is normally registered with a measuring device 64 .
The spectrometer 10 having the measuring area 11 located in the outlet plane of the outlet channel 52 , measures the groundwood in the outlet channel 52 . The measured signal, following evaluation in a neural network corresponding to FIG. 2 a , is fed to the grinder model of the device 65 , for example, for the purpose of so-called regulation of the degree of beating.
Beyond the description of the individual examples, it is noted that, in a continuous production process in the production of pulp and paper, including the preparation of waste paper, at least one spectrometer or, if appropriate, several spectrometers may be arranged at suitable locations in the production process. Using corresponding signal evaluation, statements about the quality of the intermediate product and/or final product to be expected may be derived. As a result of the combination of the individual statements, correction variables can be introduced at various locations into the regulation process, as a result of which overall an improvement in quality is achieved. | In the production of de-inked pulp, measuring devices are used to register spectral and/or physical characteristic values of a starting material. These values are then fed to a neural network, by means of which correction variables are obtained for a regulating or controlling device which in provided. According to the invention, the measuring device is used to evaluate at least the starting materials of the production of pulp and/or paper. The evaluation of the characteristics of the raw material used in the production of pulp and paper is thereby possible. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a container for holding liquid, and is more particularly concerned with a container having an angled spout for pouring the liquid, which spout includes a dripless lip assembly at its outer end. A cap for covering the orifice of said spout includes threads along its interior side walls and defines a retaining plug along its outer wall. The cap can be threaded over said lip assembly, or alternatively can plug said spout by insertion of the retaining plug into the pouring orifice of the lip assembly. Another embodiment of the present invention includes an alternative spout cap having tamper resistant means, and plug means within its interior, for securing the cap to a dripless lip assembly.
2. Description of the Prior Art
Cooking oils such as olive oil or corn oil, are frequently used while cooking, in a manner such that the oil must be readily available during the cooking process. For example, when foods are fried in a skillet or wok at very high temperatures, the cooking oil must be easily accessible and immediately available, otherwise the product may be overcooked. Various types of containers are used to house the cooking oil. The known commercial containers have one orifice which is used for both filling the container and pouring the oil. Usually, this orifice is at the top of the container and in concentric alignment with the walls of the container. These types of containers with vertically aligned, upwardly extending pouring orifices, sometimes incorporate a dripless lip assembly. The dripless lip assemblies presently known have cylindrical side walls and an annular lip.
It is desireable, however, for the cooking oil container to have a angled spout rather than an upwardly extending, vertically aligned spout, as previously employed. An angled spout permits more control over the pouring of the oil. Dripless lip assemblies previously known, however, do not function optimumly when placed at an angle, such as in an angled spout. Hence, known cooking oil containers which incorporate a dripless lip assembly, align the spout vertically with the container.
Containers utilizing pouring spouts and those which incorporate various assemblies for controlling the flow of liquid from the spout are generally well known in the art. For example, U.S. Pat. No. 2,815,155 discloses a container having a spout designed to discourage drippage during pouring, and to insure that liquid flow through the spout is retarded so that the liquid does not flow too rapidly from the spout. These advantages are accomplished by providing a spout which is tapered at its outer end, which incorporates a bend intermediate its ends, and which has a flared outlet portion that is flattened in a transverse direction. U.S. Pat. No. 3,367,532 also discloses a container having an angled spout, but which further incorporates over its filling orifice, a cap or lid which is designed with waving indentations to prevent its slipping from the container. U.S. Pat. No. 3,414,165 discloses another type of liquid container which incorporates a specially designed spout. The spout extends within the interior of the container to the bottom thereof, in order to prevent ambient air from entering the container and reacting with volatile liquids contained therein. This reference also discloses an internally threaded cap for closing the spout. U.S. Pat. No. 4,230,238 discloses yet another design for a container and spout assembly. This invention is directed to a container having a funnel-like pouring attachment secured to its open top. The attachment includes an apertured face to enable the user to see the contents as they are poured through the spout, and to enable additional ingredients to be poured into the container. The spout is angled to prevent dripping when the container is vertically oriented, but the spout does not include a dripless lip assembly.
U.S. Pat. No. 4,298,145 discloses a device for managing liquid which drips from the spout. In this reference, a spout adapter for containers, especially for cooking oil containers, is provided with an upwardly angled pouring lip in an attempt to reduce dripping somewhat. Further, oil dripping from the pouring lip will flow through the adapter and is channeled back into the container.
U.S. Pat. No. 4,550,862 similarly provides a liquid dispenser which utilizes the combination of a pouring spout received within a drain, which collects liquid dripping from the spout. This reference is also directed to incorporating a drain-back feature to manage the liquid dripping from the spout, and not necessarily directed to preventing drippage from the spout.
The present invention overcomes many of the disadvantages of the containers of the prior art. As disclosed herein a specially designed container incorporates a dripless spout assembly with an angled spout. Further, a dual-purpose cap is disclosed which allows the spout to be readily opened and closed during the cooking process, or alternatively be more securely closed for transportation or storage.
SUMMARY OF THE INVENTION
Briefly described, the present invention includes a container having an upstanding side wall and a bottom wall. The container is for liquid, such as cooking oil, and preferably includes a filling orifice at its top end, and a spout extending from its upper side wall. The spout is angled at approximately 40 degrees to 50 degrees from a vertical axis. Received on the dispensing or pouring end of the spout is a dripless lip assembly, which is specially designed to be incorporated with an angled spout. The assembly comprises a cylindrical side wall and a conical body portion tapering and angling inwardly and terminating at an annular, dripless lip which defines a dispensing orifice. As is well known in the art and not further described herein, protective aluminum seals can be fitted over the filling orifice and the dispensing orifice after the bottle is filled, in order to discourage tampering with its contents.
In one embodiment, internally threaded caps are received over the filling and dispensing orifices. In a second embodiment, a dual-purpose cap seals the pouring orifice. This along the periphery of the dripless lip assembly. The cap also includes a retaining plug integrally molded along its outer surface. The cap can be inverted from its normal threaded engagement, and the retaining plug can be inserted into the pouring orifice to seal the spout. It should be understood that references to sealing or plugging the spout, and to sealing or plugging the pouring or dispensing orifices, are used interchangeably herein. When the container is transported, the cap is threadedly received over the dispensing orifice. When the bottle is being used, however, the retaining plug can be used. This second arrangement allows the user to quickly plug and unplug the dispensing orifice when, for example, the container is used while cooking, as described earlier.
A third embodiment utilizes another cap assembly to seal the spout. In this embodiment, a cylindrical cap having an internal, annular abutment means is fitted over the dripless lip assembly so that the abutment means of the cap abuts a retaining ring on the dripless lip assembly. The cap also includes a pull tab attached to its lower side wall. When the cap is installed, the engagement of the abutment means on the cap and the retaining ring of the dripless lip assembly, secures the cap to the dripless lip assembly. The only way that the cap can be practically removed is to pull the tab, thus separating the lower portion of the cap, which disengages the abutment means from the retaining ring. This feature discourages tampering with the cap. This embodiment of the cap further includes a retaining plug along the interior of its top wall. This plug is received in the pouring orifice to hold the plug in place after the lower portion of the cap is removed. The cap can therefore be easily placed onto and removed from the spout.
Accordingly, it is an object of the present invention to provide a container which is inexpensive to manufacture, durable in structure, and efficient in operation.
Another object of the present invention is to provide a container having an angled spout which incorporates a dripless lip assembly.
Another object of the present invention is to provide a container having a dual purpose cap covering the pouring orifice, so that the cap can be selectively placed in either a transport or a ready-use position.
Another object of the present invention is to provide a container having a tamper resistant cap assembly.
Another object of the present invention is to provide a container which is specially designed to be used to dispense cooking oil or similarly viscous liquid.
Another object of the present invention is to provide a container which is specially designed for efficient use while cooking.
Other objects, features and advantages of the present invention will become apparent from the following description when taken in conjunction with the accompanying drawings, wherein like characters of reference designate corresponding parts throughout the several views.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational, perspective view of the present invention, utilizing internally threaded orifice caps.
FIG. 2 is a cross-sectional view of the dripless lip assembly, cap and spout.
FIG. 3 is a fragmentary view of another embodiment of the present invention, depicting an alternate form of the spout cap covering the dripless lip assembly.
FIG. 4 is a fragmentary view of the embodiment of FIG. 3, depicting the retaining plug of the spout cap in position for insertion into the dispensing orifice.
FIG. 5 is a fragmentary view of another embodiment of the present invention, depicting a spout cap which incorporates a pull tab and a dripless lip assembly incorporating a retaining ring.
FIG. 6 is a fragmentary view of the embodiment of FIG. 5 depicting a portion of the lower wall of the cap being separated.
FIG. 7 is a cross-sectional, fragmentary view of the embodiment of FIG. 6, with the bottom portion of the cap removed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the embodiments chosen for the purpose of illustrating the present invention, FIG. 1 depicts a container 10 having curved side wall 11 and flat bottom wall 12. Container 10 is supported in an upright position by wall 12 along vertical axis Y. Container 10 can be made of any suitable material such as glass, but is preferably comprised of relatively flexible, transparent material such as polyethylene, high density polyethylene tercilate (HDPET), high density polyvinyl chloride (HDPVC) or polypropylene. Measuring indicia 9 are marked on the clear side wall 11 of container 10, and may, for example, be delineated in units of fluid ounces and tablespoons. Container 10 also includes angled spout 13, integrally molded with the upper portion of wall 11, as shown in FIG. 1. Spout 13 is tubular in design, and tapers toward a spout orifice 14. Spout 13 terminates at its outer end 15 with annular flange 16, which is integrally formed with spout 13. Spout 13 is angularly disposed as shown in FIG. 1, being essentially concentric with axis X. Spout 13 is preferably formed onto wall 11 so that angle a between axis X and axis Y is approximately 40 to 50 degrees, and ideally is 45 degrees.
The top end 17 of container 10 is preferably cylindrical in design and terminates in a filling orifice 18 (shown in phantom lines). Filling orifice 18 is preferably larger in diameter than that of spout orifice 14, in order to permit container 10 to be readily refilled with liquid. End 17 includes external threads 19 which engage internal threads 20 of cap 21, when cap 21 is threaded onto container 10.
Container 10 preferably has fluted neck 22, which allows container 10 to be readily lifted and tilted for pouring. Further, integral handle 23 is also incorporated during the forming process of container 10, to allow for an alternate means for lifting and tilting.
It is well known in the art that receptacles such as container 10 can be formed by various means, such as blow molding. It is also understood that features of container 10 such as spout 13, threads 19, fluted neck 22 and handle 23 can be integrally formed with wall 11 in the blow molding process.
Mounted unto flange 16 of spout 13 is a frustoconical shaped dripless lip assembly 24. Assembly 24 includes cylindrical lower wall 25 which defines annular channel 26 along its lower edge. The width of channel 26 preferably approximates the thickness of flange 16. Wall 25 includes external threads 25A along its outer periphery. Wall 25 begins tapering at edge 27 to form conical upper wall 28 which terminates at annular collar or lip 29, that defines pouring or dispensing orifice 14A. Lip 29 includes arc-shaped portion 30 having radius 31. Arc-shaped portion 30 terminates at edge 32. Shoulder 33 is then formed in diametric relationship to arc-shaped portion 30, as shown in FIG. 2. Arc-shaped portion 30 is preferably semicircular, having a radius 31 equal to the thickness t of side wall 28. It has been found that 0.04 inch is a preferred value for radius 31 and thickness t. Assembly 24 is made of a material having a low coefficient of friction, such as polyethylene.
Channel 26 of assembly 24 can be securely fixed to spout 13 by, for example, spin welding or other commonly known method, so that there is no leakage between spout 13 and assembly 24.
After assembly 24 is mounted to spout 13, assembly 24 essentially becomes an extension of spout 24 as shown in FIG. 4. For optimum function, dripless lip assembly 24 must be incorporated with the angled spout so that the angle θ between axis Z, which is parallel to axis X, and the conical side wall 28, plus angle α of the spout, equals approximately 70 to 90 degrees. For example, if the spout is angled at its preferable angle α of 45 degrees, the angle θ must equal from 25 degrees to 45 degrees in order for assembly 24 to prevent droplets of oil from dripping from lip 29. Ideally, the sum of angles α and θ equals, but does not exceed, 90 degrees.
In operation, oil is poured by tilting container 10 so that the oil flows through orifice 14A. When container 10 is righted vertically, a quantity of oil will remain momentarily around lip 29. If the assembly is made in accordance with the present invention, the oil on lip 29 will not cross point 32 and drop from lip 29. Instead, because the polyethylene of assembly 24 has a low coefficient of friction, the surface tension of the oil is more apparent. The oil tends to stick to itself rather than the polyethylene lip 29, and will flow back into container 10 rather than drip from lip 29. If the sum of angles α and θ are less than 70 degrees or more than 90 degrees, the oil is more likely to drip from lip 29. Received over assembly 24 in threaded engagement therewith is internally threaded cap 34, which completes the first embodiment of the present invention.
In a second embodiment shown in FIGS. 3 and 4, an alternate cap 50 rather than cap 34, is employed to cover assembly 24. All features of the embodiment previously described are included in this second embodiment, with exception of cap 50. Cap 50 is a frustoconical shaped cap, having cylindrical side wall 51 with friction ridges 52. Extending upwardly from side wall 51 is conical wall 53 which terminates in retaining plug 54. Plug 54 is disk-shaped, having an outer diameter slightly larger than the diameter of orifice 14A. Cap 50 includes internal threads 55 which engage threads 25A of assembly 24, to close orifice 14A, as shown in FIG. 3. Alternatively, cap 50 can be inverted, as depicted in FIG. 4, and installed by inserting plug 54 into the orifice 14A. Using this method for closure of orifice 14A allows cap 54 to be readily installed and removed. This ready-use position is useful when, for example, the container 10 must be tilted while cooking, then recapped quickly.
In a third embodiment, an alternate cap 75 is used to seal dispensing orifice 14A. Cap 75 includes cylindrical side wall 76, and angled side wall 77 which integrally joins wall 76 at abrupt edge 78. Joining wall 77 at edge 79 is cylindrical wall 80 which is concentrically disposed with respect to wall 76. Top wall 81 is joined to wall 80 is shown in FIG. 5. Pull tab 82 joins wall 76, being integrally molded therewith.
Cap 75 includes inner abutment means or annulus 83 along the inner surface of wall 76. Annulus 83 includes upwardly extending, angled surface 84. Annular retaining plug 85 extends downwardly from top wall 81, and includes lip 86 having upwardly angled engaging surface 87. It is well known in the art that cap 75 can be injection molded to integrally include elements 76 through 87.
Dripless lip assembly 88 is identical to assembly 24, except that assembly 88 utilizes retaining ring 89 instead of threads 25A, to secure cap 75 to assembly 88. Retaining ring 89 includes downwardly extending angled surface 90. Cap 75 is initially installed onto assembly 88 by forcing cap 75 over assembly 88 so that surface 90 of retaining ring 89 engages surface 84 of annulus 83. Simultaneously, retaining plug 85 is received into orifice 14A so that upper surface 87 abuts interior conical side wall 91 just below lip 29. Thus cap 75 is securely mounted onto assembly 88, and will be so maintained until surfaces 84 and 90 and surfaces 87 and 91, respectively, are disengaged.
To remove cap 75, tab 82 is pulled in a circular direction around cap 75 as illustrated in FIG. 6. The abrupt edge 78 between side wall 76 and wall 77 causes wall 76 to tear from cap 75 as tab 82 is pulled. Because retaining ring 83 is molded to wall 76, when wall 76 is torn from cap 75, surfaces 84 and 90 are disengaged. Thus, it is readily apparent when cap 75 has been tampered with by removal. Retaining plug 85, therefore, remains as a retaining means to secure cap 75 to assembly 88, as discussed above. Cap 75 can be disengaged from assembly 88 by pulling the cap upwardly to disengage surface 82 of lip 87 from the interior side wall 91 of assembly 88.
It is readily understood by those skilled in the art that such a tamper resistant feature of a tear-away tab can be incorporated into cap 21, which covers filling orifice 18, by the substitution of the above-described features, for the threads of cap 21 and upper end 17.
It will be obvious to those skilled in the art that many variations may be made in the embodiments here chosen for the purpose of illustrating the present invention, and full result may be had to the doctrine of equivalents without departing from the scope of the present invention, as defined by the appended claims. | A container for liquids having a dripless lip assembly incorporated with an angled spout. The container includes various caps for closing the pouring orifice. The caps may include an external retaining plug for sealing and unsealing the pouring orifice quickly. The caps may also include a tamper resistant pull tab. A separate filling orifice is provided. | 1 |
[0001] This application claims the benefit of U.S. Provisional Application No. 61/787,749, filed Mar. 15, 2013, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present disclosure relates to fluid conduits and, more particularly, to flexible hoses.
BACKGROUND
[0003] Flexible hoses are widely utilized in a wide variety of industrial, household, and commercial applications. One commercial application for hoses are garden or water hoses for household or industrial use. For instance, the hoses are used for watering grass, trees, shrubs, flowers, vegetable plants, vines, and other types of vegetation, cleaning houses, buildings, boats, equipment, vehicles, animals, or transfer between a fluid source and an appliance. For example, the appliance can be a wash stand, a faucet or the like for feeding cold or hot water. Another commercial application for hoses are automotive hose for fuel delivery, gasoline, and other petroleum-based products. Another application for hoses are vacuum cleaner hoses for household or commercial applications. For instance, the hoses are used with vacuum cleaners, power tools, or other devices for collecting debris or dispensing air. Fluids, such as beverages, fuels, liquid chemicals, fluid food products, gases and air are also frequently delivered from one location to another through a flexible hose.
[0004] Flexible hoses have been manufactured for decades out of polymeric materials such as natural rubbers, synthetic rubbers, thermoplastic elastomers, and plasticized thermoplastic materials. Conventional flexible hoses commonly have a layered construction that includes an inner tubular conduit, a spiraled, braided, or knitted reinforcement wrapped about the tubular conduit, and an outer cover.
[0005] Kinking and collapsing are problems that are often associated with flexible hoses. Kinking is a phenomenon that occurs, for example, when the hose is doubled over or twisted. A consequence of kinking is that the flow of fluid through the hose is either severely restricted or completely blocked. Kinking becomes a nuisance and causes a user undue burden to locate and relieve the kinked portion of the hose.
[0006] There have been previous attempts to make hoses more resistant to kink, crush, collapse, and/or burst by incorporating a spiral or helical reinforcement strip into the outer tubular layer of the hose. This construction, however, has often made these reinforced hoses unduly stiff because the embedded helix lacks the ability to flex freely. This construction in some cases has often required thicker and more rigid inner tubular layers. What is needed, therefore, is a reinforced fluid conduit in which the structural reinforcement is readily customizable to suit the different performance needs of its users.
SUMMARY
[0007] A fluid conduit in one embodiment includes a flexible member having a tubular wall configured to convey a fluid, the tubular wall defining a central axis extending through the flexible member, and a plurality of geometric segments disposed adjacent to the tubular wall, the geometric segments disposed circumferentially about and longitudinally along the central axis and spaced apart relative to each other to define a gap therebetween, the gap sized to be closed by contact between adjacent geometric segments upon a predetermined flexure of the flexible member.
[0008] A fluid conduit in another embodiment includes a flexible member having a tubular wall configured to convey a fluid, the tubular wall defining a central axis extending through the flexible member, and a plurality of geometric segments disposed adjacent to the tubular wall, the geometric segments defined by a first plurality of spaced helical grooves formed in the tubular wall at a first angle relative to the central axis and a second plurality of spaced helical grooves formed in the tubular wall at a second angle relative to the central axis, the first angle and the second angle being mutually opposite with respect to the central axis.
[0009] A method of forming a fluid conduit includes forming a flexible member with a tubular wall, the tubular wall defining a central axis extending through the flexible member, and forming a plurality of geometric segments adjacent to the tubular wall, the geometric segments disposed circumferentially about and longitudinally along the central axis and spaced apart relative to each other to define a gap therebetween, the gap sized to be closed by contact between adjacent geometric segments upon a predetermined flexure of the flexible member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a section cut through a portion of a flexible fluid conduit having a structural layer formed in accordance with the present disclosure;
[0011] FIG. 2 is a perspective view of the structural layer of FIG. 1 ;
[0012] FIG. 3 is a side plan view of the structural layer of FIG. 1 ;
[0013] FIG. 4 is an auxiliary view of a one geometric unit of a plurality of geometric units forming the structural layer;
[0014] FIG. 5 is a section cut through the geometric unit of FIG. 4 along line A-A;
[0015] FIGS. 6-8 are section cuts through three embodiments of a conduit having the structural layer of FIG. 1 positioned differently in each embodiment;
[0016] FIGS. 9-13 are front plan views illustrating alternative methods to alter an intermediate layer of the conduit to form the geometric units of the structural layer;
[0017] FIG. 14 is a perspective view showing the structural layer formed by positioning the geometric units on a mesh liner;
[0018] FIG. 15 is a front plan view showing the structural layer formed by positioning the geometric units on the conduit;
[0019] FIG. 16 is a front plan view showing two of the mesh liners of FIG. 12 positioned on respective inner and outer surfaces of the intermediate layer to form the structural layer;
[0020] FIGS. 17-21 are section cuts through the conduit of FIG. 1 depicting the interaction between adjacent geometric units of the structural layer when the conduit is bent;
[0021] FIGS. 22-26 are section cuts through the conduit of FIG. 1 illustrating how dimensional changes to the features of the structural layer impact the flexibility of the conduit when the conduit of is bent;
[0022] FIGS. 27-29 are section cuts through the conduit of FIG. 1 illustrating how the flexibility and compressibility of the intermediate layers and the geometric units of the structural layer effect the flexibility of the conduit;
[0023] FIGS. 30-31 are section cuts through a portion of the conduit having a portion of an intermediate layer embedded between the geometric units of the structural layer; and
[0024] FIG. 32 is a perspective view of a portion of the structural layer of FIG. 1 showing the interaction of the geometric units after the conduit is bent.
DETAILED DESCRIPTION
[0025] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the disclosure is thereby intended. It is further understood that the disclosure includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the disclosure as would normally occur to one skilled in the art to which this disclosure pertains.
[0026] FIG. 1 shows a straight portion of flexible fluid conduit 100 sectioned along its central axis 102 . The conduit 100 includes an outer liner 106 and inner liner 104 that forms a flow path through the conduit 100 . In the embodiment shown, the conduit 100 further includes a structural layer 108 positioned between the inner and outer liners 104 , 106 . The structural layer 108 , as discussed in more detail below, is configured to prevent the restriction of fluid flow along the flow path due to bending or kinking of the conduit 100 .
[0027] As best shown in FIGS. 2 and 3 , the structural layer 108 is formed from a plurality of spaced geometric units 110 positioned circumferentially about the central axis 102 . For purposes of this disclosure, the central axis 102 of the structural layer 108 and the central axis 102 of the conduit 100 are coincident, and any further reference to “central axis” refers to both axes. In the embodiment shown, each geometric unit 110 is formed in the shape of an elongated diamond and has a peripheral gap 111 formed between each adjacent geometric unit in the plurality of geometric units 110 . In other embodiments, the gap 111 is vacuum or air filled. The consecutive gaps between the adjacent geometric units 110 of the structural layer 108 enable the structural layer 108 to flex and to extend and compress axially. As discussed in more detail below, it is the interaction between the spaced adjacent geometric units in the plurality of geometric units 110 that enables the structural layer 108 to reduce restrictions in the flow path when the conduit 100 is subjected to a collapsing or bending force.
[0028] The geometric units 110 are formed from any flexible, semi-flexible, or rigid material that enables practical reproduction of the geometric units 110 in an intended shape and size. Although the geometrics units 110 of FIGS. 2 and 3 are shown as elongated diamonds, other geometric shapes are possible. In some embodiments, for example, the geometric units are circular, square, or triangular. The size, number, and spacing of the geometric units 110 are also variable.
[0029] FIG. 4 depicts an auxiliary view of one geometric unit of the plurality of geometric units 110 when the structural layer 108 is viewed from the arrow 113 of FIG. 3 . FIG. 5 shows a cross section of the geometric unit 110 of FIG. 4 taken along line A-A with the section line oriented perpendicular to a pair of parallel side edges 114 of the one geometric unit 110 . In the embodiment shown, the geometric unit 110 has a rectangular cross section with a constant width W and a constant height H. In other embodiments, however, the width W and the height H of the cross section can vary across the plurality of geometric units 110 .
[0030] FIGS. 6-8 show three embodiments 116 , 117 , 118 of a conduit with the structural layer 108 at a different position on the conduit in each embodiment. The conduit of each of the embodiments includes an inner liner 104 , a woven sleeve 120 , a foamed liner 122 , and an outer liner 106 each radially positioned from inside to outside about the central axis 102 . In the embodiments shown, the woven sleeve 120 is depicted as a one-dimensional line between adjacent conduit layers. The structural layer 108 in each embodiment is at a different position within the conduit. For example, FIG. 6 shows the structural layer 108 positioned on the exterior of the conduit 116 adjacent to the outer liner 106 . FIG. 7 shows the structural layer 108 of the conduit 117 positioned between the inner liner 104 and the woven sleeve 120 . FIG. 8 shows the structural layer 108 positioned within the interior of the conduit 118 adjacent to the flow path on the inside and the inner liner 104 on the outside. The embodiments of FIGS. 6-8 show the conduit as comprising five layers with the structural layer 108 positioned at three different locations within these layers. In other embodiments, the conduit can include lesser or greater numbers of layers with the structural layer 108 positioned between any of the provided layers.
[0031] The structural layer 108 in some embodiments is free to move or float rotationally around and/or axially along the central axis 102 of the conduit regardless of its position within the conduit. In other embodiments, the structural layer 108 is bonded to one or more adjacent layers of the conduit to restrict its relative movement about or along the central axis 102 . The bonding of the structural layer 108 in these embodiments can be accomplished by any practical method. In one embodiment, an adhesive is used to secure the structural layer 108 to one or more of the adjacent conduit layers. In some embodiments in which movement of the structural layer 108 is at least partially restricted, the structural layer 108 and at least one adjacent layer are integrated into a single layer. The integration of the structural layer 108 and the at least one adjacent layer can be accomplished as part of an extrusion process that forms the adjacent layer or by altering the adjacent layer after the extrusion process.
[0032] FIGS. 9-13 schematically illustrate methods to alter the adjacent layer 123 for integration with or formation of the structural layer 108 . FIG. 9 , for example, depicts the use of a tool 124 , such as a laser, to thermally remove portions of the adjacent layer 123 to form each of the geometric units 110 of the structural layer 108 . In other embodiments, the use of the laser 124 can modify a portion of the material from the adjacent layer 123 to release the structural layer 108 . In some embodiments, the tool 124 forms the geometric units 110 by a non-thermal, non-contact method. The tool 124 in these embodiments directs an effect such as a frequency pulse, air wave, ripple effects or the like at the adjacent layer 123 to form each of the geometric units 110 of the structural layer 108 .
[0033] FIG. 10 shows the use of a tool 125 , such as one or more rollers, to form the geometric units 110 on the adjacent layer 123 . In this embodiment, the rollers 125 form the geometric units 110 on the adjacent layer 123 while the adjacent layer 123 is still soft. In some embodiments, such as the embodiment of FIG. 12 , the tool 125 is a rolling tool used on the adjacent layer 123 to relieve or remove material from the adjacent layer 123 , depending on the application, to create the geometric units 110 . The tool 125 in some embodiments is rotated about the adjacent layer 123 in the direction of arrow 126 to form the geometric units 110 . In other embodiments, a plurality of tools rotate about the adjacent layer 123 in opposite directions to form the geometric units 110 . In other embodiments, the rolling tool 125 is fixed and the adjacent layer 123 is rotated in the direction of arrow 127 to form each of the geometric units 110 of the structural layer 108 .
[0034] FIG. 11 depicts the use of one or more cutters 128 to remove material from the adjacent layer 123 after the extrusion process. In one embodiment implementing the cutters 128 , the cutters 128 are circular cutters. In some embodiments, such as the embodiment shown in FIG. 13 , a fixed cutting tool 129 is used and the adjacent layer 123 is rotated about the fixed cutting tool 129 to form the geometric units 110 . The tool can be, for example, a rotating padding tool, a blade or scribing tool ( FIG. 13 ), or the like, or any combination thereof.
[0035] In each of the methods depicted in FIGS. 9-13 , the adjacent layer 123 is extruded to a thickness that allows approximately half of the thickness of the adjacent layer 123 to be compressed or removed to form the geometric units 110 of the structural layer 108 . In some of these embodiments, less than approximately half of the thickness of the adjacent layer is compressed or removed to form the geometric units 110 .
[0036] FIGS. 14-16 schematically depict methods to form the structural layer 108 of the conduit by positioning the geometric units 110 on the adjacent layer 130 . FIG. 14 , for example, shows the geometrics units 110 attached to a mesh strip 131 . In this embodiment, the mesh strip 131 is wrapped around and bonded to the adjacent layer 130 to form the structural layer 108 . FIG. 15 shows the geometric units 110 bonded directly to the adjacent layer 130 without the use of a substrate, such as the mesh strip 131 of FIG. 14 . FIG. 16 shows the adjacent layer 130 with a first plurality of geometric units 132 attached to a first mesh and a second plurality of geometric units 133 attached to a second mesh. In this embodiment, the first mesh is bonded to an inner surface 135 of the adjacent layer 130 and the second mesh is bonded to an outer surface 137 of the adjacent layer 130 to form multiple structural layers.
[0037] FIGS. 17-21 schematically depict the interaction between adjacent geometric units 110 of the structural layer 108 when the conduit 100 of FIG. 1 is bent. FIG. 17 shows the conduit 100 of FIG. 1 having a downward bend along its central axis 102 . In the embodiment of FIG. 17 , the downward bend of the conduit 100 produces an outer bend 134 along the conduit 100 above the central axis 102 and an inner bend 136 along the conduit 100 below the central axis 102 .
[0038] For purposes of this disclosure, the relative directions “down”, “downward”, or “downwardly” refer to a direction pointing toward the bottom of the drawing sheet and the relative directions “up”, “upward”, or “upwardly” refer to a direction pointing toward the top of the drawing sheet. Similarly, the terms “bottom” or “below” refer to relative positions closer to the bottom of the drawing sheet and the terms “top” or “above” refer to relative positions closer to the top of the drawing sheet.
[0039] The following subscripts are used in conjunction with the letter X to denote the various geometric unit-to-geometric unit gap distances shown in the figures: (s)=straight conduit, (d)=downward bent conduit, (o)=outer bend position, (i)=inner bend position, (t)=tip gap between adjacent geometric units, and (b)=base gap between adjacent geometric units. For example, the gap distance X dot refers to the gap measured on a downward bent conduit (the subscript “d”) at the outer bend position (the subscript “o”) at the tip of the geometric units (the subscript “t”).
[0040] FIG. 18 shows two adjacent geometric units 110 positioned above the inner liner 104 at the approximate position of the outer bend 134 before the conduit 100 is bent. In the straight conduit of FIG. 18 , the side edges 114 of the adjacent geometric units 110 are parallel with respect to each other. Accordingly, the gap between the geometric units 110 at the base of the geometric units 110 or the base gap X sob and the gap between the geometric units 110 at the tip of the geometric units 110 or the tip gap X soy are equal. In other words, the base gap X sob and the tip gap X sot can be collectively referred to as the straight gap X so of the straight conduit at the position of the outer bend 134 . When the conduit 100 is bent downward at the outer bend 134 as depicted in FIGS. 17 and 19 , the base gap of the bent conduit X dob is approximately equal to or greater than the straight gap of the straight conduit X so . The tip gap of the bent conduit X dot , however, is typically greater than the straight gap of the straight conduit X so since the adjacent geometric units 110 rotate away from each other as the inner liner 104 bends downward.
[0041] FIG. 20 shows two adjacent geometric units 110 positioned below the inner liner 104 at the approximate position of the inner bend 136 before the conduit 100 is bent. In the straight conduit of FIG. 20 , the side edges 114 of the adjacent geometric units 110 are parallel with respect to each other. Accordingly, the gap between the geometric units 110 at the base of the geometric units 110 X sib and the gap between the geometric units 110 at the tip of the geometric units X sit are equal. In other words, the base gap X sib and the tip gap X sit can be collectively referred to as the straight gap X si of the straight conduit at the position of the inner bend 136 .
[0042] When the conduit 100 is bent downward at the inner bend 136 as depicted in FIGS. 17 and 21 , the base gap of the bent conduit X dib is approximately equal to or less than the straight gap of the straight conduit X si . The tip gap of the bent conduit X dit , however, can range from slightly less than the straight gap of the straight conduit X si to zero. In other words, after a predefined amount of bending, the tips of the geometric units 110 at the inner bend 136 contact each other and provide a positive stop to prevent further bending of the conduit 100 at positions adjacent to the contacting geometric units 110 . The geometric unit-to-geometric unit contact between each of the adjacent geometric units in the plurality of geometric units 110 prevents the conduit 100 from collapsing into the flow path and substantially restricting the fluid flow therethrough.
[0043] FIG. 22 shows two adjacent geometric units 110 positioned above the inner liner 104 at an inner bend 136 of the conduit 100 after the conduit 100 of FIG. 1 has been bent upwardly (not shown). The adjacent geometric units 110 have a height H, a width W, a base gap X, and form a contact angle A having its vertex at the contact point of the geometric units 110 . The maximum contact angle A formed between each of the adjacent geometric units in the plurality of geometric units 110 is one of a number of factors that determines the relative amount of bend of the conduit 100 over its length.
[0044] As shown by comparing FIGS. 22 and 23 , reducing the base gap between the adjacent geometric units 110 from X to X′ while holding constant the height H c and the width W c of the geometric units 110 reduces the contact angle from A to A′ and, therefore, reduces the overall amount of bend in the conduit 100 . The contact angle A′ is reduced because the reduction in the base gap between the adjacent geometric units 110 moves the effective pivot points of the geometric units 110 closer together as the conduit 100 bends in the upward direction. Accordingly, the geometric units 110 rotate less before the tips of the geometric units 110 contact each other. If the base gap X between the adjacent geometric units 110 of FIG. 23 is increased, the contact angle A similarly increases, allowing more overall bend in the conduit 100 before the tips of the geometric units 110 contact each other.
[0045] As shown by comparing FIG. 22 and FIG. 24 , reducing the height of the adjacent geometric units 110 from H to H′ while holding constant the base gap X c between the geometric units 110 and the width W c of the geometric units 110 increases the contact angle from A to A″ and, therefore, increases the overall amount of bend in the conduit 100 . The contact angle A″ is increased because the reduction in the height of the adjacent geometric units 110 allows the geometric units 110 to rotate further about their effective pivot points before the tips of the geometric units 110 contact each other. If the height H of the adjacent geometric units 110 of FIG. 24 is increased, the contact angle A decreases, allowing less overall bend in the conduit 100 before the tips of the geometric units 110 contact each other.
[0046] As explained with reference to FIGS. 25 and 26 , reducing the width of each of the geometric units 110 from W ( FIG. 25 ) to W′ ( FIG. 26 ) while holding constant the base gap X c between the geometric units 110 and the height H c of the geometric units 110 results in more flex regions 140 between the geometric units 110 for the same overall length of conduit 100 . Increasing the number of flex regions along the length of the conduit increases the overall flexibility of the conduit because the cumulative length of the conduit capable of flexing increases with each added flex region 140 .
[0047] As shown in FIGS. 27 and 28 , a reduction in the flexibility of the liner 104 can reduce the overall flexibility of the conduit 100 . In a straight conduit, the base gaps between the geometric units 110 in each of FIGS. 27 and 28 are equal. The highly flexible inner liner 104 of FIG. 27 allows the maximum distance between the effective pivot points of the geometric units 110 in the bent conduit. In contrast, the more rigid inner liner 104 ′ of FIG. 28 reduces the distance between the effective pivot points in the geometric units 110 in the bent conduit. In particular, a line 142 connecting the effective pivot points of the geometric units 110 of FIG. 27 falls along the path of the inner liner 104 , indicating that the line 142 represents the maximum distance between the effective pivots points. In contrast, a line 144 connecting the effective pivot points of the geometric units 110 of FIG. 28 does not fall along the path of the inner liner 104 ′ due to the reduced flexibility of the inner liner 104 ′.
[0048] FIG. 29 illustrates the effect that the compressibility of the geometric unit material has on the contact angle between the adjacent geometric units 110 . In the embodiment shown, the material at the contact point 146 between the two adjacent geometric units 110 is slightly deformed due to the compression of the material. For purposes of this disclosure, the term “non-deformed contact angle” refers to the angle formed when adjacent geometric units first make contact at the contact angle 146 , but before either of the geometric units begins to deform. The term “fully-deformed contact angle” refers to the angle formed after adjacent geometric units have made contact at the contact point 146 and after both of the geometric units are fully deformed. As the geometric units 110 become more compressible, especially at their tip, the difference between the non-deformed contact angle and the fully-deformed contact angle increases between the adjacent geometric units 110 , resulting in more overall flexibility in the conduit. The converse is also true. That is, as the geometric units 110 become less compressible, the difference between the non-deformed contact angle and the fully-deformed contact angle decreases between the adjacent geometric units 110 , resulting in reduced overall flexibility in the conduit.
[0049] FIGS. 30 and 31 illustrate the effect that integration of the structural layer 108 with another layer has on the flexibility of the conduit 100 . FIG. 30 depicts two adjacent geometric units 110 in a straight section of the conduit 100 . The geometric units 110 are adjacent to the inner liner 104 and integrated with the outer liner 206 . The gap between the adjacent geometric units 110 is occupied by the material of the outer liner 206 . FIG. 31 shows the two adjacent geometric units 110 after the conduit 100 of FIG. 30 has been upwardly bent. In this embodiment, as the geometric units 110 come together due to the bending of the conduit 100 , the portion 210 of the outer liner 206 between the geometric units 110 is compressed. The density of the outer liner material, therefore, determines how close the geometric units 110 can get to each other. Bending of the conduit 100 in the opposite direction causes the outer liner material to stretch between the geometric units 110 .
[0050] FIG. 32 shows the interaction among five geometric units 110 of the structural layer 108 when the conduit 100 of FIG. 1 is bent. Although each of the geometric units 110 is shown interacting with adjacent geometric units substantially along its side edges 114 , the interaction among the geometric units 110 can also occur as point contacts. For example, the adjacent geometric units 110 in some embodiments can make point contact at or near respective perimeter vertexes 148 instead of edge contact along the side edges 114 . In some embodiments, the adjacent geometric units 110 can interact as a combination of point contact at the perimeter vertexes 148 and edge contact along the side edges 114 . Various factors can effect whether or not adjacent geometric units 110 interact as point contact or edge contact. For example, in some embodiments, the relative amount of twist along different portions of the conduit 100 effects the type of contact between the adjacent geometric units 110 at each different portion of the conduit 100 .
[0051] The geometric reinforced fluid conduit of the present disclosure is suitable for automotive, household, commercial, aerospace, medical, and industrial uses. The plurality of geometrical reinforcement members enable the structural layer to flex and to extend and compress axially.
[0052] While the disclosure has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the disclosure are desired to be protected. | A fluid conduit includes a flexible member having a tubular wall and a plurality of geometric segments located adjacent to the tubular wall. The geometric segments are disposed about a central axis of the conduit and spaced apart relative to each other to define a gap therebetween. The gap is sized to be closed by contact between adjacent geometric segments upon a predetermined flexure of the flexible member. A method of forming the conduit includes forming a flexible member with a tubular wall and forming a plurality of grooves about the central axis in the tubular wall. The geometric segments in one embodiment are formed from the intersections of a first plurality of helical grooves formed at a first angle relative to the central axis and a second plurality of helical grooves formed at a second angle mutually opposite from the first angle. | 8 |
BACKGROUND OF THE INVENTION
Electric drive carts are not new to the art. However, an electric drive cart that has the attributes of the present invention does not exist. The present invention is compact, powerful, electrically driven game cart. The cart was originally developed to retrieve big game animals from the roughest of terrains. The low center of gravity permits the cart to remain stable even when used at a heavy incline. This anti roller feature allows the cart to traverse large rocks and logs while fully loaded. The support frame, axel position and handle bars are positioned so the load is easily balance allowing the user to move large objects with very little effort. This makes remote retrieval possible for any user.
The powerful motor operates the drive train with virtually unstoppable power, but is compact enough to store in the box of a pickup truck.
The present device allows a lone individual the ability to remove large big game animals by themselves, while quietly, odorlessly and effortlessly walking through the terrain.
The uses to the cart are limitless; one use is to haul hunting or camping gear. It is used for hauling bait, hunting stands and firewood. It also has unlimited uses around a farm. The device is safe for indoor operation for such projects as moving, construction and any other use of an indoor application as well as outdoor.
Other embodiments include a remote for the winch, a hitch attachment for ATV's, a pulley system to use with the winch for loading, dumping capabilities and tire chains.
The applicant recognizes that the follow prior art is available but not relevant to the present invention. U.S. Pat. No. 7,886,853 issued to Konopa on Feb. 15, 2011, entitled “Motorized hand cart for lifting and moving large heavy objects”, U.S. Pat. No. 4,429,758 issued to Mechulam on Feb. 7, 1984, entitled “Motorized cart”, U.S. Pat. No. 6,062,328 issued to Campbell et. al. on May 16, 2000, entitled “Electric handcart”, United States Patent issued to Yamano on Oct. 12, 2010, entitled “Traveling device”, U.S. Pat. No. 7,210,545 issued to Waid on May 1, 2007, entitled “Motorized beach cart”, U.S. Pat. No. 6,398,477 issued on Jun. 4, 2002, entitled “Electric hand truck”, U.S. Pat. No. 6,688,635 issued to Watts on Feb. 10, 2004, entitled “Multi-purpose deer hunting cart”.
SUMMARY OF THE INVENTION
The present invention is an electrical drive cart. The cart comprises a support frame that has a long axis. The support frame is comprised of two essentially parallel, spaced apart side members forming the long axis. The frame also includes a front cross member, a back cross member and at least two additional cross members located between the front cross member and the back cross member. There is also a center cross member essentially located on the long axis and essentially equally spaced apart from the side members.
The support frame has at least two wheel fender support frames and a wheel fender mounted on each wheel fender support frame.
The support frame of the invention also has surmounted upon it a wheel axle. This wheel axle has two opposing ends with a hub drive assembly mounted on each end of the wheel axle. The hub drive assembly has locking wheel hub capabilities.
The support frame of this invention has a mounting tower mounted near the front cross member and it has a top end. This top end has a pulley to guide a cable mounted on the mounting tower near the top end.
The cart has a winch mounted on the support frame near the front member. The cart has a tow plate mounted on the front cross member.
The cart carries at least one battery, each battery is housed in a battery frame. The battery frame is attached to the support frame.
The cart is electrically driven with a drive assembly comprised of a drive plate mounted on the support frame that has a position-adjustable variable speed drive motor mounted on the drive plate. The drive motor has a drive axle and attached to the drive axle is a chain sprocket. Upon the drive sprocket is a drive chain that connects the drive chain to the hub drive assembly.
There are also present at least one control handle mounted on a speed control throttle. The speed control that is mounted on a speed control bracket is mounted to the handle bar support. The speed control is electrically connected to at least one direct current controller and at least one the batteries.
There is a freewheeling lockout hub mounted to the drive axle to drive the winch.
The cart also has at least two handle bars; each handle bar is rotatable with respect to a forward and backward motion. Each of the handle bars is rotatably affixed to the support frame by use of a handle bar plate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the support frame from the top.
FIG. 2 shows the support frame from the side.
FIG. 3 shows the wheel for the electric cart.
FIG. 4 shows the wheel lockout assembly.
FIG. 5 a shows the hub drive assembly.
FIG. 5 b shows the hub drive assembly.
FIG. 6 shows the mounted axle and the hub drive assembly.
FIG. 7 shows the winch tower.
FIG. 8 shows the winch tower support from the front.
FIG. 9 shows the winch tower support from the side.
FIG. 10 is the drive plate from the top.
FIG. 11 is the motor mount from the top.
FIG. 12 shows the winch and its control.
FIG. 13 shows a handle bar plate.
FIG. 14 shows a handle bar.
FIG. 15 shows speed or throttle control bracket.
FIG. 16A shows a speed or throttle control handle.
FIG. 16B shows a speed or throttle control handle.
FIG. 17 shows the near end of the support frame with the control panel.
FIG. 18 shows the distal end of the electrically driven cart.
FIG. 19 shows the battery charger.
FIG. 20 shows the power converter.
FIG. 21 is an electrical schematic of the electrically driven cart.
FIG. 22 is an electrical schematic of the electrically driven cart.
FIG. 23 is an electrical schematic of the electrically driven cart.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the support frame 4 of the electric drive cart 2 from the top. The support frame 4 consists of two side members 6 and 8 . The first side member 6 and the second side member 8 are joined by the front cross member 10 at the support frame 4 near end 94 . The first side member 6 and the second side member 8 are joined by the back cross member 12 at the support frame 4 distal end 96 . The first side member 6 and the second side member 8 are joined by at least three more cross member supports. The first cross member 14 joins both side members 6 and 8 near the near end 94 . The second cross member 16 joins both of the side members 6 and 8 near the distal end 96 for the support frame 4 . There is also an additional cross member 15 that joins both the first and second side members 6 and 8 near the mid section 132 of the support frame 4 . The center cross member 18 runs length wise from the near end 94 to the distal end 96 adding additional support. Other embodiments have more than one of the cross members' 18 running length wise.
The first side member 6 has a first fender support 20 attached to it beginning at the mid section 132 and running to near the distal end 96 . The second side member 8 has a second fender support 22 attached to it beginning at the mid section 132 and running to the distal end 96 . Each fender support 20 and 22 has two braces 134 that support each fender 24 and 26 .
Under the second cross member 16 is the axle 28 that runs from the first wheel 30 to the second wheel 32 . The axle 28 is affixed to the support frame 4 , which is explained in greater detail further within the specification. Each of the wheels 30 and 32 has a hub 34 and 36 that the axle 28 runs through. The axle 28 has a near end 38 and a distal end 40 . Both the near end 38 and the distal end 40 of the axle 28 have a hub lockout assembly 42 . The hub lockout assembly 42 engages the hub 34 and or 36 to drive the electric cart 2 . The hub lockout assembly 42 and the drive aspects will be discussed further in the appropriate figures.
The electric cart 2 can also be equipped with a winch 52 , not shown, the winch 52 runs from the drive mechanism 60 and will also be discussed further.
FIG. 2 shows the support frame 4 from the side. This shows the first side member 6 . Each side member 6 and 8 has an upper member 136 and a lower member 138 . At this point it is assumed that each side member 6 and 8 are identical in regard to their structural aspects. Also visible in this figure is the distal end plate 144 at the distal end 96 of the side member 6 . Mounted to the near end 94 is the tow plate 54 . The tow plate 54 is important because there are other embodiments that originate from the tow plate 54 that will come into play later.
FIG. 3 shows the wheel 30 for the electric cart 2 . Also visible is the axle near end 38 , wheel hub 34 and axle 28 . There is also one of many openings 110 in the locking hub. Here there is one opening 110 where in actuality there are at least eight. These openings 110 allow the hub to be locked and drive the wheel 30 .
FIG. 4 shows the hub lockout assembly 42 . This aspect of the present invention is one discovery that gives the invention a greater utility over the prior art. The hub lockout assembly 42 slides over the axle 28 at its near end 38 . The hub drive assembly 106 is on the back side of the hub lockout assembly 42 . The first wheel hub 34 has a drive locking pin 98 . The drive locking pin 98 is in a housing 102 that is spring bias by a bias spring 104 . When the drive locking pin 98 is not engaged the wheel 30 moves freely. When the drive locking pin 98 is engaged it will pass through the opening 110 locking the hub lockout assembly 42 to the hub drive assembly 106 and therefore directly to the axle 28 . When the axle 28 is being driven by the electric motor 64 it will drive the electrically driven cart 2 . Each side of the electric driven cart 2 has a hub lock out assembly 42 . Therefore one hub lockout assembly 42 can be engaged while the other is not. Also both can be locked in giving a direct drive from both wheels 30 and 32 . The other alternative is that neither of the hub lockout assemblies 42 is engaged and the wheels 30 and 32 spin freely. Designation 108 is an axle nut and designation 100 is a drive locking pin knob.
FIGS. 5 a and 5 b shows the hub drive assembly 106 . Again this component is attached directly to axle 28 . Here the multiple openings 110 are visible. The drive locking pin 98 can easily lock into the nearest opening 110 when it is engaged. The hub drive assembly would function in the same manner even if there was only one opening 110 . It is just faster to have multiple openings 110 for the engagement of the drive locking pin 98 .
FIG. 6 shows the mounted axle 28 and the hub drive assemblies 106 . The axle 28 is mounted to plates 146 . There are two of these plates 146 with the attachment being on the bottom of the plate 146 which is not visible. The axle 28 has a near end 38 and a distal end 40 . Near each of the ends of 38 and 40 there is a hub drive assembly 106 attached to the axle 28 . Also visible are the battery supports 56 and 58 . These supports 56 and 58 have the capacity to each carry one battery. The battery supports 56 and 58 have the ability to have the battery slide out at the rear of each support 56 and 58 . The batteries are secured in place by a restraint, typically a bungee strap.
FIG. 7 shows the winch tower 44 . In FIG. 2 we discussed the tow plate 54 and that it has multiple functions. One of those functions is to support a winch tower 44 . The winch tower 44 is attached to the tow plate 54 and is upright away from the support frame 4 of the electrically drive cart 2 . The winch tower 44 has a top end 46 . This top end 46 supports a pulley 48 and in other embodiments supports multiple pulleys 48 . The tow plate 54 has a bracket 148 that support the winch tower 44 that is quickly detachable.
Also quickly detachable from the tow plate 54 is a pneumatic tire 184 , discussed later.
FIG. 8 shows the winch tower 44 bracket 148 from the front. Visible here at the near end 94 of the support frame 4 is the Reese hitch 112 . This is another aspect of the tow plate 54 . The Reese hitch 112 allows the electrically driven cart 2 to be towed by a vehicle, preferable an ATV. The tow plate 54 also has the winch tower 44 bracket 148 where the winch tower 44 is attached by a pin 150 . Visible at the top end 46 is the pulley 48 . This pulley 48 supports the cable 50 . The cable 50 is stored in the winch 52 . This cable runs from the winch 52 through a bronze guide bushing 196 , not shown, guiding the cable 50 to the pulley 48 and terminates in this embodiment with a D snap ring 198 .
FIG. 9 shows the winch tower 44 bracket 148 from the side. The near end 94 of the support frame 4 has the tow plate 54 attached to it. The bracket 148 supports the winch tower 44 by a pin 150 attachment.
FIG. 10 is the drive plate 62 from the top. The drive plate 62 is mounted on the support frame 4 . The drive plate 62 supports the drive assembly 60 , not shown.
FIG. 11 is the motor mount plate 92 from the top. The motor mount plate 92 has a near end 114 and a distal end 116 . This motor mount plate 92 is mounted to the support frame 4 with the near end 114 facing the near end 94 of the support frame 4 . The motor mounting plate 92 has a series of elongated openings 118 . The motor 64 is mounted to the motor mounting plate 92 in an adjustable manner. The elongated slots or openings 118 allow the motor 64 to slide and taking slack out of the drive chain 70 , not shown. The adjustment feature also allows for the drive chain 70 to be loosened allowing for maintenance.
FIG. 12 shows the winch 52 and its control. The winch 52 is slidably mounted to the axle 28 . There is a winch locking handle 152 that has three positions of locking, not shown here. The winch control handle 152 is attached to winch control shifter 122 which controls the actual movement of the winch 52 with regard to its position on the axle 28 . In this figure the winch 52 is locked out and is inoperable. The second position is a neutral position where the winch 52 is unlocked but not engaged. On the axle 28 is a winch driver 120 that is affixed to the axle 28 . In the third position the winch 52 engages or meshes with the winch drive 120 and locks into position engaging the winch 52 . Generally this is done with the wheels 30 and 32 unlocked. The drive is energized thus rotating the winch 52 and drawing the winch cable 50 around the winch 52 . If the throttle is ran in reverse the winch cable 50 is drawn out. Also visible are the winch bearings 124 and bronze bushings 126 .
The winch 52 and its operation is also key to the utility of the invention in that it has been discovered that the electrically driven cart 2 can be operated in the steepest of terrain by simply drawing the winch cable 50 out a significant distance, then securing it around a structure such as a tree. With the wheels 30 and 32 unlocked the operator can simply draw the winch 50 in and pull the electrically driven cart 2 up the incline loaded without any guidance from the user except throttle control and minor steering.
FIG. 13 shows a handle bar plate 84 . There are two handle bar supports 84 and 86 , both being identical the applicant will disclose the first handle bar plate 84 with the understanding that the other or second handle bar plate 86 is identical and is attached to the opposite side or second side member 8 . With that said the first handle bar plate 84 attaches to the distal end 96 of the support frame 4 . The handle bar plate 84 has multiple openings therethrough 154 for adjusting the handle bars 88 and 90 to height of the operator. The handle bar plate 84 is attached to the distal end 160 with the handle bars 88 and 90 being attached with a pin 156 giving the quick adjustable capabilities.
FIG. 14 shows a handle bar 88 . There are two handle bar 88 and 90 , both being identical the applicant will disclose the first handle bar with the understanding that the other or second handle bar 90 is identical and is attached to the opposite side or second side member 8 . The handle bar 88 has a near end 158 and a distal end 160 . The near end 158 attaches to the distal end 96 of the electrically driven cart 2 . The distal end 160 of the handle bar 88 is where the throttle control bracket 80 is mounted.
FIG. 15 shows throttle control bracket 80 . The throttle control bracket 80 has the throttle control 74 is attached to it. The first handle bar 88 and the second handle bar 90 are identical. So each of the handle bars 88 and 90 are mounted and equipped in the same manner.
FIG. 16 shows the speed control or throttle control handles 74 and 76 . Each of the throttle controls 74 and 76 are identical as is their attachment. The first throttle control 74 is attached to the distal end 160 of the handle bar 88 . Each of the throttle controls 74 and 76 is wired to the power source or batteries 164 , 166 and the motor 64 to energize the drive assembly 60 to operate the winch 52 and drive the wheels 30 and 32 .
FIG. 17 shows the near end 94 of the support frame 4 with the control panel 168 . The control panel 168 has the on/off power switch 170 , the light on/off switch 172 , battery charge indicator 174 , tow plate 54 , winch forward and reverse switch 176 , the remote control power point 178 , rear LED light 180 and the high/low speed switch 182 . Also visible are the handle bar plates 84 and 86 . The openings therethrough 154 with the pins 156 are also clear as well as the first handle bar 88 and the second handle bar 90 .
This embodiment has a pneumatic tire 184 detachably mounted by the pin 186 to the tow plate 54 .
FIG. 18 shows the distal end 96 of the electrically driven cart 2 . Shown here is the front LED light 188 and the recharge outlet 190 . Also visible here are the first fender 24 and second fender 26 , with three center cross members 18 . This also shows the first battery 164 and the second battery 166 as well as the battery charger 192 .
FIG. 19 shows the battery charger 192 close up.
FIG. 20 shows the power converter 194 of the invention close up.
FIG. 21 is an electrical schematic of the electrically driven cart.
FIG. 22 is an electrical schematic of the electrically driven cart.
FIG. 23 is an electrical schematic of the electrically driven cart.
Another embodiment includes different sized and configured poly binds that are mounted to the cart. | The present invention is an electrically driven cart. The cart allows one person to do the job of many. The cart features silent running, exceptional power on demand and ergonomical design. The applications for the present invention uses are limitless. They do include big game hauler, farming applications, vendor uses, outdoor uses, indoor uses and many others. The electrically driven cart features variable speed control for either hand, remote speed control, winch, wheel lockouts, front and rear lighting, charge indicator, convenient control panel and a detachedly mounted pneumatic tire. The cart is light weight and can easily be handled by one person in any of the arenas mentioned prior. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to a device for locking a roll-up curtain used for protection of window openings and the like, particularly for use with mosquito-nets, in the fully drawn or unwound position of the curtain, which position substantially covers the opening.
DESCRIPTION OF THE PRIOR ART
It is known that to protect rooms from mosquitoes and other insects, use is generally made of screens consisting of a close-meshed metal net fastened to a frame mounted in the window opening. More recently, it has been suggested to use a roll-up curtain with a close-meshed net suited to allow the window to be opened. The curtain is fastened at the upper edge to a take-up roller, and at the lower edge to a flap section which is slidable at its ends inside guides formed by the window frame posts.
Such a section usually includes a device for locking the roll-up curtain in the fully drawn position. The conventional locking devices generally consist of latch means driven by spring means and suited to fit, in the fully drawn position, into a seat made beside the guides and integral with their lower end.
The latches are sliding and supported by the flap section and are suited to stop, in the fully drawn position, against strikers provided on the section itself.
Such a solution may sometimes cause the disengagement of latches from the respective seats, owing to possible oscillations of the section or to any indentation of said guides in the associated guide-bearing sections.
Furthermore, the known devices require an extreme accuracy in positioning the guides, owing to the fact that the latches are stopping against the section, and the respective stop seats are integral with the guides themselves.
As a matter of fact, an improper mounting of guides may make it impossible for the stop seats to be engaged by latches.
In the known devices, when it is additionally required to move the latches from outside the room to be protected, it is necessary to provide further latches, with associated guides and lock seats, which can be operated from the outside, said latter latches being connected with the other latches, which can be operated from inside. Obviously, the constructional complexity resulting from the doubling of latches, and of their associated guides and lock seats, besides having an impact on costs, also further enhances the drawbacks mentioned above.
Moreover, the fact that the device can be operated only from the mounting side of the latches and associated lock seats, i.e., from the inside of the room to be protected, is a serious drawback too.
Besides that, the known devices leave openings, at the ends of the section, not sufficiently protected and often present a roll-up curtain not perfectly stretched and of difficult operation.
SUMMARY OF THE INVENTION
The object of the invention is to find solutions for the drawbacks mentioned above, with a device ensuring perfect locking of a roll-up curtain, for protection of window openings and the like, in the fully drawn position.
A further object of this invention is to present a locking device that is characterized by simplicity, ease of mounting, true functionality and reliability, as well as versatility.
The aforementioned objects are achieved by this device for locking a roll-up curtain in the fully drawn position, for protection of window openings and the like; said device includes a flap section defining, in the upper side, a lock seat for the lower edge of the curtain, and having at the opposite ends, two sliders which are driven in respective vertical guides inserted in the posts of a frame enclosing said opening. Two latch means which are symmetrically driven and sliding longitudinally as to said section, are suited to protrude from the ends of the same section so to engage, in said fully drawn position, respective lock seats made in associated bases of said posts. Push-button means are provided with elastic means suited to drive said latch means elastically outwards, and suited to be operate for releasing the device.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of this invention will be evident from the description of a preferred form of the device for locking a roll-up curtain, for protection of window openings and the like, in the fully drawn position, shown in the drawings enclosed herewith, where:
FIG. 1 shows a front view, partial and sectional, of the device according to this invention.
FIG. 1a sectional view according to the line I--I of FIG. 1.
FIG. 2 shows a detailed view of the engagement area of said latch means in said lock seat.
FIG. 3 shows a sectional view of the section according to the line III--III of FIG. 1.
FIG. 4 shows a sectional view of the section according to the line IV--IV of FIG. 1.
FIG. 5 shows a sectional view of the locking area according to the line V--V of FIG. 2.
FIG. 6 shows a sectional view of a slider of the section according to the line VI--VI of FIG. 1.
FIG. 7 shows an enlarged view of the detail A in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With particular reference to said figures, a roll-up curtain 1, as illustrated, if for protection of the opening 2 of a window or the like, e.g., to avoid the passage of mosquitoes.
The curtain is mounted so as to be rolled up to the upper side (top of FIG. 1) on a roller device of known type, which accordingly is not shown in the drawings.
A flap section 3 is fastened to the lower edge of the curtain 1, and bears the locking device which is the subject of this invention. The section 3 slides at its ends, by means of special heads 4, in two vertical guides 5 inserted in the posts 6 of a metal frame enclosing the window opening 2. The section 3 includes, as may be seen from FIG. 3, two walls 3a,3b, vertically facing one another, and made integral with each other by an upper septum 3c and by a lower septum 3d; septa 3c,3d extend horizontally for the whole length of the section 3.
The upper septum 3c has an increased thickness and forms opposed dovetail seats 7 for the insertion of respective handgrips 8, that are suited to make the curtain movement easier and protrude from the opposed faces of the section 3. The upper septum 3c defines the bottom of the seat 9 for mounting two complementary strips 10,11, designed for clamping the lower edge of the curtain 1, as shown in the enlarged detail A in FIG. 7.
The strips 10,11, each have longitudinally a respective tooth 10a,11a, with triangular contour, suited to couple with a corresponding slot of the other one. On the opposite faces from the teeth 10a,11a, the strips 10,11, respectively include two saw-tooth ribs 10b,11b, suited to fit into corresponding recesses of the seat 9 so as to avoid extraction of the strips themselves. The strips are inserted into the seat 9 by the elastic outward deformation of the walls 3a,3b.
Under the lower septum 3d, on the contrary, the coupling seat 12 of the body 13 of a small brush 14 is positioned. The brush 14 extends longitudinally for the whole length of the section and is suited to provide closure on the base of the opening 2.
The facing walls 3a,3b, of the section 3, bear respective longitudinal slots 15 which communicate with associated channels 16 defined, inside the section 3 itself, by two little walls 3e formed by the walls 3a,3b, in basically a central position between the septa 3c,3d.
The channels 16 define the sliding seat for two respective latches 17 making up the locking means of the device.
In practice, both latches 17 are mounted lined-up in a single channel 16, on the inward side facing the room to be protected. The latches 17 are urged in opposite directions, towards the section ends, by respective helical springs 18 acting in correspondence with a handle 19, shown in detail in FIG. 4.
The handle 19 includes a body 20 which is fastened to the section 3 at the center by means of a screw 21 which is tightened with a nut 22 held in the same body 20 and inserted in the channel 16. The body 20 forms opposed cylindrical seats 20a, housing two cup-shaped push buttons 23. Springs 18 are mounted inside the push buttons 23. The springs 18 act on the bottom of the seats 20a by compression.
The push buttons 23 externally form an anchor 24 which is inserted and slides in the channel 16. The buttons 23 are made integral with a respective latch 17 by a pin 25.
The heads 4 are provided with a slider 26 of flattened shape, which is suited to be fitted inside the guide 5, as can be seen in FIGS. 1 and 1a. The slider 26 forms, in the upper side, an extension 26a with reduced thickness, where the curtain 1 is fastened by a special rivet 27.
The slider extends from a transversal plate 28 which is suited to act as a cover of the section end; the plate 28 includes two openings 29 corresponding to the channels 16 of the section, to allow the latches 17 to come through (see FIG. 6).
From the inner face of the plate 28, an extension 30 protrudes, having an H section, which extension is inserted by pressure between the little walls 3e of the section. The posts 6 are made up of a guide-bearing channel section, fastened to the wall by means of screws 31.
The guides 5 are, in their turn, made up on an H-section, provided with folded edges 5a between which a vertical opening is defined, where the sliders 26 of the heads 4 are inserted so as to slide (see FIG. 1a). In the lower ends of the posts 6, a respective base 32 is placed, to define the engaging seat of the latches 17. Such base 32 is made up of a body 33 having a basically parallelpipedal shape, with a vertical median slit 34 into which the slider 26 can fit.
The body 33 is inserted into a shoe housing 35 having a channel section, and being fastened to the wall by a screw 36.
The shoe housing 35 has a tab 35a in the upper side, associated with the lower end of the post 6. The body 33 presents, in the upper side, a narrowed portion 33a on which the guide 5 is engaged; the portion 33a defines, peripherally as to the top of the body 33, a shoulder 33b on which the same guide 5 is resting. The body 33 includes, made on the opposed faces, two oblong recesses 37 extending horizontally, in which respective levers 38,39, are mounted so that they may slide.
The lever 38 presents a transversal pin 40 by which it is made integral with a corresponding hole of the lever 39, so as to form a release leverage. The pin 40 passes through a slot 41 passing longitudinally as to the oblong recesses 37.
The levers 38,39, have respective transversal teeth 38a,39a, protruding from the edge of the shoe 35 and suited to allow the leverage to move along the recesses 37.
The levers 38,39, define, according to the mounting side of the locking device, the front striker of the latches 17 in correspondence with a lock seat defined by the associated recess 37 in the body 33 of the base 32. The recesses 37 have a slightly greater height in the inward side of the opening 2, and they are a little higher than the latches 17.
Under said lock seat, the base 32 presents, at opposed sides, two wings 42 protruding so as to act as a protection of the angle area corresponding, in practice, to the ends of the small brush 14.
Finally, the base 32 includes a horizontal hole, made in its lower side, for an adjusting screw 43 which is suited to act on the bottom of the shoe housing 35, so as to bring about a suitable inclination of the base itself. The operation of the device may be easily understood from the above description. In a partially or totally open position of the opening 2, the latches 17 strike against the edge 5a of the guides 5, as it is shown in FIGS. 1 and 1a. When the section 3 is lowered to the fully drawn position, the ends of the latches 17 snap into the respective lock seats defined by the recesses 37, as it is shown in FIGS. 2 and 5.
In fact, the latches 17 are pushed by the respective springs 18 acting on the push-buttons 23 guided in the channel 16 of the section 3 and integral with the same latches.
In the fully drawn position, the push-buttons 23 take the position indicated by dotted line 23a in FIG. 4, partially extracted form the associated seats 20a of the body 20 of the handle 19.
In said drawn position, the device assures the locking of the roll-up curtain 1. In fact, since the latches 17 are inserted with their ends in the lock seats provided in the bases 32, and strike elastically against the teeth 38a of the levers 38, the mutual engagement is assured even in the case of oscillations of the section 3. Said engagement is also assured even when there are slight clearances between the section 3 and the guides 5. Therefore, a particular accuracy in the assembly phase is not required.
In order to release the device and to lift the roll-up curtain 1, it is necessary to press the push-buttons 23, against the springs 18, so that the latches 17 are extracted from the respective lock seats. However it is also possible to carry out the release, when necessary, from the outer side of the curtain, by moving the leverage formed by the levers 38,39 along the recesses 37, so that the ends of the latches are pushed out of the lock seats. It is to be pointed out that the roll-up curtain is always perfectly stretched, owing to its lower edge being clamped between the strips 10,11, which extend for the whole length of the section 3, that is the width of the opening between the posts 6.
Furthermore, the curtain is prevented from coming out of the guides 5, at its ends, by the rivet 27 by which the same curtain is fastened to the slider 26.
It is also to be pointed out that the wings 42 of the bases 32 close the angle area at the ends of the small brush 14, so assuring the closure of the whole surface of the window opening 2. It is also to be stated that the screws 43 make it possible to adjust, when required, the inclination of the guides 5 with respect to the posts 6, in such a way as to assure their verticality even when the window opening 2 is not perfectly square. By the adjusting screws 43, the associated bases 3 are moved with respect to the shoe housing 35 fixed to the wall, moving the guides 5 which are inserted on top of the same bases. Furthermore, the screws 43 have the function to prevent the guides 5 from being indented in the posts 6. | A device for locking a roll-up curtain used for protection of window openings and the like, in the fully drawn position, comprises a flap section that defines on its upper side, a seat for clamping the lower edge of the curtain. The flap section includes at opposite ends, two sliders which ride in respective vertical guides inserted in the posts of a frame enclosing the opening. Two latches are slidingly mounted in the flap section, and push-buttons have springs that drive the latches laterally into respective engagement with a lock seat provided in the base of each post. The lock seats are in post bases that are adjustable relative to the post. A fully unwound and locked curtain is released by simultaneously pressing the push-buttons. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of application Ser. No. 08/765,905, filed Jan. 7, 1997, now U.S. Pat. No. 6,398,998; which is a US national phase of PCT/DK95/00296 filed Jul. 5, 1995.
TECHNICAL FIELD
[0002] The present invention relates to a method for producing shaped bodies.
BACKGROUND ART
[0003] A method of this kind is disclosed in BE-A-653,349 and SE-B-304,711 (both based on FR priority application No. 955,561 of Nov. 29, 1963). In this known method, an unhardened mixture comprising hydraulic cement and aggregate material (sand and gravel) with surplus water is compressed in an extruder of constant cross-sectional shape by means of a reciprocating piston, and in the terminal part of said extruder, the walls of which are suitably perforated, part of the water is removed by applying a vacuum to the outside of said walls, all this taking place while the material is moving slowly through the extruder.
[0004] Obviously, the pressure differential that can be produced by said vacuum arrangement is at the highest of the order of one bar. In addition to this, the reciprocating piston does, admittedly, exert a certain force, thus causing a corresponding increase in the pressure differential effecting the dewatering, but if sufficiently increased, this force will simply push the material out of the extruder, as no counter-force is provided to prevent this. This means, of course, that the total pressure differential across the perforated walls will at the most be of the order of a few bar. This in turn means that the ability of this previously known method to remove liquid from the spaces between the particles of the material is limited, and in many cases the quantity of the remaining liquid is sufficient: to prevent the shaped bodies produced from attaining more structural strength than just needed to keep their shape against the force of gravity, so that they, unless extreme care is taken, cannot be handled without deforming, collapsing or falling apart.
[0005] The above problem is, of course, less serious in the case of shaped bodies of clay, as such bodies can be allowed to or be made to harden respectively by well known methods before being moved, but the method referred to above is obviously insufficient, if the shaped bodies are to have a reasonable strength immediately upon having been produced by carrying out the method.
SUMMARY OF THE INVENTION
[0006] It is the object of the present invention to provide a method of the kind referred to initially, with which it is possible to produce shaped bodies having a considerable mechanical strength, so that they can be handled or manipulated mechanically immediately upon completion of the final step of the method without any risk of deforming, collapsing or falling apart.
[0007] By proceeding in this manner, the high pressure differential, produced by applying a high positive pressure to the inside of the perforated walls in the mould, will cause so much of the liquid between the particles to be expelled and the particles to come into such mutual engagement, that a shaped body having a considerable mechanical strength is produced, and as the slurry has already been homogenized, the shaped body will have a uniform structure throughout: its volume.
[0008] If the squeezing-out of the liquid occurs at the same time over the whole surface of the mould, there is a risk that dewatered and un-dewatered material moves about uncontrollably in the moulding space with the result that the end product does not become fully homogeneous. This disadvantage may be avoided by proceeding as set forth by the use of a mold, in which the perforations are distributed and adapted in such a manner so that the liquid will be expressed first from the parts of the mold situated most distant from the slurry inlet, then from parts of the mold less distant from said inlet, then from parts still closer to the inlet and so forth, until the complete molding space is occupied by closely packed and consolidated particulate material forming a compact body with very low porosity.
[0009] When proceeding in this manner, the final part of the pressing process, when no further water can be squeezed out, can be characterized as powder pressing.
[0010] Thus, the process as such commences in the form of high-pressure slurry pumping in one end of the mould and terminates as a powder-pressing process steadily progressing from the other end of the mould. It will be understood that in this case, the low-viscosity suspension will have no difficulty in flowing out into all nooks and crannies of the mould, and any air having been trapped during the filling-up of the mould will leave the mould cavity through its perforations together with the surplus liquid. The finished press-moulded object will constitute an accurate replica of the internal surfaces of the mould, and since the composite material already has solidified in the mould in the same moment as all surplus water has been squeezed out and mutual contact between the solid-matter particles has been achieved, it is now possible to remove the moulded object from the mould immediately just as with any other powder-pressing method—since this object is now fully rigid and self-supporting and requires no more than being allowed to harden completely by hydration in a suitable manner.
[0011] Similar results with regard to making the dewatering and consolidation process progress steadily from one end or side of the mould to the other may be achieved by A) using a mold in which the liquid-permeability of the perforations diminishes steadily from the end of the mold most distant from the inlet towards the latter so as to make the removal of the liquid occur at the highest rate at said distant end and not a steadily diminishing rate when approaching the inlet or B) use of a mold in which the perforations may be closed and opened from the outside, the removal of the liquid being carried out by opening the perforations in a sequence beginning at the point in the mold most distant from the inlet and ending at the latter.
[0012] The perforations or holes in the walls of the moulds should, of course, be extremely fine, so that the water, but not the solid-matter particles may escape from the mould, but since water molecules are extremely small (approximately 20 Å), this should not be a problem.
[0013] The end product made by proceeding according to one of the embodiments of the method according to the invention is characterized by being exceptionally dense and with an absolute minimum of porosity and being highly homogeneous, and by, in the fully-hardened condition, to possess valuable physical properties comprising an optimum combination of strength and toughness.
[0014] Since, as described above, the mixing process is carried out with an arbitrary surplus amount of liquid, and the concentration of the material subsequently during the casting or moulding process is increased without “demixing” taking place, until no more liquid can be squeezed out from the confined material, it is possible in this case to achieve a considerably higher concentration of fibers in the end product than by using any other known moulding or casting principle, still with the fibers lying fully dispersed and well distributed and oriented throughout the product.
[0015] During the terminal part of the pressing process, during which the solid particles are closely wedged and pressed together, so that the material solidifies, the particles are also pressed firmly against all fiber surfaces—in certain cases even into the surfaces of the fibers—resulting in optimum bond between the fiber and the matrix material and hence optimum fiber effect in the end product.
[0016] In this process, fibers and matrix material “grow together” in a manner not being known from other casting or moulding processes, and after having fully hardened, the end product possesses unique physical properties.
[0017] With uniaxial tension loading, which is the most problematic form of loading to such brittle-matrix materials (because it is difficult for the fibers to take over the whole: tensional load when the matrix is over-strained), it is possible with a correctly reinforced BMC (Brittle-Matrix-Composite) material produced according to the present invention to achieve a stress-strain curve more reminiscent of the stress-strain curve for a metal or for a plastic material than for an ordinary brittle matrix material normally exhibiting an ultimate elongation at rupture of only approximately 0.01-0.02 per cent (0.1-0.2 mm, per m).
[0018] After hardening, a correctly made BMC material produced according to the present invention will have a tensile stress-strain curve exhibiting so-called strain hardening, in which the tensile stress continues to increase—without any formation of visible or harmful cracks—even right up to a strain of 1-2% or more. Thus, the strainability (elasticity or flexibility if so preferred) of the matrix material has, by extreme utilization of the admixed fibers, been increased by a factor of 100 or more—and this without causing any damage to the composite material.
[0019] The mechanism behind the dramatically increased strainability of the composite material is that the internal rupturing of the matrix material between the fibers due to tensile straining occurs in a different manner than in similar non-reinforced material, as, on a microscopic level, an evenly distributed pattern of extremely fine and short microscopic cracks are formed, increasing in number with increased straining of the material; these microscopic cracks are, however, so small that they may be stopped or blocked by the surrounding fibers, and for this reason they cause no dramatic damage to the material as such.
[0020] This is in itself extremely valuable and applies in general to the high-quality BMC materials mentioned above as produced by the methods according to the invention. Further, experience has shown that for so-called FRC material produced with a normal Portland-cement matrix, the network of micro-cracks formed in the manner referred to above (with possible crack lengths of approximately 0.5-1 mm or less, width typically 10-50 gm) after being formed shows a marked tendency to self-healing, so that the material in the presence of moisture will again be dense, and so that the material when again being tension loaded achieves its original rigidity and strength and may be subjected to increased stresses in the same manner as during the first loading, also here exhibiting a smooth stress-strain curve and a convincing strain hardening with steadily increasing tensile stresses up to an ultimate straining capacity of 1-2% or more before the stresses begin to decrease.
[0021] The present invention also relates to an apparatus for carrying out the method of the invention.
[0022] Finally, the invention relates to a product, comprising a non-flowable body of consolidated closely-packed particles of solid materials produced by the method and/or apparatus of the invention.
[0023] Advantageous embodiments of the method and the apparatus, the effects of which—beyond what is self-evident—are explained in the following detailed part of the present description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] In the following detailed portion of the present description, the invention will be explained in more detail with reference to the drawings.
[0025] [0025]FIG. 1 is a diagrammatic. longitudinal sectional view through the parts of an extruder relevant to the invention.
[0026] [0026]FIG. 2 shows an example of the formation of draining openings in the part of the extruder wall constituting the drainage section.
[0027] [0027]FIG. 3 is a sectional view through a ring adapted to co-operate with a number of similar rings to form an extruder wall with draining slits.
[0028] [0028]FIG. 4 shows a part of an extruder wall composed of a number of rings of the kind shown in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] [0029]FIG. 1 shows the parts of an extruder essential to the invention, specially, designed for producing tubular products, it being obvious that an extruder based on the same principles could also be used for extruding products with other cross-sectional shapes, such as flat or corrugated sheets or profiled stock of various cross-sectional shapes.
[0030] The parts of the extruder shown comprise an outer part 1 , an inner part 2 , a plurality of nozzles or slits 3 for draining-off liquid, as well as a pressure-regulating chamber 5 .
[0031] As shown, the extruder is divided into four consecutive sections, i.e.
[0032] an inlet section A for the supply of flowable suspension to be compacted, and
[0033] a flow section B, in which the suspension having been supplied flows towards
[0034] a drainage and consolidation section C leading into
[0035] a solid-friction section D.
[0036] Further, FIG. 1: shows a further section, designated the exit section E, in which the extruded product leaves the extruder.
[0037] For ease of understanding, FIG. 1 shows the above-mentioned sections as quite distinct from each other, but in practice, two or more sections may overlap to a greater or lesser degree. Thus, the nozzles 3 , shown in FIG. 1 as solely being present in the drainage and consolidation section C, may well also extend along at least a part of the solid-friction section D.
[0038] In the inlet section A, a flowable suspension containing the requisite amounts of powder, liquid (normally water) and possibly further components flows into the flow section B. The suspension supplied to the extruder comprises a surplus of water or other liquid, making it possible to achieve a good and homogeneous intermixing of the components of the suspension, that may have a consistency ranging from a thin slurry to a thick paste. Preferably, the ratio between liquid and dry matter is 1:1.
[0039] The mixing process may be carried out in a manner known per se, i.e. by using a high-performance mixer producing a paste-like particle suspension with the desired flowability, prior to supplying the latter to the inlet section A of the extruder by means of a high-pressure pump of a type capable of pumping material of this kind.
[0040] From the inlet section A, the suspension flows in the forward direction through the flow section B. The cross-sectional shape of the shaped product in this section B and the subsequent drainage and consolidation section C is determined by the internal shape of the outer part 1 and the external shape of the inner part 2 . In the drainage and consolidation section C, surplus liquid is drained off, and the suspension is consolidated to form a solid material with direct contact between the individual particles throughout the product, as substantially all surplus liquid, i.e. substantially all liquid not remaining to occupy the interspaces between the closely packed particles in direct mutual contact, is removed. This draining-off function is caused by the pressure differential across the outer part 1 in the drainage and consolidation section C being applied to the nozzles or slits 3 . The pressure differential constitutes the difference between on the one hand the hydrostatic pressure in the suspension in the flow section B and part of the drainage and consolidation section C, which may lie in the range of 20-400 bar, and on the other hand the pressure within the pressure-regulating chamber 5 , that may be atmospheric pressure or somewhat higher or lower, as will be explained below.
[0041] Obviously, the high hydrostatic pressure reigning in the flow section B and at least the adjacent part of the drainage and consolidation section C can only be maintained, if the part of the extruder downstream of the drainage and consolidation section C comprises some means of obstructing flow. In the method according to the present invention, these means are provided by the non-flowable extruded product resulting from the drainage and consolidation described above, being present in the solid-friction section D. In this section D, the friction between the product 4 and the walls of the outer part 1 and the inner part 2 in contact with it is sufficient to provide a reaction force of substantially the same magnitude as the oppositely acting hydraulic force resulting from the hydraulic pressure upstream of the solid-friction section D. In operation, the supply pressure and the pressure in the pressure-regulating chamber 5 are attuned to each other and to the friction referred to in the solid-friction section D so as to allow the product 4 to advance at a suitable speed.
[0042] When the product 4 leaves the extruder in the exit section E, its porosity is extremely low and it contains substantially no more liquid than that occupying the interspaces between the closely packed particles, so that the product 4 is now rigid and has a sufficient dimensional stability to withstand handling during the subsequent processing without being deformed due to its own weight. Such subsequent processing may i.e. be firing in the case of a product containing clay, or hardening in the case of a product based on cement.
[0043] When starting-up the process, it is necessary to provide the reaction force referred to above by separate means, as the non-flowable product part has not yet been formed in the solid-friction section D. This may suitably be achieved by inserting a reaction-force plug (not shown) into the downstream end of the interspace between the outer part 1 and the inner part 2 so as to effect a temporary closure.
[0044] As soon as the non-flowable “plug” of consolidated material has been formed in the solid-friction section D, it will normally provide a sufficient reaction force, but will on the other hand, of course, require a considerable force to act upon it to overcome the friction against the extruder walls and move it forward.
[0045] With an extruder constructed according to the principle shown in FIG. 1, it may not always be possible to attune the pressures referred to above in such a manner, that the consolidated product in the solid-friction section D will be moved, as an increase in the supply pressure, i.e. an increase in the inlet section A and in the flow section B, may, cause the friction between the consolidated product and the extruder walls to produce a reaction force that will always be too high. The effects of this high frictional force may be reduced in a number of different ways to be explained below.
[0046] A first method of reducing the effect of friction between the consolidated material and the walls of the extruder consists in subjecting the exit portion of the extruder or a part of same to mechanical vibrations. The frequency of these vibrations may lie in the interval 10-400 Hz, while the interval 20-200 Hz is preferred and the interval 50-150 Hz is more preferred.
[0047] Another method of reducing the effect of the high friction referred to above is to subject the flowable suspension upstream of the consolidated product to pressure variations, so that periods with a first, lower pressure alternate with second, shorter periods with a second, higher pressure, said second pressure being approximately 1.58, preferably 2-4 times greater than said first pressure.
[0048] A third method of reducing the effect of the high friction referred to above is to vary the pressure in the pressure regulating chamber 5 , so that the surface of the product in some periods is subjected to reduced pressure to support the draining-off process, and in other periods being subjected to a high-pressure to reduce the friction between the product and the extruder walls.
[0049] A fourth method of reducing the effect of the high friction referred to above is based on using an extruder, in which a first part, i.e. the outer part 1 shown in FIG. 1, is capable of being reciprocated in the longitudinal direction relative to another part of the extruder, e.g. the inner parts 2 . With such relative movement, that may e.g. be effected by using a crank mechanism (not shown), the product 4 will be made to “walk” stepwise in the downstream direction. The stepwise “walking” movement of the product is achieved through the following mechanism: when both parts of the extruder are stationary, the resulting frictional force between the product and the extruder walls will act in the upstream direction with a magnitude always equal to the resulting force on the product in the downstream direction from the pressure in the flowable suspension.
[0050] However, when the movable part of the extruder is moved in the downstream direction, the friction stresses between the product and the movable extruder wall will change direction and result in a frictional force in the downstream direction. In this situation it is possible to attune the pressure in the flowable suspension in such a way that the resulting frictional force acting in the downstream direction together with the resulting force from the pressure in the flowable suspension is larger than or equal to the resulting frictional force acting in the upstream direction, thus causing the product to move in the downstream direction.
[0051] When the movement of the extruder is stopped or changed to the upstream direction, the resulting frictional forces on the product from both parts of the extruder will again act in the upstream direction causing the movement of the product to stop. It follows from the above that an extruder working according to this principle should be designed taking into consideration the cross-sectional area of the product, the working pressure in the flowable suspension and the size and frictional characteristics of on the one hand the surface between the stationary part of the extruder and the product and on the other hand the surface between the movable part of the extruder and the product.
[0052] [0052]FIG. 2 shows one example of how the requisite permeability of the extruder wall in the drainage and consolidation section C may be achieved. Thus, in the outer part 1 a number of holes 6 have been drilled into the outer part 1 from the outside. As shown, the holes 6 only extend to within approx. 1 mm from the inside wall 7 . In the latter, a plurality of extremely fine perforations 8 with transverse dimensions of the order of 0.001-0.01 mm extend through the respective drilled holes 6 . The perforations 8 may be produced by means of e.g. spark erosion or by using a laser beam. FIG. 2 also shows the central axis 9 of the extruder.
[0053] Another way of providing the requisite openings in the drainage and consolidation section C is shown in FIGS. 3 and 4. Thus, FIG. 3 shows a ring to be used for this purpose, and FIG. 4 shows how a number of such rings are assembled to form a number of slits constituting said openings.
[0054] The ring 12 shown in FIG. 3 comprises an inner periphery 10 and an outer periphery 11 . The width b 1 of the inner periphery 10 is a trifle, typically approximately 0.0010.01 mm, less than the width b 2 of the outer periphery 11 . Thus, when a number of rings 12 are clamped axially together in the extruder, slits 3 will be formed between them with a width of typically approximately 0.001-0.01 mm in the drainage and consolidation section C, through which the liquid to be drained off may escape. FIG. 4 shows a number of rings 12 of the kind shown in FIG. 3 mounted in the axial direction in the outer part 1 of the extruder, so that the inner peripheries 10 of the rings are aligned with the inside surface of the outer part 1 of the extruder. FIG. 4 shows the outer parts 1 and a plurality, in this case a total of six, individual rings 12 with the drainage slits 3 between the rings. The central axis 9 of the extruder will also be seen. | Shaped bodies of particulate material produced by introducing an easily flowable slurry of water and particulate material into a mold with perforated walls and applying a sufficiently high pressure to the slurry in the mold so as to express a sufficient proportion of the liquid to allow physical contact and interengagement between the particles. The method may be carried out continuously in an extension process including: (A) introducing the slurry under high pressure, (B) conveying the slurry through a shaping section to (C) a draining and consolidation section with drain holds or slits ( 3 ), to leave the extruder through (E) an exit section in the form of a solid body ( 4 ). | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a method for the synthesis of 2-(4-hydroxyphenoxy)alkanoic acid esters. Such compounds are useful in the production of herbicides and dyes.
It is known in the art to produce herbicidal agents which are of the 2-(aryloxyphenoxy)alkanoic acid class. Within this context aryl includes phenyl, pyridyl, benzoxazolyl, etc.
These and other compounds are more fully described in U.S. Pat. Nos. 4,589,908; 4,130,413; 4,391,995; 4,301,295; 4,238,626; 3,784,697; 3,721,703; and 3,954,442; 4,657,577; 4,046,553, 4,629,493; and 4,368,068, all of which are incorporated herein by reference.
The production of these herbicides requires the use of an intermediate which is a 2-(4-hydroxyphenoxy)alkanoic acid ester (I) of the formula: ##STR1## wherein the variables are hereinafter defined.
However, prior processes for producing these intermediate compounds have employed hydroquinone and other compounds as starting materials. Mono-o-alkylation of hydroquinone is achieved by using a large excess of hydroquinone, but this method warrants low conversion. Alternatively, one can make mono-o-protected hydroquinone, alkylate, and remove the protecting group. However, the cost of such a manufacturing procedure is very large. Mono-o-alkylated hydroquinone derivatives, such as 2-(4-hydroxyphenoxy)propanoic acid are difficult to obtain because both of the hydroxyl groups of hydroquinone tend to react with the alkylating agent. Such processes are discussed at length in U.S. Pat. Nos. 3,600,437; 4,532,346; 4,547,583; 4,613,677; 4,489,207; and 4,368,068 and British Patent 1,591,063. U.S. Pat. No. 4,665,212 teaches condensed hydroquinone or hydroquinone salts with certain aromatic sulfonyl containing acids, esters and salts. U.S. Pat. No. 4,511,731 teaches the preparation of certain propanoate monoethers of hydroquinone via sequential alkylation and oxidation of hydroxystyrene. While such processes are effective for producing herbicide precursors, they are economically disadvantageous since the rate of conversion and selectivity, and hence the yield, is relatively low; on the order of about 10%. U.S. Pat. No. 4,528,394 describes a method which improves upon this yield by using a benzaldehyde precursor, such that the yield is increased to about 50%. However, this system is disadvantageous because of the vigorous reaction conditions required and undesired side reactions which occur such as the self-condensation of the benzaldehyde. These may also undergo undesired oxidation to carboxylic acids under Baeyer-Villiger conditions. The present invention improves on these methods by preparing intermediates derived from certain ketones and conducting a Baeyer-Villager oxidation thereon. The intermediates are prepared in a stepwise fashion and several advantages are thereby noted. These include a higher yield, perhaps in the 80-95% range, easier purification of the intermediates and less vigorous reaction conditions.
SUMMARY OF THE INVENTION
The invention provides a method for synthesizing 2-(4-hydroxyphenoxy)alkanoic acid esters which comprises reacting a hydroxyaromatic ketone derivative (II) of the formula ##STR2## or a salt thereof; with a substituted ester of the formula ##STR3## under basic conditions to thereby form a 2-(acylphenoxy)alkanoic acid ester (III) of the formula ##STR4## and then oxidizing the thusly formed 2-(acylphenoxyl)alkanoic acid ester (III) with a peracid or peroxide to obtain a 2-(acyloxyphenoxy)alkanoic acid ester of the formula (IV) ##STR5## and then hydrolyzing or alcoholizing acid 2-(acyloxyphenoxy)alkanoic acid ester with R 3 OH/H + to obtain a 2-(4-hydroxyphenoxy)alkanoic acid ester of the formula (I) ##STR6## wherein R is C 1 to C 18 alkyl or C 6 to C 10 aryl, preferably C 1 to C 4 alkyl, and most preferably methyl; and
wherein R 1 is H, phenyl or C 1 to C 18 alkyl, preferably C 1 to C 4 alkyl and most preferably H or methyl; and
wherein R 2 and R 3 are independently C 1 to C 18 alkyl, preferably
C 1 to C 4 alkyl or aryl such as phenyl or naphthyl which may be substituted or unsubstituted; and
wherein A, B, C and D are independently H, X, CN, C 1 to C 18 alkyl, or C 6 to C 10 aryl, protected using methods well-known to those skilled in the art so to avoid reaction of said substituents under the conditions of the process, i.e., alkylation, oxidation, solvolysis; and X is F, Cl, Br, I or a sulfonic ester. It must however be noted that the invention is not limited to 4-substituted isomers of 2-(acylphenoxy)alkanoic acid esters but also contemplates 2- and 3-substituted 2-(acylphenoxy)alkanoic acid esters.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the production of the 2-(4-hydroxyphenoxy)alkanoic acid esters (I) of this invention, one begins with a hydroxyaromatic ketone (II) and reacts it with one of the aforesaid substituted esters under basic conditions. This reaction product is then subjected to a Baeyer-Villiger oxidation with peracetic acid being the preferred reagent. The resulting product is then hydrolyzed or alcoholized to afford the desired 2-(4-hydroxyphenoxy)alkanoic acid esters (I). The reaction sequence may be generalized as: ##STR7## The compounds of the formulae I, III, and IV possess an asymmetrio carbon center and can therefore occur as pure enantiomers (optically active) or racemic as mixtures of enantiomers. An important feature of this invention is to begin the synthesis with an aromatic ketone which is specifically a 4-hydroxyphenyl ketone compound (II). The most preferred ketone being 4-hydroxyacetophenone, as well as its sodium or potassium salts. These hydroxyaromatic ketones are then reacted with one of the aforesaid X-substituted esters which may be either racemic or optically active. Preferred esters are halogen substituted propanoates such as methyl 2-chloropropanoate, methyl 2-bromopropanoate, ethyl 2-chloropropanoate, ethyl 2-[(methylsulfonyl)oxy]propanoate and ethyl 2-[(toluylsulfonyl)oxy]propanoate. This reaction proceeds by the Williamson's ether synthesis which is well-known to the skilled artisan. The reaction may take place by refluxing the hydroxyaromatic ketone with the ester in a solvent such as dimethylformamide under basic conditions. The basic conditions may be provided either by direct use of a base such as an alkali metal or alkaline earth metal hydroxide or carbonate, amines or a hydride such as sodium hydride. Alternatively, within the meaning of this invention, the basic media may be provided by using one of the aforesaid salt forms of the hydroxyaromatic ketone, such as 4-hydroxyacetophenone sodium or potassium salt. Alternative solvents for the refluxing reaction non-exclusively include polar protic solvents, e.g., water, or alcohol; or polar aprotic solvents, e.g., ketones, ethers, nitriles, and sulfoxides. The reaction may take place at from about 0.1 to about 72 hours, or more preferably from about 1 to about 48 hours at a temperature of from about 0° C. to about 300° C. or more preferably from about 25° C. to about 200° C. The reaction product of this juncture is a 2-(acylphenoxy)alkanoic acid ester (III). In one preferred embodiment the foregoing reactants are 4-hydroxyacetophenone potassium salt and ethyl 2-chloropropanoate with refluxing in dimethylformamide. Alternatively, the reactants are 4-hydroxyacetophenone, potassium hydroxide and ethyl 2-chloropropanoate with refluxing in dimethylformamide. Therefore the preferred 2-(acylphenoxy)alkanoic acid ester produced is ethyl 2-(4-acetylphenoxy)propanoate. This is then oxidized by the Baeyer-Villiger oxidation process which is also well-known to the skilled artisan per se. The oxidation is conducted by refluxing the 2-(acylphenoxy)alkanoic acid ester with a peracid or peroxide in a suitable solvent. The most preferred oxidizing agent is peracetic acid. Others non-exclusively include hydrogen peroxide, alkyl peroxides, chloroperacetic acid, peroxybenzoic acid, meta-chloroperoxybenzoic acid and trifluoroperoxyacetic acid. One preferred solvent for the refluxing is acetic acid. Alternative solvents for the refluxing reaction non-exclusively include water, alcohols, esters, ethers, halogenated hydrocarbons and carboxylic acids. The reaction may take place at from about 0.01 to about 24 hours, or more preferably from about 0.1 to about 10 hours at a temperature of from about 0° C. to about 100° C. or more preferably from about 25° C. to about 75° C. The reaction may take place at either elevated or reduced pressures, however, preferably it is performed at reduced pressure to remove heat generated during the reaction.
The reaction product of this juncture is a 2-(acyloxyphenoxy)alkanoic acid ester which in the most preferred embodiment is alkyl 2-(4-acetoxyphenoxy)propanoate. This latter component is then hydrolyzed or alcoholized. The alcoholysis may be conducted by contacting with alcohols under acidic conditions and elevated temperatures for a period of time sufficient to permit the reaction to approach completion. The amount of alcohol used may be, for example, about 0.5 to about 1,000 mol equivalents, preferably about 1 to about 100 mol equivalents based on the ester being alcoholized. The acids which may be employed for this purpose are organic acids such as methanesulfonic acid, para-toluenesulfonic acid, mineral acids such as sulfuric, hydrochloric and phosphoric acids, and acidic ion exchange resins. In some instances, it may be desirable to employ a combination of alcohol and water to achieve a measure of solvolysis.
Alcoholysis may take place at from about 0.1 to about 10 hours, or more preferably from about 0.5 to about 4 hours at a temperature of from about 20° C. to about 200° C. or more preferably from about 60° C. to about 140° C. The reaction is conducted with an anticipated conversion of from about 90% to about 99% with a selectivity of from about 90% to about 98%. The solvolysis product is a 2-(4-hydroxyphenoxy)alkanoic acid ester which in the preferred embodiment is alkyl 2-(4-hydroxyphenyl)propanoate. The alcoholysis process of this invention provides for the recovery of the phenolic product in relatively higher yields. The product may be recovered by conventional purification methods usually involving a combination of crystallization, filtration, washing and distillation in any order deemed advantageous for the system at hand.
The following non-limiting examples serve to illustrate the invention.
EXAMPLE 1
To a solution of 4-hydroxyacetophenone potassium salt (8.8g, 500 mmol) in methanol (50 mL) is added methyl 2-bromopropanoate (11.08, 65.0 mmol) dropwise over 30 minutes under nitrogen. The mixture is refluxed under nitrogen for 24 hours during which KBr is accumulated. The reaction is monitored by thin layer chromatography using 100% ethyl acetate. The reaction is cooled to room temperature and the KBr is filtered out. Ethyl acetate (50 mL) is added to give a turbid solution which is refiltered. The reaction product is analyzed by GLC and found to yield methyl 2-(4-acetylphenoxy)propanoate (13.2 g). (m.p. 54.8 ° C.); IR (KBr) 1757.7 (vs), 1666.8 (vs); 1 H NMR (CDC1 3 ) delta 1.54 (d, J=6.8 Hz, 3H), 2.42 (s, 3H), 3.64 (s, 3H), 4.76 (q, J=6.8 Hz, 1H), 6.79 and 7.80 (dd, J=8.0 Hz, 4H).
EXAMPLE 2
To a solution of the potassium salt of 4-hydroxyacetophenone (25.0 g, 0.14 mol) in dimethylformamide (DMF) (100 mL) is added methyl 2-chloropropanoate (24.5 g, 0.20 mol) over 30 minutes and stirred at 85-90° C. for 3 hours under nitrogen. The reaction is filtered to remove KCl and the filtrate is concentrated under reduced pressure to remove DMF and the product analyzed by GLC. The product is dissolved in ethyl acetate (300 mL) and extracted with 2N NaOH (2×100 mL) and water (100 mL). The organic phase is dried and concentrated to give pure methyl 2-(4-acetylphenoxy)propanoate (25 g) (yield 64%).
EXAMPLE 3
To a solution of the potassium salt of 4-hydroxyacetophenone (25.0 g, 0.14 mol) in DMF (100 mL) is added ethyl 2-chloropropanoate (27.3 g, 0.20 mol) over 30 minutes and stirred at 85-90° C. for 3 hours under nitrogen. The reaction is filtered to remove KC1 and the filtrate is concentrated under reduced pressure to remove DMF and the product is analyzed by GLC. The product is dissolved in ethyl acetate (300 mL) and extracted with 2N NaOH (2×100 mL) and water (100 mL). The organic phase is dried and concentrated to give pure ethyl 2-(4-acetylphenoxy)-propanoate (30 g) (yield 75%); m.p. 49.6° C.; IR (KBr) 1747.7 (vs), 1669.8 (vs); 1 H NMR (CDC1 3 ) delta 1.18 (t, J=7.2 Hz, 3H), 1.58 (d, J=6.8 Hz, 3H), 2.46 (s, 3H), 4.15 (q, J=7.2, 2H), 4.77 (q, J=6.8, 1H), 6.83 and 7.84 (dd, J=9.0 Hz, 4H).
EXAMPLE 4
A solution of the potassium salt of 4-hydroxyacetophenone (17.6 g, 0.1 mol) in DMF (50 mL) is added to a solution of ethyl L-2-[(methylsulfonyl)oxy]propanoate (21.5 g, 0.11 mol) in DMF (40 mL) over 15 minutes at 80° C. and stirred at 80° C. for 2 hours. To the reaction is added ethyl acetate (100 mL) and filtered. The filtrate is concentrated under reduced pressure whereupon the product is analyzed by GLC. The product is dissolved in ethyl acetate (250 mL) and extracted with saturated sodium bicarbonate solution (2×100 mL) and water (2×60 mL). The organic phase is dried and concentrated to give ethyl 2-(4-acetylphenoxy)propanoate (20.2 g).
EXAMPLE 5
To a solution of methyl 2-(4-acetylphenoxy)propanoate (5.6g, 25.0 mmol) in acetic acid (25 mL) is added peracetic acid (35%, 6.5g, 30.0 mmol) dropwise over 30 minutes at 25° C. The reaction is refluxed at 70° C. for 5 hours to give an orange-brown liquid. Acetic acid and residual peracetic acid are removed by high vacuum. The solution is kugelrohr distilled to give a light brown-orange product which contains methyl 2-(4-acetoxyphenoxy)propanoate (conversion 93%, selectivity 76%, yield 71%) and methyl 2-(4-hydroxyphenoxy)propanoate.
EXAMPLE 6
Methyl 2-(4-acetylphenoxy)propanoate (22.4 g, 100.0 mL) is dissolved in acetic acid (100 mL). Purified peracetic acid (19%, 58.0 g, 145.0 mmol) is dropwise added to the reaction at 58° C. and 60 mmHgA. The reaction is refluxed for 10 hours at 58° C. and 60 mm HgA whereupon the reaction is analyzed by GLC. The reaction is cooled to room temperature and concentrated under reduced pressure to give pure methyl 2-(4-acetoxyphenoxy)propanoate (20.13 g) (yield 84%):b.p 96-98° C. at 0.15 mm HgA, IR(neat) 1757.8 (vs); 1 H NMR (CDC1 3 ) delta 1.58 (d, J=6.9 Hz, 3H), 2.23 (s, 3H), 3.72 (s, 3H), 4.70 (q, J=6.9 Hz, 3H), 6.84 and 6.96 (dd, J=9.2 Hz, 4H).
EXAMPLE 7
To a solution of ethyl 2-(4-acetylphenoxy)propanoate (5.01 g, 21.0 mmol) in equilibrium with acetic acid (50 mL) is added peracetic acid (16%, 15.61 g, 33.0 mmol) dropwise over 30 minutes at 58° C. and 60 mm HgA until all is added. The reaction mixture is refluxed at a temperature of 48°-54° C. and a vacuum of 55-60 mm Hg. The reaction continues for 8 hours, is cooled to room temperature and concentrated under reduced pressure to remove the acetic acid from which ethyl 2-(4-acetoxyphenyl)propanoate (5.34 g) is obtained. (yield 90%):b.p. 120-122° C. at 0.06 mm HgA, IR (neat) 1752 (vs); 1 H NMR (CDC1 3 ) delta 1.22 (t, J=7.0 Hz, 3H), 1.57 (d, J=6.8 Hz, 3H), 2.23 (s, 3H), 4.18 (q, J=7.0 Hz, 2H), 4.70 (q, J=6.8 Hz, 1H), 6.85 and 6.96 (dd, J=9.4 Hz, 4H).
EXAMPLE 8
Ethyl 2-(4-acetylphenoxy)propanoate (5.01 g, 21.0 mmol) is dissolved in acetic acid (10 mL) and Amberlyst-15.sup.(R) (0.24 g) added. Hydrogen peroxide (70%), 1.58 g, 33.0 mmol) is then charged dropwise over 30 minutes to the reaction. The reaction is refluxed for 8 hours at 45-60° C. and 57-60 mm HgA whereupon the reaction is analyzed by GLC. The reaction is cooled to room temperature and concentrated under reduced pressure to give ethyl 2-(4-acetoxyphenoxy)propanoate (4.72 g) (yield 88.3%).
EXAMPLE 9
Methyl 2-(4-acetoxyphenoxy)propanoate (1.0 g, 4.2 mmol) is hydrolyzed by refluxing for 2 hours at 80° C. with methanol (10 mL) and concentrated HCL (36%, 2 drops). The reaction product is concentrated under reduced pressure to obtain methyl 2-(4-hydroxyphenoxy)propanoate (0.81 g). Conversion 99%, selectivity 99%, yield 97%; IR (neat) 1757 (vs) 1 H NMR (CDC1 3 ) delta 1.60 (d, J=7.0 Hz, 3H), 3.80 (s, 3H), 4.85 (q, J=7.0 Hz, 1H), 6.82 (s, 4H). | A method for synthesizing 2-(4-hydroxyphenoxy)alkanoic acid esters by reacting a hydroxyaromatic ketone derivative with a 2-substituted alkanoic acid ester under basic conditions and thereafter oxidizing the intermediate with subsequent hydrolysis. | 2 |
FIELD OF THE INVENTION
This invention concerns a process for the preparation of titanium from titanium halides, such as titanium tetrachloride. This invention further relates to production of finely divided particulate titanium and titanium alloys from titanium tetrachloride.
BACKGROUND OF THE INVENTION
Many diversified applications have been found for titanium and its alloys. Titanium metal has been essential to the aerospace industry since the early 1950's because it combines a high-strength to weight ratio with the ability to perform at much higher temperatures than aluminum or magnesium. It has therefore been used in compressor blades, turbine disks, and many other forged parts of jet engines and aircraft frames. It is also widely employed in the chemical processing industry because of its excellent resistance to chloride corrosion. Because of its scarcity and high cost, titanium has frequently been used in the form of a titanium powder to produce articles which are too expensive or difficult to produce by machining or forging from massive metal shapes. More efficient processes for the production of titanium powder have therefore been sought.
A majority of the world's titanium is made by the Kroll process, which produces titanium "sponge" in the form of a metallic powder. The titanium sponge is produced by reducing titanium tetrachloride (TiCl 4 ) with magnesium or sodium in a heated steel vessel. After cooling, an intimate mixture of titanium sponge and frozen chloride salt forms. The sponge and salt are separated by crushing and water leaching the products to dissolve the salt and produce a purer titanium product. The titanium sponge is then compressed into an electrode bar and vacuum arc remelted (VAR) to consolidate the metallic sponge. The expensive VAR process must be repeated once and sometimes twice to remove residual chloride salt and produce a clean consolidated bar of titanium. Alloying agents may be introduced during resulting if special purpose titanium alloys are desired.
The most important consideration for any process of making titanium is to prevent contamination with either metallic or non-metallic impurities, because even small amounts of some impurities can make the product brittle and unworkable. This is an especially serious problem for aerospace and other critical applications where such impurities can lead to defects in the final product manufactured from titanium. It is crucial, for example, that titanium components of jet engines or guided missiles maintain their structural integrity at all times in stressful environments. To help preserve this integrity, many processes have been developed for producing titanium powder free of contaminants which impair the structural integrity of the end product.
U.S. Pat. No. 4,602,947, for example, discloses a method of producing titanium sponge or titanium alloy powder by reducing gaseous titanium tetrachloride with magnesium. This method, which is schematically summarized in FIG. 2, produces titanium metal in the form of finely divided particles by first forming a liquid mixture of titanium and zinc, then solidifying the liquid mixture to produce finely divided alloy particles, and finally evaporatively separating zinc from the particles to produce pure titanium powder. In particularly disclosed embodiments, titanium chloride vapor is injected into a molten zinc-magnesium bath. Titanium replaces magnesium in the liquid alloy such that liquid zinc titanium and liquid magnesium chloride are produced. The less dense liquid magnesium chloride, which is completely immiscible with the liquid zinc titanium alloy, floats to the top of the reactor where it is removed. The resulting liquid zinc titanium mixture is recovered, solidified, and passed to a zinc evaporation zone where the zinc is sublimed to produce sponge titanium.
Although the process disclosed in U.S. Pat. No. 4,602,947 produces a relatively pure titanium sponge product, it suffers from the expensive drawback of requiring large amounts of zinc. Titanium has a very low solubility in zinc at temperatures up to the normal boiling point of zinc (907° C.). As a practical matter, the titanium solubility in liquid zinc is limited to about five weight percent. This is shown by the zinc rich end of the zinc titanium binary phase diagram reproduced in FIG. 1. This low solubility is significant because the solubility limit cannot be exceeded if a liquid mixture of titanium and zinc is desired. Such a liquid mixture is required in the '947 patent, and because of the limited titanium solubility, approximately 20 lbs. of zinc must be consumed for each pound of titanium produced. A substantial amount of zinc is also lost through evaporation at the elevated temperatures preferred in that prior process. Although a cover of molten salt theoretically prevents zinc evaporation up to its boiling point at the gas over-pressure (usually one atmosphere or less), as a practical matter it is usually necessary to operate at temperatures over 907° C. to increase the solubility of titanium in zinc. The zinc evaporates at this temperature and is lost from the reaction.
Other United States patents disclose methods for producing titanium sponge by reducing titanium chloride salts with aluminum. See, for example, U.S. Pat. Nos. 4,359,449; U.S. Pat. No. 4,390,365; and U.S. Pat. No. 4,468,248. None of these patents disclose reduction of gaseous titanium chloride by magnesium in a liquid zinc alloy. Other U.S. patents teach producing titanium powder and titanium alloy powder from binary and more complex zinc-titanium alloys by removing the zinc through sublimation. Such patents include U.S. Pat. No. 4,470,847; U.S. Pat. No. 4,595,413; and U.S. Pat. No. 4,655,825. Removal of zinc from zinc titanium alloys is also taught in U.S. Pat. No. 4,602,947.
SUMMARY OF THE INVENTION
The present invention overcomes the drawback of U.S. Pat. No. 4,602,947 by contradicting the teaching of that patent that a liquid mixture of titanium and zinc is desired in producing titanium powder. In the present invention, zinc and a titanium halide are reacted in the presence of a reducing agent to form a solid zinc titanium product. The solid product is obtained by introducing titanium halide vapor into a liquid alloy of zinc and a reducing metal in amounts beyond the solubility limit of titanium metal in zinc to precipitate zinc titanium intermetallic compounds. The reaction also produces a lower density salt comprised of the reducing metal and halide, which is immiscible with the liquid alloy and floats to the top of the reaction mixture. The zinc titanium intermetallic compounds form and accumulate at the interface between the salt and liquid alloy layers. The zinc titanium compounds are removed from the interface, crushed, and the zinc evaporatively separated to produce pure titanium sponge.
In more specific embodiments, titanium tetrachloride vapor is injected into a liquid alloy of zinc and magnesium at temperatures above 650° C. but below the zinc boiling temperature of 907° C. Titanium tetrachloride injection is continued well beyond the titanium solubility limit to precipitate a zinc titanium product which includes intermetallic compounds. Zinc rich intermetallic compounds such as Zn 3 Ti or Zn 4 Ti are unstable above 650° C. and decompose peritectically to solid Zn 2 Ti and Zn 2 Ti. Even Zn 2 Ti is unstable above the peritectic decomposition temperature of Zn 2 Ti (about 750° C.), and ZnTi will be the sole product of the reaction above this temperature. The titanium content in ZnTi is above 40 weight percent, while the titanium content in Zn 2 Ti is about 27 weight percent. In either case, the titanium content is much greater than the liquid solubility limit of about 10-15 atomic percent, and a process producing either of these intermetallic compounds is much more efficient and economic in its use of zinc than previous processes for titanium sponge production. The low reaction temperatures also diminish the amount of zinc lost through evaporation.
In prior art processes, such as that disclosed in U.S. Pat. No. 4,602,947, approximately 20 pounds of zinc are consumed for each pound of titanium produced. The process of the present invention, however, requires only 1.37 pounds of zinc per pound of titanium when the process is performed above the peritectic decomposition temperature of Zn 2 Ti (about 750° C.) to produce ZnTi. When the process is carried out between the peritectic temperature of decomposition of Zn 3 Ti (650° C.) and Zn 2 Ti (about 750° C.), about 2.73 pounds of zinc would be required for each pound of titanium produced. The differing requirements for zinc reflect the changing atomic percent of zinc in the final product. In a commercial process, additional amounts of liquid zinc (saturated in titanium) would be attached to the intermetallic compound dross removed from the furnace, and more zinc would be required than the theoretical amounts given above. The amount of zinc required in the present invention, however, is much less than the amount of zinc needed to produce a liquid alloy that is thereafter frozen and vacuum sublimed as in the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a zinc-titanium phase diagram.
FIG. 2 is a schematic diagram of the prior art process disclosed in U.S. Pat. No. 4,602,947 for producing titanium sponge.
FIG. 3 is a schematic diagram of a reaction vessel in which the process of the present invention can be performed.
FIG. 4 is a schematic diagram of the reaction vessel of FIG. 3 in which the process of the present invention is occurring, with subsequent steps of the process also shown schematically.
FIG. 5 is a schematic diagram of an alternative embodiment of the present invention for producing titanium powder.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A cylindrical carbon crucible or reactor 10 is shown in FIG. 3 into which titanium tetrachloride vapor is introduced through a gas conduit 11. The conduit 11 enters reactor 10 through an open top 13 and extends along a sidewall 14 until conduit 11 terminates adjacent bottom 15. Before the reaction begins, reactor 10 contains a liquid alloy of zinc and a reducing metal in layer 16. In the disclosed embodiment, the reducing metal is magnesium, but it can also be sodium, potassium, lithium, calcium, or mixtures thereof. Magnesium is the preferred reducing metal. The disclosed process operates at one atmosphere pressure, until the zinc vapor pressure increases at higher temperatures.
As TiCl 4 is introduced into layer 16 of liquid zinc magnesium alloy, TiCl 4 bubbles 17 are formed in the mixture. As the amount of TiCl 4 introduced into and reduced to titanium in layer 16 exceeds the solubility limit of titanium in zinc, a zinc-titanium intermetallic dross 18 (FIG. 4) is formed. The dross is the product of a reaction in which titanium displaces magnesium from the zinc to precipitate intermetallic compounds which then concentrate in situ beyond the solubility limit of titanium in zinc. The intermetallic compounds include ZnTi and Zn 2 Ti, and in preferred embodiments are limited to ZnTi and Zn 2 Ti, rather than compounds having a higher Zn content. The magnesium liberated from the ZnMg alloy reacts with chlorine liberated from the TiCl 4 to produce magnesium chloride (MgCl 3 ) liquid which is immiscible with, and has a lower density than, the layer 16 or dross 18. The magnesium chloride, therefore, forms a liquid layer 20 at the top of the reaction vessel. Dross 18 accumulates at interface 22 between layers 16 and 20.
Dross 18 is periodically removed from the crucible, for example, by an inert alloy sieve basket described in connection with FIG. 4 below. The dross is removed from reactor 10 as a solid ZnTi compound, which is crushed to form a powdered ZnTi product that is then heated to remove zinc by sublimation and yield a pure titanium powder. Examples of methods for subliming zinc from binary and more complex zinc titanium alloys are disclosed in U.S. Pat. No. 4,470,847; U.S. Pat. No. 4,595,413; and U.S. Pat. No. 4,655,825.
Zinc and magnesium are continuously or intermittently replenished through an airlock into reactor 10. Accumulating magnesium chloride is removed from layer 20 by a cup, siphon pipette, or overflow weir (not shown) through an airlock. Thus, the process can be quasi-continuous if desired, rather than a batch process. Other methods of replenishing reactants and removing solid and liquid products of the reduction reaction are possible and within the scope of this invention. It would be possible, for example, to continuously add titanium scrap to liquid zinc and allow the titanium to dissolve to its solubility limit, then precipitate out the titanium-zinc intermetallic compound as a dross for removal.
The titanium halide reduction reaction has fast chemical kinetics and is essentially stoichiometric. The reaction between magnesium and titanium tetrachloride produces two moles of magnesium chloride for each mole of titanium tetrachloride injected:
TiCl.sub.4 (g)+2 Mg→Ti+2 MgCl.sub.2
A second embodiment of the invention is shown in FIG. 5 wherein a cylindrical crucible or reactor 30 is contained within and surrounded by a cylindrical furnace 32. Reactor 30 and furnace 32 for controlling the reaction temperature are both enclosed in a furnace chamber 34 which is filled with an inert gas such as argon or helium to provide an inert atmosphere for the reaction. Argon (at one atmosphere) is the preferred inert gas because of its low cost compared to helium. An inert atmosphere is desireable to prevent introducing impurities such as oxygen or nitrogen into the titanium which weaken the product and can make it brittle. An airlock chamber 36 communicates with furnace chamber 34 but is separated from it by a vacuum valve 38. A second vacuum valve 40 is interposed between airlock chamber 36 and the outside atmosphere.
As shown in FIG. 5, reactor 30 contains a lower layer 42 of zinc magnesium liquid alloy, and an upper layer 44 of liquid magnesium chloride which is produced as a by-product of the reaction in reactor 30. Titanium chloride vapor is introduced through conduit 48 into layer 42 to form a solid intermetallic compound which accumulates as dross 50 at the interface 52 of layers 42 and 44. A sieve basket 54 is suspended in reactor 30 to retrieve dross 50 periodically from the reactor. Basket 54 includes a perforated plate 56, imperforate cylindrical sidewall 58, and suspension hanger 60 for suspending basket 54 in the reactor. Arms 62 of hanger 60 are connected to the top of sidewall 58 by hinges 63 at several positions circumferentially around the top of the sidewall. Hanger 60 is connected to a conventional device (not shown) for raising or lowering sieve basket 54.
In operation, basket 54 is suspended in reactor 30 below the surface of layer 42 before TiCl 4 is introduced into the zinc magnesium liquid alloy. As TiCl 4 is introduced through conduit 48 into layer 42, titanium displaces magnesium from the zinc and the zinc titanium dross 50 forms at interface 52. After a predetermined period of time, or after a predetermined amount of dross 50 has accumulated, hanger 60 exerts an upward force on basket 54 to elevate the basket and move plate 56 upwardly. The liquids of layers 42 and 44 drain through perforated plate 56, while solid dross 50 is retained in basket 54 and removed from reactor 30. The ZnTi dross 50 is removed from the protective inert atmosphere of furnace chamber 34, and into airlock chamber 36 by opening vacuum valve 38, which allows basket 54 to enter airlock chamber 36. Vacuum valve 36 is then closed once again to protect the inert atmosphere in furnace chamber 34. Valve 40 is then opened to allow dross 50 to be removed from chamber 36 without contaminating the inert atmosphere of chamber 34.
Zinc and magnesium are replenished by introducing them through airlock chamber 36 into reactor 30. Accumulating magnesium chloride is also removed periodically from layer 44 through airlock chamber 36, either by a cup, siphon pipette, or overflow weir (not shown). Alternative methods for removing the dross (such as slurry pumping) would also be acceptable if oxidation of the product was prevented or diminished. The process is, therefore, quasi-continuous and efficient.
An advantage of the present invention is that it produces a zinc-titanium intermetallic compound having a high titanium content. The principle which permits the process to operate efficiently is illustrated in FIG. 1, which is a zinc-titanium phase diagram at one atmosphere. As the temperature rises upon heating, zinc melts at 419.5° C. and begins to dissolve titanium. The curve in FIG. 1 is the liquidus composition, which is the composition of zinc liquid saturated with dissolved titanium at the corresponding temperature, e.g., point 2 at about 830° C. At equilibrium point 2, zinc liquid is saturated with dissolved titanium. As further titanium is added, the excess dissolved titanium solute reacts with the zinc solvent to precipitate ZnTi crystals, with composition at point 3, from the melt in a liquid metal crystallization process. In the example shown in FIG. 1, an aggregate initial composition of about 13 atomic percent titanium, point 2 will yield equilibrium products that are solid TiZn and saturated liquid. The relative amounts are 90 percent liquid and 10 percent TiZn.
Above 650° C., the peritectic decomposition temperature of Zn 3 Ti is exceeded, and a mixture of only Zn 2 Ti and ZnTi are produced from the saturated liquid. The peritectic decomposition temperature of Zn 2 Ti is exceeded at about 750° C., and a pure ZnTi product is obtained at or above this temperature. The high vapor pressure of zinc renders difficult a precise determination of the peritectic decomposition temperature for Zn 2 Ti. The present inventors have determined, however, that Zn 2 Ti will peritectically decompose to liquid ZnTi at a temperature below 800° C. and near 750° C.
A clear advantage of this invention is that Zn 2 Ti decomposes peritectically at a temperature at which the zinc vapor pressure is not excessively high. Moreover, when operating above the Zn 2 Ti peritectic temperature, the solubility of titanium in liquid zinc is very low (less than 10 atomic percent). In addition, the precipitation product ZnTi is very high in titanium (50 atomic percent, or about 42 weight percent). It is possible to continually introduce titanium into solution, letting it react with zinc to precipitate solid ZnTi, which can then be harvested as a dross. The process is performed above 650° C., which is the decomposition temperature of the peritectically decomposing Zn 3 Ti compound. Addition of excess titanium to a melt above this temperature will precipitate only Zn 2 Ti or ZnTi, because higher zinc intermetallic compounds such as Zn 3 Ti and Zn 4 Ti are unstable, will not form, and if present by addition would decompose peritectically to Zn 2 Ti or ZnTi and liquid. If the temperature of the melt is maintained above the peritectic decomposition temperature of Zn 2 Ti (about 750° ), addition of excess titanium will precipitate only ZnTi because compounds containing higher atomic percents of Zn are unstable and will spontaneously decompose to ZnTi. Although operating temperatures above the peritectic decomposition temperature of Zn 2 Ti may cause operational difficulties, it does produce a product having a greater atomic percent of titanium. However, even the Zn 2 Ti product produced between 650° C. and about 750° C. has a much greater atomic percent of titanium than the liquid solutions of titanium produced by prior art processes.
Having illustrated and described the principles of the invention in two preferred embodiments, it should be apparent to those skilled in the art that the invention can be modified in arrangement and detail without departing from such principles. | A process for producing salt free titanium powder by reacting zinc and a titanium halide in the presence of a reducing agent to form a solid zinc titanium product. Titanium halide vapor is introduced into a liquid alloy of zinc and the reducing agent at a temperature between 650°-907° C. The titanium halide is introduced beyond the titanium solubility limit in zinc to precipitate a zinc titanium intermetallic compound and also produce a liquid halide salt. The intermetallic compound forms and accumulates at an interface between the salt and liquid alloy. The compound is periodically removed from the interface, crushed into a powder, and the zinc is evaporatively separated from the titanium to produce pure titanium powder. The process preferably occurs above the peritectic decomposition temperature of Zn 3 Ti, and most preferably above the peritectic decomposition temperature of Zn 2 Ti, to maximize the titanium content of the resulting product. | 8 |
[0001] This application is a continuation-in-part of U.S. Ser. No. 08/078,985, filed Jun. 16, 1993, which is hereby incorporated by reference.
TECHNICAL FIELD
[0002] The invention relates to the field of sustained release pharmaceutical preparations and more specifically to a sustained release pharmaceutical preparation containing L-carnitine or gamma butyrobetaine.
BACKGROUND OF THE INVENTION
[0003] L-carnitine 3-hydroxy-4-(trimethylamino-)butyrate is a naturally occurring quaternary amine that is required in energy metabolism in mammals. The L-carnitine molecule has been shown to promote oxidation of branched-chain amino acids, the utilization of acetyl-coenzyme A, and the removal of extra or “toxic” acyl groups from the mitochondria and cell as carnitine esters. Arguably its most important function, however, is the promotion of beta-oxidation of long-chain fatty acids by facilitating their transfer across the mitochondrial membrane.
[0004] Because of its central role in transporting fatty acids to the site of oxidation, adequate levels of L-carnitine are required for normal fatty acid and energy metabolism in those tissues, such as the heart, which preferentially metabolize fatty acids. In the human, L-carnitine is synthesized endogenously from the amino acids, lysine and methionine. Meat products, particularly red meats (beef, lamb and pork) and dairy products are important dietary sources of L-carnitine. None-the-less, carnitine deficiency can occur in humans and presents a characteristic syndrome. Affected individuals may display mild to severe muscle weakness, hypoglycemia, liver dysfunction and cardiomyopathy. If detected early, the syndrome is often completely reversible with daily administration of adequate amounts of L-carnitine.
[0005] Gamma-butyrobetaine (“GBB”) is the immediate precursor to L-carnitine in the biosynthetic pathway of the latter compound. It is disclosed in U.S. Pat. No. 4,382,092, incorporated herein by reference, that GBB given orally will be readily converted to L-carnitine in carnitine deficient patients and is thus a suitable substitute for L-carnitine in treating such deficiencies. GBB has the advantage of being much less expensive to chemically synthesize than is L-carnitine. Hereafter, the term “carnitine” will be understood to refer to either L-carnitine or GBB, as well as their biologically active salts and esters, but not D-carnitine, the latter compound being hereby specifically excluded.
[0006] Some forms of organic aciduria have been treated with L-carnitine administration. In some such cases the affected individual must be given as much as 400 mg/k/day of L-carnitine.
[0007] Carnitine is also considered by some authorities to be a useful and important nutritional supplement, particularly for older persons who frequently show elevated esterified carnitine levels in the serum. Some evidence exists that carnitine supplementation enhances the immune system, muscle efficiency, and overall well being of the person using carnitine supplementation.
[0008] More recently, it has been found that carnitine is useful in patients suffering from or predisposed to osteoporosis. In such individuals it is believed that daily administration of carnitine will reduce the loss of bone mass. Co-pending U.S. application Ser. No. 07/907,847, incorporated herein by reference, discloses that daily administration of carnitine in amounts from 50 to 200 mg/kilogram will result in a significantly reduced loss of bone mass.
[0009] Oral formulations of L-carnitine are available in tablet or capsule form. The inventors are not aware of any commercially available oral dosage formulation of GBB. None of the heretofore known oral formulations of L-carnitine provide a sustained release of L-carnitine. Common dosage forms of the presently available oral formulations are usually 250 to 500 mg per tablet or capsule. Principal suppliers of pharmaceutical grade L-carnitine are Sigma Tau SpA, Rome, Italy; Aginomoto, Terrance, Calif.; and Lanza Chemical Company, Berne, Switzerland.
[0010] Where L-carnitine is being administered to treat carnitine deficiency dosages as high as 400 mg/K/day may have to be given. The customary dosage amount for mild to moderate carnitine deficiency is 50 to 100 mg/k/day.
[0011] Because the half-life L-carnitine in the human is approximately 30 minutes, the usual dosage regimen is to administer an excess amount of L-carnitine four times each day. If the dosage formulation is 250 mg/tablet, one would expect a 70 kilogram mildly deficient individual to take 7 tablets, four times each day (or 28 tablets/day) in order to restore L-carnitine to normal plasma levels.
[0012] A number of disadvantages exist with the presently available dosage forms of L-carnitine. First, the renal threshold for L-carnitine is about 80 to 120 microM/L. This threshold is invariably exceeded when large amounts of L-carnitine are given and thus much of the otherwise useful L-carnitine is “dumped” in the urine. Second, L-carnitine is subject to breakdown by the bacteria of the gut and when large boluses of the drug are given, a fair amount is lost through bacterial breakdown. Third, L-carnitine can cause gastrointestinal irritation resulting in gastrointestinal distress and diarrhea. Such problems are exacerbated when frequency of administration and dosage levels are both high.
[0013] The present invention avoids most, if not all, of the above stated disadvantages. Additionally, it allows for a much more convenient dosage regimen (e.g., once or twice per day) with greater efficacy than its nonsustained release counterpart.
SUMMARY OF THE INVENTION
[0014] The present invention provides an oral formulation of carnitine which virtually eliminates the above recited problems of dumping of carnitine in the urine, bacterial breakdown of carnitine by intestinal bacteria, and gastrointestinal distress and diarrhea when daily administration of large amounts of L-carnitine are recommended. Using the invention, methods of treating various carnitine responsive disorders are disclosed.
[0015] Accordingly, it is an object of this invention to provide a sustained release carnitine drug preparation useful in the treatment or prevention of L-carnitine deficiency or other L-carnitine responsive disorders, such as osteoporosis, which does not cause adverse GI symptoms, such as gastrointestinal distress and diarrhea.
[0016] It is a specific object of this invention to provide a sustained release, unitary dosage, oral formulation of carnitine which upon administration releases carnitine at a slow rate over the course of at least several hours, preferably a maximum of eight hours without causing the gastrointestinal irritation.
[0017] It is another object of the invention to provide a method for treating or preventing L-carnitine deficiency by administering, at least once daily, to a patient suffering from or at risk for L-carnitine deficiency, a sustained release, unitary dosage product containing sufficient amount of carnitine effective to increase the serum L-carnitine to normal level.
[0018] It is a further object of the invention, to provide a method for treating or preventing carnitine responsive, age-related disorders, such as osteoporosis, by administering, at least once daily, to a patient suffering from or predisposed to said carnitine responsive, age-related disorder a sustained release, unitary dosage formulation of carnitine (alone or in combination with one or more other active ingredients) effective for the maintenance of or formation and strengthening of diseased or weakened tissues such as muscle and bone.
[0019] In accordance with these objectives and other objects, which will become apparent from the following description, the present invention provides, in one aspect thereof, a medication for providing carnitine for the treatment or prevention of L-carnitine deficiency or osteoporosis, which is in the form of a unitary dosage formulation containing from about 100 milligrams (mg) to about 500 mg of carnitine. The formulation of the invention further includes a means for slowly releasing the aforesaid active ingredient(s) over a period of several to eight hours upon exposure to the gastrointestinal fluids. The formulation of the invention is designed to release carnitine at such a rate that the quantity of carnitine present in the stomach or intestine at any one time is below the amount likely to cause gastrointestinal irritation. The slowly released carnitine is readily absorbed and exposes less carnitine to bacterial degradation. The formulation of the invention is further designed so that the dosage of carnitine is slowly absorbed over period of several to eight hours. This controlled absorption of carnitine over a period of hours limits the loss of carnitine due to dumping in the urine and thus makes more of the carnitine in the formulation available for use by the body.
[0020] The sustained release unitary dosage product of this invention may include L-carnitine or GBB as the sole active ingredient. Alternatively, L-carnitine or GBB may be used together in varying proportions, or one or the other may be used in combination with other active ingredients when used to treat other L-carnitine responsive age-related conditions such as osteoporosis. In the latter case, co-pending U.S. patent application Ser. No. 08/078,985, incorporated herein by reference, discloses the combination of L-carnitine or GBB and the hormone dehydroepiandrosterone or dehydroepiandrosterone-sulfate (hereafter referred to collectively as “DHEA”) as a useful and desirable combination.
[0021] In a specific and preferred embodiment of the invention, the means for controlling release of carnitine and any other active ingredient includes a matrix of water swelling polymerization products. In the preferred embodiment, these products are acrylic and methacrylic acid esters having a low content of quaternary ammonium groups. The aforesaid polymerization products form a thin lacquer which completely coats small granules of the carnitine or GBB and other active ingredients if present. The polymer coating is water insoluble but slowly permeable. Upon introduction of the unitary dosage product into an aqueous medium, the polymeric coating swells and allows water to slowly permeate the preparation. Carnitine or GBB, both of which are highly water soluble, are dissolved in the slowly permeating water thereby slowly and uniformly released into the gastrointestinal tract.
[0022] According to the method aspect of the invention, a patient suffering from L-carnitine deficiency or from a carnitine responsive disorder such as osteoporosis is treated with at least one of the sustained release unitary dosage carnitine products of this invention.
DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a graph of the percent carnitine released from coated carnitine versus time.
[0024] FIG. 2 is a graph of total serum carnitine versus time.
[0025] FIG. 3 is a graph of total serum carnitine versus time.
DETAILED DESCRIPTION
[0026] In accordance with the present invention, it has been found that by incorporating L-carnitine or GBB alone or in combination with one another in varying amounts, or in combination with another active ingredient, in a slow release dosage formulation, the occurrence of GI irritation associated with present administration practices can be completely avoided. Although not wishing to be bound by any particular theory, it is presumed that by only gradually releasing the carnitine from the unitary dosage product, the quantity of carnitine present in the stomach or intestine at any given time is below the threshold value at which gastrointestinal irritation will occur. By whatever means of action, by incorporating the carnitine with means for controlling the release of the carnitine over a period extending up to a maximum of eight hours from the time of ingestion, gastrointestinal irritation will be avoided.
[0027] The invention also permits more of the carnitine to be made available for use by the body than was heretofore possible with previously available oral dosage formulations of carnitine. This is because the present invention reduces the amount of carnitine lost through bacterial degradation and dumping in the urine. Again, without being bound by any particular theory, it is believed that by providing a slow release of carnitine in the gastrointestinal tract, the carnitine released at any one time is rapidly absorbed into the blood stream. Thus, the carnitine is not exposed to the intestinal bacterial for any significant period of time unlike heretofore oral dosage formulations of carnitine. The very limited exposure to intestinal bacteria greatly reduces the proportion of carnitine degraded by bacterial action. Additionally, by allowing for absorption of carnitine into the blood stream over a period of hours rather than minutes, the increase in plasma carnitine is gradual and sustained. Under such circumstances, the renal threshold is only modestly exceeded, if at all, and less of the carnitine is dumped in the urine. As a consequence of both the decrease in bacterial degradation and urine dumping more of the administered carnitine is available for use by the body.
[0028] The present invention surprisingly results in greater carnitine tissue concentrations than was heretofore possible with previously available oral dosage formulations of carnitine. It is known that tissue carnitine levels are dependent on plasma carnitine levels. Thus, chronically low plasma carnitine will ultimately result in all body tissues having lower carnitine levels. Restoration toward normal of carnitine tissue concentrations in a chronically carnitine deficient individual has heretofore been only moderately successful with oral dosing of carnitine for the reasons discussed above.
[0029] With the present invention, plasma carnitine levels are maintained at a higher level than was heretofore possible. This results in a greater proportion of the administered carnitine being used to load the tissues thus serving to make the treatment more effective.
[0030] The means for providing controlled (i.e., sustained) release of the active ingredient may be selected from any of the known sustained-release delivery systems for controlling the release of an active ingredient over a course of about four or more hours including the wax matrix system, the miniature osmotic “pump” system and the Eudragit RL/RS system (of Rohm Pharma, GmbH, Weiterstadt, Germany).
[0031] The wax matrix system disperse the active ingredient(s) in a wax binder which slowly dissolves in body fluids to gradually release the active ingredient(s).
[0032] In the miniature osmotic “pump” an active ingredient is coated with a semipermeable membrane. The pump works when water-soluble drugs are released through a hole drilled in the membrane.
[0033] The preferred controlled-release oral drug delivery system is the Eudragit RL/RS system in which the active ingredient, L-carnitine or GBB, is formed into granules having a dimension of 25 to 30 mesh. The granules are then uniformly coated with a thin polymeric lacquer which is water insoluble but slowly water permeable. The coated granules are mixed with optional additives such as flavoring, binder, lubricant, processing aids and the like. The mixture is compacted into a tablet which, prior to use, is hard and dry. After the tablet is swallowed and comes into contact with the aqueous stomach and intestinal fluids, the thin lacquer begins to swell and slowly allows permeation of water. As water slowly permeates the lacquer coating, the active ingredients become dissolved in the water and are thereby slowly released. By the time the tablet has passed through the GI tract, after about four to eight hours, the active ingredients will have been slowly but completely released. Accordingly, the ingested tablet will release a stream of the L-carnitine or GBB as well as any other active ingredient.
[0034] The Eudragit system is comprised of high permeability lacquers (RL) and low permeability lacquers (RS). The permeability of the coating and thus the time course of drug release can be titrated by varying the proportion of RS to RL coating material.
[0035] For further details of the Eudragit RL/RS system, reference is made to technical publications available from Rohm Tech, Inc., 195 Canal Street, Maiden, Mass. 02146. See also, K. Lehmann, D. Dreher “Coating of tablets and small particles with acrylic resins by fluid bed technology,” Int. J. Pharm. Tech. & Prod. Mfr. 2(r), 31-43 (1981).
[0036] The amount of the L-carnitine can generally be varied over a range of from about 250 mg to about 1.0 gm L-carnitine per tablet (or pill, capsule, etc.). Therefore, based on the current recommended dosage for treatment of carnitine deficiency of 50 mg/k/day to about 100 mg/k/day, total daily dosages of one or two tablets twice each day can provide the total recommended requirement of L-carnitine.
[0037] In the case of prevention or treatment of osteoporosis, the recommended daily dosage of L-carnitine, as per co-pending U.S. patent application Ser. No. 08/078,985 incorporated herein by reference, is approximately 2 gm/day. This dosage of carnitine is preferably given in combination with DHEA or DHEAS as disclosed in the aforementioned co-pending U.S. patent application Ser. No. 08/078,985. For purposes of the present invention the DHEA should be given in an amount of approximately 0.1 to 10 mg per day and more preferably in an approximate amount of 0.5 mg per day. Based on that recommendation, two tablets having a unit dosage of 500 mg carnitine and 0.175 mg DHEA given each morning and each evening of each day will provide the total recommended requirement of L-carnitine.
EXAMPLE 1
Sustained Release Formulation of Carnitine
[0038] A preferred formulation of a sustained-release unitary dosage tablet according to the invention which utilizes the Eudragit RL/RS system referred to above is shown immediately below:
Ingredient Amount L-Carnitine 155.4 gm Eudragit RS100 72.7 gm
[0039] L-carnitine was obtained in a fine powder form from Metabolic Analysis Labs, Inc of Madison, Wisconsin The carnitine was wetted so as to form granules. The granules were screened through a 20 mesh screen. Eudragit RS100 was prepared as recommended by the manufacturer. The 20 mesh granules of carnitine were coated with the Eudragit coating using the Wurster™ process. This formulation provided a coating of about 39% by weight of very slowly water permeable lacquer. The coated carnitine was tested for sustained release by placing a known amount of the coated carnitine in a known volume of water. Samples of the water containing the coated carnitine were taken at 30 min., 60 min., 120 min., 240 min., and 360 min. The samples were analyzed for concentration of L-carnitine. Samples were also prepared using a 30% by-weight coating of Eudragit RS100 and a 40% by-weight coating of ethylene cellulose, another commonly-used, sustained release coating. The graph of FIG. 1 shows the results of this study depicted as percent carnitine released v. time. As illustrated in the graph of FIG. 1 , the L-carnitine having a 39% by-weight coating of RS100 prepared according to the present example gave a sustained release of L-carnitine over a period greater than six hours. The other two formulations gave too rapid a release of L-carnitine and are not preferred.
[0040] For administration to animals or humans, the coated material prepared in a manner described in Example 1, may be poured into a standard size gelatin capsule, or it may be compressed into a tablet form along with pharmaceutically acceptable filler material giving a final concentration per capsule (or tablet) of 500 mg carnitine/capsule. The final product is designed to release the L-carnitine in the gastrointestinal tract slowly over a period of up to eight hours after ingestion.
EXAMPLE 2
Pharmacokinetics Testing of Sustained Release L-Carnitine
[0041] A dog receives orally a capsule of sustained release L-carnitine formulated as described in this invention. Another dog receives a similar amount of the orally administered L-carnitine in a nonsustained release formulation. Blood is drawn at 0, 0.5, 1, 1.5, 2, 3, 4, 6, 9, and 15 hours after dose administration. The blood is analyzed for total plasma L-carnitine levels. The animal administered the drug in the sustained release formulation shows a slower rise in total plasma concentration of L-carnitine, a lower maximum concentration of total plasma L-carnitine and prolonged elevation of total plasma L-carnitine relative to the animal receiving the carnitine in a nonsustained release formulation. FIG. 2 depicts the total plasma levels of L-carnitine in μmoles per liter v. time expected from the above-described experiment.
EXAMPLE 3
Pharmacokinetics Testing of Sustained Release GBB
[0042] A study is done following the same protocol as that described in Example 2, above, except that GBB is orally administered in a sustained release form rather than L-carnitine. The study shows a slow rise in total plasma carnitine, a lower maximum concentration of L-carnitine and a prolonged elevation of total plasma L-carnitine relative to control. The pharmacokinetics of the sustained release GBB is similar to the sustained release L-carnitine, but as shown in the graph of FIG. 3 , the expected pharmacokinetic curve is shifted to the right. This study shows that GBB is a suitable substitute for L-carnitine.
EXAMPLE 4
Treatment of Carnitine Deficiency
[0043] A study is done with sustained release L-carnitine in carnitine deficient patients over the age of 60. The population is separated into a control group and an experimental group. The control group is administered one nonsustained release tablet containing 500 mg. each of L-carnitine, four times each day. The experimental group is administered sustained release tablets prepared according to the disclosure of Example 1, above, each tablet containing 500 mg of L-carnitine. The dosage regiment for the sustained release experimental group is two tablets twice daily, i.e., two tablets each morning at rising and two tablets each evening before bedtime. The study is continued for 20 weeks. Serum carnitine levels are checked in each patient at 0, 4, 8, 12, 16 and 20 weeks. The results of the study indicate that both the L-carnitine administered four times per day in the control group and the sustained release formulation administered twice each day, restore serum carnitine to a normal range. However, the control group shows a slight decrease in serum L-carnitine levels after eight weeks. The sustained release formulation consistently provides a slower rise in serum carnitine and a sustained higher average level of serum L-carnitine than does the nonsustained release tablet formulation. The study also shows that a significantly greater number of the control population experience gastrointestinal distress after taking L-carnitine than do the experimental population.
EXAMPLE 5
Treatment of Osteoporosis
[0044] A clinical study is conducted with postmenopausal osteoporotic outpatients having ages between 55 and 75 years. The study involves up to 120 patients randomly divided into three treatment groups, and continues for 24 months. Two of the treatment groups receive daily 2 grams of L-carnitine and 0.5 mg DHEAS. One of the treatment groups (“T1”) receives the L-carnitine plus DHEAS in a nonsustained release dosage formulation containing 500 mg/tablet of L-carnitine and 0.175 mg DHEAS. The regimen for T1 is 1 tablet four times each day. The second treatment group (“T2”) receives the L-carnitine in a sustained release formulation containing 500 mg/tablet of L-carnitine and 0.175 mg DHEAS. The regimen for T2 is 2 tablets twice a day, two upon rising in the morning and two before bedtime each evening. A third group receives a matching placebo; two tablets twice each day. All patients maintain a normal intake of dietary calcium (500 to 800 mg/day) and refrain from using calcium supplements. Efficacy is evaluated by pre- and post-treatment comparisons of the patient groups with regard to (a) total body, radial, femoral, and/or spinal bone mineral density as determined by x-ray absorptiometry (DEXA), and (b) determinations of serum osteocalcin. Safety is evaluated by comparisons of urinary hydroxyproline excretion, serum and urine calcium levels, creatinine clearance, blood urea. nitrogen, and other routine determinations and patient complaints related to gastrointestinal disturbances.
[0045] This study is expected to demonstrate that T2 patients treated with orally administered sustained release formulation L-carnitine and DHEAS exhibit significantly higher total body, radial, femoral, and/or spinal bone densities relative to the Ti patients treated with nonsustained release dosage form or placebo. The T2 treated patients also exhibit significant elevations in serum osteocalcin relative to the other groups. The monitored safety parameters confirm an insignificant incidence of gastrointestinal irritation for the T2 treatment group and the placebo. A significant proportion of the T1 treatment group, however, complain of gastrointestinal irritation.
EXAMPLE 6
Prevention of Osteoporosis
[0046] A clinical study is conducted with healthy postmenopausal women having ages between 55 and 60 years. The study involves up to 80 patients randomly divided into two treatment groups, and continues for 12 to 24 months. One treatment group receives sustained release formulation L-carnitine and DHEAS (twice each day; dosage: 2 mg L-carnitine and 0.5 mg DHEAS each day) and the other receives a matching placebo. The study is conducted as indicated in Example 5 above.
[0047] This study demonstrates that patients treated with sustained release formulation L-carnitine exhibit reduced losses in total body, radial, femoral, and/or spinal bone densities relative to baseline values. In contrast, patients treated with placebo show significant losses in these parameters relative to baseline values. The monitored safety parameters confirm that none of the treatment groups experienced gastrointestinal irritation as a-result of taking the sustained release formulation L-carnitine.
[0048] While the present invention has now been described and exemplified with some specificity, those skilled in the art will appreciate the various modifications, including variations, additions, and omissions, that may be made in what has been described. Accordingly, it is intended that these modifications also be encompassed by the present invention and that the scope of the present invention be limited solely by the broadest claims. | A sustained release, orally administered pharmaceutical composition comprising carnitine and an acceptable pharmaceutical excipient is described for the treatment of carnitine deficiency and other carnitine responsive conditions. The sustained release formulation avoids the characteristic problems of gastrointestinal invitation, dumping in the urine and bacterial degradation attendant previously known oral formulations of carnitine. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a damper for spin-drying washing machines.
2. Background Art
Dampers of the generic type are used for vibration damping in cylinder washing machines, ensuring smooth and vibrationless operation of the cylinder washing machine. Known dampers, at varying speeds of the washing cylinder, exhibit a damping behaviour that depends on the vibration amplitude. A reduced damping effect of the dampers is desirable in the range of small amplitudes, whereas great amplitudes require as strong as possible a damping effect. This amplitude-dependent damping behaviour leads to a constructionally complicated design of the dampers.
SUMMARY OF THE INVENTION
It is an object of the invention to improve a damper of amplitude-dependent damping behaviour in such a way that it is easy to manufacture at a low cost.
This object is attained by a damper for spin-drying washing machines comprising a tubular casing which has a central longitudinal axis; a tappet which is guided for displacement in the casing and projects from an end thereof; fastening elements which are mounted on a free end of the casing and of the tappet, respectively; and a frictional damping unit, which is disposed inside the casing, comprising at least one elastic frictional damping lining which is displaceable in relation to the casing and the tappet along the central longitudinal axis and which lies bare at least sectionally in a lengthwise axial direction, producing a given frictional damping effect, and at least one stop element which is stationary in relation to the casing and turned towards the at least one frictional damping lining, defining the motion of the at least one frictional damping lining, with the at least one stop element being configured such that, for motion damping, it directly cooperates with the at least one frictional damping lining. The gist of the invention resides in that the elastic frictional damping lining lies open at least sectionally in the axial direction so that the stop element, in the case of great vibration amplitudes, cooperates directly with the frictional damping lining. Thus, the frictional damping lining simultaneously fulfills the task of a stop buffer, this leading to constructional simplicity of design and to manufacture of the damper at a low cost.
Further features, details and advantages of the invention will become apparent from the ensuing description of several exemplary embodiments, taken in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a diagrammatic side view of a cylinder washing machine with a damper according to a first embodiment;
FIG. 2 is an elevation of the cylinder washing machine according to FIG. 1 ;
FIG. 3 is an axial sectional view of the damper of FIG. 1 ;
FIG. 4 is a perspective view of a contact-pressure piston of the damper of FIG. 1 ;
FIG. 5 is a perspective view of a cap of the damper of FIG. 1 ;
FIG. 6 is an elevation of the cap of FIG. 5 ;
FIG. 7 is a side view of the cap of FIG. 5 ;
FIG. 8 is an axial sectional view of a damper according to a second embodiment;
FIG. 9 is an axial sectional view of a damper according to a third embodiment;
FIG. 10 is a perspective view of a contact-pressure piston of the damper of FIG. 9 ;
FIG. 11 is a plan view of the contact-pressure piston of FIG. 10 ;
FIG. 12 is an axial sectional view of a damper according to a fourth embodiment; and
FIG. 13 is a perspective view of a contact-pressure piston of the damper according to FIG. 12 .
DESCRIPTION OF PREFERRED EMBODIMENTS
A first embodiment of the invention is going to be described below, taken in conjunction with FIGS. 1 to 7 . A cylinder washing machine seen in FIGS. 1 and 2 with a horizontal or inclined cylinder axis 1 comprises a vibratory washing aggregate 2 with a drive motor 3 which, via a belt drive 4 , actuates a washing cylinder, details of which are not shown. To simplify matters, further components that are connected to the washing aggregate 2 , for instance a transmission, are not shown. By means of helical extension springs 5 , the vibratory washing aggregate 2 is suspended from a washing-machine casing 6 which is supported on, and connected to, a machine frame 8 that stands on the ground 7 and constitutes a base frame. On the one hand, the helical extension springs 5 are fixed to eyelets 9 which are disposed in the top area of the washing aggregate 2 . On the other hand, they are suspended from eyelets 10 which are formed on the washing-machine casing 6 . The casing 6 is covered by a cover plate 11 .
Two frictional dampers 12 , details of which will be described below, are mounted centrically on the bottom side of the washing aggregate 2 ; they are connected to the machine frame 8 . Each frictional damper 12 comprises a tubular casing 13 with a central longitudinal axis 14 , with a tappet 15 being coaxially displaceable therein. At its free end, the tappet 15 comprises a first fastening element 16 , by means of which the frictional damper 12 is fixed to a bearing 17 on the washing aggregate 2 for the frictional damper 12 to be able to pivot in relation to the washing aggregate 2 about a pivoting axis 18 that is parallel to the cylinder axis 1 . Mounted on the free end of the casing 13 is a second fastening element 19 , by means of which the frictional damper 12 is fixed to a bearing 20 on the machine frame 8 in such a way that the frictional damper 12 is able to pivot in relation to the machine frame 8 about a pivoting axis 21 that is parallel to the cylinder axis 1 . A flap 22 which is disposed on the washing aggregate 2 serves for laundry to be put in and taken out.
The design of the frictional damper 12 will be described in detail in the following, taken in conjunction with FIGS. 3 to 7 . The tubular casing 13 of the frictional damper 12 comprises a guiding section 23 and a take-up section 24 which forms one piece therewith. The guiding section 23 is disposed downstream of the take-up section 24 in a direction of insertion 25 . The free end of the guiding section 23 , which is simultaneously the free end of the casing 13 , is closed by means of a bottom 26 . The bottom 26 and the fastening element 19 are one piece. The guiding section 23 has an inside diameter selected for the tappet 15 to have as little play as possible in the direction of insertion 25 and to be displaceable without static friction.
The take-up section 24 is disposed upstream of the guiding section 23 in the direction of insertion 25 . The take-up section 24 has an inside diameter which is greater than that of the guiding section 23 . The take-up section 24 is fixed to the end, on the side of the tappet, of the guiding section 23 by means of an annular stop collar 27 .
At its end turned away from the guiding section 23 , the take-up section 24 is closed by means of a cap 28 . The cap 28 possesses an annular collar 29 and a tubular fastening section 30 fixed thereto, the fastening section 30 extending in the direction of the central longitudinal axis 14 and encompassing the take up section 24 . The end, turned away from the guiding section 23 , of the take-up section 24 bears against the cap collar 29 , and the cap 28 is safeguarded against displacement in the vicinity of the fastening section 30 by means of a locking mechanism (not shown). The annular cap collar 29 forms a cap aperture 31 where the tappet 15 is guided with as little play as possible.
Within the casing 13 , a frictional damping unit 32 is provided in the vicinity of the take-up section 24 . The frictional damping unit 32 comprises a contact-pressure piston 33 which is displaceable along the central longitudinal axis 14 . The contact-pressure piston 33 is substantially tubular, comprising a centric contact-pressure section 34 where an encircling annular groove 35 is provided which is turned towards the tappet 15 . The annular groove 35 holds an annularly encircling, elastic frictional damping lining 36 which bears against side walls 37 of the annular groove 35 so that it is safeguarded against displacement in relation to the contact-pressure piston 33 , when rubbing against the tappet 15 . The side walls 37 of the annular groove 35 are embodied in such a way that the contact-pressure piston 33 is guided along the central longitudinal axis 14 on the tappet 15 .
A first stop section 38 which forms one piece with the contact-pressure section 34 proceeds from the side wall 37 that is turned towards the casing 13 . The first stop section 38 is tubular and does not bear against the take-up section 24 of the casing 13 as it is spaced apart from section 24 . The stop section 38 , on its inside circumference, comprises several longitudinal grooves 39 which are regularly spaced and extend along the central longitudinal axis 14 and which taper in the direction of the frictional damping lining 36 ; the grooves 39 extend as far as to the frictional damping lining 36 . Thus the frictional damping lining 36 is bare in the vicinity of the grooves 39 in the axial direction as FIG. 4 shows the opposite ends 36 ′ of the lining facing open ends 39 ′ of grooves 39 are uncovered. Two grooves 39 at a time face each other diametrically. A wedge 40 is located between two side by side grooves 39 , tapering in a direction opposite to the grooves 39 and extending in the form of a ramp in the direction of the side wall 37 with which it forms one piece. Each wedge 40 has side walls 41 , each of which define a bottom 42 of an adjacent groove 39 . Each bottom 42 also extends in the form of a ramp in the direction of the frictional damping lining 36 .
A second stop section 43 , corresponding to the first stop section 38 , proceeds from the side wall 37 that is turned towards the tappet 15 . The second stop section 43 corresponds in design to the first stop section 38 and forms one piece with the contact-pressure section 34 . The grooves 39 and 10 wedges 40 of the second stop section 43 are displaced in relation to the first stop section 38 . This means that a wedge 40 of the first stop section 38 is located opposite a groove 39 of the second stop section 43 and vice versa. For simplicity of mounting of the frictional damping lining 36 , the contact-pressure piston 33 may also be embodied in several pieces.
For the motion of the contact-pressure piston 33 with the frictional damping lining 36 to be defined and for damping operation to be obtained, the frictional damping unit 32 comprises a first stop element 44 on the side of the casing 13 and a second stop element 45 on the side of the tappet 15 . The first stop element 44 comprises several stop pins 46 which, proceeding from the stop collar 27 of the casing 13 , extend along the central longitudinal axis 14 . The stop pins 46 of the first stop element 44 form one piece with the stop collar 27 and the guiding section 23 of the casing 13 . A two-piece design, possibly of various materials, is just as well conceivable. The stop pins 46 are disposed and embodied for prolonging the guiding section 23 so that the tappet 15 is additionally guided by the stop pins 46 of the first stop element 44 . The stop pins 46 are further embodied and disposed for the contact-pressure piston 33 , by the grooves 39 of the first stop section 38 , to be able to encompass the stop pins 46 so that the contact-pressure piston 33 is movable into a first annular space 47 between the take-up section 24 and the stop pins 46 . A detailed description of the stop pins 46 and the arrangement thereof will follow, taken in conjunction with the description of the second stop element 45 .
The second stop element 45 also comprises several stop pins 46 which form one piece with the collar 29 of the cap 28 and extend along the central longitudinal axis 14 . A two-piece design, possibly of various materials, is also conceivable. The stop pins 46 are disposed in a circle around the central longitudinal axis 14 , forming a flush prolongation of the cap aperture 31 so that the tappet 15 is additionally guided by the stop pins 46 . To this end, the stop pins 46 are embodied as ring segments, with a guide wall 48 that is turned towards the tappet 15 being arched, corresponding to the periphery of the tappet 15 . Proceeding from the cap collar 29 , each stop pin 46 tapers towards the frictional damping lining 36 , having two side walls 49 and a front wall 50 . On its side turned away from the tappet 15 , each stop pin 46 additionally comprises an outside wall 51 which extends in the form of a ramp in the direction of the cap collar 29 . Two stop pins 46 at a time oppose each other diametrically, these two stop pins 46 being of uniform length along the central longitudinal axis 14 , but deviating in length as compared to the remaining stop pins 46 . A different arrangement is possible too. The stop pins 46 of the second stop element 45 combine with the take-up section 24 of the casing 13 to form a second annular space 52 into which to move the second stop section 43 of the contact-pressure piston 33 .
The detailed design of the first stop element 44 corresponds to that of the second stop element 45 , with the stop pins 46 of the second stop element 45 being displaced as compared to those of the first stop element 44 so that they may engage with the displaced grooves 39 of the second stop section 43 .
Fundamentally, any design of the stop pins 46 , in particular of the length and shape thereof, is possible as long as the stop pins 46 correspond in length and shape to the corresponding grooves 39 so that the stop pins 46 are able to cooperate with the frictional damping lining 36 . Pins of varying lengths are preferred, ensuring continuous, progressive damping.
Within the casing 13 , the tappet 15 is guided for displacement along the central longitudinal axis 14 by means of the guiding section 23 and the aperture 31 of the cap collar 29 . The tappet 15 is tubular and has a tapering end.
In the following, the mode of operation of the frictional damper 12 , upon operation of the cylinder washing machine, will be described in detail. At first, a load of laundry is being put into the washing aggregate 2 and the washing cylinder is being set rotating by means of the drive motor 3 and the belt drive 4 . The damping behaviour of the frictional damper 12 in the case of small vibration amplitudes is going to be described first. These small vibration amplitudes occur in the case of so-called uncritical speeds, for example with the cylinder washing machine spinning. In this case, the motion of the tappet 15 in relation to the casing 13 along the central longitudinal axis 14 is so insignificant that the contact-pressure piston 33 , together with the frictional damping lining 36 , does not touch the first and second stop element 44 , 45 . Owing to the static friction of the frictional damping lining 36 , there is no motion of the contact-pressure piston 33 in relation to the tappet 15 so that the frictional damping lining 36 does not rub against the tappet 15 . This status is termed friction-less idle stroke. In this condition, the frictional damper 12 exhibits insignificant damping behaviour which is characterized by the other friction losses upon the motion of the tappet 15 . In this condition, the casing 13 and the tappet 15 are un-coupled as far as possible.
If however the speed of the cylinder washing machine is in the range of a so-called critical speed or should there be significant imbalance, then there are important vibration amplitudes of the tappet 15 in relation to the casing 13 . This is when the contact-pressure piston 33 , together with the frictional damping lining 36 , and the stop elements 44 , 45 start interacting and the contact-pressure piston 33 moves in relation to the tappet 15 so that the frictional damping lining 36 rubs against the tappet 15 . If, proceeding from the position seen in FIG. 3 , the tappet 15 moves in the direction of insertion 25 , then the contact-pressure piston 33 starts being entrained in the direction of insertion 25 because of the static friction between the frictional damping lining 36 and the tappet 15 . As the depth of insertion grows, the first stop section 38 is being guided by its grooves 39 encompassing the stop pins 46 of the first stop element 44 . When the stop pins 46 , by their front wall 50 , touch the frictional damping lining 36 which is bare in the vicinity of the grooves 39 , then the motion of the contact-pressure piston 33 is being braked, with motion of the frictional damping lining 36 relative to the tappet 15 occurring. The frictional damping lining 36 rubs against the tappet 15 , producing damping behaviour. The damping behaviour is dependent on the speed of the relative motion and independent of the depth of penetration of the stop pins 46 into the frictional damping lining 36 . In the frictional damper 12 , the elastic frictional damping lining 36 has the additional task of a stop buffer. Owing to their varying lengths, the stop pins 46 penetrate successively into the frictional damping lining 36 , there being no abrupt impact of the contact-pressure piston 33 and, consequently, no abrupt increase of load on the machine frame 8 . With two opposite stop pins 46 at a time having an identical length, the contact-pressure piston 33 is safely precluded from getting tilted on the tappet 15 .
Upon return of motion of the tappet 15 , the contact-pressure piston 33 is at first being entrained counter to the direction of insertion 25 because of the static friction between the frictional damping lining 36 and the tappet 15 , the contact-pressure piston 33 not moving in relation to the tappet 15 . As the motion counter to the direction of insertion 25 continues, the second stop section 43 is being moved with the grooves 39 encompassing the stop pins 46 of the second stop element 45 . By the stop pins 46 penetrating into the frictional damping lining 36 , the motion of the contact-pressure piston 33 is being braked so that the frictional damping lining 36 makes a motion relative to the tappet 15 and rubs against the tappet 15 . The cooperation of the second stop element 45 with the frictional damping lining 36 corresponds to the above-mentioned penetration behaviour of the first stop element 44 . The cap collar 29 serves as a final stop of the contact-pressure piston 33 . Upon renewed return of motion of the tappet 15 , the contact-pressure piston 33 is again being entrained in the direction of insertion 25 because of the static friction between the frictional damping lining 36 and the tappet 15 . The described motion cycle recurs.
With the frictional damping lining 36 additionally working as a stop buffer, the frictional damper 12 is of simple design and can be manufactured at a low cost. Moreover, the idle stroke without friction can be adjusted arbitrarily by simple constructional modifications.
A second embodiment of the invention will be described below, taken in conjunction with FIG. 8 . Constructionally identical parts have the same reference numerals as in the first embodiment, to the description of which reference is made. Parts that differ constructionally, but are identical functionally, have the same reference numerals with an “a” suffixed. The essential difference from the first embodiment resides in that the contact-pressure piston 33 a and the stop elements 44 a, 45 a are designed in such a way that at least one of the stop pins 46 a is disposed at least sectionally in one of the grooves 39 a. Such a design of the contact-pressure piston 33 a and the stop elements 44 a, 45 a ensures that either at least one stop pin 46 a of the first stop element 44 a or at least one stop pin 46 a of the second stop element 45 a will be in engagement with one of the grooves 39 a of the contact-pressure piston 33 a, this providing for a safeguard against rotation of the contact-pressure piston 33 a in relation to the stop elements 44 a, 45 a. Preferably the stop elements 44 a, 45 a have four stop pins 46 a each. Such a number of stop pins 46 a helps optimize the constructional implementation while ensuring invariable functionality of the frictional damper 12 a. As regards the further mode of operation, reference is made to the first embodiment.
A third embodiment of the invention will be described below, taken in conjunction with FIGS. 9 to 11 . Constructionally identical parts have the same reference numerals as in the first embodiment, to the description of which reference is made. Parts that differ constructionally, but are identical functionally, have the same reference numerals with a “b” suffixed. The essential difference from the preceding embodiments resides in that stop buffers 53 are provided, preventing the contact-pressure piston 33 b from hitting hard against the stop collar 27 or the cap collar 29 in the case of extreme vibration amplitudes. The stop sections 38 b, 43 b of the contact-pressure piston 33 b each have four grooves 39 b and wedges 40 b which are disposed between the grooves 39 b. Each stop section 38 b, 43 b further comprises two stop buffers 53 which are formed on the front walls 54 of two wedges 40 b that face each other. The stop buffers 53 of the first stop section 38 b are displaced in relation to the stop buffers 53 of the second stop section 43 b about the central longitudinal axis 14 .
The stop buffers 53 are identical, only one stop buffer 53 being described in the following. The stop buffer 53 comprises two flexible stop-buffer elements 55 which are formed in one piece with the wedge 40 b, having the shape of bent tongues that proceed from the wedge side walls 41 towards each other. The stop-buffer elements 55 in the form of tongues project over the front walls 54 of the adjoining wedges 40 b along the central longitudinal axis 14 and, as seen along the central longitudinal axis 14 , they taper proceeding from the side walls 41 . The stop-buffer elements 55 and the associated wedge front wall 54 substantially define a stop-buffer recess 56 which extends sectionally into the contact-pressure piston 33 b so that the wedge front wall 54 that is allocated to the stop-buffer elements 55 stands back from the front walls 54 of the adjacent wedges 40 b. The stop-buffer elements 55 are flexibly extensible into the stop-buffer recess 56 . A stop-buffer opening 57 is formed between the stop-buffer elements 55 that run towards each other so that the stop-buffer elements 55 are spaced apart centrically and do not touch each other. A convex stop-buffer limit 58 , which is integral with the wedge front wall 54 , is disposed opposite the stop-buffer opening 57 as related to the stop-buffer recess 56 . For defined flexion of the stop-buffer elements 55 , the stop-buffer limit 58 proceeds from the wedge front wall 54 along the central longitudinal axis 14 into the stop-buffer recess 56 . By alternative, the stop-buffer limit 58 can be dropped, the flexion of the stop-buffer elements 55 being defined by the associated wedge front wall 54 .
The following is a description of the mode of operation of the frictional damper 12 b in the case of extreme vibration amplitudes. Upon motion of the tappet 15 in the direction of insertion 25 , the stop pins 46 b of the first stop element 44 b penetrate into the frictional damping lining 36 so that the contact-pressure piston 33 b, entrained by the tappet 15 , makes a motion relative to the tappet 15 and rubs against the tappet 15 . As a result of the stop pins 46 b penetrating, the elastic frictional damping lining 36 counteracts the motion of the contact-pressure piston 33 b, buffering the impact of the stop pins 46 b on the frictional damping lining 36 . If the vibration amplitude of the frictional damper 12 b is such that the buffering action of the frictional damping lining 36 does not sufficiently define the motion of the contact-pressure piston 33 b, then the stop buffers 53 start working. In the case of extreme vibration amplitudes, the stop-buffer elements 55 of the stop buffers 53 hit against the stop collar 27 of the guiding section 23 . As the motion of the contact-pressure piston 33 b continues in the direction of insertion 25 , the flexible stop-buffer elements 55 bend in a direction towards the stop-buffer limit 58 , buffering the motion of the contact-pressure piston 33 b. When the motion of the contact-pressure piston 33 b stops, then the flexible stop-buffer elements 55 rebound, moving the contact-pressure piston 33 b back against the direction of insertion 25 until they relax. In the case of extreme vibration amplitudes, the flexion of the stop-buffer elements 55 is defined by them hitting on the stop-buffer limit 58 or, should there be not stop-buffer limit 58 , by them hitting on the associated wedge front wall 54 . Simultaneously, the front walls 54 of the wedges 40 b that adjoin the stop buffers 53 hit on the stop collar 27 . Upon return motion of the tappet 15 , the contact-pressure piston 33 b is entrained counter to the direction of insertion 25 , the described process repeating when the contact-pressure piston 33 b hits on the cap collar 29 . Alternatively, the stop buffers 53 may also be formed on the stop collar 27 and the cap collar 29 . As for the further mode of operation, reference is made to the preceding embodiments.
A fourth embodiment of the invention will be described below, taken in conjunction with FIGS. 12 and 13 . Constructionally identical parts have the same reference numerals as in the preceding embodiments, to the description of which reference is made. Parts that differ constructionally, but are identical functionally, have the same reference numerals with a “c” suffixed. The essential difference from the preceding embodiments resides in that the stop buffers 53 c each have a continuous, convex stop-buffer element 55 c which narrows centrically, entirely defining the stop-buffer recess 56 on the side opposite the wedge front wall 54 . A stop-buffer opening is not provided. Alternatively, the stop buffers 53 c may also be disposed on the stop collar 27 and the cap collar 29 . As regards the mode of operation of the frictional damper 12 c, reference is made to the preceding embodiments. | In a damper for spin-drying washing machines, it is provided, with a view to amplitude-dependent damping behaviour being obtained accompanied with manufacture at a low cost, that a frictional damping unit, which is disposed inside a casing, comprises an at least sectionally bare and elastic frictional damping lining for producing a given frictional damping effect, and at least one stop element which is stationary in relation to the casing and turned towards the at least one frictional damping lining, with the at least one stop element being designed for direct cooperation with the at least one frictional damping lining. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based on and claims priority of Japanese Patent Application No. 2002-318908 filed on Oct. 31, 2002, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] A) Field of the Invention
[0003] The present invention relates to a semiconductor device, and more particularly to a semiconductor device having a fuse circuit and a dummy structure not functioning as an electronic circuit. The dummy structure may be an active region dummy, a gate electrode dummy and the like.
[0004] B) Description of the Related Art
[0005] Since the integration degree of recent semiconductor integrated circuit devices is high, shallow trench isolation (STI) excellent in planarization has been adopted as isolation techniques in place of local oxidation of silicon (LOCOS). Since the gate length is becoming shorter than ever, a high patterning precision is required to form a gate electrode. For example, a buffer silicon oxide film and a silicon nitride film are formed on a silicon substrate, and an opening is formed through the buffer silicon oxide film and silicon nitride film, the opening having a shape corresponding to an isolation region which defines active regions. By using the silicon nitride film as a mask, the silicon substrate is etched to form an element separation or isolation trench.
[0006] An insulating layer such as a silicon oxide film is deposited to bury or embed the isolation trench with the insulating layer. An unnecessary insulating film deposited on the silicon nitride film is removed by chemical mechanical polishing (CMP). With the above processes, such a silicon substrate can be obtained which has an STI type isolation region and a flat surface.
[0007] The silicon nitride film used as the mask is removed and necessary ion implantation is performed to form desired wells. Thereafter, a gate oxide film and a polysilicon film are formed on the surface of the active region. The gate oxide film and polysilicon film are patterned to form a gate electrode (and word line) through anisotropic etching using a photoresist pattern. The gate electrode having a short gate length can be formed through high precision patterning.
[0008] After ions are implanted into the regions on both sides of the gate electrode to form extension regions, an insulating film such as a silicon oxide film is deposited and anisotropic etching is performed to form side wall spacers from the insulating film. By using the gate electrode and side wall spacers as a mask, ion implantation is performed to form deep and high impurity concentration source/drain regions. Annealing is performed to activate implanted impurity ions.
[0009] If the resistances of the gate electrode and source/drain regions are to be reduced, metal capable of silicidation such as Co or Ni is deposited over the silicon substrate and a silicide layer is formed on the silicon surface by a silicide process.
[0010] Thereafter, an interlayer or interlevel insulating film is deposited burying or embedding the gate electrode. An irregular surface due to the gate electrode and the like is planarized by CMP. Contact holes for deriving leads are formed through anisotropic etching. Local interconnect grooves may be formed at the same time. A metal layer such as a lamination of Ti, TiN and W is deposited to fill or bury the contact holes and other grooves with the metal layer. An unnecessary metal layer deposited on the surface of the interlayer insulating film is removed by CMP or the like. In this manner, contact plugs deriving upward the electrodes of a semiconductor device can be formed. Thereafter, necessary upper level wirings and interlayer insulating films will be formed.
[0011] If the distribution of areas of the isolation region has a large variation in an STI process, the central area of the silicon oxide film buried in a trench having a large width is polished faster than other areas, resulting in dishing. In an active region having a small width sandwiched between trench isolation regions having a large width or in a region where active regions having a small width are dense, CMP does not stop at the silicon nitride film and the active regions may be excessively polished, resulting in erosion.
[0012] If the flatness of the substrate surface is lost because of such phenomena, a later lithography process is adversely affected. High precision photolithography requires a flat surface of an underlying layer. If the surface is irregular, an image transfer precision of photolithography lowers. In order to guarantee the surface flatness, it is desired to form such an isolation region which disposes active region dummies in addition to active regions for making semiconductor elements.
[0013] Gate electrodes on the surface of a silicon substrate have a high integration degree. The highest patterning precision is required to form such gate electrodes. If the distribution of gate electrodes to be etched from a conductive layer has a variation, etch rates change with this variation. It is desired to form gate electrode dummies in order to make the distribution of gate electrodes uniform.
[0014] Such dummy patterns are generally usually automatically designed in accordance with the data processing compatible with some rules in order to reduce a design load. Some problems may occur if dummy structures are formed in such a way.
[0015] It is becoming more difficult to maintain a high yield in manufacturing highly integrated semiconductor devices. To increase the yield, generally redundant circuits are prepared to replace defective circuits with redundant circuits to recover the function of the semiconductor device. A fuse circuit is used for the replacement with the redundant circuit.
[0016] It is necessary to properly design the fuse element so as not to erroneously break it, by taking into consideration the spot diameter of a laser beam. The fuse element requires a relatively large area depending upon the spot diameter of a laser beam.
[0017] As the scale of redundant circuit becomes large and the number of fuse elements increases correspondingly, the area of a fuse circuit occupied in a semiconductor substrate becomes large. A dummy pattern DP for planarization is required to be inserted also inside a guard ring GR, similar to an ordinary circuit.
[0018] As described above, a pattern of active region dummies and gate electrode dummies is generally automatically designed. This is also true for a dummy pattern in a fuse circuit. As a dummy pattern is disposed in the fuse circuit, a margin of a fuse breaking process may be lowered or the substrate may be damaged.
[0019] There is a proposal to form a block layer of tungsten under the fuse circuit. Each fuse is broken through laser abrasion. The block layer stops the laser abrasion with good controllability. (Refer to JP-A-HEI-11-345880)
SUMMARY OF THE INVENTION
[0020] An object of this invention is to provide a semiconductor device having a dummy structure also in a fuse circuit and being able to maintain surface flatness and line width controllability while a breaking margin is prevented from being lowered and a substrate damage is avoided.
[0021] According to one aspect of the present invention, there is provided a semiconductor device comprising: a semiconductor substrate having a principal surface; a fuse circuit formed above the principal surface, the fuse circuit having fuse elements each having a predetermined breaking point; a first trench isolation region formed in a surface layer of the semiconductor substrate under the fuse circuit; and a plurality of active region dummies formed through the first trench isolation region in an area excepting a predetermined area around the predetermined breaking point.
[0022] According to another aspect of the present invention, there is provided a semiconductor device comprising: a semiconductor substrate having a principal surface; a fuse circuit formed above the principal surface, the fuse circuit having fuse elements each having a predetermined breaking point; a first trench isolation region formed in a surface layer of the semiconductor substrate under the fuse circuit; a plurality of active region dummies formed through the first trench isolation region; and an insulting film covering a semiconductor surface of the active region dummies.
[0023] As above, even if the dummy structure is disposed, the adverse influence of the dummy structure upon the breaking characteristics of the fuse circuit can be mitigated and the influence upon a substrate damage can also be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] [0024]FIG. 1 is a partial plan view of a semiconductor device according to a first embodiment of the invention.
[0025] [0025]FIG. 2 is a partial cross sectional view of the semiconductor device of the first embodiment.
[0026] [0026]FIG. 3 is a partial plan view of a semiconductor device according to a modification of the first embodiment.
[0027] [0027]FIG. 4 is a partial cross sectional view of the semiconductor device according to the modification of the first embodiment.
[0028] [0028]FIG. 5 is a partial plan view of a semiconductor device according to a second embodiment of the invention.
[0029] [0029]FIG. 6 is a partial cross sectional view of the semiconductor device of the second embodiment.
[0030] [0030]FIG. 7 is a partial plan view of a semiconductor device according to a third embodiment of the invention.
[0031] [0031]FIG. 8 is a partial cross sectional view of the semiconductor device of the third embodiment.
[0032] [0032]FIGS. 9A to 9 I are cross sectional views illustrating dummy pattern forming processes according to related art.
[0033] [0033]FIG. 10 is a plan view showing the layout of fuse elements according to related art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] First, new facts found during the developments by the present inventors will be described. An example of dummy region forming processes will be described first.
[0035] As shown in FIG. 9A, on the surface of a silicon substrate 1 , a silicon oxide film 2 is grown to a thickness of about 10 nm through oxidation by hydrochloric acid at 900° C. On this silicon oxide film 2 , a silicon nitride film 3 is grown to a thickness of about 110 nm by chemical vapor deposition (CVD).
[0036] A resist pattern is formed on the silicon nitride film 3 , and the silicon nitride film 3 and silicon oxide film 2 are etched through anisotropic etching. The resist pattern is thereafter removed. By using the silicon nitride film 3 as a mask, the silicon substrate 1 is subjected to anisotropic etching. For example, a silicon substrate surface layer of about 300 nm thick is etched to form a trench having a depth of about 300 nm.
[0037] As shown in FIG. 9B, on the silicon substrate formed with trenches, a silicon oxide film 4 is grown to a thickness of about 500 nm by CVD. An unnecessary silicon oxide film 4 deposited on the silicon nitride film 3 is removed by chemical mechanical polishing (CMP). The silicon nitride film 3 functions as a CMP stopper. Trench isolation regions are therefore formed. By forming active region dummies, the density of areas of the isolation or element separation region can be made uniform so that dishing and erosion can be suppressed.
[0038] As shown in FIG. 9C, the silicon nitride film 3 is removed by hot phosphoric acid solution. The silicon oxide film 2 may be removed by hydrofluoric acid solution. In this case, a new silicon oxide film 2 ′ is grown to a thickness of about 10 nm through oxidation by hydrochloric acid at 900° C. A resist mask separating the n- and p-channel regions is formed on the surface of the silicon substrate 1 and ion implantation for each of the n- and p-channel regions is performed to form wells.
[0039] For example, impurity ions are implanted at a dose of about 1×10 13 cm −2 . After an n-well 6 and a p-well 5 are formed, the silicon oxide film 2 ′ used for ion implantation is removed.
[0040] As shown in FIG. 9D, a gate oxide film 7 is grown to a thickness of about 1 nm on the exposed silicon surface by thermal oxidation. On this gate oxide film 7 , a polysilicon layer 8 is formed to a thickness of about 110 nm by CVD. On the polysilicon layer 8 , a resist pattern PRG for gate electrodes is formed. This pattern includes also the pattern for gate electrode dummies. By using the resist pattern PRG as a mask, the polysilicon layer 8 is etched. A gate electrode is therefore formed above the active region. Gate electrode dummies are also formed above the active region dummies.
[0041] If isolated gate electrodes and dense gate electrodes are mixed, the isolated gate electrode is likely to be etched excessively. By disposing gate electrode dummies, etching of gate electrodes can be made uniformly. Next, ion implantation is performed at a dose of, for example, about 1×1 0 14 cm −2 for each of p- and n-channel regions to form shallow extension regions E. When a mask is used in this ion implantation, the dummy region may be masked not to form extention.
[0042] As shown in FIG. 9E, on the substrate surface, a silicon oxide layer 9 having a thickness of about 100 nm is formed by CVD. The silicon oxide film 9 is subjected to anisotropic etching to remove the silicon oxide film 9 on the flat surface. The silicon oxide film 9 is left on the side walls of the gate electrode 8 to form side wall spacers.
[0043] As shown in FIG. 9F, ion implantation is performed at a high impurity concentration, for example, at a dose of about 1×10 15 cm −2 , for each of p- and n-channel regions to form deep source/drain regions S/D having a high impurity concentration. After ion implantation, rapid thermal annealing (RTA) is performed at about 1050° C. to activate implanted ions.
[0044] Next, on the surface of the substrate 1 , a cobalt film 10 having a thickness of, for example, 5 nm is formed by sputtering. Annealing at about 850° C. is performed to form a cobalt silicide layer on the surfaces of the gate electrodes and on the exposed surfaces of the source/drain regions S/D.
[0045] As shown in FIG. 9G, after the cobalt silicide layer 10 x is formed, an unreacted metal layer is removed and a silicon nitride film 11 is deposited to a thickness of about 40 nm by CVD. On the silicon nitride film 11 , a silicon oxide film 12 is formed having a thickness of about 650 nm. The surface of the silicon oxide film 12 is planarized by CMP. A photoresist pattern PRL is formed on the planarized surface and contact holes are formed by anisotropic etching. After etching, the photoresist patter PRL is removed.
[0046] As shown in FIG. 9H, on the surface of the substrate formed with contact holes, a titanium film and a titanium nitride film each having a thickness of about 10 nm are formed by CVD. A tungsten film having a thickness of about 200 nm is formed on the titanium nitride film by CVD. Each contact hole is therefore filled or buried with a contact plug made of a laminated metal layer 13 . An unnecessary metal layer deposited on the silicon oxide film 12 is removed by CMP. A local interconnect may also be formed at the same time when the contact plug is formed. In this manner, a MOS transistor is formed on the right side of FIG. 9 H and a dummy structure is formed on the left side.
[0047] [0047]FIG. 9I is a schematic cross sectional view showing the structure of the dummy region formed in the manner described above. An active region dummy 18 is formed by partially removing the isolation or element separation region 4 . Extention is not formed in the active region dummy 18 . A gate electrode dummy 19 is formed above the active region dummy.
[0048] In the example described above, a laminated dummy structure is made of a lamination of the active region dummy and a gate electrode dummy. By forming the active region dummy and gate electrode dummy in the same area, it becomes easy to make parasitic capacitances uniform and prevent electric shortage between wells. The laminated dummy structure is not limited only to that described above. Either one of the active region dummy and gate electrode dummy may be formed.
[0049] [0049]FIG. 10 shows an example of a plan layout of a fuse circuit. In a fuse area surrounded by a guard ring GR, a plurality of fuses F are formed. At the level lower than that of the fuse F, dummy patterns DP are disposed. A dummy pattern is an active region dummy, a gate electrode dummy or a lamination thereof such as shown in FIG. 9I. Under the dummy patterns, an n-type well NW is formed. The fuse F is broken or cut by applying a laser beam at a predetermined position BP of the fuse F. The fuse F is made of, for example, aluminum or tungsten.
[0050] In a multilevel wiring structure, Cu is now commonly used as the material of a lower level wiring. If aluminum or tungsten is used as the material of the uppermost level wiring, fuses F are formed at the same time when the uppermost level wiring is formed. If the dummy patterns DP are disposed by automatic design and the fuses F are designed independently from the dummy patterns DP, the layout of the dummy patterns DP under respective fuses F become different. The fuse F in the upper portion and the fuse F in the lower portion in FIG. 10 have different layouts of the dummy patterns DP under the fuses F near the breaking point BP.
[0051] The state under the breaking point is different because the layout of the dummy patterns DP under the breaking point is different. This difference influences the fuse breaking process upon application of a laser beam, resulting in an unstable process having a small margin.
[0052] For example, depending upon whether or not there is a dummy just under the breaking point, the reflectivity of a laser beam on the surface of the semiconductor substrate changes so that the optimum breaking conditions change. If a polysilicon gate electrode dummy or a silicidated active region dummy is disposed just under the breaking point, not only the reflectivity of a laser beam is influenced but also the dummy pattern DP absorbs the laser beam and this may cause some damage to the semiconductor substrate.
[0053] Description will be given on the embodiments of the invention.
[0054] [0054]FIG. 1 is a plan view showing the structure of a semiconductor device according to a first embodiment of the invention. For example, the semiconductor device has eleven multilevel wiring layers. A main circuit area MC is disposed in the upper area as viewed in FIG. 1. Formed in this main circuit area MC are MOS transistors, active region dummies 18 and gate electrode dummies 19 such as those described with FIGS. 9A to 9 H. A guard ring GR of a loop shape surrounds a fuse circuit area, the guard ring being made of the same metal layers as the multilevel wiring layers.
[0055] Active region dummies 18 are also disposed in the fuse circuit area. Fuse elements F are made of the uppermost eleventh wiring layer M 11 L and disposed traversing the fuse circuit area above the active region dummies 18 .
[0056] A breaking point BP is designed or set to each fuse element F. The active region dummy 18 is not formed in a region having a diameter of X+2α with the center being set to the breaking point BP. X represents a spot diameter of a laser beam and α represents a position misalignment between the spot and the fuse breaking point BP.
[0057] If the center of a laser beam is set to the breaking point, the laser beam is irradiated in the region having a radius of X/2 from the center. If the center of a laser beam is displaced by α, the laser beam can be irradiated in the region having a radius of X/2+α (diameter of X+2α) from the breaking point BP. The active region dummy 18 is not disposed in the region where a laser beam can be irradiated. For example, the active region dummies 18 are not disposed in the region having a radius of 2 μm from the breaking point BP.
[0058] [0058]FIG. 2 is a cross sectional view showing the fuse circuit and taken along line II-II shown in FIG. 1.
[0059] An isolation or element separation region 4 of shallow trench isolation (STI) is formed in the surface layer of a silicon substrate 1 . Active dummy regions 18 are also formed in the fuse circuit area by partially removing the isolation region 4 . A silicide layer 10 x is formed on the surface of the active region dummy 18 . A silicon nitride layer 11 is formed covering the silicide layer 10 x.
[0060] On the surface of the silicon nitride layer 11 , an interlayer insulating film 12 of silicon oxide or the like is formed. Contact plugs 13 (FIG. 9H) are formed through the interlayer insulating film 12 and silicon nitride layer 11 . A guard ring 17 of a ring shape is formed by the same process as that of forming the contact plug 13 .
[0061] Covering the contact plugs 13 and guard ring 17 , a Cu diffusion preventive and etch stopper layer 20 of SiN, SiC or the like is formed to a thickness of about 50 nm on the surface of the interlayer insulating film 12 . On the diffusion preventive and etch stopper layer 20 , an insulating layer 21 is formed to a thickness of, for example, about 500 nm. The insulating layer 21 is made of silicon oxide, SiLK (registered trademark) or the like. On the surface of the insulating layer 21 , a hard mask layer 25 of SiN, SiC or the like is deposited to a thickness of about 50 nm for example. Via holes and wiring trenches are formed by anisotropic etching using a photoresist process. The photoresist pattern is removed and thereafter, a barrier metal layer of TaN or the like and a Cu seed metal layer are formed by sputtering. A metal material layer of Cu or the like is filled or buried in the via holes and wiring trenches by plating.
[0062] An unnecessary metal layer on the surface of the hard mask layer 22 is removed by CMP. In this manner, a first wiring layer M 1 L is formed. After the first wiring layer M 1 L is formed, a Cu diffusion preventive and etch stopper layer 23 of SiN, SiC or the like is formed to a thickness of about 50 nm on the substrate surface. Second to fourth wiring layers M 2 L to M 4 L are formed having the structure similar to that of the first wiring layer M 1 L.
[0063] On the surface of the fourth wiring layer M 4 L, a Cu diffusion preventive layer 24 of SiN or the like having a thickness of about 70 nm, an insulating layer 25 of silicon oxide, SIOC or the like having a thickness of about 330 nm, an etch stopper layer 26 of SiN, SiC or the like having a thickness of about 30 nm and an insulating layer 27 of silicon oxide, SIOC or the like having a thickness of about 350 nm are laminated. Wiring trenches and via holes are formed through this insulating layer structure. A barrier metal layer of TaN or the like and a seed metal layer of Cu or the like are formed by sputtering. A metal material layer of Cu or the like is filled or buried in the via holes and wiring trenches by plating. An unnecessary metal layer on the surface of the insulating layer structure is removed by CMP. In this manner, a fifth wiring layer M 5 L is formed. Sixth to eighth wiring layers M 6 L to M 8 L are formed having the structure similar to that of the fifth wiring layer M 5 L.
[0064] On the surface of the eighth wiring layer M 8 L, a Cu diffusion preventive layer 29 of SiN, SiC or the like having a thickness of about 70 nm, an insulating layer 30 of silicon oxide, SiOC or the like having a thickness of about 530 nm, an etch stopper layer 31 of SiN, SiC or the like having a thickness of about 20 nm and an insulating layer 32 of silicon oxide, SiOC or the like having a thickness of about 850 nm are laminated.
[0065] Wiring trenches and via holes are formed through this insulating layer structure. A barrier metal layer of TaN or the like and a Cu seed metal layer are formed by sputtering. A metal material layer is filled or buried in the via holes and wiring trenches by plating. An unnecessary metal layer on the surface of the insulating layer structure is removed by CMP. In this manner, a ninth wiring layer M 9 L is formed. A tenth wiring layer M 10 L is formed having the structure similar to that of the ninth wiring layer M 9 L.
[0066] On the tenth wiring layer M 10 L, a Cu diffusion preventive layer 35 of SiN, SiC or the like having a thickness of about 70 nm and an insulating layer 36 of silicon oxide or the like having a thickness of about 600 nm are laminated. A conductor 38 is buried through this insulating layer structure. According to necessity, an electrode layer 41 of aluminum or the like is deposited to a thickness of 1170 nm on an insulating layer 39 of SiC, SiN or the like. An eleventh wiring layer M 11 L including fuses is formed by anisotropic etching using a resist pattern. A silicon oxide layer 37 , an SiN layer 40 and the like are laminated covering the eleventh wiring layer M 11 L. Selected regions of the silicon oxide layer 37 and SiN layer 40 are removed to form openings which expose pad electrodes and a fuse breaking region.
[0067] In this embodiment, the active region dummies 18 are formed in the fuse circuit area and the silicide layer 10 x is formed on the surface of each active region dummy. The active region dummies 18 are not disposed in a selected area, e.g. a region having a radius of X/2+α from the fuse breaking point BP. Therefore, the active region dummies will not change the optimum conditions of laser irradiation and will not damage the substrate.
[0068] [0068]FIGS. 3 and 4 shows a modification of the first embodiment. FIG. 3 is a plan view and FIG. 4 is a cross sectional view taken along line IV-IV shown in FIG. 3. In the first embodiment, the active region dummies 18 are not disposed in the region having a diameter of X+2α having as a center the fuse breaking point BP of each fuse F, and the silicide layer 10 x is formed on the surface of the active region dummy 18 .
[0069] In this modification, the surface of each active region dummy 18 is covered with an insulating layer 9 . The surface of the active region dummy 18 is not silicidated because it is covered with an insulating film 9 . The influence of the dummy layout during the fuse breaking process is less. The other points are similar to the first embodiment.
[0070] [0070]FIGS. 5 and 6 show the structure of a semiconductor device according to a second embodiment of the invention. FIG. 5 is a plan view and FIG. 6 is a cross sectional view taken along line V-V shown in FIG. 5.
[0071] In this embodiment, a dummy pattern is made of a lamination of an active region dummy 18 and a gate electrode dummy 19 . The lamination dummies 18 , 19 are not disposed in the region having a diameter of X+2α having as a center the fuse breaking point BP of each fuse F. Since the gate electrode dummy is used, a precision of gate electrode patterning in the main circuit area can be ensured, and since the dummy pattern is not disposed in the predetermined region around the breaking point in the fuse circuit area, a fuse breaking margin can be ensured. Damage to the substrate is also avoided. Other points are similar to the first embodiment.
[0072] [0072]FIGS. 7 and 8 show a semiconductor device according to a third embodiment of the invention. FIG. 7 is a plan view and FIG. 8 is a cross sectional view taken along line VIII-VIII shown in FIG. 7.
[0073] In this embodiment, active region dummies are formed in the whole fuse circuit area. The active region dummies are disposed also under the breaking point BP. In the fuse circuit area, a continuous insulating film 42 is formed covering the surfaces of the active region dummies 18 . The insulating film 42 prevents the surfaces of the active region dummies 18 from being silicidated.
[0074] The active region dummy 18 has an exposed silicon substrate surface. This silicon substrate surface is covered with the insulating film 42 of silicon oxide or the like. This structure is analogous to a silicon substrate under STI. Although a step structure exists, the influence upon laser beam reflection is considered to be less. Although the active region dummy 18 exists just under the breaking point BP, laser beam absorption is limitative because there is no polysilicon layer and silicide layer. It is therefore possible to ensure an operation margin and reduce damage to the substrate.
[0075] The present invention has been described in connection with the preferred embodiments. The invention is not limited only to the above embodiments. It will be apparent to those skilled in the art that other various modifications, improvements, combinations, and the like can be made. | A semiconductor device has: a semiconductor substrate having a principal surface; a fuse circuit formed above the principal surface, the fuse circuit having fuse elements each having a predetermined breaking point; a first trench isolation region formed in a surface layer of the semiconductor substrate under the fuse circuit; and a plurality of active region dummies formed through the first trench isolation region in an area excepting a predetermined area around the predetermined breaking point. Although a dummy structure is formed also in a fuse circuit, a breaking margin is prevented from being lowered and a substrate damage is avoided, while surface flatness and line width controllability are ensured. | 7 |
RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Provisional Patent Application No. 61/511,532, filed Jul. 25, 2011 and this application is a CIP of U.S. patent application Ser. No. 13/314,059, filed Dec. 7, 2012 which in turn benefit of U.S. Provisional Patent Application Nos. 61/511,535, filed Jul. 25, 2011; 61/511,532, filed Jul. 25, 2011; 61/488,692, filed May 31, 2011; 61/438,631, filed Feb. 1, 2011; and 61/420,729, filed Dec. 7, 2010, respectively. The teachings of the '535, '532, and '059 applications are incorporated herein by reference as if set forth in full herein.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of inertial sensing and data capturing and more particularly to inertial sensing and data capture by handheld devices, such as smart phones, wherein captured inertial data is used to interpret motions of the device as writings or drawings.
BACKGROUND OF THE INVENTION
[0003] Inertial data from hand held devices has been used for, or proposed for use in, a variety of applications some of which are discussed in published US Patent Application Publication No. US 2010/0214216, Aug. 26, 2010, by Nasiri et al., and entitled Motion Sensing and Processing on Mobile Devices. This application is incorporated herein by reference as if set forth in full herein.
[0004] Consumers can benefit from additional mobile device applications that can further enhance productivity and usefulness of such devices.
SUMMARY OF THE INVENTION
[0005] It is an object of some embodiments of the invention to provide a method for recording and capturing information about a writing or drawing using at least one inertial sensor and then displaying that information or otherwise using that information for an intended purpose of the writing or drawing.
[0006] Other objects and advantages of various embodiments of the invention will be apparent to those of skill in the art upon review of the teachings herein. The various embodiments of the invention, set forth explicitly herein or otherwise ascertained from the teachings herein, may address one or more of the above objects alone or in combination, or alternatively may address some other object ascertained from the teachings herein. It is not necessarily intended that all objects be addressed by any single aspect of the invention even though that may be the case with regard to some aspects.
[0007] In a first aspect of the invention a method for creating a writing or drawing includes: (a) providing a handheld device having at least one inertial measurement sensor; (b) initiating a writing or drawing capture event; (c) undergoing a series of writing or drawing motions wherein the motions are detected by the at least one inertial measurement sensor; (d) ending a writing or drawing capture event; and (e) processing the sensor recordings into a writing or drawing.
[0008] In a second aspect of the invention the handheld device of the first aspect of the invention includes a cell phone.
[0009] In a third aspect of the invention the cell phone of the second aspect includes a smart phone.
[0010] In a fourth aspect of the invention the at least one inertial sensor of any of the first-third aspects includes at least one sensor for detecting a linear acceleration along an axis.
[0011] In a fifth aspect of the invention the at least one inertial sensor of the first-third aspects includes at least one sensor for detecting linear acceleration along at least two perpendicular axes.
[0012] In a sixth aspect of the invention the at least one inertial sensor of any of the first-third aspects includes at least one sensor for detecting linear acceleration along three perpendicular axes.
[0013] In a seventh aspect of the invention the at least on inertial sensor of any of the first-sixth aspects includes at least one sensor for detecting an angular acceleration about an axis.
[0014] In an eighth aspect of the invention the at least one inertial sensor of any of the first-sixth aspects includes at least one sensor for detecting an angular acceleration about at least two perpendicular axes.
[0015] In a ninth aspect of the invention the at least one inertial sensor of any of the first-sixth aspects includes at least one sensor for detecting an angular acceleration about three perpendicular axes.
[0016] In a tenth aspect of the invention the initiating of a writing capture event in any of the first-ninth aspects occurs by a writer entering a particular application running on the handheld device and performing an action selected from the group consisting of: (1) pressing a button on the body of the device, (2) activating a touch sensor associated with a writing contact feature of the device, and (3) applying adequate pressure to a pressure sensor associated with a writing contact feature of the device.
[0017] In an eleventh aspect of the invention the initiating of a writing capture event of any of the first-ninth aspect occurs by a writer causing the handheld device to move through a defined sequence of motions.
[0018] In a twelfth aspect of the invention the defined sequence of motions of the eleventh aspect is preceded by running a particular application on the handheld device.
[0019] In a thirteenth aspect of the invention the initiating of writing capture of any of the first-twelfth aspects includes pressing one or more contact locations on a touch screen on the handheld device.
[0020] In a fourteenth aspect of the invention the initiating of writing capture of the first-thirteenth aspect includes issuance of a voice command.
[0021] In a fifteenth aspect of the invention the writing or drawing motions of any of the first-fourteenth aspects are also detected by a proximity sensor that provides a distance indication relative to a surface over which the handheld device is moved.
[0022] In a sixteenth aspect of the invention the writing or drawing motions of any of the first-fifteenth aspects are also detected by a contact sensor that provides a contact/no-contact indication relative to a surface over which the handheld device is moved.
[0023] In a seventeenth aspect of the invention the writing or drawing motions of any of the first-sixteenth aspects are also detected by a pressure sensor that provides a pressure indication when a surface over which the handheld device is moved.
[0024] In an eighteenth aspect of the invention, the method of any of the first-seventeenth aspects include a camera that is used to detect landmarks on a surface over which the device is moved during the writing or drawing motions.
[0025] In a nineteenth aspect of the invention, the method of any of the first-seventeenth aspects include a camera that is used to detect marks on a surface when the device contacts the surface during the writing or drawing motions.
[0026] In a twentieth aspect of the invention the marks of the nineteenth aspect include the writing or drawing made during the writing or drawing motions.
[0027] In a twenty-first aspect of the invention the handheld device of any of the first-twentieth aspects of the invention includes a stylus that is moved against a surface during at least a portion of the writing or drawing motions.
[0028] In a twenty-second aspect of the invention the handheld device of any of the first-twentieth aspects of the invention includes a writing instrument that can mark a surface and that is moved against a surface during at least a portion of the writing or drawing motions.
[0029] In a twenty-third aspect of the invention the handheld device of any of the first-twentieth aspects includes a laser that can at least temporarily mark a surface and that is made to mark the surface during at least a portion of the writing or drawing motions.
[0030] In a twenty-fourth aspect of the invention the handheld device of any of the first-twenty-third aspects includes a display screen that displays an image derived from the writing or drawing that is being created.
[0031] In a twenty-fifth aspect of the invention the handheld device of any of the first-twenty-third aspects includes a display screen which does not display an image that is derived from writing or drawing being created.
[0032] In a twenty-sixth aspect of the invention the writing or drawing motions of any of the first-twenty-fifth aspects give rise to data that is transferred from the handheld device to another device and the transferred data is interpreted by the other device to create and display the writing or drawing.
[0033] In a twenty-seventh aspect of the invention the writing or drawing of any of the first-twenty-sixth aspects are interpreted as 2-D writing or drawings.
[0034] In a twenty-eighth aspect of the invention the writing or drawing of any of the first-twenty-sixth aspects in interpreted as a 3-D structure.
[0035] In a twenty-ninth aspect of the invention the writing or drawing of any of the first-twenty-eight aspects is interpreted using character recognition algorithms (e.g. OCR algorithms).
[0036] In a thirtieth aspect of the invention the processing of the motions into a writing or drawing of any of the first-twenty-ninth aspects occurs in real time by the handheld device.
[0037] In a thirty-first aspect of the invention the processing of the motions into a writing or drawing of any of the first-twenty-ninth aspects occur after completion of the writing or drawing movements.
[0038] In a thirty-second aspect of the invention information extracted from the writing or drawing motions of any of the first-thirty-first aspects in an application selected from the group consisting of (1) a text message; (2) a phone number; (3) a web search; (4) a report; (5) notes; and (6) a signature.
[0039] In a thirty-third aspect of the invention information extracted from the writing or drawing motions of any of the first-thirty-second aspects is compared to previously recorded information to provide a writing analysis, signature verification, or identity verification or confirmation.
[0040] Other aspects of the invention will be understood by those of skill in the art upon review of the teachings herein. Other aspects of the invention may involve combinations of the above noted aspects of the invention. These other aspects of the invention may provide other configurations, structures, functional relationships, and processes that have not been specifically set forth above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 illustrates the result of a movement of a smart phone, the detection of at least certain aspects of the motion by inertial sensors within the phone, the capture of at least certain features of the detected motion, and the translation of at least a portion of the captured features into a display image that is shown on the screen of the smart phone.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0042] A smart Phone, or other handheld device such as a camera or a PDA, may be held like a pen, and a corner of it, or some device attached to it, may be used as if it is the tip of the pen. The handheld device may go through the motions of writing or drawing things on a surface (as shown in FIG. 1 ), or even in the air. Before or at the time of starting the motion, the handheld device may be instructed to capture and record the motion (e.g. by pressing a button or series of buttons, entering information into a touch screen, by voice command, by tapping a writing or drawing instrument that forms part of the handheld device against a surface in a particular way, or possibly but moving the device through a motion or series of motions that signal initiation of recording). After the capture motion, the device may be instructed to stop recording. During the record and capture period, the inertial sensors (e.g. accelerometers and gyroscopes) and possibly other sensors (e.g. proximity sensors, touch sensors, pressure sensors, and/or optical devices, e.g. digital or video cameras,) may capture information about the motion (linear accelerations in one or more directions, rotational accelerations about one or more axes), information about the relative location of the device to a surface, contact with a surface, absolute or relative pressure exerted by the device on a surface, recording of landmarks on the surface, and even marks made on the surface by the movement of the smart phone. In some embodiment variations, the handheld device may include or be capable of receiving a stylus or an actual writing instrument, or even laser pointer that can be used to make permanent or temporary marks on the surface.
[0043] This captured and recorded information may be processed by appropriate software and the device's microprocessor to re-create an actual or an appropriately scaled image of the writing on a display screen of the device. In other variations, the screen may remain blank or at least not show the image associated with the motions but instead the captured information may be sent to an external device (e.g. computer or data storage device) via a hardwired connection or via a wireless connection (e.g. over a phone network, a wireless internet connection, or the like) for subsequent processing, display, and/or other usage. In some embodiment variations the information stored on the screen may be limited to drawings (e.g. non characters) and characters that are recognized as such and then possibly displayed in a desired font.
[0044] In some embodiment variations, the processing of the recorded sensor data may be performed in real-time. In such variations, recorded information may be limited to information displayed and it may include, or be limited to, the original information that was captured and processed.
[0045] In some variations, any corner or side of the hand held device (e.g. smart phone) may be utilized as the tip of a virtual pen. In such variations, the corner being used may be specified by the user or may be automatically determined (e.g. based on an initial lowest corner of the device when data capture begins). In other variations, when an attachment is added to the device or extends from the device, an effective writing tip may be something located at a distance spaced from the normal surface of the device.
[0046] In still other variations, a realistic pen-tip may be placed, and held in place (e.g. in the headphone port of the smart phone, such that the user may actually be writing or drawing physically while the phone is recording the inertial and/or other data.
[0047] After the recorded data is processed and the handwriting is revealed, the data may then be processed by a character recognition software (e.g. optical character recognition software) to translate the handwriting into digital form. This may be done on the smart phone or a separate device/computer.
[0048] In some embodiment variations, recording of inertial data and/or other data may occur continuously and be sent to data storage wherein earlier recorded data is overwritten by new data as an allocated storage capacity is filled. In such embodiments, captured information, for example, may be processed into a writing or drawing after the motions have already occurred. In other variations, writing may be recognized and saved based on motion delimitating, or start/stop, signals to which the device has been subjected.
[0049] In some embodiment variations, the writing or drawing motions may give rise to data that is transferred from the handheld device to another device, the transferred data may be interpreted by the other device, and then transformed information sent back to the handheld device to display the writing or drawing.
[0050] Applications of such writings or drawings are extensive. The writing may be used as a data entry method for text messaging, entering phone numbers, web searching, report typing, memo or note taking including text and images, signature providing, and the like. In some such applications, the writing may remain in strictly an image format while in other applications some or all of the data may undergo some form of character recognition process (e.g. OCR process). In some variations, data to undergo conversion, or not to undergo conversion, via a character recognition algorithm may be automatically determined by the data processing while in other variations, the user may indicate whether particular writings are to undergo character recognition (e.g. by holding a button during writing, by tapping button before or after writing, or by moving the device through a certain recognizable movement to provide processing start and stop signals). In some applications the device may be used as a three-dimensional drawing tool such as for defining structures or components of a solid model that is being created (e.g. as a data entry device for a 3-D computer aided design system).
[0051] In some embodiment variations the writings or drawings captured or interpreted from the handheld device sensors, and/or the captured data itself, may be correlated to other writings/drawings, and/or data associated with these other writings/drawings to establish the similarities and differences between them (e.g. for the purpose of authenticating handwriting or signature of a person. Use of such authentication may allow access to otherwise secured data files, programs, facilities, rooms and the like. Examples of some such applications are provided in a concurrently filed application having Docket No. PASP-006US-A, by Vacit Arat, and entitled “Methods for Using Biometric Authentication Methods for Securing Files and for Providing Secure Access to Such Files by Originators and/or Authorized Others”. This referenced application is incorporated herein by reference as if set forth in full herein.
[0052] In view of the teachings herein, many further embodiments, alternatives in design and uses of the embodiments of the instant invention will be apparent to those of skill in the art. As such, it is not intended that the invention be limited to the particular illustrative embodiments, alternatives, and uses described above but instead that it be solely limited by the claims presented hereafter. | Embodiments are directed to apparatus, methods and systems for capturing and using writing or drawing motions made while holding a handheld electronic device (e.g. smart phone) that include one or more of a variety of sensors (e.g. inertial sensors, touch sensors, pressure sensors, optical sensors, and the like). The writing or drawing movements are processed into writing or drawing data that may be used as communication data or as verification data when compared to previously recorded data. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to novel silane compounds, and more particularly the present invention relates to novel silane compounds which can be used as glass sizing agents or as adhesion promoters.
Acrylate functional silanes are well known; see for instance, the patent application of Keating, Ser. No. 109,727, filed on Jan. 4, 1980, which discloses the use of acrylate silanes along with other compounds as adhesion promoters for SiH olefin platinum catalyzed RTV compositions. The use of amine-functional silanes as adhesion promoters for two-component alkoxy-functional RTV systems is also well known as disclosed in Lampe, et al., U.S. Pat. No. 3,888,815, which is hereby incorporated by reference. There is also the disclosure of Mitchell, U.S. Pat. No. 4,026,880, where there is disclosed a particular amine-functional silane as an organic flocculent which is also disclosed in the foregoing Lampe et al. patent as an adhesion promoter.
Recently, there has been discovered novel alkoxy-functional curing one-component RTV systems are exemplified for instance, by the disclosure of White et al., U.S. Pat. No. 4,395,526. Certain adhesion promoters for such RTV systems, among them amine-functional adhesion promoters, are for instance disclosed in the Docket of Lucas et al., Ser. No. 349,538, which was filed on the same date as the present case.
Other pertinent patents disclosing certain amine-functional silanes for various purposes, are U.S. Pat. No. 4,100,075, U.S. Pat. No. 3,751,371, U.S. Pat. No. 3,615,538, and U.S. Pat. No. 3,716,569. All the patents disclosed in the present patent application are incorporated by reference. With respect to the patent of White et al., U.S. Pat. No. 4,395,526, there has been a constant effort to develop adhesion promoters for such a composition. For instance, note the novel adhesion promoter disclosed in Beers, docket Ser. No. 349,537 which was filed on the same date as the present case. It is the purpose of the present disclosure to broadly disclose and claim the novel class of compounds to which the adhesion promoter of Beers, docket Ser. No. 349,537, belongs.
It is one object of the present invention to provide for a novel class of silane compounds.
It is an additional object of the present invention to disclose a novel class of amine-functional silanes.
It is still a further object of the present invention to disclose a novel class of silanes which have utility as adhesion promoters and glass fiber treating agents.
It is still a further object of the present invention to disclose a novel process for producing novel silane compounds which are useful as adhesion promoters.
These and other objects of the present invention are accomplished by means of the disclosure set forth here in below.
SUMMARY OF THE INVENTION
In accordance with the above objects, there is provided by the present invention, a novel compound useful as a glass sizing agent and adhesion promoter having the formula ##STR1## where R, R 1 are selected from C.sub.(1-8) monovalent hydrocarbon radicals, R 2 , R 3 are selected from C.sub.(1-12) divalent hydrocarbon radicals, R 7 is selected from hydrogen and methyl, X is selected from an ##STR2## radical and a ##STR3## radical, Z is selected from O radicals, S radicals, and ##STR4## radicals, and Z' is selected from O radicals, S radicals, and ##STR5## radicals where R 5 is selected from hydrogen and C.sub.(1-3) alkyl radicals, R 4 , R 6 are selected from hydrogen and C.sub.(1-6) monovalent hydrocarbon radicals, and t varies from 0 to 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the compounds of Formula (1), R and R 1 are selected from C.sub.(1-8) monovalent hydrocarbon radicals such as for instance alkyl radicals, such as methyl, ethyl, propyl; cycloalkyl radicals, such as cyclohexyl, cycloheptyl, etc.; alkenyl radicals such as vinyl, allyl, etc.; mononuclear aromatic radicals such as phenyl, methylphenyl, ethylphenyl, etc.; and fluoroalkyl radicals. The R 2 and R 3 radicals can be any C.sub.(1-12) divalent hydrocarbon radicals and are more preferably selected from C.sub.(2-8) divalent hydrocarbon radicals which can be substituted or unsubstituted and which are preferably selected from radicals such as alkylene and arylene radicals of 2 to 8 carbon atoms.
The X radical is selected from the group consisting of ##STR6## radical or ##STR7## radical and is more preferably a ##STR8## radical. The radical R 7 can be hydrogen or methyl and it can have either substitution, there being no preference between one and the other. Further, the Z radical is selected from the group consisting of oxygen, sulfur and ##STR9## radicals, and is most preferably an ##STR10## radical. The Z' is also preferably selected from the group consisting of an O radical, an S radical, and a ##STR11## radical, and is more preferably an ##STR12## radical. The radical R 5 is preferably selected from C.sub.(1-3) alkyl radicals and R 4 and R 6 are selected from hydrogen and C.sub.(1-6) monovalent hydrocarbon radicals such as the radicals previously given for R and R 1 with the caveat that the R 4 and R 6 radicals desirably should not have more than 6 carbon atoms. The preferable nitrogen radicals for the Z and Z' symbols in the compounds of Formula (1) are particularly desired when the compounds are to be utilized as adhesion promoters, and particularly as adhesion promoters for the compositions of White et al., U.S. Pat. No. 4,395,526 and Dziark, U.S. Pat. No. 4,417,042. Further, t may vary from 0 to 3, and is preferably 0 when the compound is to be utilized as an adhesion promoter. Accordingly, it is desired that the compound have as many alkoxy groups appended to the silicon atom as it can have when the compound is to be utilized as an adhesion promoter.
A preferred class of compounds coming within the scope of Formula (1) which are useful as adhesion promoters desirably have the formula ##STR13## where R, R 1 , R 2 , R 7 , R 5 , R 3 , R 6 , R 4 are as previously defined. As stated previously in the compounds of Formula (2) it is preferable that t=0, R, R 7 are methyl and R 5 , R 6 , and R 4 are hydrogen.
Specific compounds within the scope of Formula (2) which are desirably used as adhesion promoters in the instant invention, are for instance: ##STR14##
It should be noted, however, that X can be equal to C═O in Formula (1) and Z can be a sulfur group or an oxygen group. Such a compound would be useful as a glass sizing agent and would be useful as an adhesion promoter. The compounds of Formula (1) may be prepared by reacting a first compound of a formula ##STR15## with a second compound of the formula
H--Z--R.sup.3 --Z'--R.sup.4 (4)
where R, R 1 , R 2 , R 3 , R 7 , Z, Z', R 5 , R 6 , and R 4 are as previously defined.
Preferably, the first reactant compound has the formula ##STR16## which is reacted with a second compound which preferably has the formula ##STR17## where R, R 1 , R 2 , R 7 , R 3 , R 6 , and R 4 are as previously defined. Again, preferably t=0 when the compound is to be utilized as an adhesion promoter and R 7 is methyl and R 5 , R 6 , R 4 are hydrogen. To get the maximum yield from the above process, preferably there is reacted at least two moles of the second compounds of Formula (4) above or Formula (6) above with 1 mole of the first compound of Formula (3) or of Formula (5) above.
No heat is necessary for this reaction and the process is preferably carried out at room temperature. The reaction is exothermic. However, a temperature in the range generally of room temperature to 100° C. can be utilized. However, as the temperature is increased to higher levels, or approaching 100° C., there is the possibility that in the case where there is an acrylate or similar reactant, that the material may partially polymerize. Accordingly, as the temperature of the reaction is increased, there are competing side reactions taking place which lower the yield. Accordingly, the reaction is preferably carried out at a temperature of room temperature to 60° C. Further, the reaction period may vary from 2 hours to 24 hours and more preferably for a period of time varying from 8 hours to 24 hours. The reaction time can be decreased by increasing the temperature of the reaction, however, as noted above, with the increase in temperature there are competing side reactions which take place.
Preferably, there is utilized a solvent to allow intimate contact between the reactants. The solvent is desirably selected from organic solvents such as aromatic solvents, for instance, xylene, toluene, benzene, etc. and hydrocarbon solvents such as hexane, heptane, octane, etc. or well known other solvents such as dioxane, tetrahydrofuran etc.
Preferably, in the above formula, R 2 is selected from propylene and R 3 ethylene. It should be noted that no catalyst is necessary in the foregoing reaction when the compound of Formula (5) is reacted with a compound of Formula (6). However, in the cases where Z is equal to sulfur or oxygen, catalysts such as boron trichloride, hydrogen chloride, boron trifluoride etherate, aluminum chloride and other Lewis acid type catalysts may be utilized.
The compounds of Formulas (3), (4), (5) and (6) are well known compounds and may be obtained from any specialty chemical manufacturer such as for instance Aldrich Chemical Co., Wisconsin, Silar Laboratories, Inc. New York, and Petrarch Systems, Inc., Pennsylvania. The silane intermediates of Formula (3) and Formula (5) are well known compounds that may be purchased from specialty chemical houses such as the above, or for instance, from Union Carbide Corporation, Connecticut, or Dow Corning Corporation, Michigan. In the case of the silane intermediates, the silanes of Formula (3) and Formula (5) may be obtained by reacting the appropriate hydride methoxylated silane with an olefinic acrylate in the presence of a platinum catalyst to add the hydride of the silane onto the olefinic group of the acrylate or in the case where X is equal to C═O, the olefinic group of the ketone compound. Such reactions are well known in the art. In the case where R 2 is methylene, the sodium salt of the acrylates is reacted with trimethoxychloromethylsilane to produce the desired compound in a manner known in the art.
The reaction can be carried out at room temperature or preferably at an elevated temperature of 100° C., preferably there is used stoichiometric amounts of the reactants and the reaction proceeds without any difficulty. For more details on such a process, one is referred to the foregoing Keating patent application, Ser. No. 109,727 and the general art.
The compounds of Formulas (4) and (6) are well known in the art and are available from the specialty chemical houses disclosed above and no further disclosure as to their preparation is necessary. After the compounds have been reacted in the desired stoichiometric amounts at the temperatures set forth above, there is obtained, in most cases, a yield of at least 80 to 90% of the desired compounds of Formula (1) or Formula (2). After the reaction is terminated, the compound may be purified by stripping off the excess reactants and the excess solvent by heating above the reflux temperature of the solvent to leave behind the pure compound of the foregoing Formulas (1) and (2) and the other formulas set forth in the specification.
It should be noted that when any of the foregoing catalysts mentioned above, are necessary, they may be used at a concentration of either 1 to 10% by weight of the total two reactants. Further, the process of reacting the compounds of Formulas (3) and (4) or the compounds of Formulas (5) and (6), is preferably carried out at atmospheric pressure. A vacuum is preferably utilized when the solvent and the excess reactants are stripped off to yield the desired product.
In all other respects, the reactions for producing the compounds of Formulas (1) and (2) may be carried out in a manner that is well known to a worker skilled in the art with the above information. It should be noted that the compounds in the instant case broadly are desirable as as glass sizing agents, and more particular, it has been found under actual testing that the compounds of Formula (2) are particularly desirable as adhesion promoters for the RTV systems of White et al., U.S. Pat. No. 4,395,526 Beers, Docket 60Si-640 Ser. No. 349,537, Dziark, U.S. Pat. No. 4,417,042, and Chung, Ser. No. 338,518, filed on Jan. 11, 1982. Dockets Lucas et al., Ser. No. 349,538, and Beers, 60Si-640 Ser. No. 349,537, were all filed on the same date as the present application.
The example below is given for the purpose of illustrating the present invention. It is not given for setting limits and boundaries to the instant invention. All parts are by weight.
EXAMPLE 1
To a 1,000 ml three-necked flask was added 248 parts (1.0 mol) of 3-methacryloxypropyltrimethoxysilane followed by the slow addition of 120 parts (2.0 mol) or 1,2-ethylenediamine. The flask was equipped with a mechanical stirrer, a thermometer and a reflux condenser. The mixture was stirred at room temperature for 40 hours while sampling periodically. Analysis by gas chromatography showed peaks due to the two starting compounds and the two products. The predominant peak, however, was that of the desired product, 3-(trimethoxysilyl)propyl 1-methyl-2-[N-(2-aminoethyl)amino]propionate, 3. The reaction mixture was subjected to a vacuum distillation to remove excess ethylenediamine. The residue obtained was 94.7% pure by gas chromatography. The yield obtained was 300 grams (97%). Analysis by titration for percent amine gave a value of 8.97% (theory=10.04%). | The present case relates in one instance to novel amine-functional alkoxy silanes. These novel amine-functional alkoxy silanes are particularly useful as adhesion promoters in one-component alkoxy-functional low modulus, fast-curing, shelf stable RTV systems. | 2 |
FIELD OF THE INVENTION
The present invention relates to novel skin conditioning emulsion compositions which form a water-resistant barrier whereby the skin is kept in a smooth and supple condition for an extended period of time.
PRIOR ART
The treatment of human skin with various agents has been undertaken for many years with the goal being to keep the skin in a smooth and supple condition. Skin has the tendency to dry out when exposed to conditions of low humidity or to extended periods in a detergent solution. From a biochemical standpoint, dryness is a measure of the water content of the skin. Under normal conditions, the water content and vapor pressure of the epidermis are higher than those of the surrounding air with consequent evaporation of water from the skin surface. Skin becomes dry because of excessive loss of water from the surface and the subsequent loss of water from the stratum corneum.
Continuous and prolonged immersion in soap or detergent solutions may contribute to dryness of the stratum corneum. The reason for this is that the surfactant medium promotes dissolution of the skin surface lipids, the horny layer lipids, and the dissolution of the hygroscopic water-soluble components in the corneum.
To alleviate the aforementioned conditions, emollient creams as described in Sagarin, Cosmetics, Science and Technology, 2nd Edition, Vol. 1, Wiley Interscience (1972) have been recommended for application to the skin. The emollient materials probably increase the state of hydration of the corneous layer of the skin by altering the rate of diffusion of water from the lower epidermal and dermal layers, the rate of evaporation of water from the skin's surface, and the ability of the corneous layer to hold moisture.
Sagarin, at pages 27-104 and pages 179-222, discloses many emollient and hand lotion compositions containing some of the ingredients of the current invention, but not in the critical combination which is the basis of the current invention. Bennett, The New Cosmetic Formulary, Chemical Publishing Company, Inc., New York (1970), at page 74, discloses a formulation comprising fatty acids, a polysiloxane fluid, a neutralizing agent, lubricants, emollients, minors and water. Water-soluble polymers are disclosed for use in hand lotions in the aforementioned Sagarin reference, but it does not disclose the use of these polymers in the compositions of the present invention.
SUMMARY OF THE INVENTION
The present invention relates to a skin conditioning emulsion composition which utilizes a synergistic combination of ingredients to keep skin in a smooth and supple condition for an extended period of time. The conditioning composition of the present invention is an emulsion comprising a fatty acid or a mixture of fatty acids having an average carbon chain length of 10 to 31 carbon atoms wherein about 20% to about 80% of the acid groups are neutralized, a polysiloxane fluid having the formula -- [R 2 SiO] -- wherein R is C 1 -C 4 alkyl or phenyl and wherein said polysiloxane has a viscosity at 25°C. of from about 5 to about 2,000 centistokes, a water-soluble polymer having a molecular weight of from about 500 to about 5,000,000, and water, wherein the fatty acids and the polysiloxane fluid are present in a weight ratio of from about 12:1 to about 1:20 and comprise from about 0.35% to about 5.0% by weight of the total skin conditioning composition, while the water-soluble polymer comprises from about 0.015% to about 0.5%, and water comprises from about 50% to about 94.5% by weight of the total skin conditioning composition.
DETAILED DESCRIPTION OF THE INVENTION
The present invention can be broadly defined as a synergistic skin conditioning emulsion composition comprising:
A. a fatty acid or a mixture of fatty acids having an average carbon chain length of 10 to 31 carbon atoms wherein from about 20% to about 80% of the acid groups are neutralized;
B. a polysiloxane fluid having the formula -- [R 2 SiO] -- wherein R is C 1 -C 4 alkyl or phenyl and wherein said polysiloxane has a viscosity at 25°C. of from about 5 to about 2,000 centistokes;
C. a water-soluble polymer having a molecular weight of from about 500 to about 5,000,000; and
D. water,
wherein (A) and (B) are present in a weight ratio of from about 12:1 to about 1:20 and comprise from about 0.35% to about 5.0% by weight of the total skin conditioning composition, while (C) comprises from about 0.015% to about 0.5% and (D) comprises, from about 50% to about 94.5% by weight of the total skin conditioning composition.
In a preferred embodiment, (A) and (B) are present in a ratio of about 1.5:1 and comprise from about 1% to about 3% by weight of the total skin conditioning composition, while (C) comprises from about 0.03% to about 0.10% and (D) comprises from about 65% to about 88% by weight of the total skin conditioning composition.
The fatty acids suitable for use in the compositions of the present invention contain an average of 10 to 31 carbon atoms in their chain. Examples of such acids are capric, undecyclic, lauric, myristic, palmitic and stearic. Preferred types of fatty acids are the lanolin fatty acids which include the following formulas:
Ch.sub.3 -- (CH.sub.2).sub.n -- COOH (n = 8 to 24 inclusive); ##EQU1##
As used herein, the term "lanolin fatty acids" means all of the fatty acids as shown above. These can be separated from lanolin by saponification as described in Amerchol Lanolin Derivatives, Vol. II (1971), Amerchol, a unit of CPC International, Inc., incorporated herein by reference. Amerchol markets lanolin fatty acids under the names Amerlate LFA and Amerlate WFA.
The acids may be neutralized either prior to their addition to the oil phase or in situ in the skin conditioning composition.
Any of a wide variety of water-soluble polymers can be used in the present invention. These include, for example, cellulose ethers, quaternary ammonium substituted cellulose ether derivatives as described in U.S. Pat. No. 3,472,840, Oct. 14, 1969, to Stone et al., incorporated herein by reference, hydroxyethyl cellulose, hydroxypropyl methyl cellulose, methyl cellulose, sodium carboxymethyl cellulose, acrylic polymers, polyvinyl pyrrolidone, polyvinyl alcohol, and polyvinylmethyl ether maleic anhydride. The polymers should have a molecular weight of about 500 to about 5,000,000.
Preferred water-soluble polymers are acrylic acid/ethyl acrylate copolymers. Other preferred polymers are the carboxyvinyl polymers sold by the B. F. Goodrich Company under the trade mark of Carbopol resins. These resins consist essentially of a colloidally water-soluble polymer of acrylic acid crosslinked with from 0.75% to 2.00% of a crosslinking agent selected from the class consisting of polyallyl sucrose and polyallyl pentaerythritol. A most preferred polymer is Carbopol 934 which has an average molecular weight of about 3,000,000. Carbopol 934 is a water-soluble polymer of acrylic acid crosslinked with about 1% of a polyallyl ether of sucrose having an average of about 5.8 allyl groups for each sucrose molecule.
The polysiloxane fluids acceptable for use in the compositions of the present invention have the formula -- R 2 SiO] -- wherein R is C 1 -C 4 alkyl or phenyl and has a viscosity at 25°C. of from about 2,000 centistokes. A preferred polysiloxane is Silicone 200 Fluid (dimethyl polysiloxane) supplied by the Dow Corning Corporation, having a viscosity at 25°C. of about 350 centistokes.
The neutralizing agents suitable for use in neutralizing the fatty acids and acidic group containing water-soluble polymers of the present invention include those organic and inorganic bases which will form salts with the fatty acids and will neutralize the water-soluble polymer where such polymers contain free acid groups. Included in the group of such bases are sodium hydroxide, potassium hydroxide, ammonium hydroxide, monoethanol amine, diethanol amine and triethanol amine.
The skin conditioning emulsion compositions of the present invention may also contain emollient/humectant materials which serve to moisturize the skin, and materials which serve to make the compositions cosmetically acceptable. Included in the list of acceptable ingredients are emollient/humectant agents such as hydrocarbon oils and waxes, monoglyceride esters, triglyceride esters, acetoglyceride esters, ethoxylated glyceride, alkyl esters, alkenyl esters, fatty alcohols, fatty alcohol ethers, fatty acid esters of ethoxylated fatty alcohols, lanolin alcohols, sterols extracted from lanolin, lanolin esters, hydroxylated lanolin derivatives, polyhydric alcohols, polyether derivatives, polyhydric alcohol esters, wax esters, beeswax derivatives, vegetable waxes, phospholipids, sterols and amides. Preferred types of emollient/humectant materials are fatty alcohols containing from about 12 to about 18 carbon atoms such as lauryl, myristyl, cetyl and stearyl, and fatty acid esters of aliphatic alcohols where said esters contain from about 10 to about 31 carbon atoms such as ethyl laurate, isopropyl myristate, isopropyl palmitate, isopropyl behenate, isopropyl esters of lanolin fatty acids and hexadecyl acetate. These emollient/humectant materials may comprise from about 0% to about 20% of the skin conditioning composition, preferably from about 1% to about 10%. The skin conditioning compositions may also contain such things as perfumes and preservatives such as propyl-p-hydroxy-benzoate and methyl-p-hydroxy-benzoate at a level of about 0% to 1.0%, and coloring agents such as FD&C dyes and titanium dioxide at a level of about 0% to 0.5%.
The pH of the skin conditioning compositions may be from 4.5 to 8.0.
The water-soluble polymers, fatty acids, neutralizing agents and polysiloxane fluids are well known and are available commercially. The compositions of the present invention generally have a lotion consistency and may be in the form of oil-in-water or water-in-oil emulsions with the former being preferred because of their more pleasing cosmetic properties.
The compositions of the present invention are made by:
A. preparing the oil phase;
B. preparing the water phase; and
C. adding the oil phase to the water phase.
Step (A) is carried out by heating a proper mixture of fatty acids and polysiloxane to a temperature of about 75°C. to about 100°C. Step (B) is carried out by heating the water-soluble polymer in water to a temperature about the same as that of the oil phase. The emulsion is formed by slowly adding the oil phase prepared in step (A) to the water phase prepared in step (B) with stirring. Other ingredients may be added to the phase in which they are soluble prior to the mixing of the two phases or added directly to the mixed water and oil phases.
While not wishing to be limited to any particular theory, it is believed that the ingredients of the present invention form a longer-lasting protective barrier than do prior art compositions by utilizing the barrier properties of the individual ingredients in a synergistic manner. Thus, the benefits of the compositions are greater than one would expect from the individual components. The polymer forms a film in which the silicone fluid is likely interspersed while the fatty acids partly neutralized form a layer over the water-soluble polymer/silicone film and fill in the interstices of such film. This film matrix causes the skin to be less likely to become dry and scaly due to the film reducing evaporation of water from the surface of the skin and the corneous layers. The film is resistant to being washed off, thereby extending the duration of the skin conditioning benefits.
Specific examples embodying this invention follow and are not meant to be limiting. All percentages used herein in the specification and the claims are by weight unless otherwise specified.
EXAMPLE I
The following skin conditioning formulation was made and gave improved skin conditioning:IngredientPart A Percent by Weight______________________________________ 1 Amerlate WFA (lanolin fatty acids) 0.50 1 Amerlate W (isopropyl esters of 0.75 lanolin fatty acids) 1 Amerchol CAB (lanolin derived 1.25 stearol extract and PetrolatumStearic acid 1.00Cetyl alcohol 1.50Stearyl alcohol 0.75 1 OH Lan (hydroxylated lanolin 0.25 derivative, high OH value)Isopropyl myristate 1.25 2 Arlacel 165 (glycerol monostearate 0.75 and polyoxyethylene stearate) 3 Silicone 200 Fluid (dimethyl- 1.00 polysiloxane with viscosity at 25°C. of 350 centistokes)Part B Percent by Weight______________________________________ 4 1.5% Carbopol 934 solution 3.25 in H 2 O (carboxy vinyl polymer with molecular weight of about 3,000,000)Propylene glycol 2.5070% sorbitol solution in H 2 O 2.50Triethanolamine 0.65Distilled water 81.50Part C Percent by Weight______________________________________Methyl paraben (methyl p-hydroxy 0.20 benzoate - preservative)Propyl paraben (Propyl p-hydroxy 0.10 benzoate - preservativeTitanium dioxide 0.20Perfume 0.10______________________________________ 1 All supplied by Amerchol, a unit of CPC International, Inc. 2 Supplied by Atlas Chemicals, a division of ICI America, Inc. 3 Supplied by Dow Corning Corporation 4 Supplied by the B.F. Goodrich Company
Parts A and B were heated separately to a temperature of 80°C. Part A was then added to Part B with stirring, forming an oil-in-water emulsion. Part C was then added to the mixture of Parts A and B. The result was a skin conditioning composition of increased effectiveness due to the synergistic activity of the silicone fluid, the fatty acids and the water-soluble polymer.
EXAMPLE II
The following formulation was prepared in the same manner as that described in Example I.
______________________________________IngredientPart A Percent by Weight______________________________________.sup.1 Acetulan (acetylated lanolin) 0.60.sup.1 Amerlate P (isopropyl esters of 0.20 lanolin fatty acids)Stearic acid 0.60.sup.1 Amerlate WFA (lanolin fatty acids) 0.15Cetyl alcohol 2.00.sup.2 Silicone 200 Fluid (dimethyl 0.80 polysiloxane with viscosity at 25°C. of 350 centistokes)Part B Percent by Weight______________________________________.sup.3 1.5% Carbopol 934 solution in 6.00 H.sub.2 O (carboxy vinyl polymer with molecular weight of about 3,000,000)Propylene glycol 3.00Triethanolamine 0.40Distilled water 86.10Part C Percent by Weight______________________________________Perfume 0.10Titanium dioxide 0.05______________________________________ .sup.1 All supplied by Amerchol, a unit of CPC International, Inc. .sup.2 Supplied by Dow Corning Corporation .sup.3 Supplied by B. F. Goodrich Company
EXAMPLE III
The following formulation was prepared in the same manner as that described in Example I.
IngredientPart A Percent by Weight______________________________________.sup.1 Amerlate WFA (lanolin fatty acids) 0.50Stearic acid 1.00.sup.1 Amerlate W (isopropyl esters 0.75 of lanolin fatty acids)Cetyl alcohol 1.50Stearyl alcohol 0.75.sup.1 OH Lan (hydroxylated lanolin 0.75 derivative, high OH value)Isopropyl myristate 1.25.sup.2 Arlacel 165 (glycerol monostearate 0.75 and polyoxyethylene stearate).sup.1 Amerchol CAB lanolin derived 1.25sterol extract and Petrolatum).sup.3 Silicone 200 Fluid (dimethyl 1.00 polysiloxane with viscosity at 25°C. of 350 centistokes)Part B Percent by Weight______________________________________.sup.4 4% JR-1L resin 3.5070% sorbitol solution in H.sub.2 O 2.50Propylene glycol 2.50Triethanolamine 0.65Distilled water 80.85Part C Percent by Weight______________________________________Propyl paraben (propyl p-hydroxy- 0.20 benzoate)Methyl paraben (methyl p-hydroxy- 0.10 benzoate)Titanium dioxide 0.10Perfume 0.10______________________________________ .sup.1 All supplied by Amerchol, a unit of CPC International, Inc. .sup.2 Supplied by Atlas Chemicals, a division of ICI America, Inc. .sup.3 Supplied by Dow Corning Corporation .sup.4 Supplied by the Union Carbide Corporation.
The description of the polymer is as follows:
JR-1L is a cationic cellulose ether derivative having a molecular weight in the range of 100,000 to 1,000,000 and the structure: ##EQU2## wherein R cell is a residue of an anhydroglucose unit, wherein y is an integer of 50 to 20,000, and wherein each R individually represents a substituent of the formula: ##EQU3## wherein m is an integer from 0 to 10, n is an integer of 0 to 3, and p is an integer of 0 to 10.
The composition given above can also be made using water-soluble polymers having a molecular weight of from 500to 5,000,000 and selected from the group consisting of cellulose ethers, hydroxyethyl cellulose, hydroxypropyl cellulose, methyl cellulose, sodium carboxymethyl cellulose, polyvinyl pyrrolidone, polyvinyl alcohol, or polyvinyl methyl ether maleic anhydride, in place of JR-1L with an effective skin conditioning product being obtained. | A synergistic skin conditioning emulsion composition comprising a fatty acid or a mixture of fatty acids, a polysiloxane fluid, a water-soluble polymer and water. The fatty acids, the polysiloxane and the water-soluble polymer combine to form a water-resistant barrier which allows skin to stay in a smooth and supple condition for an extended period of time. | 0 |
BACKGROUND OF THE DISCLOSURE
[0001] 1. Field of the Invention
[0002] The invention relates to a method of thin film deposition and, more particularly to a method of forming titanium and/or titanium nitride films.
[0003] 2. Description of the Background Art
[0004] In the manufacture of integrated circuits, a titanium and/or titanium nitride film is often used as a barrier layer to inhibit the diffusion of metals into regions underlying the barrier layer. These underlying regions include transistor gates, capacitor dielectric, semiconductor substrates, metal lines, and many other structures that appear in integrated circuits.
[0005] For example, when a gate electrode of a transistor is fabricated, a barrier layer is often formed between the gate material (e.g., polysilicon) and the metal (e.g., aluminum) of the gate electrode. The barrier layer inhibits the diffusion of the metal into the gate material. Such metal diffusion is undesirable because it potentially changes the characteristics of the transistor, rendering the transistor inoperable. A stack of titanium/titanium nitride (Ti/TiN) films, for example, is often used as a diffusion barrier.
[0006] The Ti/TiN stack has also been used to provide contacts to the source and drain of a transistor. For example, in a tungsten (W) plug process, a Ti layer deposited on a silicon (Si) substrate is converted to titanium silicide (TiSi x ), followed by TiN layer deposition and tungsten (W) plug formation. The conversion of the Ti layer to TiSi x is desirable because the TiSi x forms a lower resistance contact to the silicon substrate then does the TiN layer. In addition to being a barrier layer, the TiN layer also serves two additional functions: 1) preventing chemical attack of TiSi x by tungsten hexafluoride (WF 6 ) during W plug formation; and 2) acting as a glue layer to promote adhesion of the W plug.
[0007] Ti and/or TiN layers are typically formed using physical and/or chemical vapor deposition techniques. A Ti/TiN combination barrier layer may be formed in a multiple chamber “cluster tool” by depositing a Ti film in one chamber followed by TiN film deposition in another chamber. For example, titanium tetrachloride (TiCl 4 ) may be reacted with different reactant gases to form both Ti and TiN films using CVD (e.g., under plasma conditions, Ti is formed when TiCl 4 reacts with hydrogen (H 2 ), and TiN is formed when TiCl 4 reacts with nitrogen (N 2 )).
[0008] However, when a TiCl 4 -based chemistry is used to form a Ti/TiN combination barrier layer, reliability problems can occur. In particular, if the Ti film thickness exceeds about 150 Å, the Ti/TiN stack can peel off an underlying field oxide layer or exhibit a haze, which may result, for example, from TiCl 4 or other species arising from TiCl 4 , chemically attacking the Ti film prior to TiN deposition.
[0009] Another reliability problem can occur for TiN films. TiN films formed using CVD techniques at process temperatures greater than about 550° C., tend to have intrinsically high tensile stresses (e.g., tensile stress on the order of about 2×10 10 dyne/cm 2 for a film thickness of about 200 Å). Since tensile forces increase with increasing film thicknesses, cracks can begin to develop in TiN films having thicknesses that exceed about 400 Å. When the process temperatures are reduced below about 500° C., thicker TiN films (e.g., thicknesses above about 1500 Å) having lower tensile stresses (e.g., tensile stress on the order of about 1-2×10 9 dyne/cm 2 ), without cracks can be produced. However, these low tensile stress TiN films typically have a high Cl content (e.g., chlorine content greater than about 3%). A high chlorine content is undesirable because the chlorine may migrate from the Ti/TiN film stack into the contact region of, for example the source or drain of a transistor, which can increase the contact resistance of such contact region and potentially change the characteristics of the transistor.
[0010] Therefore, a need exists in the art for a method of forming a reliable Ti and/or TiN films for integrated circuit fabrication.
SUMMARY OF THE INVENTION
[0011] The present invention relates to a method of forming a film structure (e.g., film stack) comprising titanium (Ti) and/or titanium nitride (TiN) films. The Ti film is formed by alternately depositing and then plasma treating thin films (less than about 100 Å thick) of titanium. The TiN film is formed by alternately depositing and then plasma treating thin films (less than about 300 Å thick) of titanium nitride.
[0012] The titanium film is formed using a plasma reaction of titanium tetrachloride (TiCl 4 ) and a hydrogen-containing gas. The titanium nitride film is formed by thermally reacting titanium tetrachloride with a nitrogen-containing gas. The plasma treatment step comprises a nitrogen/hydrogen-containing plasma.
[0013] Alternatively, a TiSi x film is formed by alternately depositing and then plasma treating thin films (less than about 100 Å thick) of titanium formed on a silicon substrate. The TiSi x is formed using, for example, a plasma reaction between titanium tetrachloride (TiCl 4 ) and a hydrogen-containing gas. The plasma treatment step comprises a nitrogen/hydrogen-containing plasma.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The teachings of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
[0015] [0015]FIG. 1 depicts a schematic illustration of an apparatus that can be used for the practice of this invention;
[0016] [0016]FIGS. 2 a - 2 e depict cross-sectional views of a substrate structure at different stages of integrated circuit fabrication incorporating a Ti/TiN film stack;
[0017] [0017]FIG. 3 is a graph of the resistivity and sheet resistance uniformity of a TiN film plotted as a function of the plasma treatment time;
[0018] [0018]FIG. 4 is a graph of the film stress for a TiN film plotted as a function of the plasma treatment time; and
[0019] [0019]FIGS. 5 a - 5 b depict cross-sectional views of a capacitive structure at different stages of integrated circuit fabrication incorporating a TiN electrode.
DETAILED DESCRIPTION
[0020] [0020]FIG. 1 depicts a schematic illustration of a wafer processing system 10 that can be used to practice embodiments of the present invention. The system 10 comprises a process chamber 100 , a gas panel 130 , a control unit 110 , along with other hardware components such as power supplies 106 and vacuum pumps 102 . One example of the process chamber 100 is a TiN chamber which has previously been described in commonly-assigned U.S. patent application Ser. No. 09/211,998, entitled “High Temperature Chemical Vapor Deposition Chamber”, filed on Dec. 14, 1998, which is herein incorporated by reference. The salient features of process chamber 100 are briefly described below.
[0021] Chamber 100
[0022] The process chamber 100 generally houses a support pedestal 150 , which is used to support a substrate such as a semiconductor wafer 190 within the process chamber 100 . The pedestal 150 can typically be moved in a vertical direction inside the chamber 100 using a displacement mechanism (not shown). Depending on the specific process, the semiconductor wafer 190 can be heated to some desired temperature prior to layer deposition.
[0023] In chamber 100 , the wafer support pedestal 150 is heated by an embedded heater 170 . For example, the pedestal 150 may be resistively heated by applying an electric current from an AC power supply 106 to the heater element 170 . The wafer 190 is, in turn, heated by the pedestal 150 , and can be maintained within a desired process temperature range of, for example, about 250° C. to about 750° C. A temperature sensor 172 , such as a thermocouple, is also embedded in the wafer support pedestal 150 to monitor the temperature of the pedestal 150 in a conventional manner. For example, the measured temperature may be used in a feedback loop to control the electric current applied to the heater element 170 by the power supply 106 , such that the wafer temperature can be maintained or controlled at a desired temperature which is suitable for the particular process application. The pedestal 150 is optionally heated using radiant heat (not shown).
[0024] A vacuum pump 102 is used to evacuate the process chamber 100 and to help maintain the proper gas flows and pressure inside the chamber 100 . A showerhead 120 , through which process gases are introduced into the chamber 100 , is located above the wafer support pedestal 150 .
[0025] A “dual-gas” showerhead 120 has two separate pathways or gas lines (not shown), which allow two gases to be separately introduced into the chamber 100 without pre-mixing. Details of the showerhead 120 have been disclosed in commonly-assigned U.S. patent application Ser. No. 09/098,969, entitled “Dual Gas Faceplate for a Showerhead in a Semiconductor Wafer Processing System”, filed Jun. 16, 1998, which is herein incorporated by reference.
[0026] The showerhead 120 is connected to a gas panel 130 , which controls and supplies various gases used in different steps of the process sequence. During wafer processing, a purge gas supply 104 may also provide a purge gas, for example, an inert gas, around the bottom of the pedestal 150 , to minimize undesirable deposit formation on the backside of the pedestal 150 .
[0027] The showerhead 120 and the wafer support pedestal 150 also form a pair of spaced apart electrodes. When an electric field is generated between these electrodes, the process gases introduced into the chamber 100 are ignited into a plasma 180 . The electric field can be generated, for example, by connecting the wafer support pedestal 150 to a source of radio frequency (RF) power (not shown) through a matching network (not shown). Alternatively, the RF power source and matching network may be coupled to the showerhead 120 , or coupled to both the showerhead 120 and the wafer support pedestal 150 .
[0028] Plasma enhanced chemical vapor deposition (PECVD) techniques promote excitation and/or disassociation of the reactant gases by the application of the electric field to the reaction zone near the substrate surface, creating a plasma 180 of reactive species. The reactivity of the species in the plasma 180 reduces the energy required for a chemical reaction to take place, in effect lowering the required temperature for such PECVD processes.
[0029] Proper control and regulation of the gas flows through the gas panel 130 is performed by mass flow controllers (not shown) and a controller unit 110 , such as a computer. The showerhead 120 allows process gases from the gas panel 130 to be uniformly introduced and distributed in the process chamber 100 . Illustratively, the control unit 110 comprises a central processing unit (CPU) 112 , support circuitry 114 , and memories containing associated control software 116 . The control unit 110 is responsible for automated control of the numerous steps required for wafer processing—such as wafer transport, gas flow control, temperature control, chamber evacuation, and other steps. The control unit 110 may be one of any form of general purpose computer processor that can be used in an industrial setting for controlling various chambers and sub-processors. The computer processor may use any suitable memory, such as random access memory, read only memory, floppy disk drive, hard disk, or any other form of digital storage, local or remote. Various support circuits may be coupled to the computer processor for supporting the processor in a conventional manner. Software routines as required may be stored in the memory or executed by a second processor that is remotely located. Bi-directional communications between the control unit 110 and the various components of the system 10 are handled through numerous signal cables collectively referred to as signal buses 118 , some of which are illustrated in FIG. 1.
[0030] Ti and TiN Layer Formation
[0031] The following embodiments are methods for titanium and/or titanium nitride (Ti/TiN) formation, which advantageously provide a Ti and/or TiN film stack with improved reliability and good step coverage for the both the Ti and/or TiN films.
[0032] [0032]FIGS. 2 a - 2 e illustrate one preferred embodiment of the present invention in which Ti and TiN films are formed. In general, the substrate 200 refers to any workpiece upon which film processing is performed, and a substrate structure 250 is used to generally denote the substrate 200 as well as other material layers formed on the substrate 200 . Depending on the specific stage of processing, the substrate 200 may be a silicon semiconductor wafer, or other material layer, which has been formed on the wafer. FIG. 2 a , for example, shows a cross-sectional view of a substrate structure 250 , having a material layer 202 thereon. In this particular illustration, the material layer 202 may be an oxide (e.g., silicon dioxide). The material layer 202 has been conventionally formed and patterned to provide a contact hole 202 H extending to the top surface 200 T of the substrate 200 .
[0033] A Ti film 204 is formed on the substrate structure 250 . The Ti layer 204 is formed by depositing a Ti layer using, for example, plasma-enhanced decomposition of a gas mixture comprising a titanium compound such as titanium tetrachloride (TiCl 4 ) and a hydrogen-containing compound. The Ti film can be deposited in a process chamber 100 similar to that shown in FIG. 1. In general, the decomposition of the titanium compound may be performed at a substrate temperature of about 400° C. to about 700° C., a chamber pressure of about 5 torr to about 30 torr, a titanium compound flow rate of about 50 mg/min and above, a hydrogen gas flow rate of about 2000 sccm to about 4000 sccm, an RF power of about 1 watt/cm 2 to about 3 watts/cm 2 , and a plate spacing of about 300 mils to about 500 mils. Dilutant gases such as hydrogen (H 2 ), argon (Ar), helium (He), or combinations thereof may be added to the gas mixture. The above deposition parameters provide a deposition rate for the titanium of about 1 Å/sec to about 3 Å/sec.
[0034] The deposited Ti film 204 also contacts a portion of the substrate 200 at the bottom 200 T of the contact hole 202 H. Due to the non-conformal nature of the plasma deposited Ti film 204 , the sidewalls 202 S of the contact hole 202 H are typically covered by a much thinner film of titanium than is deposited on the bottom 200 T of the contact hole 202 H. The thickness of titanium deposited in the bottom 200 T of the contact hole 202 H may be controlled by the adjusting the process time.
[0035] The titanium film is deposited to a thickness of less than about 100 Å. Thereafter the titanium film is treated with a hydrogen/nitrogen-containing plasma. The Ti film can be treated in a process chamber 100 similar to that shown in FIG. 1. In general, the titanium layer plasma treatment may be performed at a substrate temperature of about 450° C. to about 680° C., a chamber pressure of about 5 torr to about 30 torr, a nitrogen/hydrogen gas flow ratio of about 0.1 to about 1, an RF power of about 0.5 watts/cm 2 to about 10 watts/cm 2 , and a plate spacing of about 300 mils to about 500 mils. Hydrogen (H 2 ), nitrogen (N 2 ), ammonia (NH 3 ), and hydrazine (N 2 H 4 ), among others, may be used for the nitrogen/hydrogen plasma. Dilutant gases such as hydrogen (H 2 ), argon (Ar), helium (He), or combinations thereof may be added to the gas mixture. The titanium film is plasma treated for about 5 seconds to about 60 seconds.
[0036] After the titanium layer is plasma treated, another later of titanium is formed thereon and then plasma treated according to the process parameters detailed above. The alternating deposition/plasma treatment steps are preformed until a desired layer thickness is achieved. Alternatively, when the Ti layer is formed on a silicon substrate a layer of TiSi x may be formed during the first plasma treatment step. After the first cycle, subsequent Ti depositions followed by plasma treatments with the H 2 /N 2 gases can result in the formation of a composite titanium/titanium nitride layer. The titanium silicide thickness varies as a function of the plasma treatment time as well as the plasma treatment temperature.
[0037] The as-deposited plasma treated titanium layer when formed on silicon dioxide (S i O 2 ) has a resistivity of less than about 70 μω-cm, which is about 3 times smaller than the resistivity of films obtained using standard CVD processes (typically about 200 μω-cm). Additionally, the as-deposited Ti layers have better sheet resistance uniformity across the deposited film.
[0038] After the formation of the Ti layer 204 , a TiN layer 208 is deposited in the contact hole 202 H, as illustrated in FIG. 2 b . The TiN film 208 can be formed, for example, by CVD using a reaction of TiCl 4 and NH 3 in the chamber 100 of FIG. 1. In one embodiment, helium (He) and nitrogen (N 2 ) are introduced into the chamber 100 , along with TiCl 4 , via one pathway (gas line) of the showerhead 120 . NH 3 , along with N 2 , is introduced into the chamber 100 via the second pathway of the showerhead 120 . He and argon (Ar), or other inert gases, may also be used, either singly or in combination (i.e., as a gas mixture) within either gas line of the showerhead 120 . A bottom inert gas purge flow (e. g., Ar) of about 500 sccm is also established through a separate gas line and gas supply 104 provided at the bottom of the chamber 100 .
[0039] Typically, the reaction can be performed at a TiCl 4 flow rate of about 50 mg/min to about 350 mg/min, and a NH 3 flow of about 100 sccm to about 500 sccm, introduced into the chamber 100 though the first pathway of the showerhead 120 . A total pressure range of about 5 torr to about 30 torr and a pedestal temperature between about 400° C. to about 700° C. may be used. The above deposition parameters provide a deposition rate for the titanium nitride of about 5 Å/sec to about 13 Å/sec.
[0040] The titanium nitride film is deposited to a thickness of less than about 300 Å. Thereafter the titanium nitride film is treated with a hydrogen/nitrogen-containing plasma. The TiN film can be treated in a process chamber 100 similar to that shown in FIG. 1. In general, the titanium nitride layer plasma treatment may be performed at a substrate temperature of about 400° C. to about 700° C., a chamber pressure of about 5 torr to about 30 torr, a nitrogen/hydrogen gas flow ratio of about 0.1 to about 1, an RF power of about 0.5 watts/cm 2 to about 10 watts/cm 2 , and a plate spacing of about 300 mils to about 500 mils. Hydrogen (H 2 ), nitrogen (N 2 ), ammonia (NH 3 ), and hydrazine (N 2 H 4 ), among others, may be used for the nitrogen/hydrogen plasma. Dilutant gases such as hydrogen (H 2 ), argon (Ar), helium (He), or combinations thereof may be added to the gas mixture. The titanium nitride film is plasma treated for about 5 seconds to about 60 seconds.
[0041] After the titanium nitride layer is plasma treated, another layer of titanium nitride is formed thereon and then plasma treated according to the process parameters detailed above. The alternating deposition/plasma treatment steps are preformed until a desired layer thickness is achieved.
[0042] [0042]FIG. 3 is a graph of the resistivity and sheet resistance uniformity plotted as a function of the plasma treatment time. As shown in the graph of FIG. 3, an as-deposited plasma treated titanium nitride layer having a thickness of about 300 Å has a resistivity of less than about 20 ω-sq and a sheet resistance uniformity of 8-10% as compared to a resistivity of about 75 ω-sq and a sheet resistance uniformity of about 14% for non-plasma treated layers.
[0043] [0043]FIG. 4 is a graph of the film stress plotted as a function of the plasma treatment time. Referring to FIG. 4, an as-deposited TiN layer having a thickness of about 300 Å has reduced stress. In particular, TiN layers formed using previous deposition processes typically have tensile stresses of about 3-8×10 9 dynes/cm 2 . In contrast, TiN layers formed according to the process conditions described herein have a compressive stress of about −1-3×10 9 dynes/cm 2 .
[0044] Thereafter, as illustrated in FIG. 2 c , a tungsten (W) plug 210 is formed on the TiN layer 208 of FIG. 2 b . The W plug 210 may be formed from, for example, a reaction between WF 6 and H 2 . Adhesion of the W-plug layer is improved by the presence of the TiN layer 208 .
[0045] Alternatively, a TiN layer deposited according to the process parameters described above can also be used to form a TiN-plug contact 208 on a Ti layer 204 , as shown in FIGS. 2 d - 2 e . The TiN-plug contact 208 has good adhesion to Ti layer 204 .
[0046] [0046]FIGS. 5 a - 5 b illustrate schematic cross-sectional views of a substrate 300 at different stages of a capacitive memory cell fabrication sequence. Depending on the specific stage of processing, substrate 300 may correspond to a silicon wafer, or other material layer that has been formed on the silicon wafer. Alternatively, the substrate may have integrated circuit structures (not shown) such as logic gates formed on regions thereof.
[0047] [0047]FIG. 5 a , for example, illustrates a cross-sectional view of a silicon substrate 300 having a material layer 302 formed thereon. The material layer 302 may be an oxide (e.g., fluorosilicate glass (FSG), undoped silicate glass (USG), organosilicates) or a silicon carbide material. Material layer 302 preferably has a low dielectric constant (e.g., dielectric constant less than about 5). The thickness of material layer 302 is variable depending on the size of the structure to be fabricated. Typically, material layer 302 has a thickness of about 1,000 Å to about 20,000 Å. Apertures 301 having widths less than about 0.5 μm (micrometer) wide and depths of about 0.5 μm to about 2 μm, providing aspect ratio structures in a range of about 1:1 to about 4:1 are formed therein.
[0048] A bottom electrode 308 is conformably deposited along the sidewalls and bottom surface of aperture 301 . The bottom electrode 308 is conformably deposited using conventional PVD or CVD techniques. An example of a suitable electrode material is TaN, among others. The thickness of the bottom electrode 308 is variable depending on the size of the structure to be fabricated. Typically, the bottom electrode 308 has a thickness of about 1,000 Å to about 10,000 Å.
[0049] Above the bottom electrode 308 is deposited a Ta 2 O 5 memory cell dielectric layer 310 . The Ta 2 O 5 memory cell dielectric layer 310 is conformably deposited using conventional CVD. The thickness of the Ta 2 O 5 memory cell dielectric layer 310 is variable depending on the size of the structure to be fabricated. Typically, the Ta 2 O 5 memory cell dielectric layer 310 has a thickness of about 100 Å to about 500 Å.
[0050] Referring to FIG. 5 b , the capacitive memory cell is completed by conformably depositing a TiN top electrode 312 on the Ta 2 O 5 memory cell dielectric layer 310 . The TiN top electrode 312 is conformably deposited using CVD techniques according to the process parameters described above. The thickness of the TiN top electrode 312 is variable depending on the size of the structure to be fabricated. Typically, the TiN top electrode 312 has a thickness of about 1,000 Å to about 10,000 Å.
[0051] Although several preferred embodiments, which incorporate the teachings of the present invention have been shown and described in detail, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings. | A method of forming a film structure (e.g., film stacks) comprising titanium (Ti) and/or titanium nitride (TiN). The Ti film structure is formed by alternately depositing and then plasma treating thin films (less than about 100 Å thick) of titanium. The TiN film structure is formed by alternately depositing and then plasma treating thin films (less than about 300 Å thick) of titanium nitride. The titanium films are formed using a plasma reaction of titanium tetrachloride (TiCl 4 ) and a hydrogen-containing gas. The titanium nitride films are formed by thermally reacting titanium tetrachloride with a nitrogen-containing gas. The subsequent plasma treatment steps comprise a nitrogen/hydrogen-containing plasma. | 7 |
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